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1997 Jeep XJ Cherokee Service Manual – PDF DOWNLOAD
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Description
1997 Jeep XJ Cherokee Service Manual – PDF DOWNLOAD
DESCRIPTION:
1997 Jeep XJ Cherokee Service Manual – PDF DOWNLOAD
GENERAL INFORMATION :
INTRODUCTION :
- Service and maintenance procedures for components and systems listed in Schedule “A” or “B” can be found by using the Group Tab Locator index at the front of this manual. If it is not clear which group contains the information needed, refer to the index at the back of this manual.
- There are two maintenance schedules that show proper service based on the conditions that the vehicle is subjected to. Schedule “A” , lists scheduled maintenance to be performed when the vehicle is used for general transportation. Schedule “B” , lists maintenance intervals for vehicles that are operated under the conditions listed at the beginning of the Maintenance Schedule section. Use the schedule that best describes your driving conditions. Where time and mileage are listed, follow the interval that occurs first.
PARTS AND LUBRICANT RECOMMENDATIONS
When service is required, Chrysler Corporation recommends that only Mopart brand parts, lubricants and chemicals be used. Mopar provides the best engineered products for servicing Chrysler Corporation vehicles.
TABLE OF CONTENTS:
1997 Jeep XJ Cherokee Service Manual – PDF DOWNLOAD
INTRODUCTION...............................................................................1715 GENERAL INFORMATION....................................................................1715 VEHICLE IDENTIFICATION NUMBER......................................................1715 VEHICLE IDENTIFICATION NUMBER..................................................1715 VEHICLE IDENTIFICATION NUMBER DECODING CHART...................................1715 VEHICLE SAFETY CERTIFICATION LABEL.................................................1716 BODY CODE PLATE—LINE 3.........................................................1716 BODY CODE PLATE....................................................................1716 LOCATION AND DECODING..........................................................1716 BODY CODE PLATE—LINE 2.........................................................1716 VEHICLE DIMENSIONS.................................................................1717 BODY CODE PLATE LINE 1.........................................................1717 VEHICLE EXTERIOR DIMENSIONS....................................................1717 VEHICLE INTERIOR DIMENSIONS....................................................1717 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS......................................1718 INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS..................................1718 INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS..............................1718 FASTENER IDENTIFICATION............................................................1718 FASTENER IDENTIFICATION........................................................1718 FASTENER IDENTIFICATION........................................................1719 FASTENER STRENGTH..............................................................1720 METRIC SYSTEM......................................................................1721 TORQUE REFERENCES..................................................................1721 CONVERSION FORMULAS AND EQUIVALENT VALUES......................................1721 METRIC CONVERSION..............................................................1722 TORQUE SPECIFICATIONS..........................................................1723 SPECIFIED TORQUE FOR STANDARD BOLTS............................................1723 LUBRICATION AND MAINTENANCE................................................................ 1 GENERAL INFORMATION.................................................................... 1 GENERAL INFORMATION................................................................ 1 INTRODUCTION................................................................... 1 PARTS AND LUBRICANT RECOMMENDATIONS............................................ 1 INTERNATIONAL SYMBOLS.......................................................... 1 CLASSIFICATION OF LUBRICANTS................................................... 2 ENGINE OIL................................................................. 2 FLUID CAPACITIES............................................................... 3 FUEL TANK.................................................................. 3 ENGINE OIL................................................................. 3 COOLING SYSTEM............................................................. 3 AUTOMATIC TRANSMISSION..................................................... 3 MANUAL TRANSMISSION........................................................ 3 TRANSFER CASE.............................................................. 3 FRONT AXLE................................................................. 3 REAR AXLE.................................................................. 3 POWER STEERING............................................................. 3 MAINTENANCE SCHEDULES.................................................................. 4 GENERAL INFORMATION................................................................ 4 MAINTENANCE SCHEDULES.......................................................... 4 EMISSION CONTROL SYSTEM MAINTENANCE........................................ 4 FLUID FILL LOCATIONS AND LUBRICATION POINTS................................ 4 SCHEDULE “A”............................................................... 4 SCHEDULE “B”............................................................... 6 JUMP STARTING, TOWING AND HOISTING..................................................... 9 SERVICE PROCEDURES................................................................. 9 JUMP STARTING PROCEDURE........................................................ 9 TO JUMP START A DISABLED VEHICLE:.......................................... 9 TOWING RECOMMENDATIONS......................................................... 10 SAFETY PRECAUTIONS......................................................... 10 GROUND CLEARANCE........................................................... 10 FLAT-BED TOWING RAMP ANGLE................................................. 10 TWO-WHEEL-DRIVE VEHICLE TOWING................................................. 10 TOWING-REAR END LIFTED (SLING-TYPE)........................................ 10 TOWING-REAR END LIFTED (WHEEL LIFT)........................................ 11 TOWING-FRONT END LIFTED.................................................... 11 FOUR-WHEEL-DRIVE VEHICLE TOWING................................................ 11 TOWING-REAR END LIFTED (SLING TYPE)........................................ 11 TOWING-REAR END LIFTED (WHEEL LIFT)........................................ 11 TOWING-FRONT END LIFTED.................................................... 11 EMERGENCY TOW HOOKS............................................................ 11 HOISTING RECOMMENDATIONS....................................................... 11 FLOOR JACK................................................................. 11 HOIST...................................................................... 12 SUSPENSION................................................................................. 175 ALIGNMENT.............................................................................. 175 GENERAL INFORMATION................................................................ 175 WHEEL ALIGNMENT................................................................ 175 DIAGNOSIS AND TESTING.............................................................. 177 SUSPENSION AND STEERING SYSTEM................................................. 177 SERVICE PROCEDURES................................................................. 178 PRE-ALIGNMENT.................................................................. 178 WHEEL ALIGNMENT................................................................ 178 CAMBER..................................................................... 178 CASTER..................................................................... 178 TOE POSITION (LHD)......................................................... 178 TOE POSITION (RHD)......................................................... 179 SPECIFICATIONS..................................................................... 180 ALIGNMENT...................................................................... 180 FRONT SUSPENSION....................................................................... 181 DESCRIPTION AND OPERATION.......................................................... 181 SUSPENSION COMPONENTS.......................................................... 181 DIAGNOSIS AND TESTING.............................................................. 182 SHOCK DIAGNOSIS................................................................ 182 REMOVAL AND INSTALLATION........................................................... 183 SHOCK ABSORBER................................................................. 183 REMOVAL.................................................................... 183 INSTALLATION............................................................... 183 COIL SPRING/JOUNCE BUMPER...................................................... 183 REMOVAL.................................................................... 183 INSTALLATION............................................................... 183 STEERING KNUCKLE............................................................... 183 LOWER SUSPENSION ARM........................................................... 184 REMOVAL.................................................................... 184 INSTALLATION............................................................... 184 UPPER SUSPENSION ARM........................................................... 184 REMOVAL.................................................................... 184 INSTALLATION............................................................... 184 FRONT AXLE BUSHING............................................................. 184 REMOVAL.................................................................... 184 INSTALLATION............................................................... 184 STABILIZER BAR................................................................. 185 REMOVAL.................................................................... 185 INSTALLATION............................................................... 185 TRACK BAR...................................................................... 185 REMOVAL.................................................................... 185 INSTALLATION............................................................... 185 FRONT HUB BEARING.............................................................. 186 REMOVAL.................................................................... 186 INSTALLATION............................................................... 186 WHEEL MOUNTING STUDS-FRONT..................................................... 186 REMOVAL.................................................................... 186 INSTALLATION............................................................... 186 SPECIFICATIONS..................................................................... 187 TORQUE CHART................................................................... 187 SPECIAL TOOLS...................................................................... 187 FRONT SUSPENSION............................................................... 187 REAR SUSPENSION........................................................................ 188 DESCRIPTION AND OPERATION.......................................................... 188 SUSPENSION COMPONENT........................................................... 188 DIAGNOSIS AND TESTING.............................................................. 188 SPRING AND SHOCK DIAGNOSIS..................................................... 188 REMOVAL AND INSTALLATION........................................................... 189 SHOCK ABSORBER................................................................. 189 REMOVAL.................................................................... 189 INSTALLATION............................................................... 189 STABILIZER BAR................................................................. 189 REMOVAL.................................................................... 189 INSTALLATION............................................................... 190 LEAF SPRING.................................................................... 190 REMOVAL.................................................................... 190 INSTALLATION............................................................... 190 LEAF SPRING AND SHACKLE BUSHING................................................ 190 SPECIFICATIONS..................................................................... 191 TORQUE CHART................................................................... 191 DIFFERENTIAL AND DRIVELINE................................................................. 737 GENERAL INFORMATION.................................................................... 737 PROPELLER SHAFTS................................................................... 737 LUBRICATION........................................................................ 737 PROPELLER SHAFT JOINT ANGLE........................................................ 738 PROPELLER SHAFT JOINTS............................................................. 738 DIAGNOSIS AND TESTING.................................................................. 739 VIBRATION.......................................................................... 739 UNBALANCE.......................................................................... 739 DRIVELINE VIBRATION............................................................ 740 RUNOUT............................................................................. 740 SERVICE PROCEDURES..................................................................... 741 DRIVELINE ANGLE MEASUREMENT PREPARATION............................................ 741 PROPELLER SHAFT ANGLE MEASUREMENT.................................................. 741 RUNOUT SPECIFICATIONS.......................................................... 741 REMOVAL AND INSTALLATION............................................................... 742 FRONT PROPELLER SHAFT.............................................................. 742 REMOVAL........................................................................ 742 INSTALLATION................................................................... 742 REAR PROPELLER SHAFT............................................................... 742 REMOVAL........................................................................ 742 INSTALLATION................................................................... 743 DISASSEMBLY AND ASSEMBLY............................................................... 743 SINGLE CARDAN UNIVERSAL JOINT...................................................... 743 DISASSEMBLY.................................................................... 743 ASSEMBLY....................................................................... 745 DOUBLE CARDAN JOINT................................................................ 745 DISASSEMBLY.................................................................... 745 ASSEMBLY....................................................................... 747 CLEANING AND INSPECTION................................................................ 748 PROPELLER SHAFT.................................................................... 748 ADJUSTMENTS............................................................................ 748 ADJUSTMENT AT AXLE WITH LEAF SPRINGS............................................... 748 FRONT AXLE ANGLE ADJUSTMENT........................................................ 749 SPECIFICATIONS SPECIAL TOOLS........................................................... 750 PROPELLER SHAFTS AND U–JOINTS PROPELLER SHAFT...................................... 750 GENERAL INFORMATION.................................................................... 751 FBI AXLE........................................................................... 751 LUBRICANT SPECIFICATIONS........................................................... 751 DESCRIPTION AND OPERATION.............................................................. 752 STANDARD DIFFERENTIAL.............................................................. 752 DIAGNOSIS AND TESTING.................................................................. 752 GENERAL INFORMATION................................................................ 752 GEAR NOISE......................................................................... 752 VIBRATION.......................................................................... 753 BEARING NOISE...................................................................... 753 DRIVELINE SNAP..................................................................... 753 LOW SPEED KNOCK.................................................................... 753 FRONT AXLES........................................................................ 754 DIAGNOSIS...................................................................... 754 SERVICE PROCEDURES..................................................................... 756 LUBRICANT CHANGE................................................................... 756 REMOVAL AND INSTALLATION............................................................... 756 DRIVE AXLE ASSEMBLY................................................................ 756 REMOVAL........................................................................ 756 TUBE AXLE ASSEMBLY................................................................. 757 REMOVAL INSTALLATION........................................................... 757 INSTALLATION................................................................... 757 AXLE SHAFT—CARDAN U-JOINT.......................................................... 758 REMOVAL........................................................................ 758 INSTALLATION INSTALLATION...................................................... 759 PINION SHAFT SEAL.................................................................. 759 REMOVAL........................................................................ 759 HUB BEARING AND AXLE SHAFT......................................................... 760 REMOVAL........................................................................ 760 INSTALLATION................................................................... 760 KNUCKLE REMOVAL................................................................ 761 UPPER BALL STUD REPLACEMENT.................................................... 761 LOWER BALL STUD REPLACEMENT.................................................... 761 KNUCKLE INSTALLATION........................................................... 761 STEERING KNUCKLE AND BALL STUDS.................................................... 761 AXLE BUSHING REPLACEMENT........................................................... 762 DIFFERENTIAL....................................................................... 762 REMOVAL........................................................................ 762 INSTALLATION................................................................... 762 DIFFERENTIAL SIDE BEARINGS......................................................... 764 REMOVAL........................................................................ 764 INSTALLATION................................................................... 764 AXLE SHAFT OIL SEAL................................................................ 765 REMOVAL........................................................................ 765 INSTALLATION................................................................... 765 RING GEAR.......................................................................... 765 REMOVAL........................................................................ 765 PINION GEAR........................................................................ 766 REMOVAL........................................................................ 766 INSTALLATION................................................................... 766 INSTALLATION................................................................... 767 DISASSEMBLY AND ASSEMBLY............................................................... 770 STANDARD DIFFERENTIAL.............................................................. 770 DISASSEMBLY.................................................................... 770 ASSEMBLY....................................................................... 770 FINAL ASSEMBLY..................................................................... 770 CLEANING AND INSPECTION................................................................ 771 CARDAN U-JOINT..................................................................... 771 AXLE COMPONENTS.................................................................... 771 ADJUSTMENTS............................................................................ 771 PINION GEAR DEPTH.................................................................. 771 GENERAL INFORMATION............................................................ 771 PINION DEPTH MEASUREMENT AND ADJUSTMENT........................................ 772 PINION GEAR DEPTH VARIANCE..................................................... 773 DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH..................................... 774 INTRODUCTION................................................................... 774 SHIM SELECTION................................................................. 774 GEAR CONTACT PATTERN ANALYSIS...................................................... 777 SPECIFICATIONS......................................................................... 779 FBI AXLE........................................................................... 779 FBI AXLE........................................................................... 779 SPECIAL TOOLS.......................................................................... 779 FBI AXLE........................................................................... 779 GENERAL INFORMATION.................................................................... 783 RBI AXLE........................................................................... 783 LUBRICANT SPECIFICATIONS........................................................... 783 DESCRIPTION AND OPERATION.............................................................. 784 STANDARD DIFFERENTIAL.............................................................. 784 TRAC-LOK OPERATION................................................................. 784 GEAR NOISE......................................................................... 785 BEARING NOISE...................................................................... 785 DIAGNOSIS AND TESTING.................................................................. 785 GENERAL INFORMATION................................................................ 785 LOW SPEED KNOCK.................................................................... 786 VIBRATION.......................................................................... 786 TRAC–LOK DIFFERENTIAL NOISE........................................................ 786 DRIVELINE SNAP..................................................................... 786 TRAC–LOK TEST...................................................................... 789 SERVICE PROCEDURES..................................................................... 789 LUBRICANT CHANGE................................................................... 789 INSTALLATION................................................................... 790 REMOVAL AND INSTALLATION............................................................... 790 REAR AXLE.......................................................................... 790 REMOVAL........................................................................ 790 PINION SHAFT SEAL.................................................................. 791 REMOVAL........................................................................ 791 INSTALLATION................................................................... 791 REMOVAL W/PINION REMOVED....................................................... 792 COLLAPSIBLE SPACER................................................................. 792 REMOVAL W/PINION INSTALLED..................................................... 792 INSTALLATION................................................................... 793 AXLE SHAFT......................................................................... 794 REMOVAL........................................................................ 794 AXLE SHAFT SEAL AND BEARING........................................................ 795 REMOVAL........................................................................ 795 INSTALLATION................................................................... 795 INSTALLATION................................................................... 795 DIFFERENTIAL....................................................................... 796 REMOVAL........................................................................ 796 INSTALLATION................................................................... 797 DIFFERENTIAL SIDE BEARINGS......................................................... 798 REMOVAL........................................................................ 798 INSTALLATION................................................................... 798 RING GEAR.......................................................................... 798 REMOVAL........................................................................ 798 INSTALLATION................................................................... 798 PINION GEAR........................................................................ 799 REMOVAL........................................................................ 799 INSTALLATION................................................................... 800 FINAL ASSEMBLY..................................................................... 803 ASSEMBLY....................................................................... 803 DISASSEMBLY AND ASSEMBLY............................................................... 803 STANDARD DIFFERENTIAL.............................................................. 803 DISASSEMBLY.................................................................... 803 TRAC-LOK DIFFERENTIAL.............................................................. 804 DISASSEMBLY.................................................................... 804 ASSEMBLY....................................................................... 806 ADJUSTMENTS............................................................................ 808 PINION GEAR DEPTH.................................................................. 808 GENERAL INFORMATION............................................................ 808 CLEANING AND INSPECTION................................................................ 808 AXLE COMPONENTS.................................................................... 808 TRAC-LOK........................................................................... 808 PRESOAK PLATES AND DISC........................................................ 808 PINION GEAR DEPTH VARIANCE..................................................... 809 PINION DEPTH MEASUREMENT AND ADJUSTMENT........................................ 809 DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH..................................... 810 SHIM SELECTION................................................................. 810 GEAR CONTACT PATTERN ANALYSIS...................................................... 812 SPECIFICATIONS......................................................................... 814 RBI AXLE........................................................................... 814 RBI AXLE........................................................................... 814 SPECIAL TOOLS.......................................................................... 814 RBI AXLE........................................................................... 814 GENERAL INFORMATION.................................................................... 819 1/4 AXLES.......................................................................... 819 AXLE IDENTIFICATION................................................................ 819 LUBRICANT SPECIFICATIONS........................................................... 819 DESCRIPTION AND OPERATION.............................................................. 820 STANDARD DIFFERENTIAL.............................................................. 820 TRAC-LOK OPERATION................................................................. 821 DIAGNOSIS AND TESTING.................................................................. 821 GENERAL INFORMATION................................................................ 821 LOW SPEED KNOCK.................................................................... 822 GEAR NOISE VIBRATION............................................................... 822 BEARING NOISE DRIVELINE SNAP....................................................... 822 TRAC–LOK DIFFERENTIAL NOISE........................................................ 823 TRAC–LOK TEST...................................................................... 826 SERVICE PROCEDURES..................................................................... 826 LUBRICANT CHANGE................................................................... 826 INSTALLATION................................................................... 827 AXLE SHAFT......................................................................... 827 REMOVAL AND INSTALLATION............................................................... 827 REAR AXLE.......................................................................... 827 REMOVAL........................................................................ 827 AXLE SEAL AND BEARING.............................................................. 828 REMOVAL........................................................................ 828 INSTALLATION................................................................... 828 INSTALLATION................................................................... 828 INSTALLATION................................................................... 829 PINION SEAL........................................................................ 829 REMOVAL........................................................................ 829 DIFFERENTIAL....................................................................... 831 REMOVAL INSTALLATION........................................................... 831 DIFFERENTIAL SIDE BEARINGS......................................................... 831 REMOVAL........................................................................ 831 INSTALLATION................................................................... 831 RING GEAR.......................................................................... 832 REMOVAL........................................................................ 832 INSTALLATION................................................................... 832 PINION GEAR........................................................................ 832 REMOVAL........................................................................ 832 INSTALLATION................................................................... 834 DISASSEMBLY AND ASSEMBLY............................................................... 836 STANDARD DIFFERENTIAL.............................................................. 836 DISASSEMBLY.................................................................... 836 ASSEMBLY....................................................................... 837 TRAC-LOK DIFFERENTIAL.............................................................. 837 DISASSEMBLY.................................................................... 837 ASSEMBLY....................................................................... 839 CLEANING AND INSPECTION................................................................ 840 1/4 AXLES.......................................................................... 840 TRAC-LOK........................................................................... 841 PRESOAK PLATES AND DISC........................................................ 841 ADJUSTMENTS............................................................................ 841 1/4 AXLE PINION GEAR DEPTH......................................................... 841 GENERAL INFORMATION............................................................ 841 PINION GEAR DEPTH VARIANCE..................................................... 842 PINION DEPTH MEASUREMENT AND ADJUSTMENT........................................ 842 DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH..................................... 843 SIDE GEAR CLEARANCE................................................................ 844 GEAR CONTACT PATTERN ANALYSIS...................................................... 844 SPECIFICATIONS......................................................................... 846 1/4 INCH AXLE...................................................................... 846 1/4 INCH AXLE...................................................................... 846 SPECIAL TOOLS.......................................................................... 847 1/4 AXLES.......................................................................... 847 BRAKES..................................................................................... 851 GENERAL INFORMATION.................................................................... 852 BRAKE SYSTEM....................................................................... 852 SERVICE WARNINGS & CAUTIONS........................................................ 852 DESCRIPTION AND OPERATION.............................................................. 852 BRAKE PEDAL........................................................................ 852 STOP LAMP SWITCH................................................................... 852 RED BRAKE WARNING LAMP............................................................. 852 POWER BRAKE BOOSTER................................................................ 852 FRONT DISC BRAKES.................................................................. 853 MASTER CYLINDER.................................................................... 853 COMBINATION VALVE.................................................................. 853 REAR DRUM BRAKE.................................................................... 853 PARKING BRAKE...................................................................... 854 PARKING BRAKE OPERATION........................................................ 854 PRELIMINARY BRAKE CHECK........................................................ 855 BRAKE HOSES AND LINES.............................................................. 855 ROAD TESTING................................................................... 855 DIAGNOSIS AND TESTING.................................................................. 855 BASE BRAKE SYSTEM.................................................................. 855 RED BRAKE WARNING LAMP............................................................. 858 STOP LAMP SWITCH................................................................... 858 SWITCH CIRCUIT IDENTIFICATION.................................................. 858 SWITCH CONTINUITY TEST......................................................... 858 MASTER CYLINDER/POWER BOOSTER...................................................... 858 POWER BOOSTER VACUUM TEST...................................................... 859 COMBINATION VALVE.................................................................. 859 PRESSURE DIFFERENTIAL SWITCH................................................... 859 REAR PROPORTIONING VALVE....................................................... 859 POWER BOOSTER CHECK VALVE TEST................................................. 859 DISC BRAKE ROTOR................................................................... 859 ROTOR MINIMUM THICKNESS........................................................ 860 ROTOR RUNOUT................................................................... 860 BRAKE DRUM......................................................................... 860 BRAKE DRUM RUNOUT.............................................................. 860 BRAKE LINE AND HOSES............................................................... 860 ROTOR THICKNESS VARIATION...................................................... 860 BRAKE FLUID CONTAMINATION.......................................................... 861 SERVICE PROCEDURES..................................................................... 861 BRAKE FLUID LEVEL.................................................................. 861 BRAKE BLEEDING..................................................................... 861 MASTER CYLINDER BLEEDING........................................................... 861 BLEEDING PROCEDURE............................................................. 861 MANUAL BLEEDING................................................................ 862 DISC ROTOR MACHINING............................................................... 862 BRAKE DRUM MACHINING............................................................... 862 PRESSURE BLEEDING.............................................................. 862 BRAKE LINE......................................................................... 862 FLARING PROCEDURE.............................................................. 863 REMOVAL AND INSTALLATION............................................................... 863 STOP LAMP SWITCH................................................................... 863 REMOVAL........................................................................ 863 COMBINATION VALVE.................................................................. 864 INSTALLATION................................................................... 864 REMOVAL........................................................................ 864 BRAKE PEDAL........................................................................ 864 REMOVAL........................................................................ 864 INSTALLATION................................................................... 864 POWER BRAKE BOOSTER................................................................ 865 REMOVAL INSTALLATION........................................................... 865 MASTER CYLINDER.................................................................... 865 REMOVAL........................................................................ 865 INSTALLATION................................................................... 865 DISC BRAKE CALIPER................................................................. 866 REMOVAL........................................................................ 866 INSTALLATION................................................................... 866 INSTALLATION................................................................... 866 DISC BRAKE SHOES................................................................... 867 REMOVAL........................................................................ 867 DISC BRAKE ROTOR................................................................... 868 REMOVAL........................................................................ 868 INSTALLATION................................................................... 868 INSTALLATION INSTALLATION...................................................... 869 DRUM BRAKE SHOES................................................................... 869 REMOVAL........................................................................ 869 BRAKE SUPPORT PLATE................................................................ 870 REMOVAL........................................................................ 870 WHEEL CYLINDER..................................................................... 870 REMOVAL INSTALLATION........................................................... 870 INSTALLATION................................................................... 870 INSTALLATION................................................................... 871 REAR PARKING BRAKE CABLES.......................................................... 871 REMOVAL........................................................................ 871 PARKING BRAKE LEVER................................................................ 871 REMOVAL........................................................................ 871 INSTALLATION................................................................... 871 DISASSEMBLY AND ASSEMBLY............................................................... 872 MASTER CYLINDER RESERVOIR.......................................................... 872 REMOVAL........................................................................ 872 INSTALLATION................................................................... 872 DISC BRAKE CALIPER................................................................. 873 DISASSEMBLY.................................................................... 873 ASSEMBLY....................................................................... 873 WHEEL CYLINDER..................................................................... 874 DISASSEMBLY.................................................................... 874 ASSEMBLY....................................................................... 875 CLEANING AND INSPECTION................................................................ 875 CALIPER............................................................................ 875 CLEANING....................................................................... 875 INSPECTION..................................................................... 875 REAR DRUM BRAKE.................................................................... 875 CLEANING....................................................................... 875 INSPECTION..................................................................... 876 ADJUSTMENTS............................................................................ 876 STOP LAMP SWITCH................................................................... 876 WHEEL CYLINDER..................................................................... 876 CLEANING....................................................................... 876 REAR DRUM BRAKE.................................................................... 876 INSPECTION..................................................................... 876 ADJUSTMENT WITH BRAKE GAUGE.................................................... 876 ADJUSTMENT WITH ADJUSTING TOOL................................................. 877 PARKING BRAKE CABLE TENSIONER...................................................... 878 ADJUSTMENT..................................................................... 878 SPECIFICATIONS......................................................................... 878 BRAKE FLUID........................................................................ 878 BRAKE COMPONENTS................................................................... 879 SPCIAL TOOLS........................................................................... 879 BASE BRAKES........................................................................ 879 TORQUE CHART....................................................................... 879 GENERAL INFORMATION.................................................................... 880 ANTILOCK BRAKE SYSTEM.............................................................. 880 DESCRIPTION AND OPERATION.............................................................. 880 ANTILOCK BRAKE SYSTEM.............................................................. 880 NORMAL BRAKING................................................................. 881 ANTILOCK BRAKING............................................................... 881 HYDRAULIC CONTROL UNIT............................................................. 881 CONTROLLER ANTILOCK BRAKES......................................................... 881 WHEEL SPEED SENSORS AND TONE WHEEL................................................. 882 COMBINATION VALVE.................................................................. 882 SPEED SENSOR AIR GAP........................................................... 882 ACCELERATION SWITCH................................................................ 882 SERVICE PROCEDURES..................................................................... 883 BLEEDING ABS BRAKE SYSTEM.......................................................... 883 ABS WARNING LAMP................................................................... 883 REMOVAL AND INSTALLATION............................................................... 883 HYDRAULIC CONTROL UNIT/CONTROLLER ANTILOCK BRAKES.................................. 883 REMOVAL........................................................................ 883 DIAGNOSIS AND TESTING.................................................................. 883 ANTILOCK BRAKES.................................................................... 883 INSTALLATION................................................................... 884 FRONT WHEEL SPEED SENSOR........................................................... 884 REMOVAL........................................................................ 884 INSTALLATION................................................................... 884 REAR WHEEL SPEED SENSOR............................................................ 884 REMOVAL........................................................................ 884 INSTALLATION................................................................... 885 ACCELERATION SWITCH................................................................ 886 REMOVAL........................................................................ 886 DISASSEMBLY AND ASSEMBLY............................................................... 886 HYDRAULIC CONTROL UNIT/CONTROLLER ANTILOCK BRAKE................................... 886 DISASSEMBLY.................................................................... 886 INSTALLATION................................................................... 886 ASSEMBLY....................................................................... 886 SPECIFICATIONS......................................................................... 887 T0RQUE CHART....................................................................... 887 CLUTCH..................................................................................... 889 GENERAL INFORMATION.................................................................... 889 CLUTCH COMPONENTS.................................................................. 889 SAFETY PRECAUTIONS................................................................. 889 HYDRAULIC LINKAGE COMPONENTS................................................... 889 CLUTCH HYDRAULIC FLUID............................................................. 890 DESCRIPTION AND OPERATION.............................................................. 890 CLUTCH OPERATION................................................................... 890 CLUTCH LUBRICATION................................................................. 890 INSTALLATION METHODS AND PARTS USAGE............................................... 890 DIAGNOSIS AND TESTING.................................................................. 891 GENERAL INFORMATION................................................................ 891 CLUTCH CONTAMINATION............................................................... 891 CLUTCH RUNOUT...................................................................... 891 CLUTCH DISC.................................................................... 891 CLUTCH COVER................................................................... 891 FLYWHEEL....................................................................... 891 IMPROPER CLUTCH RELEASE OR ENGAGEMENT.............................................. 891 SERVICE PROCEDURES..................................................................... 893 CLUTCH COMPONENT LUBRICATION....................................................... 893 MISALIGNMENT....................................................................... 893 RECOMMENDED LUBRICANTS......................................................... 893 CLUTCH LINKAGE FLUID............................................................... 893 DIAGNOSTIC CHARTS.................................................................. 893 CLUTCH FLUID LEVEL FLYWHEEL........................................................ 898 INSTALLATION................................................................... 899 REMOVAL AND INSTALLATION............................................................... 899 CLUTCH COVER AND DISC.............................................................. 899 REMOVAL........................................................................ 899 INSTALLATION................................................................... 900 CLUTCH HOUSING REPLACEMENT—AX15.................................................... 900 REMOVAL........................................................................ 900 RELEASE BEARING.................................................................... 901 REMOVAL........................................................................ 901 INSTALLATION................................................................... 902 PILOT BEARING...................................................................... 902 REMOVAL........................................................................ 902 REMOVAL........................................................................ 902 INSTALLATION................................................................... 902 CLUTCH HYDRAULIC LINKAGE........................................................... 902 INSTALLATION................................................................... 902 SPECIFICATIONS......................................................................... 903 TORQUE............................................................................. 903 COOLING SYSTEM............................................................................. 905 GENERAL INFORMATION.................................................................... 905 COOLING SYSTEM..................................................................... 905 ENGINE ACCESSORY DRIVE BELTS....................................................... 905 WATER PUMPS........................................................................ 906 COOLANT COOLING SYSTEM COMPONENTS.................................................. 906 RADIATORS.......................................................................... 906 SYSTEM COOLANT ROUTING............................................................. 906 ENGINE BLOCK HEATER................................................................ 907 DESCRIPTION AND OPERATION.............................................................. 907 AUTOMATIC TRANSMISSION OIL COOLER.................................................. 907 WATER-TO-OIL COOLER............................................................ 907 AIR-TO-OIL COOLER.............................................................. 907 ACCESSORY DRIVE BELT TENSION....................................................... 907 DOMESTIC LEFT HAND DRIVE VEHICLES.............................................. 907 COOLANT RESERVE/OVERFLOW SYSTEM.................................................... 907 DOMESTIC RIGHT HAND DRIVE VEHICLES............................................. 907 ENGINE BLOCK HEATER................................................................ 908 COOLING SYSTEM FANS................................................................ 908 ACCESSORY DRIVE BELT TENSION....................................................... 908 THERMOSTAT......................................................................... 908 COOLANT PERFORMANCE................................................................ 909 ETHYLENE-GLYCOL MIXTURES....................................................... 909 COOLANT SELECTION-ADDITIVES........................................................ 909 RADIATOR PRESSURE CAP.............................................................. 909 COOLING SYSTEM HOSES............................................................... 910 WATER PUMPS........................................................................ 910 VISCOUS FAN DRIVE.................................................................. 911 NOISE.......................................................................... 912 DIAGNOSIS AND TESTING.................................................................. 912 ON-BOARD DIAGNOSTICS (OBD)......................................................... 912 COOLING SYSTEM RELATED DIAGNOSTICS............................................. 912 AUXILIARY ELECTRIC COOLING FAN..................................................... 912 ACCESSING DIAGNOSTIC TROUBLE CODES............................................. 912 DRB SCAN TOOL...................................................................... 912 ENGINE ACCESSORY DRIVE BELTS....................................................... 913 BELT DIAGNOSIS................................................................. 913 SERPENTINE BELT DIAGNOSIS CHAR T............................................... 913 PRELIMINARY CHECKS................................................................. 914 ENGINE COOLING SYSTEM OVERHEATING.............................................. 914 COOLING SYSTEM DIAGNOSIS........................................................... 916 RADIATOR COOLANT FLOW CHECK........................................................ 923 TESTING COOLING SYSTEM FOR LEAKS................................................... 923 ULTRAVIOLET LIGHT METHOD....................................................... 923 PRESSURE TESTER METHOD......................................................... 923 INTERNAL LEAKAGE INSPECTION.................................................... 924 VISCOUS FAN DRIVE.................................................................. 924 LEAKS.......................................................................... 924 TESTING........................................................................ 924 COMBUSTION LEAKAGE TEST (WITHOUT PRESSURE TESTER).............................. 924 AUXILIARY ELECTRIC COOLING FAN..................................................... 925 ELECTRIC COOLING FAN AND RELAY DIAGNOSIS....................................... 925 RADIATOR CAP-TO-FILLER NECK SEAL— PRESSURE RELIEF CHECK............................ 925 PRESSURE TESTING RADIATOR CAPS..................................................... 926 DEAERATION......................................................................... 926 SERVICE PROCEDURES..................................................................... 926 COOLANT LEVEL CHECK—ROUTINE........................................................ 926 COOLANT SERVICE.................................................................... 926 ADDING ADDITIONAL COOLANT—ROUTINE.................................................. 926 COOLANT LEVEL CHECK—SERVICE LOW COOLANT LEVEL-AERATION............................. 926 DRAINING AND FILLING COOLING SYSTEM................................................ 927 DRAINING 2.5L 4-CYLINDER ENGINE................................................ 927 REFILLING COOLING SYSTEM....................................................... 927 DRAINING 4.0L 6-CYLINDER ENGINE................................................ 927 REVERSE FLUSHING................................................................... 927 CHEMICAL CLEANING.............................................................. 928 REMOVAL AND INSTALLATION............................................................... 928 TRANSMISSION OIL COOLERS........................................................... 928 WATER-TO-OIL COOLER............................................................ 928 REVERSE FLUSHING RADIATOR...................................................... 928 AIR-TO-OIL COOLER.............................................................. 928 REVERSE FLUSHING ENGINE........................................................ 928 COOLANT RESERVE TANK............................................................... 929 REMOVAL........................................................................ 929 INSTALLATION................................................................... 929 WATER PUMP......................................................................... 929 REMOVAL-2.5L ENGINE (LHD/RHD).................................................. 930 INSTALLATION-2.5L ENGINE (LHD/RHD)............................................. 930 REMOVAL-4.0L ENGINE (LHD/RHD).................................................. 931 INSTALLATION-4.0L ENGINE (LHD/RHD)............................................. 932 THERMOSTAT......................................................................... 933 REMOVAL........................................................................ 933 INSTALLATION................................................................... 933 RADIATOR........................................................................... 934 L 4-CYLINDER ENGINE............................................................ 934 L 6-CYLINDER ENGINE............................................................ 935 AUXILIARY ELECTRIC COOLING FAN..................................................... 938 REMOVAL........................................................................ 938 INSTALLATION................................................................... 938 INSTALLATION................................................................... 938 ENGINE ACCESSORY DRIVE BELTS....................................................... 938 ENGINE BLOCK HEATER................................................................ 938 REMOVAL........................................................................ 938 BELT SCHEMATICS................................................................ 938 INSTALLATION................................................................... 939 BELT REPLACEMENT OR ADJUSTMENT— LEFT HAND DRIVE................................ 939 INSTALLATION................................................................... 940 BELT REPLACEMENT OR ADJUSTMENT— RIGHT HAND DRIVE (4.0L)........................ 940 COOLING SYSTEM FANS................................................................ 941 REMOVAL........................................................................ 941 INSTALLATION................................................................... 941 VISCOUS FAN DRIVE REMOVAL/INSTALLATION............................................. 942 Viscous Fan Drive Fluid Pump Out Requirement:.................................. 942 CLEANING AND INSPECTION................................................................ 942 COOLING SYSTEM HOSES RADIATOR PRESSURE CAP......................................... 942 INSPECTION INSPECTION.......................................................... 942 RADIATOR CLEANING.................................................................. 942 SPECIFICATIONS......................................................................... 942 COOLING SYSTEM CAPACITIES.......................................................... 942 BELT TENSION....................................................................... 942 COOLING SYSTEM CLEANING............................................................ 942 FAN BLADE INSPECTION............................................................... 942 TORQUE SPECIFICATIONS.............................................................. 943 SPECIAL TOOLS.......................................................................... 943 COOLING............................................................................ 943 BATTERY.................................................................................... 945 GENERAL INFORMATION.................................................................... 945 OVERVIEW........................................................................... 945 INTRODUCTION....................................................................... 945 DESCRIPTION AND OPERATION.............................................................. 946 BATTERY............................................................................ 946 BATTERY SIZE AND RATINGS........................................................... 946 GROUP SIZE..................................................................... 946 COLD CRANKING AMPERAGE......................................................... 946 RESERVE CAPACITY............................................................... 947 AMPERE-HOURS................................................................... 947 BATTERY MOUNTING................................................................... 947 DIAGNOSIS AND TESTING.................................................................. 947 BATTERY............................................................................ 947 ABNORMAL BATTERY DISCHARGING................................................... 948 BUILT-IN TEST INDICATOR............................................................ 948 HYDROMETER TEST.................................................................... 950 OPEN-CIRCUIT VOLTAGE TEST.......................................................... 951 LOAD TEST.......................................................................... 952 IGNITION-OFF DRAW TEST............................................................. 953 DIAGNOSIS...................................................................... 953 VOLTAGE DROP TEST.................................................................. 954 SERVICE PROCEDURES..................................................................... 955 BATTERY CHARGING................................................................... 955 CHARGING A COMPLETELY DISCHARGED BATTERY....................................... 956 CHARGING TIME REQUIRED......................................................... 957 REMOVAL AND INSTALLATION............................................................... 957 BATTERY............................................................................ 957 SPECIFICATIONS......................................................................... 959 BATTERY............................................................................ 959 STARTING SYSTEMS........................................................................... 961 GENERAL INFORMATION.................................................................... 961 OVERVIEW........................................................................... 961 INTRODUCTION....................................................................... 961 DESCRIPTION AND OPERATION.............................................................. 962 STARTING SYSTEM.................................................................... 962 STARTER............................................................................ 962 STARTER RELAY...................................................................... 962 COLD CRANKING TEST................................................................. 963 DIAGNOSIS AND TESTING.................................................................. 963 STARTING SYSTEM.................................................................... 963 INSPECTION..................................................................... 963 FEED CIRCUIT TEST.................................................................. 963 CONTROL CIRCUIT TEST............................................................... 966 RELAY TEST..................................................................... 966 SOLENOID TEST.................................................................. 966 RELAY CIRCUIT TEST............................................................. 966 PARK/NEUTRAL POSITION SWITCH TEST.............................................. 967 IGNITION SWITCH TEST........................................................... 967 STARTER NOISE - 2.5L ENGINE........................................................ 967 REMOVAL AND INSTALLATION............................................................... 968 STARTER............................................................................ 968 L ENGINE....................................................................... 968 STARTER RELAY...................................................................... 969 L ENGINE....................................................................... 969 SPECIFICATIONS......................................................................... 970 STARTING SYSTEM.................................................................... 970 CHARGING SYSTEM............................................................................ 971 GENERAL INFORMATION.................................................................... 971 OVERVIEW........................................................................... 971 DESCRIPTION AND OPERATION.............................................................. 971 CHARGING SYSTEM OPERATION.......................................................... 971 GENERATOR.......................................................................... 972 DIAGNOSIS AND TESTING.................................................................. 972 CHARGING SYSTEM.................................................................... 972 INSPECTION..................................................................... 972 BATTERY TEMPERATURE SENSOR......................................................... 972 ELECTRONIC VOLTAGE REGULATOR....................................................... 972 TEST........................................................................... 973 CHARGING SYSTEM RESISTANCE TESTS................................................... 973 CURRENT OUTPUT TEST................................................................ 973 PREPARATION.................................................................... 973 PREPARATION.................................................................... 974 TEST 2......................................................................... 974 TEST 1......................................................................... 974 RESULTS........................................................................ 975 ON-BOARD DIAGNOSTIC TEST FOR CHARGING SYSTEM....................................... 975 BATTERY TEMPERATURE SENSOR......................................................... 975 REMOVAL AND INSTALLATION............................................................... 975 GENERATOR.......................................................................... 975 REMOVAL........................................................................ 975 INSTALLATION................................................................... 976 REMOVAL........................................................................ 977 BATTERY TEMPERATURE SENSOR......................................................... 977 INSTALLATION................................................................... 977 SPECIFICATIONS......................................................................... 977 GENERATOR RATINGS.................................................................. 977 TORQUE CHART....................................................................... 977 IGNITION SYSTEM............................................................................ 979 GENERAL INFORMATION DESCRIPTION AND OPERATION.......................................... 979 INTRODUCTION IGNITION SYSTEM....................................................... 979 POWERTRAIN CONTROL MODULE.......................................................... 980 SPARK PLUGS........................................................................ 980 DISTRIBUTOR........................................................................ 980 SPARK PLUG CABLES.................................................................. 980 IGNITION COIL...................................................................... 981 SENSOR OPERATION............................................................... 981 AUTOMATIC SHUTDOWN (ASD) RELAY..................................................... 981 CRANKSHAFT POSITION SENSOR......................................................... 981 CAMSHAFT POSITION SENSOR........................................................... 981 INTAKE MANIFOLD AIR TEMPERATURE SENSOR............................................. 982 IGNITION SWITCH AND KEY LOCK CYLINDER.............................................. 982 DIAGNOSIS AND TESTING.................................................................. 982 AUTOMATIC SHUTDOWN (ASD) RELAY TEST................................................ 982 TESTING FOR SPARK AT COIL.......................................................... 982 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR............................................ 982 ENGINE COOLANT TEMPERATURE SENSOR.................................................. 982 THROTTLE POSITION SENSOR........................................................... 982 IGNITION COIL TEST................................................................. 983 FAILURE TO START TEST.............................................................. 984 DISTRIBUTOR CAP.................................................................... 985 IGNITION TIMING.................................................................... 985 MAP SENSOR......................................................................... 985 CRANKSHAFT POSITION SENSOR DISTRIBUTOR ROTOR....................................... 985 CAMSHAFT POSITION SENSOR........................................................... 986 ENGINE COOLANT TEMPERATURE SENSOR.................................................. 986 INTAKE MANIFOLD AIR TEMPERATURE SENSOR............................................. 986 SPARK PLUG CABLES.................................................................. 986 TESTING........................................................................ 986 SPARK PLUG CONDITIONS.............................................................. 987 NORMAL OPERATING............................................................... 987 COLD FOULING/CARBON FOULING.................................................... 987 WET FOULING OR GAS FOULING..................................................... 987 OIL OR ASH ENCRUSTED........................................................... 988 ELECTRODE GAP BRIDGING......................................................... 988 CHIPPED ELECTRODE INSULATOR.................................................... 988 SCAVENGER DEPOSITS PREIGNITION DAMAGE.......................................... 988 SPARK PLUG OVERHEATING......................................................... 989 REMOVAL AND INSTALLATION............................................................... 989 SPARK PLUG CABLES.................................................................. 989 PLUG GAP ADJUSTMENT............................................................ 990 SPARK PLUGS........................................................................ 990 SPARK PLUG GAP................................................................. 990 PLUG REMOVAL................................................................... 990 PLUG INSTALLATION.............................................................. 990 PLUG CLEANING.................................................................. 990 IGNITION COIL...................................................................... 990 REMOVAL........................................................................ 991 AUTOMATIC SHUTDOWN (ASD) RELAY..................................................... 991 REMOVAL........................................................................ 991 INSTALLATION................................................................... 991 CRANKSHAFT POSITION SENSOR......................................................... 991 INSTALLATION................................................................... 991 INSTALLATION................................................................... 992 CAMSHAFT POSITION SENSOR........................................................... 992 REMOVAL........................................................................ 992 REMOVAL........................................................................ 992 INSTALLATION................................................................... 993 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR............................................ 993 ENGINE COOLANT TEMPERATURE SENSOR.................................................. 993 THROTTLE POSITION SENSOR........................................................... 993 INTAKE MANIFOLD AIR TEMPERATURE SENSOR............................................. 993 DISTRIBUTOR........................................................................ 993 REMOVAL—2.5L OR 4.0L ENGINE.................................................... 994 INSTALLATION................................................................... 995 POWERTRAIN CONTROL MODULE (PCM).................................................... 996 IGNITION SWITCH AND KEY CYLINDER................................................... 996 KEY CYLINDER REMOVAL........................................................... 996 IGNITION SWITCH REMOVAL........................................................ 997 KEY CYLINDER INSTALLATION...................................................... 997 IGNITION SWITCH INSTALLATION................................................... 997 IGNITION TIMING.................................................................... 998 ENGINE FIRING ORDER—2.5L 4-CYLINDER ENGINE......................................... 998 ENGINE FIRING ORDER—4.0L 6-CYLINDER ENGINE......................................... 998 SHIFTER/IGNITION INTERLOCK......................................................... 998 SPECIFICATIONS......................................................................... 998 VECI LABEL......................................................................... 998 SPARK PLUGS SPARK PLUG CABLE RESISTANCE............................................ 999 IGNITION COIL RESISTANCE........................................................... 999 TORQUE CHART....................................................................... 999 INSTRUMENT PANEL SYSTEMS...................................................................1001 GENERAL INFORMATION....................................................................1001 INTRODUCTION.......................................................................1001 INSTRUMENT CLUSTER.................................................................1002 INSTRUMENT PANEL...................................................................1002 INDICATOR LAMP.....................................................................1003 JUNCTION BLOCK.....................................................................1003 GAUGE..............................................................................1003 DESCRIPTION AND OPERATION..............................................................1004 COOLANT TEMPERATURE GAUGE..........................................................1004 ODOMETER AND TRIP ODOMETER.........................................................1004 FUEL GAUGE.........................................................................1004 TACHOMETER.........................................................................1005 OIL PRESSURE GAUGE.................................................................1005 VOLTMETER..........................................................................1005 SPEEDOMETER........................................................................1005 AIRBAG INDICATOR LAMP..............................................................1006 CHECK GAUGES LAMP..................................................................1006 ANTI-LOCK BRAKE SYSTEM LAMP........................................................1006 CIGAR LIGHTER AND POWER OUTLET.....................................................1006 CIGAR LIGHTER RELAY................................................................1006 BRAKE WARNING LAMP.................................................................1006 CLUSTER ILLUMINATION LAMP..........................................................1007 FOUR-WHEEL DRIVE INDICATOR LAMP....................................................1007 PART TIME......................................................................1007 COOLANT TEMPERATURE WARNING LAMP...................................................1007 FULL TIME......................................................................1007 CRUISE-ON INDICATOR LAMP...........................................................1007 HEADLAMP HIGH BEAM INDICATOR LAMP..................................................1007 LOW FUEL WARNING LAMP..............................................................1008 LOW WASHER FLUID WARNING LAMP......................................................1008 MALFUNCTION INDICATOR LAMP.........................................................1008 LOW OIL PRESSURE WARNING LAMP......................................................1008 SEAT BELT REMINDER LAMP VOLTAGE WARNING LAMP.......................................1009 TURN SIGNAL INDICATOR LAMP.........................................................1009 DIAGNOSIS AND TESTING..................................................................1009 INSTRUMENT CLUSTER.................................................................1009 UPSHIFT INDICATOR LAMP.............................................................1009 PRELIMINARY DIAGNOSIS..........................................................1010 ACTUATOR TEST..................................................................1010 COOLANT TEMPERATURE GAUGE..........................................................1010 FUEL GAUGE OIL PRESSURE GAUGE......................................................1013 ODOMETER AND TRIP ODOMETER.........................................................1013 SPEEDOMETER........................................................................1014 AIRBAG INDICATOR LAMP..............................................................1014 TACHOMETER.........................................................................1014 VOLTMETER..........................................................................1014 ANTI-LOCK BRAKE SYSTEM LAMP........................................................1014 BRAKE WARNING LAMP.................................................................1015 ACCESSORY POWER OUTLET.........................................................1016 CHECK GAUGES LAMP..................................................................1016 CIGAR LIGHTER..................................................................1016 CIGAR LIGHTER RELAY................................................................1016 CIGAR LIGHTER AND POWER OUTLET.....................................................1016 RELAY TEST.....................................................................1017 CLUSTER ILLUMINATION LAMP..........................................................1017 RELAY CIRCUIT TEST.............................................................1017 CRUISE-ON INDICATOR LAMP...........................................................1018 COOLANT TEMPERATURE WARNING LAMP...................................................1018 FOUR-WHEEL DRIVE INDICATOR LAMP....................................................1018 FULL TIME......................................................................1019 PART TIME......................................................................1019 HEADLAMP HIGH BEAM INDICATOR LAMP..................................................1019 LOW OIL PRESSURE WARNING LAMP......................................................1020 LOW FUEL WARNING LAMP..............................................................1020 LOW WASHER FLUID WARNING LAMP......................................................1020 SEAT BELT REMINDER LAMP............................................................1021 MALFUNCTION INDICATOR LAMP.........................................................1021 TURN SIGNAL INDICATOR LAMP.........................................................1021 VOLTAGE WARNING LAMP...............................................................1022 UPSHIFT INDICATOR LAMP.............................................................1022 REMOVAL AND INSTALLATION...............................................................1022 STEERING COLUMN OPENING COVER......................................................1022 KNEE BLOCKER.......................................................................1023 INSTRUMENT PANEL CENTER BEZEL......................................................1023 CIGAR LIGHTER RELAY................................................................1024 ACCESSORY SWITCH BEZEL.............................................................1024 CLUSTER BEZEL......................................................................1025 HEADLAMP SWITCH....................................................................1025 INSTRUMENT CLUSTER.................................................................1026 CLUSTER HOOD AND MASK..........................................................1027 CLUSTER COMPONENTS.................................................................1027 CLUSTER LENS AND ODOMETER RESET KNOB BOOT......................................1027 CLUSTER REAR COVER.............................................................1028 INSTRUMENT PANEL TOP COVER.........................................................1028 CLUSTER BULB.......................................................................1028 GLOVE BOX..........................................................................1029 ROLL DOWN......................................................................1029 GLOVE BOX LAMP AND SWITCH..........................................................1029 REMOVAL........................................................................1029 GLOVE BOX COMPONENTS...............................................................1030 HINGE, BIN, INNER DOOR AND LATCH...............................................1030 LOCK CYLINDER..................................................................1030 OUTER DOOR.....................................................................1030 INSTRUMENT PANEL END CAP...........................................................1031 DRIVER SIDE....................................................................1031 GLOVE BOX LATCH STRIKER............................................................1031 PASSENGER SIDE.................................................................1031 JUNCTION BLOCK.....................................................................1032 CENTER SUPPORT BRACKET.............................................................1032 INSTRUMENT PANEL ASSEMBLY..........................................................1033 AUDIO SYSTEMS..............................................................................1035 GENERAL INFORMATION....................................................................1035 IGNITION-OFF DRAW FUSE.............................................................1035 INTRODUCTION.......................................................................1035 DESCRIPTION AND OPERATION..............................................................1035 SPEAKER RADIO......................................................................1035 ANTENNA............................................................................1036 RADIO NOISE SUPPRESSION............................................................1036 DIAGNOSIS AND TESTING..................................................................1036 AUDIO SYSTEM.......................................................................1036 AUDIO SYSTEM DIAGNOSIS.........................................................1037 RADIO..............................................................................1038 SPEAKER............................................................................1039 ANTENNA............................................................................1040 TEST 2.........................................................................1040 TEST 3.........................................................................1040 TEST 1.........................................................................1040 TEST 4.........................................................................1041 RADIO FREQUENCY INTERFERENCE.......................................................1041 REMOVAL AND INSTALLATION...............................................................1041 RADIO..............................................................................1041 SPEAKER............................................................................1042 FRONT DOOR.....................................................................1042 AMPLIFIER..........................................................................1042 SOUND BAR......................................................................1043 ANTENNA............................................................................1044 SOUND BAR..........................................................................1044 HORN SYSTEMS...............................................................................1047 GENERAL INFORMATION....................................................................1047 INTRODUCTION.......................................................................1047 HORN SWITCH........................................................................1047 HORN...............................................................................1047 DESCRIPTION AND OPERATION..............................................................1047 HORN RELAY.........................................................................1047 RELAY CIRCUIT TEST.............................................................1048 DIAGNOSIS AND TESTING..................................................................1048 HORN RELAY.........................................................................1048 RELAY TEST.....................................................................1048 HORN SWITCH........................................................................1048 HORN...............................................................................1049 REMOVAL AND INSTALLATION...............................................................1049 HORN RELAY.........................................................................1049 HORN SWITCH........................................................................1050 HORN...............................................................................1050 VEHICLE SPEED CONTROL SYSTEM...............................................................1051 GENERAL INFORMATION....................................................................1051 INTRODUCTION.......................................................................1051 DESCRIPTION AND OPERATION..............................................................1051 SPEED CONTROL SERVO................................................................1051 STOP LAMP SWITCH...................................................................1051 SPEED CONTROL SWITCHES.............................................................1051 SERVO CABLE........................................................................1052 POWERTRAIN CONTROL MODULE..........................................................1052 VACUUM RESERVOIR...................................................................1052 ON-BOARD DIAGNOSTIC TEST FOR SPEED CONTROL SYSTEM VEHICLE SPEED SENSOR.............1052 SPEED CONTROL ELECTRICAL TEST......................................................1052 DIAGNOSIS AND TESTING..................................................................1052 ROAD TEST..........................................................................1052 VEHICLE SPEED SENSOR...............................................................1053 SPEED CONTROL SWITCHES.............................................................1053 SPEED CONTROL SERVO................................................................1053 STOP LAMP SWITCH...................................................................1053 VACUUM SUPPLY TEST.................................................................1053 REMOVAL AND INSTALLATION...............................................................1054 SPEED CONTROL SERVO................................................................1054 REMOVAL........................................................................1054 POWERTRAIN CONTROL MODULE (PCM)....................................................1054 OVERSHOOT/UNDERSHOOT FOLLOWING SPEED CONTROL SET...................................1054 INSTALLATION...................................................................1054 STOP LAMP SWITCH...................................................................1055 SPEED CONTROL SWITCH SERVO CABLE...................................................1055 REMOVAL........................................................................1055 REMOVAL........................................................................1055 INSTALLATION...................................................................1055 INSTALLATION...................................................................1055 POWERTRAIN CONTROL MODULE..........................................................1056 VACUUM RESERVOIR...................................................................1056 REMOVAL........................................................................1056 SPECIFICATIONS.........................................................................1056 TORQUE CHART.......................................................................1056 INSTALLATION...................................................................1056 VEHICLE SPEED SENSOR...............................................................1056 TURN SIGNAL AND HAZARD WARNING SYSTEMS.....................................................1057 GENERAL INFORMATION....................................................................1057 INTRODUCTION.......................................................................1057 HAZARD WARNING SYSTEM..............................................................1057 DESCRIPTION AND OPERATION..............................................................1057 TURN SIGNAL SYSTEM.................................................................1057 COMBINATION FLASHER................................................................1057 TURN SIGNAL LAMP...................................................................1058 DIAGNOSIS AND TESTING..................................................................1058 INTRODUCTION TURN SIGNAL SWITCH AND HAZARD WARNING SWITCH..........................1058 TURN SIGNAL AND HAZARD WARNING SYSTEMS.............................................1058 TURN SIGNAL INDICATOR LAMP.........................................................1058 MULTI-FUNCTION SWITCH..............................................................1059 REMOVAL AND INSTALLATION...............................................................1059 COMBINATION FLASHER................................................................1059 MULTI-FUNCTION SWITCH..............................................................1060 WIPER AND WASHER SYSTEMS...................................................................1063 GENERAL INFORMATION....................................................................1063 INTRODUCTION.......................................................................1063 WINDSHIELD WASHER SYSTEM...........................................................1063 DESCRIPTION AND OPERATION..............................................................1063 WINDSHIELD WIPER SYSTEM............................................................1063 REAR WIPER AND WASHER SYSTEM.......................................................1064 WIPER ARM AND BLADE................................................................1064 WIPER MOTOR........................................................................1064 FRONT..........................................................................1064 REAR...........................................................................1064 WIPER LINKAGE AND PIVOT............................................................1064 REAR...........................................................................1065 WIPER SWITCH AND WASHER SWITCH.....................................................1065 FRONT..........................................................................1065 WASHER RESERVOIR...................................................................1065 WASHER PUMP........................................................................1065 DIAGNOSIS AND TESTING..................................................................1066 WIPER SYSTEM.......................................................................1066 WASHER FLUID LEVEL SENSOR..........................................................1066 FRONT..........................................................................1066 WASHER NOZZLE AND PLUMBING.........................................................1066 FRONT..........................................................................1066 REAR...........................................................................1066 REAR...........................................................................1067 WASHER SYSTEM......................................................................1067 FRONT..........................................................................1067 WIPER SWITCH AND WASHER SWITCH.....................................................1068 REAR FRONT.....................................................................1068 REMOVAL AND INSTALLATION...............................................................1069 WIPER BLADE AND ELEMENT............................................................1069 FRONT..........................................................................1069 REAR...........................................................................1069 WIPER ARM..........................................................................1070 FRONT..........................................................................1070 REAR...........................................................................1070 WIPER LINKAGE AND PIVOT............................................................1071 REAR...........................................................................1071 WIPER MOTOR........................................................................1071 FRONT..........................................................................1071 REAR...........................................................................1072 WIPER SWITCH AND WASHER SWITCH.....................................................1073 FRONT..........................................................................1073 REAR...........................................................................1074 WASHER SYSTEM......................................................................1075 WASHER RESERVOIR...............................................................1075 WASHER FLUID LEVEL SENSOR......................................................1075 WASHER PUMP....................................................................1075 WASHER NOZZLE..................................................................1076 CHECK VALVE....................................................................1076 LAMPS......................................................................................1077 GENERAL INFORMATION....................................................................1077 GENERAL INFORMATION................................................................1077 SENTINEL HEADLAMP DELAY MODULE.....................................................1077 SAFETY PRECAUTIONS DAYTIME RUNNING LAMP MODULE.....................................1077 DIAGNOSIS AND TESTING..................................................................1078 HEADLAMP DIAGNOSIS.................................................................1078 DIAGNOSTIC PROCEDURES..............................................................1078 HEADLAMP DIAGNOSIS.............................................................1078 FOG LAMP DIAGNOSIS.................................................................1079 HEADLAMP DELAY MODULE..............................................................1079 DELAY FUNCTION INOPERATIVE.....................................................1079 GENERAL INFORMATION SERVICE PROCEDURES.................................................1080 HEADLAMP ALIGNMENT HEADLAMP ALIGNMENT PREPARATION..................................1080 ALIGNMENT SCREEN PREPARATION...................................................1081 HEADLAMP ADJUSTMENT................................................................1081 FOG LAMP ADJUSTMENT................................................................1082 SPECIAL TOOLS..........................................................................1082 HEADLAMP ALIGNMENT.................................................................1082 REMOVAL AND INSTALLATION...............................................................1083 FOG LAMP BULB......................................................................1083 REMOVAL........................................................................1083 HEADLAMP BULB......................................................................1083 REMOVAL........................................................................1083 INSTALLATION...................................................................1083 INSTALLATION...................................................................1083 FRONT PARK/TURN SIGNAL LAMP BULB...................................................1083 REMOVAL........................................................................1083 BACK-UP/REAR TURN SIGNAL/TAIL LAMP BULB............................................1084 REMOVAL........................................................................1084 INSTALLATION...................................................................1084 INSTALLATION...................................................................1084 SIDE MARKER LAMP BULB..............................................................1084 REMOVAL........................................................................1084 LICENSE PLATE LAMP BULB............................................................1084 REMOVAL........................................................................1084 INSTALLATION...................................................................1084 CENTER HIGH MOUNTED STOP LAMP (CHMSL) BULB.........................................1084 REMOVAL........................................................................1084 INSTALLATION...................................................................1084 MAP READING LAMP BULB..............................................................1085 REMOVAL........................................................................1085 INSTALLATION...................................................................1085 UNDERHOOD LAMP BULB................................................................1085 REMOVAL........................................................................1085 INSTALLATION INSTALLATION......................................................1085 VISOR VANITY LAMP BULB DOME LAMP BULB..............................................1085 REMOVAL REMOVAL................................................................1085 INSTALLATION...................................................................1085 INSTALLATION...................................................................1085 REMOVAL AND INSTALLATION...............................................................1086 HEADLAMP...........................................................................1086 REMOVAL........................................................................1086 FOG LAMP...........................................................................1086 REMOVAL........................................................................1086 INSTALLATION...................................................................1086 INSTALLATION...................................................................1086 FRONT PARK/TURN SIGNAL LAMP........................................................1086 REMOVAL........................................................................1086 BACK-UP/REAR TURN SIGNAL/TAIL LAMP.................................................1087 REMOVAL........................................................................1087 INSTALLATION...................................................................1087 SIDE MARKER LAMP...................................................................1087 REMOVAL INSTALLATION...........................................................1087 CENTER HIGH MOUNTED STOP LAMP (CHMSL)..............................................1087 REMOVAL........................................................................1087 INSTALLATION...................................................................1087 INSTALLATION...................................................................1087 DOME LAMP LICENSE PLATE LAMP.......................................................1088 REMOVAL REMOVAL................................................................1088 INSTALLATION...................................................................1088 UNDERHOOD LAMP.....................................................................1088 REMOVAL........................................................................1088 INSTALLATION...................................................................1088 INSTALLATION...................................................................1088 MAP/READING LAMP...................................................................1089 INSTALLATION...................................................................1089 VISOR VANITY LAMP..................................................................1089 REMOVAL........................................................................1089 REMOVAL AND INSTALLATION...............................................................1090 DAYTIME RUNNING LAMP MODULE........................................................1090 REMOVAL........................................................................1090 SENTINEL HEADLAMP DELAY MODULE.....................................................1090 REMOVAL........................................................................1090 INSTALLATION...................................................................1090 INSTALLATION...................................................................1090 GENERAL INFORMATION....................................................................1091 GENERAL INFORMATION................................................................1091 INDICATOR LAMPS................................................................1091 SPECIFICATIONS.........................................................................1091 EXTERIOR LAMPS.....................................................................1091 INTERIOR LAMPS.....................................................................1091 PASSIVE RESTRAINT SYSTEMS..................................................................1093 GENERAL INFORMATION....................................................................1093 INTRODUCTION.......................................................................1093 DESCRIPTION AND OPERATION..............................................................1094 AIRBAG MODULE......................................................................1094 DRIVER SIDE....................................................................1094 PASSENGER SIDE.................................................................1094 STORAGE........................................................................1094 IMPACT SENSOR......................................................................1095 DIAGNOSIS AND TESTING..................................................................1095 AIRBAG SYSTEM......................................................................1095 CLOCKSPRING........................................................................1095 AIRBAG CONTROL MODULE..............................................................1095 CLEANUP PROCEDURE..................................................................1096 SERVICE PROCEDURES.....................................................................1096 AIRBAG SYSTEM......................................................................1096 NON-DEPLOYED...................................................................1096 DEPLOYED.......................................................................1096 REMOVAL AND INSTALLATION...............................................................1097 AIRBAG MODULE......................................................................1097 PASSENGER SIDE.................................................................1097 DRIVER SIDE....................................................................1097 DRIVER SIDE AIRBAG TRIM COVER AND HORN SWITCH......................................1098 PASSENGER SIDE AIRBAG DOOR.........................................................1099 AIRBAG CONTROL MODULE..............................................................1100 CLOCKSPRING........................................................................1101 ADJUSTMENTS............................................................................1102 CLOCKSPRING CENTERING..............................................................1102 ELECTRICALLY HEATED SYSTEMS................................................................1103 GENERAL INFORMATION....................................................................1103 INTRODUCTION.......................................................................1103 DESCRIPTION AND OPERATION..............................................................1103 REAR GLASS HEATING GRID............................................................1103 OUTSIDE MIRROR HEATING GRID........................................................1104 DEFOGGER RELAY.....................................................................1104 DEFOGGER SWITCH....................................................................1104 DIAGNOSIS AND TESTING..................................................................1104 DEFOGGER SYSTEM....................................................................1104 INSTRUMENT CLUSTER.................................................................1104 DEFOGGER SWITCH....................................................................1105 REAR GLASS HEATING GRID............................................................1105 RELAY CIRCUIT TEST.............................................................1106 DEFOGGER RELAY.....................................................................1106 RELAY TEST.....................................................................1106 SERVICE PROCEDURES.....................................................................1107 REAR GLASS HEATING GRID REPAIR.....................................................1107 INSTRUMENT CLUSTER.................................................................1107 REMOVAL AND INSTALLATION...............................................................1108 DEFOGGER SWITCH....................................................................1108 DEFOGGER RELAY.....................................................................1109 POWER LOCK SYSTEMS.........................................................................1111 GENERAL INFORMATION....................................................................1111 INTRODUCTION POWER LOCK SYSTEM.....................................................1111 REMOTE KEYLESS ENTRY SYSTEM........................................................1111 POWER LOCK MOTOR...................................................................1112 REMOTE KEYLESS ENTRY TRANSMITTER...................................................1112 DESCRIPTION AND OPERATION..............................................................1112 POWER LOCK SWITCH..................................................................1112 DOOR MODULE REMOTE KEYLESS ENTRY RECEIVER..........................................1112 DIAGNOSIS AND TESTING..................................................................1113 POWER LOCK SYSTEM AND REMOTE KEYLESS ENTRY SYSTEM..................................1113 DOOR MODULE........................................................................1113 DRIVER DOOR MODULE.............................................................1113 PASSENGER DOOR MODULE..........................................................1113 POWER LOCK MOTOR...................................................................1115 REMOTE KEYLESS ENTRY RECEIVER......................................................1115 REMOTE KEYLESS ENTRY TRANSMITTER...................................................1115 REMOTE KEYLESS ENTRY RECEIVER PROGRAMMING..........................................1116 REMOVAL AND INSTALLATION...............................................................1116 DOOR MODULE........................................................................1116 SERVICE PROCEDURES.....................................................................1116 REMOTE KEYLESS ENTRY TRANSMITTER BATTERY REPLACEMENT...............................1116 REMOTE KEYLESS ENTRY TRANSMITTER PROGRAMMING.......................................1116 LIFTGATE.......................................................................1117 POWER LOCK MOTOR...................................................................1117 FRONT DOOR.....................................................................1117 REAR DOOR......................................................................1117 OVERHEAD CONSOLE MOUNTED TYPE..................................................1118 REMOTE KEYLESS ENTRY RECEIVER......................................................1118 MINI-DOME MOUNTED TYPE.........................................................1118 POWER SEAT SYSTEMS.........................................................................1121 GENERAL INFORMATION....................................................................1121 INTRODUCTION POWER SEAT ADJUSTER AND MOTORS........................................1121 DESCRIPTION AND OPERATION..............................................................1121 POWER SEAT SWITCH..................................................................1121 CIRCUIT BREAKER....................................................................1122 DIAGNOSIS AND TESTING..................................................................1122 POWER SEAT SYSTEM..................................................................1122 POWER SEAT SWITCH..................................................................1122 CIRCUIT BREAKER....................................................................1122 REMOVAL AND INSTALLATION...............................................................1122 POWER SEAT SWITCH..................................................................1122 POWER SEAT ADJUSTER AND MOTORS.....................................................1122 POWER SEAT ADJUSTER AND MOTORS.....................................................1123 POWER WINDOW SYSTEMS.......................................................................1125 GENERAL INFORMATION....................................................................1125 INTRODUCTION.......................................................................1125 DESCRIPTION AND OPERATION..............................................................1125 POWER WINDOW SWITCH................................................................1125 DOOR MODULE........................................................................1126 ONE WINDOW INOPERATIVE.........................................................1126 POWER WINDOW MOTOR.................................................................1126 CIRCUIT BREAKER....................................................................1126 DIAGNOSIS AND TESTING..................................................................1126 POWER WINDOW SYSTEM................................................................1126 ALL WINDOWS INOPERATIVE........................................................1126 CIRCUIT BREAKER....................................................................1127 DOOR MODULE........................................................................1127 POWER WINDOW SWITCH................................................................1127 POWER WINDOW MOTOR.................................................................1128 REMOVAL AND INSTALLATION...............................................................1128 DOOR MODULE........................................................................1128 POWER WINDOW SWITCH................................................................1129 POWER WINDOW MOTOR.................................................................1129 FRONT DOOR.....................................................................1129 REAR DOOR......................................................................1129 POWER MIRROR SYSTEMS.......................................................................1131 GENERAL INFORMATION....................................................................1131 INTRODUCTION.......................................................................1131 POWER MIRROR SWITCH................................................................1131 DESCRIPTION AND OPERATION..............................................................1131 POWER MIRROR.......................................................................1131 DOOR MODULE........................................................................1131 DIAGNOSIS AND TESTING..................................................................1132 POWER MIRROR SYSTEM................................................................1132 REMOVAL AND INSTALLATION...............................................................1132 POWER MIRROR SWITCH................................................................1132 DOOR MODULE........................................................................1134 POWER MIRROR.......................................................................1134 CHIME/BUZZER WARNING SYSTEMS...............................................................1137 GENERAL INFORMATION DESCRIPTION AND OPERATION..........................................1137 INTRODUCTION INSTRUMENT CLUSTER....................................................1137 DRIVER DOOR JAMB SWITCH............................................................1138 DIAGNOSIS AND TESTING..................................................................1138 DRIVER DOOR JAMB SWITCH............................................................1138 DRIVER SEAT BELT SWITCH............................................................1138 KEY-IN IGNITION SWITCH.............................................................1138 DRIVER SEAT BELT SWITCH............................................................1138 HEADLAMP SWITCH....................................................................1138 HEADLAMP SWITCH....................................................................1139 KEY-IN IGNITION SWITCH.............................................................1139 INSTRUMENT CLUSTER.................................................................1139 REMOVAL AND INSTALLATION...............................................................1140 CHIME WARNING SYSTEM SWITCHES......................................................1140 OVERHEAD CONSOLE SYSTEMS...................................................................1141 GENERAL INFORMATION DESCRIPTION AND OPERATION..........................................1141 INTRODUCTION TRIP COMPUTER.........................................................1141 COMPASS............................................................................1142 READING AND COURTESY LAMP..........................................................1142 GARAGE DOOR OPENER STORAGE BIN.....................................................1142 THERMOMETER........................................................................1142 SUNGLASSES STORAGE BIN.............................................................1143 SELF-DIAGNOSTIC TEST...........................................................1143 DIAGNOSIS AND TESTING..................................................................1143 TRIP COMPUTER, COMPASS, AND THERMOMETER DISPLAY MODULE.............................1143 THERMOMETER........................................................................1144 SERVICE PROCEDURES.....................................................................1144 COMPASS VARIATION ADJUSTMENT.......................................................1144 SENSOR TEST....................................................................1144 SENSOR CIRCUIT TEST............................................................1144 COMPASS CALIBRATION................................................................1145 COMPASS DEMAGNETIZING..............................................................1145 REMOVAL AND INSTALLATION...............................................................1146 OVERHEAD CONSOLE...................................................................1146 PUSH BUTTON MODULE.................................................................1147 TRIP COMPUTER, COMPASS, AND THERMOMETER DISPLAY MODULE.............................1147 READING AND COURTESY LAMP BULB.....................................................1147 GARAGE DOOR OPENER STORAGE BIN DOOR................................................1147 AMBIENT TEMPERATURE SENSOR.........................................................1148 SUNGLASSES STORAGE BIN.............................................................1148 WIRING DIAGRAMS............................................................................1149 DESCRIPTION AND OPERATION..............................................................1151 HOW TO USE THIS GROUP..............................................................1151 CONNECTOR/GROUND LOCATIONS.........................................................1151 SPLICE LOCATIONS...................................................................1151 NOTES, CAUTIONS, and WARNINGS......................................................1151 SECTION IDENTIFICATION.............................................................1151 WIRE CODE IDENTIFICATION...........................................................1152 CIRCUIT IDENTIFICATION.............................................................1153 TAKE OUTS..........................................................................1153 SYMBOLS............................................................................1153 CONNECTORS.........................................................................1153 ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES....................................1155 INTERMITTENT AND POOR CONNECTIONS..................................................1155 DIAGNOSIS AND TESTING..................................................................1155 TROUBLESHOOTING TOOLS..............................................................1155 TROUBLESHOOTING TESTS..............................................................1156 TESTING FOR VOLTAGE............................................................1156 TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS..................1156 TESTING FOR A VOLTAGE DROP.....................................................1156 TESTING FOR CONTINUITY.........................................................1156 TROUBLESHOOTING WIRING PROBLEMS....................................................1156 TESTING FOR A SHORT TO GROUND..................................................1156 TERMINAL/CONNECTOR REPAIR-MOLEX CONNECTORS.........................................1157 SERVICE PROCEDURES.....................................................................1157 WIRING REPAIR......................................................................1157 TERMINAL/CONNECTOR REPAIR—THOMAS AND BETTS CONNECTORS..............................1158 CONNECTOR REPLACEMENT..............................................................1158 CONNECTOR AND TERMINAL REPLACEMENT TERMINAL REPLACEMENT............................1159 DIODE REPLACEMENT..................................................................1160 SPECIAL TOOLS..........................................................................1161 WIRING/TERMINAL....................................................................1161 GENERAL INFORMATION....................................................................1165 INTRODUCTION.......................................................................1165 DESCRIPTION AND OPERATION..............................................................1258 CHARGING SYSTEM....................................................................1258 HELPFUL INFORMATION............................................................1258 CHARGING SYSTEM (DIESEL)...........................................................1258 DESCRIPTION AND OPERATION..............................................................1263 STARTING SYSTEM—AUTOMATIC TRANSMISSIONS............................................1263 STARTING SYSTEM (DIESEL)...........................................................1263 STARTING SYSTEM—MANUAL TRANSMISSION................................................1263 HELPFUL INFORMATION (DIESEL)...................................................1263 DESCRIPTION AND OPERATION..............................................................1296 IGNITION SWITCH....................................................................1296 ACCESSORY OR RUN POSITIONS.....................................................1296 BATTERY FEED.......................................................................1296 START POSITION.................................................................1296 HELPFUL INFORMATION............................................................1296 START OR RUN POSITION..........................................................1296 BATTERY FEED (DIESEL)..............................................................1296 HELPFUL INFORMATION............................................................1297 DIESEL POWER RELAY GROUND..........................................................1297 HELPFUL INFORMATION............................................................1297 HELPFUL INFORMATION............................................................1297 POWER GROUND (DIESEL) FUEL PUMP RELAY..............................................1297 DATA LINK CONNECTOR................................................................1297 HELPFUL INFORMATION............................................................1297 FUEL PUMP MODULE...................................................................1297 AUTOMATIC SHUT DOWN (ASD) RELAY....................................................1297 FUEL PUMP MOTOR................................................................1297 FUEL LEVEL SENSOR..............................................................1297 FUEL PUMP MODULE (DIESEL)..........................................................1298 HELPFUL INFORMATION............................................................1298 VEHICLE SPEED SENSOR...............................................................1298 HELPFUL INFORMATION............................................................1298 BATTERY TEMPERATURE SENSOR.........................................................1298 CRANKSHAFT POSITION SENSOR.........................................................1298 VEHICLE SPEED SENSOR (DIESEL)......................................................1298 HELPFUL INFORMATION............................................................1298 HEATED OXYGEN SENSORS..............................................................1298 HELPFUL INFORMATION............................................................1299 CRANKSHAFT POSITION SENSOR (DIESEL)................................................1299 CAMSHAFT POSITION SENSOR...........................................................1299 ENGINE COOLANT TEMPERATURE SENSOR (DIESEL).........................................1299 HELPFUL INFORMATION............................................................1299 THROTTLE POSITION SENSOR...........................................................1299 HELPFUL INFORMATION............................................................1299 ENGINE COOLANT TEMPERATURE SENSOR..................................................1299 MASS AIR FLOW SENSOR (DIESEL)......................................................1300 ACCELERATOR PEDAL POSITION SENSOR (DIESEL) INTAKE AIR TEMPERATURE SENSOR...........1300 LOW IDLE POSITION SWITCH (DIESEL)..................................................1300 HELPFUL INFORMATION............................................................1300 MANIFOLD ABSOLUTE PRESSURE SENSOR..................................................1300 HELPFUL INFORMATION............................................................1300 OIL PRESSURE SENSOR (DIESEL).......................................................1300 WATER IN FUEL SENSOR (DIESEL)......................................................1300 PARK/NEUTRAL POSITION SWITCH.......................................................1301 HELPFUL INFORMATION............................................................1301 FUEL INJECTION PUMP (DIESEL).......................................................1301 FUEL SHUTDOWN SOLENOID.........................................................1301 POWER STEERING PRESSURE SWITCH.....................................................1301 FUEL TIMING SOLENOID...........................................................1301 FUEL TEMPERATURE SENSOR........................................................1301 STOP LAMP SWITCH INPUT.............................................................1301 CONTROL SLEEVE POSITION SENSOR.................................................1301 FUEL INJECTORS.....................................................................1301 FUEL QUANTITY ACTUATOR.........................................................1301 FUEL HEATER (DIESEL)...............................................................1301 NEEDLE MOVEMENT SENSOR (DIESEL)....................................................1302 ELECTRIC VACUUM MODULATOR (DIESEL).................................................1302 GLOW PLUGS (DIESEL)................................................................1302 LOW COOLANT LEVEL SWITCH (DIESEL)..................................................1302 TORQUE CONVERTER CLUTCH (TCC) SOLENOID.............................................1302 IGNITION COIL......................................................................1302 HELPFUL INFORMATION............................................................1302 EXTENDED IDLE SWITCH...............................................................1302 IDLE AIR CONTROL (IAC) MOTOR.......................................................1302 CCD BUS............................................................................1302 DUTY CYCLE EVAP\PURGE SOLENOID.....................................................1302 DESCRIPTION AND OPERATION..............................................................1307 TORQUE CONVERTER CLUTCH (TCC) SOLENOID.............................................1307 TRANSMISSION CONTROL MODULE—4.0L ENGINE ONLY.......................................1307 FOUR-WHEEL DRIVE (4WD) SWITCH......................................................1307 SHIFT INTERLOCK....................................................................1307 DESCRIPTION AND OPERATION..............................................................1314 VEHICLE SPEED CONTROL..............................................................1314 HELPFUL INFORMATION............................................................1314 VEHICLE SPEED CONTROL (DIESEL).....................................................1314 DESCRIPTION AND OPERATION..............................................................1321 G-SWITCH...........................................................................1321 INTRODUCTION.......................................................................1321 ABS RELAY..........................................................................1321 ABS WARNING LAMP...................................................................1321 WHEEL SPEED SENSORS................................................................1321 STOP LAMP SWITCH INPUT.............................................................1321 DATA LINK CONNECTOR................................................................1321 DESCRIPTION AND OPERATION..............................................................1331 OVERHEAD MODULE....................................................................1331 IMMOBILIZER........................................................................1331 REMOTE KEYLESS ENTRY...............................................................1331 DESCRIPTION AND OPERATION..............................................................1350 INTRODUCTION.......................................................................1350 HELPFUL INFORMATION............................................................1350 BRAKE WARNING LAMP ILLUMINATION LAMPS..............................................1350 WARNING LAMPS—EXCEPT ABS and BRAKE.................................................1350 SPEEDOMETER........................................................................1350 TACHOMETER ABS WARNING LAMP........................................................1350 VOLTMETER..........................................................................1351 FUEL GAUGE.........................................................................1351 HIGH BEAM INDICATOR LAMP...........................................................1351 ENGINE COOLANT TEMPERATURE GAUGE...................................................1351 TURN SIGNAL INDICATOR LAMPS........................................................1351 OIL PRESSURE GAUGE.................................................................1351 MANUAL TRANSMISSION UP-SHIFT LAMP..................................................1351 FOUR-WHEEL DRIVE (4WD) SWITCH......................................................1351 CHIME..............................................................................1351 SEAT BELT WARNING LAMP.............................................................1351 TELL TALE MODULE...................................................................1352 DESCRIPTION AND OPERATION..............................................................1356 HORN...............................................................................1356 HELPFUL INFORMATION............................................................1356 POWER OUTLET.......................................................................1356 HELPFUL INFORMATION............................................................1356 CIGAR LIGHTER......................................................................1356 GENERAL INFORMATION....................................................................1365 A/C OPERATION......................................................................1365 INTRODUCTION.......................................................................1365 DESCRIPTION AND OPERATION..............................................................1365 BLOWER MOTOR.......................................................................1365 A/C OPERATION......................................................................1365 DESCRIPTION AND OPERATION..............................................................1370 AIRBAG IMPACT SENSOR...............................................................1370 INTRODUCTION.......................................................................1370 AIRBAG SQUIB (AIRBAG IGNITER)......................................................1370 DESCRIPTION AND OPERATION..............................................................1377 UNDERHOOD LAMP.....................................................................1377 INTRODUCTION.......................................................................1377 CARGO LAMP, COURTESY LAMPS AND DOME LAMP...........................................1377 INSTRUMENT PANEL ILLUMINATION LAMPS................................................1377 GLOVE BOX LAMP VISOR VANITY MIRROR LAMPS...........................................1377 READING LAMPS......................................................................1378 DESCRIPTION AND OPERATION..............................................................1384 RADIO..............................................................................1384 AMPLIFIER AND SPEAKERS—PREMIUM.....................................................1384 RADIO MEMORY.......................................................................1384 RADIO ILLUMINATION.................................................................1384 SPEAKERS—STANDARD SYSTEM...........................................................1384 DESCRIPTION AND OPERATION..............................................................1388 REAR WINDOW DEFOGGER...............................................................1388 HELPFUL INFORMATION............................................................1388 DESCRIPTION AND OPERATION..............................................................1392 INTRODUCTION.......................................................................1392 AMBIENT TEMPERATURE SENSOR.........................................................1392 DESCRIPTION AND OPERATION..............................................................1402 PARKING LAMPS......................................................................1402 HEADLAMP GROUND................................................................1402 HEADLAMP LEVELING..................................................................1402 HELPFUL INFORMATION............................................................1402 HEADLAMP DELAY MODULE..............................................................1402 HEADLAMPS..........................................................................1402 HEADLAMP SWITCH IN ON POSITION.................................................1402 FOG LAMPS..........................................................................1402 WITHOUT DAYTIME RUNNING LAMPS..................................................1402 HEADLAMP SWITCH IN OFF OR PARKING LAMP POSITION................................1402 HELPFUL INFORMATION............................................................1403 DAYTIME RUNNING LAMP (DRL) MODULE..................................................1403 WITH DAYTIME RUNNING LAMPS.....................................................1403 DESCRIPTION AND OPERATION..............................................................1411 REAR FOG LAMPS.....................................................................1411 TAIL LAMPS AND REAR LICENSE PLATE LAMPS............................................1411 BACK-UP LAMPS......................................................................1411 GROUND CIRCUIT.................................................................1411 STOP LAMPS AND CHMSL LAMPS.........................................................1411 HELPFUL INFORMATION............................................................1411 HELPFUL INFORMATION............................................................1411 DESCRIPTION AND OPERATION..............................................................1416 TURN SIGNALS.......................................................................1416 HAZARD FLASHERS....................................................................1416 HELPFUL INFORMATION............................................................1416 COMBINATION FLASHER................................................................1416 HELPFUL INFORMATION............................................................1416 DESCRIPTION AND OPERATION..............................................................1420 INTERMITTENT WIPERS................................................................1420 HELPFUL INFORMATION............................................................1420 REAR WIPER SYSTEM..................................................................1420 DESCRIPTION AND OPERATION..............................................................1424 LEFT TURN RELAY....................................................................1424 TRAILER TOW........................................................................1424 RIGHT TURN RELAY...................................................................1424 HELPFUL INFORMATION............................................................1424 HELPFUL INFORMATION................................................................1424 HELPFUL INFORMATION............................................................1424 DESCRIPTION AND OPERATION..............................................................1430 POWER WINDOW OPERATION.............................................................1430 LEFT REAR WINDOW...............................................................1430 LEFT FRONT WINDOW OPERATION....................................................1430 RIGHT FRONT WINDOW OPERATION...................................................1430 RIGHT REAR WINDOW..............................................................1430 HELPFUL INFORMATION................................................................1431 DESCRIPTION AND OPERATION..............................................................1439 INTRODUCTION.......................................................................1439 POWER DOOR LOCK OPERATION..........................................................1439 REMOTE KEYLESS ENTRY AND ILLUMINATED ENTRY.....................................1439 DOOR LOCK SWITCH OPERATION—LOCK POSITION.......................................1439 GROUND CIRCUIT.................................................................1439 HELPFUL INFORMATION............................................................1439 DESCRIPTION AND OPERATION..............................................................1446 POWER MIRRORS......................................................................1446 LEFT POWER MIRROR OPERATION....................................................1446 RIGHT POWER MIRROR OPERATION...................................................1446 HELPFUL INFORMATION............................................................1446 HELPFUL INFORMATION............................................................1447 HEATER ELEMENTS....................................................................1447 DESCRIPTION AND OPERATION..............................................................1452 POWER SEAT OPERATION...............................................................1452 HELPFUL INFORMATION............................................................1452 DESCRIPTION AND OPERATION..............................................................1551 INTRODUCTION CONNECTOR/GROUND LOCATIONS............................................1551 DESCRIPTION AND OPERATION..............................................................1599 INTRODUCTION SPLICE LOCATIONS......................................................1599 ENGINE.....................................................................................1621 GENERAL INFORMATION....................................................................1621 FORM-IN-PLACE GASKETS..............................................................1621 SURFACE PREPARATION............................................................1621 MOPAR SILICONE RUBBER ADHESIVE SEALANT.........................................1621 GASKET APPLICATION.............................................................1621 ENGINE PERFORMANCE.................................................................1622 HONING CYLINDER BORES..............................................................1622 MEASURING WITH PLASTIGAGE..........................................................1623 CRANKSHAFT MAIN BEARING CLEARANCE..............................................1623 CONNECTING ROD BEARING CLEARANCE...............................................1623 REPAIR DAMAGED OR WORN THREADS.....................................................1624 SERVICE ENGINE ASSEMBLY (SHORT BLOCK)..............................................1624 ENGINE OIL.........................................................................1624 HYDROSTATIC LOCK...................................................................1624 ENGINE OIL SPECIFICATION.......................................................1624 API SERVICE GRADE CERTIFIED....................................................1625 CRANKCASE OIL LEVEL INSPECTION.................................................1625 SAE VISCOSITY..................................................................1625 ENERGY CONSERVING OIL..........................................................1625 CONTAINER IDENTIFICATION.......................................................1625 ENGINE OIL ADDITIVES...........................................................1625 ENGINE OIL CHANGE..............................................................1626 ENGINE OIL FILTER CHANGE.......................................................1626 DIAGNOSIS AND TESTING..................................................................1628 CYLINDER COMPRESSION PRESSURE TEST.................................................1628 GENERAL INFORMATION................................................................1628 ENGINE CYLINDER HEAD GASKET FAILURE INTAKE MANIFOLD LEAKAGE DIAGNOSIS DIAGNOSIS....1628 CYLINDER-TO-CYLINDER LEAKAGE TEST..............................................1628 CYLINDER-TO-WATER JACKET LEAKAGE TEST..........................................1629 INSPECTION (ENGINE OIL LEAKS IN GENERAL)...........................................1629 CYLINDER COMBUSTION PRESSURE LEAKAGE TEST..........................................1629 Air Leak Detection Test Method.................................................1630 ENGINE OIL PRESSURE................................................................1630 INSPECTION FOR REAR SEAL AREA LEAKS............................................1630 SERVICE DIAGNOSIS—PERFORMANCE......................................................1631 ENGINE PER FOR MANCE DIAGNOSIS CHAR T..........................................1631 SERVICE DIAGNOSIS—MECHANICAL.......................................................1633 ENGINE MECHANICAL DIAGNOSIS CHART..............................................1633 DESCRIPTION AND OPERATION..............................................................1635 ENGINE DESCRIPTION.................................................................1635 BUILD DATE CODE................................................................1635 LUBRICATION SYSTEM.................................................................1636 OIL PUMP PRESSURE..................................................................1638 OVERSIZE AND UNDERSIZE COMPONENT CODES.............................................1638 PISTON FITTING.....................................................................1638 SERVICE PROCEDURES.....................................................................1638 VALVE TIMING.......................................................................1638 PISTON RING FITTING................................................................1639 FITTING CONNECTING ROD BEARINGS....................................................1641 INSPECTION.....................................................................1641 BEARING-TO-JOURNAL CLEARANCE...................................................1642 SIDE CLEARANCE MEASUREMENT.....................................................1643 FITTING CRANKSHAFT MAIN BEARINGS...................................................1643 INSPECTION FITTING BEARINGS (CRANKSHAFT INSTALLED).............................1643 MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED).............................1645 MAIN BEARING FITTING CHART.....................................................1646 REMOVAL AND INSTALLATION...............................................................1647 ENGINE MOUNTS—FRONT................................................................1647 REMOVAL........................................................................1647 INSTALLATION...................................................................1647 ENGINE MOUNT—REAR..................................................................1648 REMOVAL........................................................................1648 INSTALLATION...................................................................1648 ENGINE ASSEMBLY....................................................................1648 REMOVAL........................................................................1648 INSTALLATION...................................................................1649 INSTALLATION...................................................................1650 CYLINDER HEAD COVER................................................................1650 REMOVAL........................................................................1650 ROCKER ARMS AND PUSH RODS..........................................................1651 REMOVAL........................................................................1651 VALVE SPRINGS AND OIL SEALS........................................................1651 REMOVAL........................................................................1651 INSTALLATION INSTALLATION......................................................1651 ENGINE CYLINDER HEAD...............................................................1652 REMOVAL........................................................................1652 INSTALLATION...................................................................1653 VALVES AND VALVE SPRINGS...........................................................1654 REMOVAL........................................................................1654 INSTALLATION...................................................................1654 INSTALLATION...................................................................1655 HYDRAULIC TAPPETS..................................................................1655 REMOVAL........................................................................1655 VIBRATION DAMPER...................................................................1655 REMOVAL........................................................................1655 INSTALLATION...................................................................1655 TIMING CASE COVER OIL SEAL TIMING CASE COVER.......................................1656 REMOVAL REMOVAL................................................................1656 INSTALLATION...................................................................1656 INSTALLATION...................................................................1656 REMOVAL........................................................................1657 TIMING CHAIN AND SPROCKETS.........................................................1657 INSTALLATION...................................................................1657 CAMSHAFT...........................................................................1658 INSTALLATION REMOVAL...........................................................1658 CAMSHAFT PIN REPLACEMENT...........................................................1659 REMOVAL........................................................................1659 INSTALLATION...................................................................1660 CAMSHAFT BEARINGS..................................................................1661 CRANKSHAFT MAIN BEARINGS...........................................................1661 REMOVAL........................................................................1661 INSTALLATION...................................................................1662 OIL PAN............................................................................1663 REMOVAL........................................................................1663 INSTALLATION...................................................................1663 INSTALLATION...................................................................1664 OIL PUMP...........................................................................1664 PISTONS AND CONNECTING RODS........................................................1664 REMOVAL........................................................................1664 REMOVAL........................................................................1664 INSTALLATION...................................................................1665 DISASSEMBLY AND ASSEMBLY...............................................................1666 VALVE SERVICE......................................................................1666 REAR MAIN OIL SEALS................................................................1666 REMOVAL........................................................................1666 VALVE REFACING.................................................................1666 INSTALLATION...................................................................1666 VALVE SEAT REFACING............................................................1666 VALVE STEM OIL SEAL REPLACEMENT................................................1667 VALVE GUIDES...................................................................1667 VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT......................................1667 ASSEMBLY.......................................................................1668 CLEANING AND INSPECTION................................................................1668 ROCKER ARMS AND PUSH RODS..........................................................1668 CLEANING.......................................................................1668 CYLINDER BLOCK.....................................................................1668 DISASSEMBLY INSPECTION.........................................................1668 ENGINE CYLINDER HEAD...............................................................1669 CLEANING.......................................................................1669 INSPECTION.....................................................................1669 CYLINDER BLOCK.....................................................................1669 CLEANING.......................................................................1669 INSPECTION—CYLINDER BORE.......................................................1669 HONING—CYLINDER BORE...........................................................1670 SPECIFICATIONS.........................................................................1670 L ENGINE SPECIFICATIONS............................................................1670 L TORQUE SPECIFICATIONS............................................................1672 SPECIAL TOOLS..........................................................................1673 L ENGINE...........................................................................1673 DESCRIPTION AND OPERATION..............................................................1674 ENGINE DESCRIPTION.................................................................1674 LUBRICATION SYSTEM.................................................................1675 OIL PUMP PRESSURE..................................................................1677 OVERSIZE AND UNDERSIZE COMPONENT CODES.............................................1677 PISTON FITTING.....................................................................1677 SERVICE PROCEDURES.....................................................................1677 VALVE TIMING.......................................................................1677 PISTON RING FITTING................................................................1678 FITTING CONNECTING ROD BEARINGS....................................................1680 INSPECTION.....................................................................1680 FITTING CRANKSHAFT MAIN BEARINGS...................................................1682 INSPECTION.....................................................................1682 FITTING BEARINGS (CRANKSHAFT INSTALLED)........................................1682 SIDE CLEARANCE MEASUREMENT.....................................................1682 MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED).............................1684 MAIN BEARING FITTING CHART.....................................................1685 REMOVAL AND INSTALLATION...............................................................1686 ENGINE MOUNTS—FRONT................................................................1686 REMOVAL........................................................................1686 ENGINE MOUNT—REAR..................................................................1686 REMOVAL........................................................................1686 INSTALLATION...................................................................1686 INSTALLATION...................................................................1687 ENGINE ASSEMBLY....................................................................1687 REMOVAL........................................................................1687 INSTALLATION...................................................................1689 ENGINE CYLINDER HEAD COVER.........................................................1689 INSTALLATION...................................................................1690 REMOVAL........................................................................1690 ROCKER ARMS AND PUSH RODS..........................................................1690 REMOVAL........................................................................1690 INSTALLATION...................................................................1691 VALVE STEM SEAL AND SPRING.........................................................1691 REMOVAL INSTALLATION...........................................................1691 ENGINE CYLINDER HEAD...............................................................1691 REMOVAL........................................................................1692 INSTALLATION...................................................................1692 VALVES AND VALVE SPRINGS...........................................................1693 REMOVAL........................................................................1693 INSTALLATION...................................................................1694 VIBRATION DAMPER...................................................................1694 REMOVAL........................................................................1694 HYDRAULIC TAPPETS..................................................................1694 REMOVAL........................................................................1694 INSTALLATION INSTALLATION......................................................1694 TIMING CASE COVER..................................................................1695 REMOVAL........................................................................1695 INSTALLATION...................................................................1695 TIMING CHAIN AND SPROCKETS.........................................................1695 REMOVAL........................................................................1695 INSTALLATION...................................................................1696 CAMSHAFT...........................................................................1697 REMOVAL........................................................................1697 INSTALLATION...................................................................1697 CAMSHAFT PIN REPLACEMENT...........................................................1698 REMOVAL........................................................................1698 CAMSHAFT BEARINGS..............................................................1699 INSTALLATION...................................................................1699 CRANKSHAFT MAIN BEARINGS...........................................................1700 REMOVAL........................................................................1700 INSTALLATION...................................................................1700 INSTALLATION...................................................................1701 OIL PAN............................................................................1701 REMOVAL........................................................................1701 INSTALLATION...................................................................1702 PISTONS AND CONNECTING RODS........................................................1702 REMOVAL........................................................................1702 REAR MAIN OIL SEAL.................................................................1703 REMOVAL........................................................................1703 INSTALLATION...................................................................1703 REMOVAL........................................................................1704 INSTALLATION...................................................................1704 TIMING CASE COVER OIL SEAL OIL PUMP................................................1704 REMOVAL........................................................................1704 DISASSEMBLY AND ASSEMBLY...............................................................1705 VALVE SERVICE......................................................................1705 INSTALLATION...................................................................1705 VALVE REFACING.................................................................1705 VALVE SEAT REFACING............................................................1705 VALVE STEM OIL SEAL REPLACEMENT................................................1705 VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT......................................1706 VALVE GUIDES...................................................................1706 ASSEMBLY.......................................................................1707 VALVE SPRING TENSION TEST......................................................1707 CLEANING AND INSPECTION................................................................1707 ENGINE CYLINDER HEAD...............................................................1707 CLEANING.......................................................................1707 CYLINDER BLOCK.....................................................................1707 DISASSEMBLY....................................................................1707 HYDRAULIC TAPPETS..................................................................1708 CLEANING INSPECTION............................................................1708 INSPECTION.....................................................................1708 ENGINE CYLINDER HEAD COVER.........................................................1708 CLEANING.......................................................................1708 LEAK-DOWN TEST.................................................................1708 INSPECTION.....................................................................1708 ROCKER ARMS AND PUSH RODS..........................................................1708 CLEANING.......................................................................1708 INSPECTION.....................................................................1708 CYLINDER BLOCK.....................................................................1708 CLEANING.......................................................................1708 INSPECTION—CYLINDER BORE.......................................................1709 HONING—CYLINDER BORE...........................................................1709 SPECIFICATIONS.........................................................................1710 L ENGINE SPECIFICATIONS............................................................1710 L TORQUE SPECIFICATIONS............................................................1712 SPECIAL TOOLS..........................................................................1713 L ENGINE...........................................................................1713 EXHAUST SYSTEM............................................................................. 17 GENERAL INFORMATION.................................................................... 17 EXHAUST SYSTEM..................................................................... 17 CATALYTIC CONVERTER................................................................ 17 DIAGNOSIS AND TESTING.................................................................. 18 EXHAUST SYSTEM..................................................................... 18 REMOVAL AND INSTALLATION............................................................... 18 EXHAUST PIPE....................................................................... 18 REMOVAL........................................................................ 18 INSTALLATION................................................................... 18 CATALYTIC CONVERTER................................................................ 19 REMOVAL........................................................................ 19 INSTALLATION................................................................... 19 MUFFLER AND EXHAUST TAILPIPE....................................................... 20 REMOVAL........................................................................ 20 INSTALLATION................................................................... 21 SPECIFICATIONS......................................................................... 21 TORQUE SPECIFICATIONS.............................................................. 21 FRAME AND BUMPERS.......................................................................... 33 BUMPERS................................................................................ 33 REMOVAL AND INSTALLATION........................................................... 33 FRONT BUMPER END CAP........................................................... 33 REMOVAL.................................................................... 33 INSTALLATION............................................................... 33 FRONT BUMPER................................................................... 33 REMOVAL.................................................................... 33 INSTALLATION............................................................... 33 FRONT TOW HOOK................................................................. 34 REMOVAL.................................................................... 34 INSTALLATION............................................................... 34 REAR BUMPER END CAP............................................................ 34 REMOVAL.................................................................... 34 INSTALLATION............................................................... 35 REAR BUMPER.................................................................... 35 REMOVAL.................................................................... 35 INSTALLATION............................................................... 35 REAR TOW HOOK.................................................................. 36 REMOVAL.................................................................... 36 INSTALLATION............................................................... 36 SPARE TIRE CARRIER............................................................. 41 FRAME.................................................................................. 37 REMOVAL AND INSTALLATION........................................................... 37 FRONT SKID PLATE............................................................... 37 REMOVAL.................................................................... 37 INSTALLATION............................................................... 37 TRANSFER CASE SKID PLATE....................................................... 37 REMOVAL.................................................................... 37 INSTALLATION............................................................... 37 FUEL TANK SKID PLATE........................................................... 37 REMOVAL.................................................................... 37 INSTALLATION............................................................... 37 TRAILER HITCH.................................................................. 38 REMOVAL.................................................................... 38 INSTALLATION............................................................... 38 SPECIFICATIONS..................................................................... 38 FRAME DIMENSIONS............................................................... 38 FRAME TORQUE SPECIFICATIONS.................................................... 40 FUEL SYSTEM................................................................................ 43 FUEL DELIVERY SYSTEM................................................................... 43 DESCRIPTION AND OPERATION.......................................................... 43 PCM REPLACEMENT................................................................ 43 FUEL REQUIREMENTS.............................................................. 43 REFORMULATED GASOLINE...................................................... 44 GASOLINE/OXYGENATE BLENDS.................................................. 44 MMT........................................................................ 44 SULFUR IN GASOLINE......................................................... 44 MATERIALS ADDED TO FUEL.................................................... 44 FUEL SYSTEM CAUTIONS....................................................... 44 FUEL DELIVERY SYSTEM........................................................... 45 FUEL PUMP MODULE............................................................... 45 FUEL PUMP...................................................................... 45 DESCRIPTION................................................................ 45 OPERATION.................................................................. 46 FUEL GAUGE SENDING UNIT........................................................ 46 DESCRIPTION................................................................ 46 OPERATION.................................................................. 46 FUEL FILTER/FUEL PRESSURE REGULATOR............................................ 46 FUEL TANK...................................................................... 47 DESCRIPTION................................................................ 47 OPERATION.................................................................. 47 ROLLOVER VALVE(S).............................................................. 47 FUEL INJECTORS................................................................. 47 FUEL RAIL/FUEL DAMPER-2.5L ENGINE.............................................. 47 FUEL RAIL-4.0L ENGINE.......................................................... 47 FUEL TANK FILLER TUBE CAP...................................................... 48 QUICK-CONNECT FITTINGS......................................................... 48 DIAGNOSIS AND TESTING.............................................................. 48 FUEL PUMP PRESSURE TEST-ALL ENGINES WITH PRESSURE TEST PORT.................... 48 FUEL PUMP CAPACITY TEST........................................................ 49 FUEL PRESSURE LEAK DOWN TEST................................................... 49 FUEL PUMP AMPERAGE TEST........................................................ 50 FUEL GAUGE SENDING UNIT........................................................ 52 FUEL INJECTOR TEST............................................................. 52 SERVICE PROCEDURES................................................................. 52 FUEL SYSTEM PRESSURE RELEASE PROCEDURE......................................... 52 FUEL TUBES/LINES/HOSES AND CLAMPS.............................................. 52 OPERATION.................................................................. 52 QUICK-CONNECT FITTINGS......................................................... 53 DISCONNECTING.............................................................. 53 CONNECTING................................................................. 55 REMOVAL AND INSTALLATION........................................................... 55 FUEL FILTER/FUEL PRESSURE REGULATOR............................................ 55 REMOVAL.................................................................... 55 INSTALLATION............................................................... 55 FUEL PUMP MODULE............................................................... 56 REMOVAL.................................................................... 56 INSTALLATION............................................................... 56 FUEL PUMP INLET FILTER......................................................... 57 REMOVAL.................................................................... 57 INSTALLATION............................................................... 57 FUEL GAUGE SENDING UNIT........................................................ 57 REMOVAL.................................................................... 57 INSTALLATION............................................................... 58 FUEL INJECTOR RAIL-2.5L ENGINE................................................. 58 REMOVAL.................................................................... 58 INSTALLATION............................................................... 59 FUEL INJECTOR RAIL-4.0L ENGINE................................................. 59 REMOVAL.................................................................... 59 INSTALLATION............................................................... 59 FUEL INJECTORS................................................................. 60 REMOVAL.................................................................... 60 INSTALLATION............................................................... 60 FUEL TANK...................................................................... 60 REMOVAL.................................................................... 60 INSTALLATION............................................................... 62 FUEL TANK FILLER TUBE CAP...................................................... 62 ACCELERATOR PEDAL.............................................................. 62 REMOVAL.................................................................... 62 INSTALLATION............................................................... 63 THROTTLE CABLE................................................................. 63 REMOVAL.................................................................... 63 INSTALLATION............................................................... 63 SPECIFICATIONS..................................................................... 64 FUEL TANK CAPACITY............................................................. 64 FUEL SYSTEM PRESSURE........................................................... 64 TORQUE CHART................................................................... 64 FUEL INJECTION SYSTEM.................................................................. 65 DESCRIPTION AND OPERATION.......................................................... 66 POWERTRAIN CONTROL MODULE (PCM)................................................ 66 MODES OF OPERATION............................................................. 67 IGNITION SWITCH (KEY-ON) MODE.............................................. 67 ENGINE START-UP MODE....................................................... 67 ENGINE WARM-UP MODE........................................................ 68 IDLE MODE.................................................................. 68 CRUISE MODE................................................................ 68 ACCELERATION MODE.......................................................... 69 DECELERATION MODE.......................................................... 69 WIDE OPEN THROTTLE MODE.................................................... 69 IGNITION SWITCH OFF MODE................................................... 69 AIR CONDITIONING (A/C) CONTROLS-PCM INPUT...................................... 69 OPERATION.................................................................. 69 AUTOMATIC SHUTDOWN (ASD) RELAY SENSE-PCM INPUT................................. 70 BATTERY TEMPERATURE SENSOR-PCM INPUT........................................... 70 OPERATION.................................................................. 70 BATTERY VOLTAGE-PCM INPUT...................................................... 70 OPERATION.................................................................. 70 BRAKE SWITCH-PCM INPUT......................................................... 70 OPERATION.................................................................. 70 FIVE VOLT SENSOR SUPPLY-PRIMARY................................................ 70 OPERATION.................................................................. 70 FIVE VOLT SENSOR SUPPLY-SECONDARY.............................................. 70 OPERATION.................................................................. 70 FUEL LEVEL SENSOR-PCM INPUT.................................................... 70 OPERATION.................................................................. 70 CAMSHAFT POSITION SENSOR-PCM INPUT............................................. 71 CRANKSHAFT POSITION SENSOR-PCM INPUT........................................... 71 ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT.................................... 71 EXTENDED IDLE SWITCH-PCM INPUT................................................. 72 OPTIONAL POLICE PACKAGE WITH 4.0L ENGINE ONLY.............................. 72 GENERATOR OUTPUT-PCM INPUT..................................................... 72 OPERATION.................................................................. 72 OXYGEN SENSOR (HO2S)-PCM INPUT................................................. 72 UPSTREAM HEATED OXYGEN SENSOR.............................................. 72 DOWNSTREAM HEATED OXYGEN SENSOR............................................ 72 IGNITION CIRCUIT SENSE-PCM INPUT............................................... 72 OPERATION.................................................................. 72 INTAKE MANIFOLD AIR TEMPERATURE SENSOR-PCM INPUT............................... 72 LEAK DETECTION PUMP (SWITCH) SENSE-PCM INPUT................................... 73 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-PCM INPUT.............................. 73 OIL PRESSURE SENSOR-PCM INPUT.................................................. 73 DESCRIPTION................................................................ 73 OPERATION.................................................................. 73 POWER GROUND................................................................... 73 OPERATION.................................................................. 73 POWER STEERING PRESSURE SWITCH-PCM INPUT....................................... 73 SENSOR RETURN-PCM INPUT........................................................ 74 OPERATION.................................................................. 74 SPEED CONTROL SWITCHES-PCM INPUT............................................... 74 TRANSMISSION PARK/NEUTRAL SWITCH-PCM INPUT..................................... 74 THROTTLE POSITION SENSOR (TPS)-PCM INPUT....................................... 74 VEHICLE SPEED AND DISTANCE SENSOR-PCM INPUT.................................... 74 AIR CONDITIONING (A/C) CLUTCH RELAY-PCM OUTPUT................................. 75 AUTO SHUTDOWN (ASD) RELAY-PCM OUTPUT........................................... 75 DESCRIPTION................................................................ 75 OPERATION.................................................................. 75 CCD BUS (+/-) CIRCUITS-PCM OUTPUTS............................................. 76 DATA LINK CONNECTOR-PCM INPUT AND OUTPUT....................................... 76 DUTY CYCLE EVAP PURGE SOLENOID VALVE-PCM OUTPUT................................ 76 FUEL INJECTORS-PCM OUTPUT...................................................... 76 FUEL PUMP RELAY-PCM OUTPUT..................................................... 77 DESCRIPTION................................................................ 77 OPERATION.................................................................. 77 GENERATOR FIELD SOURCE (+)-PCM OUTPUT.......................................... 77 OPERATION.................................................................. 77 GENERATOR FIELD DRIVER (-)-PCM OUTPUT.......................................... 77 OPRATION................................................................... 77 GENERATOR LAMP-PCM OUTPUT...................................................... 77 IDLE AIR CONTROL (IAC) MOTOR-PCM OUTPUT........................................ 77 IGNITION COIL-PCM OUTPUT....................................................... 77 LEAK DETECTION PUMP-PCM OUTPUT................................................. 77 RADIATOR FAN RELAY-PCM OUTPUT.................................................. 77 MALFUNCTION INDICATOR LAMP-ECM/PCM OUTPUT...................................... 77 SPEED CONTROL SOLENOIDS-PCM OUTPUT............................................. 77 TACHOMETER-PCM OUTPUT.......................................................... 77 THROTTLE BODY.................................................................. 77 DIAGNOSIS AND TESTING.............................................................. 78 VISUAL INSPECTION.............................................................. 78 ASD AND FUEL PUMP RELAYS....................................................... 81 OPERATION.................................................................. 81 TESTING.................................................................... 82 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST................................... 82 OXYGEN (O2S) SENSORS........................................................... 83 ENGINE COOLANT TEMPERATURE SENSOR.............................................. 83 IDLE AIR CONTROL (IAC) MOTOR................................................... 84 INTAKE MANIFOLD AIR TEMPERATURE SENSOR......................................... 84 POWER STEERING PRESSURE SWITCH................................................. 84 2.5L 4-Cylinder Engine Only................................................ 84 VEHICLE SPEED SENSOR........................................................... 85 EXTENDED IDLE SWITCH TEST...................................................... 85 OPTIONAL POLICE PACKAGE ONLY............................................... 85 THROTTLE POSITION SENSOR (TPS)................................................. 86 THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE................................. 86 REMOVAL AND INSTALLATION........................................................... 87 AUTOMATIC SHUTDOWN (ASD) RELAY................................................. 87 REMOVAL.................................................................... 87 INSTALLATION............................................................... 87 FUEL PUMP RELAY................................................................ 87 REMOVAL.................................................................... 87 INSTALLATION............................................................... 87 THROTTLE BODY.................................................................. 87 REMOVAL.................................................................... 87 INSTALLATION............................................................... 88 THROTTLE POSITION SENSOR (TPS)................................................. 88 REMOVAL.................................................................... 88 INSTALLATION............................................................... 88 IDLE AIR CONTROL (IAC) MOTOR................................................... 89 REMOVAL.................................................................... 89 INSTALLATION............................................................... 89 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR........................................ 89 REMOVAL.................................................................... 89 INSTALLATION............................................................... 89 DUTY CYCLE EVAP CANISTER PURGE SOLENOID........................................ 89 POWERTRAIN CONTROL MODULE (PCM)................................................ 89 REMOVAL.................................................................... 89 INSTALLATION............................................................... 90 POWER STEERING PRESSURE SWITCH-2.5L ENGINE..................................... 90 REMOVAL.................................................................... 90 INSTALLATION............................................................... 90 OXYGEN SENSOR.................................................................. 90 REMOVAL.................................................................... 91 INSTALLATION............................................................... 91 AIR CLEANER ELEMENT (FILTER)................................................... 91 REMOVAL.................................................................... 91 INSTALLATION............................................................... 91 ENGINE COOLANT TEMPERATURE SENSOR.............................................. 92 REMOVAL.................................................................... 92 INSTALLATION............................................................... 92 INTAKE MANIFOLD AIR TEMPERATURE SENSOR......................................... 92 REMOVAL.................................................................... 92 INSTALLATION............................................................... 92 VEHICLE SPEED SENSOR........................................................... 92 REMOVAL.................................................................... 93 INSTALLATION............................................................... 93 SPECIFICATIONS..................................................................... 93 TORQUE CHART................................................................... 93 SPECIAL TOOLS...................................................................... 94 FUEL SYSTEM.................................................................... 94 STEERING................................................................................... 133 POWER STEERING......................................................................... 133 GENERAL INFORMATION................................................................ 133 STEERING SYSTEM................................................................ 133 DIAGNOSIS AND TESTING.............................................................. 134 POWER STEERING SYSTEM DIAGNOSIS CHARTS......................................... 134 POWER STEERING PUMP.................................................................... 137 DESCRIPTION AND OPERATION.......................................................... 137 POWER STEERING PUMP............................................................ 137 DIAGNOSIS AND TESTING.............................................................. 137 POWER FLOW AND PRESSURE........................................................ 137 FLOW AND PRESSURE TEST..................................................... 137 PUMP LEAKAGE DIAGNOSIS......................................................... 138 SERVICE PROCEDURES................................................................. 138 POWER STEERING PUMP - INITIAL OPERATION........................................ 138 REMOVAL AND INSTALLATION........................................................... 139 POWER STEERING PUMP............................................................ 139 REMOVAL.................................................................... 139 INSTALLATION............................................................... 139 PUMP RESERVOIR-2.5L............................................................ 140 REMOVAL.................................................................... 140 INSTALLATION............................................................... 140 DISASSEMBLY AND ASSEMBLY........................................................... 140 PUMP PULLEY.................................................................... 140 DISASSEMBLY................................................................ 140 ASSEMBLY................................................................... 140 PUMP RESERVOIR................................................................. 141 DISASSEMBLY................................................................ 141 ASSEMBLY................................................................... 141 FLOW CONTROL VALVE............................................................. 141 DISASSEMBLY................................................................ 141 ASSEMBLY................................................................... 141 SPECIFICATIONS..................................................................... 142 TORQUE CHART................................................................... 142 SPECIAL TOOLS...................................................................... 142 POWER STEERING PUMP............................................................ 142 POWER STEERING GEAR.................................................................... 143 DESCRIPTION AND OPERATION.......................................................... 143 POWER STEERING GEAR............................................................ 143 DIAGNOSIS AND TESTING.............................................................. 145 POWER STEERING GEAR LEAKAGE DIAGNOSIS.......................................... 145 REMOVAL AND INSTALLATION........................................................... 145 STEERING GEAR.................................................................. 145 REMOVAL.................................................................... 145 INSTALLATION............................................................... 145 DISASSEMBLY AND ASSEMBLY........................................................... 145 HOUSING END PLUG............................................................... 145 DISASSEMBLY................................................................ 145 ASSEMBLY................................................................... 146 PITMAN SHAFT/SEALS/BEARING..................................................... 146 DISASSEMBLY................................................................ 146 ASSEMBLY................................................................... 147 SPOOL VALVE.................................................................... 147 DISASSEMBLY................................................................ 147 ASSEMBLY................................................................... 148 RACK PISTON AND WORM SHAFT..................................................... 149 DISASSEMBLY................................................................ 149 ASSEMBLY................................................................... 150 ADJUSTMENTS........................................................................ 151 STEERING GEAR.................................................................. 151 WORM THRUST BEARING PRELOAD................................................ 151 OVER-CENTER................................................................ 152 SPECIFICATIONS..................................................................... 153 POWER STEERING GEAR............................................................ 153 TORQUE CHART................................................................... 153 SPECIAL TOOLS...................................................................... 154 POWER STEERING GEAR............................................................ 154 STEERING LINKAGE....................................................................... 155 GENERAL INFORMATION................................................................ 155 STEERING LINKAGE............................................................... 155 SERVICE PROCEDURES................................................................. 155 STEERING LINKAGE............................................................... 155 REMOVAL AND INSTALLATION........................................................... 156 TIE ROD........................................................................ 156 REMOVAL.................................................................... 156 INSTALLATION............................................................... 156 PITMAN ARM..................................................................... 157 REMOVAL.................................................................... 157 INSTALLATION............................................................... 157 DRAG LINK...................................................................... 157 REMOVAL.................................................................... 157 INSTALLATION............................................................... 157 STEERING DAMPER................................................................ 157 REMOVAL.................................................................... 157 INSTALLATION............................................................... 157 SPECIFICATIONS..................................................................... 157 TORQUE CHART................................................................... 157 SPECIAL TOOLS...................................................................... 158 STEERING LINKAGE............................................................... 158 STEERING COLUMN........................................................................ 159 GENERAL INFORMATION................................................................ 159 STEERING COLUMN................................................................ 159 SERVICE PRECAUTIONS........................................................ 159 REMOVAL AND INSTALLATION........................................................... 159 STEERING COLUMN................................................................ 159 REMOVAL.................................................................... 159 INSTALLATION............................................................... 160 SPECIFICATIONS..................................................................... 161 TORQUE CHART................................................................... 161 TRANSMISSION AND TRANSFER CASE............................................................. 193 AX5 MANUAL TRANSMISSION................................................................ 193 GENERAL INFORMATION................................................................ 193 AX5 MANUAL TRANSMISSION........................................................ 193 TRANSMISSION IDENTIFICATION.................................................... 193 GEAR RATIOS.................................................................... 193 RECOMMENDED LUBRICANT.......................................................... 193 TRANSMISSION ASSEMBLY INFORMATION.............................................. 194 DIAGNOSIS AND TESTING.............................................................. 195 LOW LUBRICANT LEVEL............................................................ 195 HARD SHIFTING.................................................................. 195 TRANSMISSION NOISE............................................................. 196 REMOVAL AND INSTALLATION........................................................... 196 TRANSMISSION................................................................... 196 REMOVAL.................................................................... 196 INSTALLATION............................................................... 197 FRONT BEARING RETAINER SEAL.................................................... 198 REMOVAL.................................................................... 198 INSTALLATION............................................................... 198 EXTENSION HOUSING SEAL......................................................... 199 REMOVAL.................................................................... 199 INSTALLATION............................................................... 199 ADAPTER HOUSING SEAL........................................................... 199 REMOVAL.................................................................... 199 INSTALLATION............................................................... 199 DISASSEMBLY AND ASSEMBLY........................................................... 200 ADAPTER/EXTENSION HOUSING AND FRONT BEARING RETAINER........................... 200 DISASSEMBLY................................................................ 200 ASSEMBLY................................................................... 203 SHIFT MECHANISM AND GEARTRAIN.................................................. 207 DISASSEMBLY................................................................ 207 ASSEMBLY................................................................... 212 COUNTERSHAFT................................................................... 218 DISASSEMBLY................................................................ 218 ASSEMBLY................................................................... 218 INPUT SHAFT.................................................................... 218 DISASSEMBLY................................................................ 218 ASSEMBLY................................................................... 218 OUTPUT SHAFT................................................................... 219 DISASSEMBLY................................................................ 219 ASSEMBLY................................................................... 221 SEMI-SYNCHRONIZED REVERSE IDLER GEAR........................................... 224 DISASSEMBLY................................................................ 224 ASSEMBLY................................................................... 224 CLEANING AND INSPECTION............................................................ 224 AX5 MANUAL TRANSMISSION COMPONENTS............................................. 224 GENERAL INFORMATION........................................................ 224 GEAR CASE, ADAPTER/EXTENSION HOUSING, INTERMEDIATE PLATE................... 225 OUTPUT SHAFT............................................................... 225 COUNTERSHAFT............................................................... 225 GEAR AND SYNCHRONIZER...................................................... 225 SPECIFICATIONS..................................................................... 227 TORQUE......................................................................... 227 SPECIAL TOOLS...................................................................... 227 AX5............................................................................ 227 AX15 MANUAL TRANSMISSION............................................................... 229 GENERAL INFORMATION................................................................ 229 AX15 MANUAL TRANSMISSION....................................................... 229 TRANSMISSION IDENTIFICATION.................................................... 229 TRANSMISSION GEAR RATIOS....................................................... 229 RECOMMENDED LUBRICANT.......................................................... 229 TRANSMISSION ASSEMBLY INFORMATION.............................................. 230 DIAGNOSIS AND TESTING.............................................................. 230 LOW LUBRICANT LEVEL............................................................ 230 HARD SHIFTING.................................................................. 231 TRANSMISSION NOISE............................................................. 232 REMOVAL AND INSTALLATION........................................................... 232 TRANSMISSION................................................................... 232 REMOVAL.................................................................... 232 INSTALLATION............................................................... 233 FRONT BEARING RETAINER SEAL.................................................... 234 REMOVAL.................................................................... 234 INSTALLATION............................................................... 234 EXTENSION HOUSING SEAL......................................................... 235 REMOVAL.................................................................... 235 INSTALLATION............................................................... 235 ADAPTER HOUSING SEAL........................................................... 235 REMOVAL.................................................................... 235 INSTALLATION............................................................... 235 DISASSEMBLY AND ASSEMBLY........................................................... 236 ADAPTER/EXTENSION HOUSING AND FRONT BEARING RETAINER........................... 236 DISASSEMBLY................................................................ 236 ASSEMBLY................................................................... 239 SHIFT MECHANISM AND GEARTRAIN.................................................. 243 DISASSEMBLY................................................................ 243 ASSEMBLY................................................................... 250 COUNTERSHAFT................................................................... 255 DISASSEMBLY................................................................ 255 ASSEMBLY................................................................... 255 INPUT SHAFT.................................................................... 256 DISASSEMBLY................................................................ 256 ASSEMBLY................................................................... 256 OUTPUT SHAFT................................................................... 256 DISASSEMBLY................................................................ 257 ASSEMBLY................................................................... 259 CLEANING AND INSPECTION............................................................ 261 AX15 MANUAL TRANSMISSION COMPONENTS............................................ 261 GENERAL INFORMATION........................................................ 261 GEAR CASE, ADAPTER/EXTENSION HOUSING, INTERMEDIATE PLATE................... 261 OUTPUT SHAFT............................................................... 261 COUNTERSHAFT............................................................... 262 GEAR AND SYNCHRONIZER...................................................... 262 SPECIFICATIONS..................................................................... 263 TORQUE......................................................................... 263 SPECIAL TOOLS...................................................................... 263 AX15........................................................................... 263 AUTOMATIC TRANSMISSION-30RH............................................................ 265 GENERAL INFORMATION................................................................ 266 30RH AUTOMATIC TRANSMISSION.................................................... 266 TRANSMISSION IDENTIFICATION.................................................... 266 RECOMMENDED FLUID.............................................................. 266 EFFECTS OF INCORRECT FLUID LEVEL............................................... 266 CAUSES OF BURNT FLUID.......................................................... 266 FLUID CONTAMINATION............................................................ 266 TORQUE CONVERTER-ELECTRONIC CLUTCH............................................. 268 TRANSMISSION GEAR RATIOS....................................................... 268 GEARSHIFT MECHANISM............................................................ 268 DESCRIPTION AND OPERATION.......................................................... 268 HYDRAULIC CONTROL SYSTEM....................................................... 268 PRESSURE SUPPLY............................................................ 268 Pressure Regulation........................................................ 268 Flow Control And Lubrication............................................... 268 Clutch/Band Application.................................................... 269 CONVERTER CLUTCH ENGAGEMENT.................................................... 269 CONVERTER DRAINBACK VALVE...................................................... 269 BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM................................... 269 DIAGNOSIS AND TESTING.............................................................. 269 AUTOMATIC TRANSMISSION DIAGNOSIS............................................... 269 PRELIMINARY DIAGNOSIS.......................................................... 269 VEHICLE IS DRIVEABLE....................................................... 269 VEHICLE IS DISABLED........................................................ 270 PARK/NEUTRAL POSITION SWITCH................................................... 270 SWITCH TEST................................................................ 270 GEARSHIFT CABLE................................................................ 271 THROTTLE VALVE CABLE........................................................... 271 ROAD TESTING................................................................... 271 ANALYZING ROAD TEST............................................................ 271 HYDRAULIC PRESSURE TEST........................................................ 272 Pressure Test Port Locations............................................... 272 PRESSURE TEST PROCEDURE.................................................... 272 CONVERTER STALL TEST........................................................... 273 STALL TEST PROCEDURE....................................................... 274 STALL TEST ANALYSIS............................................................ 274 Stall Speed Too High....................................................... 274 Stall Speed Low............................................................ 274 Stall Speed Normal But Acceleration Poor................................... 274 Converter Noise During Test................................................ 274 AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION............................. 274 Front Clutch Air Test...................................................... 274 Rear Clutch Air Test....................................................... 274 Front Servo Apply Air Test................................................. 274 Rear Servo Air Test........................................................ 275 CONVERTER HOUSING FLUID LEAK DIAGNOSIS......................................... 275 TORQUE CONVERTER LEAK POINTS............................................... 275 CONVERTER HOUSING AREA LEAK CORRECTION..................................... 275 DIAGNOSIS CHARTS............................................................... 275 SERVICE PROCEDURES................................................................. 283 FLUID LEVEL CHECK.............................................................. 283 FLUID LEVEL CHECK PROCEDURE................................................ 283 FLUID AND FILTER REPLACEMENT................................................... 283 REMOVAL.................................................................... 283 INSPECTION................................................................. 284 CLEANING................................................................... 284 INSTALLATION............................................................... 284 TRANSMISSION FILL PROCEDURE.................................................... 284 CONVERTER DRAINBACK CHECK VALVE SERVICE........................................ 284 OIL PUMP VOLUME CHECK.......................................................... 284 FLUSHING COOLERS AND TUBES..................................................... 285 COOLER FLUSH USING TOOL 6906............................................... 285 ALUMINUM THREAD REPAIR......................................................... 285 REMOVAL AND INSTALLATION........................................................... 286 TRANSMISSION................................................................... 286 REMOVAL.................................................................... 286 INSTALLATION............................................................... 287 TORQUE CONVERTER............................................................... 288 REMOVAL.................................................................... 288 INSTALLATION............................................................... 288 YOKE SEAL REPLACEMENT.......................................................... 289 REMOVAL.................................................................... 289 INSTALLATION............................................................... 289 EXTENSION HOUSING BUSHING...................................................... 289 REMOVAL.................................................................... 289 INSTALLATION............................................................... 289 EXTENSION HOUSING.............................................................. 290 REMOVAL.................................................................... 290 INSTALLATION............................................................... 290 SPEEDOMETER ADAPTER............................................................ 290 REMOVAL.................................................................... 290 INSTALLATION............................................................... 290 PARK/NEUTRAL POSITION SWITCH................................................... 291 REMOVAL.................................................................... 291 INSTALLATION............................................................... 291 GEARSHIFT CABLE................................................................ 292 REMOVAL.................................................................... 292 INSTALLATION............................................................... 292 BRAKE TRANSMISSION SHIFT INTERLOCK............................................. 292 REMOVAL.................................................................... 292 INSTALLATION............................................................... 292 VALVE BODY..................................................................... 292 REMOVAL.................................................................... 292 INSTALLATION............................................................... 293 OUTPUT SHAFT REAR BEARING...................................................... 294 REMOVAL.................................................................... 294 INSTALLATION............................................................... 294 GOVERNOR AND PARK GEAR......................................................... 294 REMOVAL.................................................................... 294 INSTALLATION............................................................... 294 PARK LOCK...................................................................... 295 REMOVAL.................................................................... 295 INSTALLATION............................................................... 295 DISASSEMBLY AND ASSEMBLY........................................................... 296 GOVERNOR AND PARK GEAR......................................................... 296 DISASSEMBLY................................................................ 296 ASSEMBLY................................................................... 296 VALVE BODY..................................................................... 297 DISASSEMBLY................................................................ 297 ASSEMBLY................................................................... 300 TRANSMISSION................................................................... 304 DISASSEMBLY................................................................ 304 ASSEMBLY................................................................... 308 OVERRUNNING CLUTCH/LOW-REVERSE DRUM............................................ 313 DISASSEMBLY................................................................ 313 ASSEMBLY................................................................... 313 FRONT SERVO PISTON............................................................. 313 DISASSEMBLY................................................................ 313 ASSEMBLY................................................................... 314 REAR SERVO PISTON.............................................................. 314 DISASSEMBLY................................................................ 314 ASSEMBLY................................................................... 314 OIL PUMP AND REACTION SHAFT SUPPORT............................................ 315 DISASSEMBLY................................................................ 315 ASSEMBLY................................................................... 316 FRONT CLUTCH................................................................... 318 DISASSEMBLY................................................................ 318 ASSEMBLY................................................................... 318 REAR CLUTCH.................................................................... 319 DISASSEMBLY................................................................ 319 ASSEMBLY................................................................... 320 PLANETARY GEARTRAIN/OUTPUT SHAFT............................................... 322 DISASSEMBLY................................................................ 322 ASSEMBLY................................................................... 322 CLEANING AND INSPECTION............................................................ 326 GOVERNOR AND PARK GEAR......................................................... 326 EXTENSION HOUSING AND PARK LOCK................................................ 328 VALVE BODY..................................................................... 328 TRANSMISSION................................................................... 329 OVERRUNNING CLUTCH/LOW-REVERSE DRUM/OVERDRIVE PISTON RETAINER.................. 330 FRONT SERVO.................................................................... 330 REAR SERVO..................................................................... 330 OIL PUMP AND REACTION SHAFT SUPPORT............................................ 331 FRONT CLUTCH................................................................... 331 REAR CLUTCH.................................................................... 331 PLANETARY GEARTRAIN/OUTPUT SHAFT............................................... 332 ADJUSTMENTS........................................................................ 332 GEARSHIFT CABLE................................................................ 332 Gearshift Adjustment Procedure............................................. 332 BRAKE TRANSMISSION SHIFT INTERLOCK CABLE ADJUSTMENT............................ 333 TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT................................... 333 Checking Throttle Valve Cable Adjustment................................... 334 Throttle Valve Cable Adjustment Procedure.................................. 334 FRONT BAND ADJUSTMENT.......................................................... 334 REAR BAND ADJUSTMENT........................................................... 335 VALVE BODY..................................................................... 335 CONTROL PRESSURE ADJUSTMENTS............................................... 335 SCHEMATICS AND DIAGRAMS............................................................ 336 HYDRAULIC SCHEMATICS........................................................... 336 SPECIFICATIONS..................................................................... 349 30RH AUTOMATIC TRANSMISSION.................................................... 349 GENERAL.................................................................... 349 THRUST WASHER/SPACER/SNAP RING DIMENSIONS.................................. 349 PRESSURE TEST-ALL.......................................................... 349 TORQUE......................................................................... 350 SPECIAL TOOLS...................................................................... 350 30RH TRANSMISSIONS............................................................. 350 AW-4 AUTOMATIC TRANSMISSION............................................................ 355 GENERAL INFORMATION................................................................ 356 AW-4 AUTOMATIC TRANSMISSION.................................................... 356 TRANSMISSION IDENTIFICATION.................................................... 356 RECOMMENDED FLUID CAPACITY..................................................... 356 EFFECTS OF INCORRECT FLUID LEVEL............................................... 356 CAUSES OF BURNT FLUID.......................................................... 357 FLUID CONTAMINATION............................................................ 357 TRANSMISSION RANGES AND SHIFT LEVER POSITIONS.................................. 357 DESCRIPTION AND OPERATION.......................................................... 358 ELECTRONIC CONTROLS............................................................ 358 TRANSMISSION CONTROL MODULE (TCM).............................................. 358 TRANSMISSION VALVE BODY SOLENOIDS.............................................. 358 SENSORS........................................................................ 358 TORQUE CONVERTER............................................................... 358 FOURTH GEAR OVERDRIVE COMPONENTS............................................... 358 FIRST/SECOND/THIRD/REVERSE GEAR COMPONENTS..................................... 359 GEARTRAIN OPERATION AND APPLICATION CHARTS..................................... 360 HYDRAULIC SYSTEM............................................................... 361 OIL PUMP....................................................................... 361 TRANSMISSION VALVE BODY COMPONENTS............................................. 361 MANUAL VALVE............................................................... 362 PRIMARY REGULATOR VALVE.................................................... 362 THROTTLE VALVE AND DOWNSHIFT PLUG.......................................... 363 CUT-BACK VALVE............................................................. 363 SECONDARY REGULATOR VALVE.................................................. 363 CONVERTER CLUTCH RELAY VALVE............................................... 364 1-2 SHIFT VALVE............................................................ 364 2-3 SHIFT VALVE............................................................ 364 3-4 SHIFT VALVE............................................................ 365 SECOND COAST MODULATOR VALVE............................................... 366 LOW COAST MODULATOR VALVE.................................................. 366 ACCUMULATOR CONTROL VALVE.................................................. 367 ACCUMULATORS............................................................... 367 TRANSMISSION VALVE BODY SOLENOIDS.......................................... 367 TRANSMISSION COOLER............................................................ 368 MAIN COOLER................................................................ 368 AUXILIARY COOLER........................................................... 368 COOLER SERVICE............................................................. 368 BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM................................... 368 DIAGNOSIS AND TESTING.............................................................. 369 GENERAL DIAGNOSIS INFORMATION.................................................. 369 PRELIMINARY INSPECTION AND ADJUSTMENT.......................................... 369 MANUAL SHIFTING TEST........................................................... 370 HYDRAULIC PRESSURE TEST........................................................ 371 Pressure Test Procedure.................................................... 371 PRESSURE TEST ANALYSIS......................................................... 371 TORQUE CONVERTER STALL TEST.................................................... 371 STALL SPEED TEST ANALYSIS...................................................... 372 TIME LAG TEST.................................................................. 372 TEST PROCEDURE................................................................. 372 TIME LAG TEST ANALYSIS......................................................... 372 SERVICE DIAGNOSIS.............................................................. 372 TRANSMISSION SOLENOID TESTING.................................................. 372 PARK/NEUTRAL POSITION SWITCH................................................... 375 SWITCH TESTING............................................................. 375 GEARSHIFT CABLE................................................................ 375 THROTTLE VALVE CABLE........................................................... 375 SPEED SENSOR TESTING........................................................... 375 FLOW TESTING TRANSMISSION MAIN COOLER.......................................... 376 TORQUE CONVERTER STATOR CLUTCH INSPECTION...................................... 376 SERVICE PROCEDURES................................................................. 377 CHECKING FLUID LEVEL........................................................... 377 CHECKING FLUID CONDITION....................................................... 377 REFILLING AFTER OVERHAUL OR FLUID/FILTER CHANGE................................ 377 TRANSMISSION CONTROL MODULE (TCM) SERVICE...................................... 377 OIL PUMP VOLUME CHECK.......................................................... 377 FLUSHING COOLERS AND TUBES..................................................... 378 COOLER FLUSH USING TOOL 6906............................................... 378 ALUMINUM THREAD REPAIR......................................................... 378 REMOVAL AND INSTALLATION........................................................... 379 TRANSMISSION AND TORQUE CONVERTER.............................................. 379 REMOVAL.................................................................... 379 INSTALLATION............................................................... 379 TORQUE CONVERTER............................................................... 380 REMOVAL.................................................................... 380 INSTALLATION............................................................... 380 ADAPTER HOUSING SEAL........................................................... 381 REMOVAL.................................................................... 381 INSTALLATION............................................................... 381 SPEED SENSOR................................................................... 381 REMOVAL.................................................................... 381 INSTALLATION............................................................... 381 SPEEDOMETER ADAPTER............................................................ 381 REMOVAL.................................................................... 381 INSTALLATION............................................................... 382 SPEED SENSOR ROTOR-SPEEDOMETER DRIVE GEAR...................................... 382 REMOVAL.................................................................... 382 INSTALLATION............................................................... 382 PARK/NEUTRAL POSITION SWITCH................................................... 383 REMOVAL.................................................................... 383 INSTALLATION............................................................... 383 GEARSHIFT CABLE................................................................ 384 REMOVAL.................................................................... 384 INSTALLATION............................................................... 384 BRAKE TRANSMISSION SHIFT INTERLOCK............................................. 385 REMOVAL.................................................................... 385 INSTALLATION............................................................... 385 TRANSMISSION VALVE BODY SOLENOIDS.............................................. 385 REMOVAL.................................................................... 385 INSTALLATION............................................................... 385 TRANSMISSION VALVE BODY........................................................ 386 REMOVAL.................................................................... 386 INSTALLATION............................................................... 387 TRANSMISSION CONTROL MODULE.................................................... 388 SOLENOID HARNESS ADAPTER SEAL.................................................. 388 REMOVAL.................................................................... 388 INSTALLATION............................................................... 389 MANUAL VALVE SHAFT SEAL........................................................ 390 REMOVAL.................................................................... 390 INSTALLATION............................................................... 390 ACCUMULATOR PISTONS AND SPRINGS................................................ 391 REMOVAL.................................................................... 391 INSTALLATION............................................................... 392 SECOND COAST BRAKE SERVO....................................................... 392 REMOVAL.................................................................... 392 INSTALLATION............................................................... 393 PARK ROD AND PAWL.............................................................. 393 REMOVAL.................................................................... 393 INSTALLATION............................................................... 394 TRANSMISSION THROTTLE CABLE.................................................... 394 REMOVAL.................................................................... 394 INSTALLATION............................................................... 395 OIL PUMP SEAL.................................................................. 395 REMOVAL.................................................................... 395 INSTALLATION............................................................... 395 DISASSEMBLY AND ASSEMBLY........................................................... 396 TRANSMISSION................................................................... 396 DISASSEMBLY................................................................ 396 ASSEMBLY................................................................... 407 OIL PUMP....................................................................... 424 DISASSEMBLY................................................................ 424 ASSEMBLY................................................................... 424 OVERDRIVE PLANETARY GEAR AND CLUTCH............................................ 426 DISASSEMBLY................................................................ 426 ASSEMBLY................................................................... 430 OVERDRIVE SUPPORT.............................................................. 432 DISASSEMBLY................................................................ 432 ASSEMBLY................................................................... 434 DIRECT CLUTCH.................................................................. 435 DISASSEMBLY................................................................ 435 ASSEMBLY................................................................... 437 FORWARD CLUTCH................................................................. 439 DISASSEMBLY................................................................ 439 ASSEMBLY................................................................... 441 FRONT PLANETARY GEAR........................................................... 444 DISASSEMBLY................................................................ 444 ASSEMBLY................................................................... 445 SUN GEAR AND NO. 1 ONE-WAY CLUTCH.............................................. 446 DISASSEMBLY................................................................ 447 ASSEMBLY................................................................... 448 SECOND BRAKE................................................................... 448 DISASSEMBLY................................................................ 448 ASSEMBLY................................................................... 450 PLANETARY/BRAKE PACK/OUTPUT SHAFT.............................................. 452 DISASSEMBLY................................................................ 452 ASSEMBLY................................................................... 455 TRANSMISSION VALVE BODY........................................................ 456 CLEANING AND INSPECTION............................................................ 459 TRANSMISSION PARTS CLEANING AND INSPECTION..................................... 459 ADJUSTMENTS........................................................................ 459 GEARSHIFT CABLE................................................................ 459 Gearshift Adjustment Procedure............................................. 459 BRAKE TRANSMISSION SHIFT INTERLOCK CABLE ADJUSTMENT............................ 459 TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT................................... 460 Checking Throttle Valve Cable Adjustment................................... 460 Throttle Valve Cable Adjustment Procedure.................................. 460 SPECIFICATIONS..................................................................... 461 AW-4 AUTOMATIC TRANSMISSION.................................................... 461 AW-4 GENERAL SPECIFICATIONS................................................ 462 AW-4 OIL PUMP WEAR LIMITS.................................................. 463 AW-4 CLUTCH DISC AND PLATE THICKNESS....................................... 463 AW-4 BUSHING AND PISTON CLEARANCE.......................................... 464 AW-4 RETAINER AND PISTON SPECIFICATIONS.................................... 465 AW-4 VALVE BODY BALL DIMENSIONS............................................ 466 AW-4 CLUTCH AND BRAKE PACK REQUIREMENTS.................................... 466 AW-4 VALVE AND SPRING IDENTIFICATION....................................... 467 AW-4 ACCUMULATOR COMPONENT IDENTIFICATION.................................. 468 AW-4 TORQUE SPECIFICATIONS................................................. 469 SPECIAL TOOLS...................................................................... 470 AW-4........................................................................... 470 NV231 TRANSFER CASE.................................................................... 472 GENERAL INFORMATION................................................................ 472 NV231 TRANSFER CASE............................................................ 472 OPERATING RANGES........................................................... 472 SHIFT MECHANISM............................................................ 472 TRANSFER CASE IDENTIFICATION................................................... 472 RECOMMENDED LUBRICANT AND FILL LEVEL........................................... 473 DIAGNOSIS AND TESTING.............................................................. 473 NV231 DIAGNOSIS................................................................ 473 REMOVAL AND INSTALLATION........................................................... 474 TRANSFER CASE.................................................................. 474 REMOVAL.................................................................... 474 INSTALLATION............................................................... 474 SHIFT LEVER.................................................................... 474 REMOVAL.................................................................... 474 INSTALLATION............................................................... 474 SPEEDOMETER.................................................................... 474 REMOVAL.................................................................... 474 INSTALLATION AND INDEXING.................................................. 475 FRONT OUTPUT SHAFT SEAL........................................................ 475 REMOVAL.................................................................... 475 INSTALLATION............................................................... 476 DISASSEMBLY AND ASSEMBLY........................................................... 477 NV231 TRANSFER CASE............................................................ 477 DISASSEMBLY................................................................ 477 ASSEMBLY................................................................... 482 CLEANING AND INSPECTION............................................................ 491 NV231 TRANSFER CASE............................................................ 491 MAINSHAFT/SPROCKET/HUB INSPECTION.......................................... 491 INPUT GEAR AND PLANETARY CARRIER........................................... 491 SHIFT FORKS/HUBS/SLEEVES................................................... 492 REAR RETAINER/BEARING/SEAL/SLINGER/BOOT.................................... 493 REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN......................................... 493 LOW RANGE ANNULUS GEAR..................................................... 493 FRONT-REAR CASES AND FRONT RETAINER........................................ 493 OIL PUMP/OIL PICKUP........................................................ 493 ADJUSTMENTS........................................................................ 495 SHIFT LINKAGE ADJUSTMENT....................................................... 495 SPECIFICATIONS..................................................................... 495 TORQUE......................................................................... 495 SPECIAL TOOLS...................................................................... 495 NV231.......................................................................... 495 NV242 TRANSFER CASE.................................................................... 498 GENERAL INFORMATION................................................................ 498 NV242 TRANSFER CASE............................................................ 498 OPERATING RANGES........................................................... 498 SHIFT MECHANISM............................................................ 498 TRANSFER CASE IDENTIFICATION................................................... 498 RECOMMENDED LUBRICANT AND FILL LEVEL........................................... 499 DIAGNOSIS AND TESTING.............................................................. 499 NV242 DIAGNOSIS................................................................ 499 REMOVAL AND INSTALLATION........................................................... 500 TRANSFER CASE.................................................................. 500 REMOVAL.................................................................... 500 INSTALLATION............................................................... 500 SHIFT LEVER.................................................................... 500 REMOVAL.................................................................... 500 INSTALLATION............................................................... 500 SPEEDOMETER.................................................................... 500 REMOVAL.................................................................... 500 INSTALLATION AND INDEXING.................................................. 501 FRONT OUTPUT SHAFT SEAL........................................................ 501 REMOVAL.................................................................... 501 INSTALLATION............................................................... 502 DISASSEMBLY AND ASSEMBLY........................................................... 503 NV242 TRANSFER CASE............................................................ 503 DISASSEMBLY................................................................ 503 ASSEMBLY................................................................... 511 CLEANING AND INSPECTION............................................................ 522 NV242 TRANSFER CASE............................................................ 522 MAINSHAFT/SPROCKET/HUB INSPECTION.......................................... 522 INPUT GEAR AND PLANETARY CARRIER........................................... 522 SHIFT FORKS/HUBS/SLEEVES................................................... 523 REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT................................... 523 REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN......................................... 523 LOW RANGE ANNULUS GEAR..................................................... 524 FRONT-REAR CASES AND FRONT RETAINER........................................ 524 OIL PUMP/OIL PICKUP........................................................ 525 ADJUSTMENTS........................................................................ 525 SHIFT LINKAGE ADJUSTMENT....................................................... 525 SPECIFICATIONS..................................................................... 526 TORQUE......................................................................... 526 SPECIAL TOOLS...................................................................... 526 NV242.......................................................................... 526 TIRES AND WHEELS........................................................................... 541 TIRES.................................................................................. 541 DESCRIPTION AND OPERATION.......................................................... 541 TIRE INFORMATION............................................................... 541 TIRE IDENTIFICATION........................................................ 541 TIRE CHAINS................................................................ 541 RADIAL-PLY TIRES............................................................... 542 SPARE TIRE-TEMPORARY........................................................... 542 TIRE INFLATION PRESSURES....................................................... 542 TIRE PRESSURE FOR HIGH SPEED OPERATION......................................... 543 REPLACEMENT TIRES.............................................................. 543 DIAGNOSIS AND TESTING.............................................................. 543 PRESSURE GAUGES................................................................ 543 TREAD WEAR INDICATORS.......................................................... 543 TIRE WEAR PATTERNS............................................................. 543 TIRE NOISE OR VIBRATION........................................................ 544 SERVICE PROCEDURES................................................................. 544 ROTATION....................................................................... 544 MATCH MOUNTING................................................................. 544 REPAIRING LEAKS................................................................ 545 CLEANING AND INSPECTION............................................................ 546 CLEANING TIRES................................................................. 546 SPECIFICATIONS..................................................................... 546 TIRE SIZE...................................................................... 546 WHEELS................................................................................. 547 DESCRIPTION AND OPERATION.......................................................... 547 WHEEL.......................................................................... 547 DIAGNOSIS AND TESTING.............................................................. 547 WHEEL INSPECTION............................................................... 547 TIRE AND WHEEL RUNOUT.......................................................... 547 METHOD 1 (RELOCATE WHEEL ON HUB)........................................... 548 METHOD 2 (RELOCATE TIRE ON WHEEL).......................................... 548 SERVICE PROCEDURES................................................................. 548 WHEEL INSTALLATION............................................................. 548 WHEEL REPLACEMENT.......................................................... 549 TIRE AND WHEEL BALANCE......................................................... 549 SPECIFICATIONS..................................................................... 550 TORQUE CHART................................................................... 550 BODY....................................................................................... 551 GENERAL SERVICE INFORMATION............................................................ 551 GENERAL INFORMATION................................................................ 551 SAFETY PRECAUTIONS AND WARNINGS................................................ 551 PAINT.................................................................................. 552 GENERAL INFORMATION................................................................ 552 PAINT CODE..................................................................... 552 BASE COAT/CLEAR COAT FINISH.................................................... 552 WET SANDING, BUFFING, AND POLISHING............................................ 552 PAINTED SURFACE TOUCH-UP....................................................... 552 TOUCH-UP PROCEDURE......................................................... 552 SPECIFICATIONS..................................................................... 553 AFTERMARKET PAINT REPAIR PRODUCTS.............................................. 553 EXTERIOR COLOR............................................................. 553 INTERIOR COLOR............................................................. 553 STATIONARY GLASS....................................................................... 554 DESCRIPTION AND OPERATION.......................................................... 554 SAFETY PRECAUTIONS............................................................. 554 REMOVAL AND INSTALLATION........................................................... 554 WINDSHIELD..................................................................... 554 REMOVAL.................................................................... 554 INSTALLATION-SHORT METHOD.................................................. 555 INSTALLATION-EXTENDED METHOD............................................... 556 REAR DOOR STATIONARY WINDOW GLASS.............................................. 557 REMOVAL.................................................................... 557 INSTALLATION............................................................... 558 REAR QUARTER WINDOW GLASS...................................................... 558 REMOVAL.................................................................... 558 INSTALLATION............................................................... 558 LIFTGATE GLASS................................................................. 559 REMOVAL.................................................................... 559 INSTALLATION............................................................... 559 SEATS.................................................................................. 560 REMOVAL AND INSTALLATION........................................................... 560 HEAD RESTRAINT SLEEVE.......................................................... 560 REMOVAL.................................................................... 560 INSTALLATION............................................................... 560 HEAD RESTRAINT COVER........................................................... 561 REMOVAL.................................................................... 561 INSTALLATION............................................................... 561 BUCKET SEAT.................................................................... 561 REMOVAL.................................................................... 561 INSTALLATION............................................................... 561 BUCKET SEAT TRACK.............................................................. 562 REMOVAL.................................................................... 562 INSTALLATION............................................................... 562 BUCKET SEAT PLATFORM........................................................... 562 BUCKET SEATBACK COVER.......................................................... 562 REMOVAL.................................................................... 562 INSTALLATION............................................................... 562 BUCKET SEATBACK................................................................ 563 REMOVAL.................................................................... 563 INSTALLATION............................................................... 563 BUCKET SEAT CUSHION COVER...................................................... 563 REMOVAL.................................................................... 563 INSTALLATION............................................................... 563 BUCKET SEAT RECLINER........................................................... 564 REMOVAL.................................................................... 564 INSTALLATION............................................................... 564 REAR SEAT CUSHION.............................................................. 564 REMOVAL.................................................................... 564 INSTALLATION............................................................... 565 REAR SEATBACK.................................................................. 565 REMOVAL.................................................................... 565 INSTALLATION............................................................... 565 REAR SEAT CUSHION COVER........................................................ 565 REMOVAL.................................................................... 565 INSTALLATION............................................................... 565 REAR SEATBACK LATCH STRIKER AND BUMPER......................................... 565 REMOVAL.................................................................... 565 INSTALLATION............................................................... 565 REAR SEATBACK COVER............................................................ 566 REMOVAL.................................................................... 566 INSTALLATION............................................................... 566 SPECIAL TOOLS...................................................................... 566 SEATS.......................................................................... 566 BODY COMPONENT SERVICE................................................................. 567 DIAGNOSIS AND TESTING.............................................................. 568 WATER LEAKS.................................................................... 568 VISUAL INSPECTION BEFORE WATER LEAK TESTS.................................. 568 WATER LEAK TESTS........................................................... 568 WATER LEAK DETECTION....................................................... 568 WIND NOISE..................................................................... 569 VISUAL INSPECTION BEFORE TESTS............................................. 569 SERVICE PROCEDURES................................................................. 569 BODY LUBRICATION............................................................... 569 REMOVAL AND INSTALLATION........................................................... 570 GRILLE......................................................................... 570 REMOVAL.................................................................... 570 INSTALLATION............................................................... 570 GRILLE OPENING PANEL (GOP)..................................................... 570 REMOVAL.................................................................... 570 INSTALLATION............................................................... 570 HOOD........................................................................... 570 REMOVAL.................................................................... 570 INSTALLATION............................................................... 570 HOOD HINGE..................................................................... 570 REMOVAL.................................................................... 570 INSTALLATION............................................................... 572 HOOD LATCH..................................................................... 572 REMOVAL.................................................................... 572 INSTALLATION............................................................... 572 HOOD LATCH STRIKER............................................................. 572 REMOVAL.................................................................... 572 INSTALLATION............................................................... 572 HOOD RELEASE CABLE............................................................. 572 REMOVAL.................................................................... 572 INSTALLATION............................................................... 572 HOOD SAFETY LATCH.............................................................. 573 REMOVAL.................................................................... 573 INSTALLATION............................................................... 573 SAFETY LATCH STRIKER........................................................... 573 REMOVAL.................................................................... 573 INSTALLATION............................................................... 573 HOOD SILENCER PAD.............................................................. 573 REMOVAL.................................................................... 573 INSTALLATION............................................................... 574 COWL WEATHERSTRIP.............................................................. 574 REMOVAL.................................................................... 574 INSTALLATION............................................................... 574 COWL GRILLE.................................................................... 574 REMOVAL.................................................................... 574 INSTALLATION............................................................... 574 BODY DECALS.................................................................... 574 REMOVAL.................................................................... 575 INSTALLATION............................................................... 575 EXTERIOR NAMEPLATES............................................................ 575 REMOVAL.................................................................... 575 INSTALLATION............................................................... 576 SIDE VIEW MIRROR............................................................... 576 REMOVAL.................................................................... 576 INSTALLATION............................................................... 576 FRONT FENDER FLARE............................................................. 576 REMOVAL.................................................................... 576 INSTALLATION............................................................... 577 FRONT WHEELHOUSE LINER......................................................... 577 REMOVAL.................................................................... 577 INSTALLATION............................................................... 577 RIGHT FRONT FENDER............................................................. 577 REMOVAL.................................................................... 577 INSTALLATION............................................................... 577 LEFT FRONT FENDER.............................................................. 577 REMOVAL.................................................................... 577 INSTALLATION............................................................... 578 FRONT DOOR TRIM PANEL.......................................................... 578 REMOVAL.................................................................... 578 INSTALLATION............................................................... 578 FRONT DOOR WATERDAM............................................................ 579 REMOVAL.................................................................... 579 INSTALLATION............................................................... 580 FRONT DOOR..................................................................... 580 REMOVAL.................................................................... 580 INSTALLATION............................................................... 580 FRONT DOOR HINGE............................................................... 580 REMOVAL.................................................................... 580 INSTALLATION............................................................... 580 FRONT DOOR RESTRAINT........................................................... 580 REMOVAL.................................................................... 580 INSTALLATION............................................................... 581 FRONT DOOR OUTSIDE HANDLE...................................................... 581 REMOVAL.................................................................... 581 INSTALLATION............................................................... 581 FRONT DOOR LOCK CYLINDER....................................................... 581 REMOVAL.................................................................... 581 INSTALLATION............................................................... 581 FRONT DOOR LATCH............................................................... 581 REMOVAL.................................................................... 581 INSTALLATION............................................................... 581 FRONT DOOR LATCH STRIKER....................................................... 582 REMOVAL.................................................................... 582 INSTALLATION............................................................... 582 FRONT DOOR INSIDE HANDLE ACTUATOR.............................................. 582 REMOVAL.................................................................... 582 INSTALLATION............................................................... 582 FRONT DOOR INNER BELT WEATHERSTRIP............................................. 582 REMOVAL.................................................................... 582 INSTALLATION............................................................... 582 FRONT DOOR OUTER BELT WEATHERSTRIP............................................. 582 REMOVAL.................................................................... 582 INSTALLATION............................................................... 582 FRONT DOOR GLASS RUN CHANNEL WEATHERSTRIP...................................... 583 REMOVAL.................................................................... 583 INSTALLATION............................................................... 583 FRONT DOOR OPENING WEATHERSTRIP................................................ 583 REMOVAL.................................................................... 583 INSTALLATION............................................................... 583 FRONT DOOR OPENING SECONDARY WEATHERSTRIP...................................... 583 REMOVAL.................................................................... 583 INSTALLATION............................................................... 584 FRONT DOOR GLASS EXTERIOR MOLDING.............................................. 584 REMOVAL.................................................................... 584 INSTALLATION............................................................... 584 FRONT DOOR WINDOW REGULATOR.................................................... 584 REMOVAL.................................................................... 584 INSTALLATION............................................................... 584 FRONT DOOR SPACER BLOCKS-TWO-DOOR VEHICLES..................................... 584 REMOVAL.................................................................... 584 INSTALLATION............................................................... 584 FRONT DOOR GLASS............................................................... 585 REMOVAL.................................................................... 585 INSTALLATION............................................................... 585 REAR DOOR TRIM PANEL........................................................... 586 REMOVAL.................................................................... 586 INSTALLATION............................................................... 587 REAR DOOR WATERDAM............................................................. 587 REMOVAL.................................................................... 587 INSTALLATION............................................................... 587 REAR DOOR...................................................................... 587 REMOVAL.................................................................... 587 INSTALLATION............................................................... 587 REAR DOOR RESTRAINT............................................................ 587 REMOVAL.................................................................... 587 INSTALLATION............................................................... 588 REAR DOOR HINGE................................................................ 588 REMOVAL.................................................................... 588 INSTALLATION............................................................... 588 REAR DOOR OUTSIDE HANDLE....................................................... 588 REMOVAL.................................................................... 588 INSTALLATION............................................................... 588 REAR DOOR LATCH................................................................ 588 REMOVAL.................................................................... 588 INSTALLATION............................................................... 589 REAR DOOR LATCH STRIKER........................................................ 589 REMOVAL.................................................................... 589 INSTALLATION............................................................... 589 REAR DOOR INSIDE HANDLE ACTUATOR............................................... 589 REMOVAL.................................................................... 589 INSTALLATION............................................................... 589 REAR DOOR INNER BELT WEATHERSTRIP.............................................. 589 REMOVAL.................................................................... 589 INSTALLATION............................................................... 589 REAR DOOR OUTER BELT WEATHERSTRIP.............................................. 589 REMOVAL.................................................................... 589 INSTALLATION............................................................... 589 REAR DOOR GLASS RUN CHANNEL WEATHERSTRIP....................................... 589 REMOVAL.................................................................... 589 INSTALLATION............................................................... 590 REAR DOOR GLASS EXTERIOR MOLDING............................................... 590 REMOVAL.................................................................... 590 INSTALLATION............................................................... 590 REAR DOOR WEATHERSTRIP......................................................... 590 REMOVAL.................................................................... 590 INSTALLATION............................................................... 590 REAR DOOR WINDOW REGULATOR..................................................... 590 REMOVAL.................................................................... 590 INSTALLATION............................................................... 591 REAR DOOR WINDOW GLASS......................................................... 591 REMOVAL.................................................................... 591 INSTALLATION............................................................... 591 BODY SIDE MOLDING.............................................................. 592 REMOVAL.................................................................... 592 INSTALLATION............................................................... 592 REAR FENDER FLARE.............................................................. 592 REMOVAL.................................................................... 592 INSTALLATION............................................................... 592 QUARTER WINDOW APPLIQUE........................................................ 592 REMOVAL.................................................................... 592 INSTALLATION............................................................... 592 DRIP RAIL MOLDING.............................................................. 592 REMOVAL.................................................................... 592 INSTALLATION............................................................... 592 LUGGAGE RACK................................................................... 593 REMOVAL.................................................................... 593 INSTALLATION............................................................... 593 AIR EXHAUST GRILLE............................................................. 593 REMOVAL.................................................................... 593 INSTALLATION............................................................... 593 A-PILLAR TRIM.................................................................. 594 REMOVAL.................................................................... 594 INSTALLATION............................................................... 594 LOWER A-PILLAR COWL TRIM....................................................... 594 REMOVAL.................................................................... 594 INSTALLATION............................................................... 594 FRONT INNER SCUFF PLATE........................................................ 595 REMOVAL.................................................................... 595 INSTALLATION............................................................... 595 DOOR SILL SCUFF PLATE.......................................................... 595 REMOVAL.................................................................... 595 INSTALLATION............................................................... 595 ASSIST HANDLE.................................................................. 595 REMOVAL.................................................................... 595 INSTALLATION............................................................... 595 B-PILLAR TRIM.................................................................. 595 REMOVAL.................................................................... 595 INSTALLATION............................................................... 595 C-PILLAR TRIM.................................................................. 595 REMOVAL.................................................................... 595 INSTALLATION............................................................... 596 QUARTER PANEL TRIM EXTENSION................................................... 596 REMOVAL.................................................................... 596 INSTALLATION............................................................... 596 QUARTER PANEL TRIM AND WHEELHOUSE COVER........................................ 596 REMOVAL.................................................................... 596 INSTALLATION............................................................... 596 LIFTGATE PILLAR TRIM........................................................... 597 REMOVAL.................................................................... 597 INSTALLATION............................................................... 597 LIFTGATE OPENING UPPER TRIM.................................................... 597 REMOVAL.................................................................... 597 INSTALLATION............................................................... 597 LIFTGATE SCUFF PLATE........................................................... 598 REMOVAL.................................................................... 598 INSTALLATION............................................................... 598 FRONT SHOULDER BELT/BUCKLE..................................................... 598 REMOVAL.................................................................... 598 INSTALLATION............................................................... 598 REAR SHOULDER/LAP BELT/BUCKLE.................................................. 599 REMOVAL.................................................................... 599 INSTALLATION............................................................... 599 FULL FLOOR CONSOLE............................................................. 600 REMOVAL.................................................................... 600 INSTALLATION............................................................... 600 FRONT CARPET/MAT............................................................... 600 REMOVAL.................................................................... 600 INSTALLATION............................................................... 600 REAR CARPET/MAT................................................................ 600 REMOVAL.................................................................... 600 INSTALLATION............................................................... 600 REARVIEW MIRROR................................................................ 601 REMOVAL.................................................................... 601 INSTALLATION............................................................... 601 REARVIEW MIRROR SUPPORT BRACKET................................................ 601 INSTALLATION............................................................... 601 SUNVISORS...................................................................... 602 REMOVAL.................................................................... 602 INSTALLATION............................................................... 602 HEADLINER...................................................................... 602 REMOVAL.................................................................... 602 INSTALLATION............................................................... 602 LIFTGATE TRIM PANEL............................................................ 603 REMOVAL.................................................................... 603 INSTALLATION............................................................... 603 LIFTGATE....................................................................... 604 REMOVAL.................................................................... 604 INSTALLATION............................................................... 604 LIFTGATE HINGE................................................................. 604 REMOVAL.................................................................... 604 INSTALLATION............................................................... 604 LIFTGATE SUPPORT ROD CYLINDER.................................................. 604 REMOVAL.................................................................... 604 INSTALLATION............................................................... 604 LIFTGATE SUPPORT ROD BALL STUD................................................. 605 REMOVAL.................................................................... 605 INSTALLATION............................................................... 605 LIFTGATE OUTSIDE HANDLE........................................................ 605 REMOVAL.................................................................... 605 INSTALLATION............................................................... 605 LIFTGATE LOCK CYLINDER......................................................... 605 LIFTGATE LATCH................................................................. 605 REMOVAL.................................................................... 605 INSTALLATION............................................................... 605 LIFTGATE LATCH STRIKER......................................................... 606 REMOVAL.................................................................... 606 INSTALLATION............................................................... 606 LIFTGATE WEATHERSTRIP.......................................................... 606 REMOVAL.................................................................... 606 INSTALLATION............................................................... 606 ADJUSTMENTS........................................................................ 607 HOOD........................................................................... 607 DOOR........................................................................... 607 IN AND OUT-MINOR ADJUSTMENT................................................ 607 UP AND DOWN-MINOR ADJUSTMENT............................................... 607 ALIGNMENT MAJOR-ADJUSTMENT................................................. 607 DOOR LATCH ADJUSTMENT.......................................................... 607 LIFTGATE....................................................................... 608 REAR SEATBACK.................................................................. 608 SPECIFICATIONS..................................................................... 608 BODY LUBRICANTS................................................................ 608 WELD LOCATIONS................................................................. 609 UPPER COWL................................................................. 609 UPPER COWL................................................................. 610 COWL....................................................................... 611 A-PILLAR................................................................... 612 A-PILLAR................................................................... 613 A-PILLAR................................................................... 614 A-PILLAR................................................................... 615 B-PILLAR................................................................... 616 D-PILLAR................................................................... 617 FUEL FILLER OPENING........................................................ 618 CARGO AREA FLOOR PAN....................................................... 619 ROOF AND D-PILLAR.......................................................... 620 LIFTGATE OPENING........................................................... 621 ROOF....................................................................... 622 ROOF....................................................................... 623 FRAME RAIL................................................................. 624 FRAME RAIL................................................................. 625 FRAME RAIL................................................................. 626 FRAME RAIL................................................................. 627 REINFORCEMENT.............................................................. 628 FRONT INNER FENDER......................................................... 629 FRONT INNER FENDER AND RADIATOR CLOSURE PANEL.............................. 630 REINFORCEMENT.............................................................. 631 FRONT FENDER............................................................... 631 BODY SIDE.................................................................. 632 REAR WHEELHOUSE............................................................ 633 REAR INNER WHEELHOUSE...................................................... 634 BODY SIDE.................................................................. 635 BODY SIDE.................................................................. 636 BODY SIDE.................................................................. 637 BODY SIDE.................................................................. 638 BODY SIDE.................................................................. 639 BODY SIDE.................................................................. 640 UNDERBODY.................................................................. 641 UNDERBODY.................................................................. 642 UNDERBODY.................................................................. 643 UNDERBODY.................................................................. 644 UNDERBODY.................................................................. 645 UNDERBODY.................................................................. 646 UNDERBODY.................................................................. 647 UNDERBODY.................................................................. 648 UNDERBODY.................................................................. 649 UNDERBODY.................................................................. 650 UNDERBODY.................................................................. 651 BODY SEALING LOCATIONS......................................................... 652 APPLICATION METHODS........................................................ 652 COWL AND DASH PANEL........................................................ 653 DASH PANEL AND FLOOR PAN................................................... 654 FLOOR PAN.................................................................. 655 REAR INNER WHEELHOUSE...................................................... 656 FRONT INNER WHEELHOUSE..................................................... 657 BODY SIDE.................................................................. 658 BODY SIDE.................................................................. 659 BODY SIDE.................................................................. 660 ROOF PANEL................................................................. 661 FUEL FILLER HOUSING........................................................ 662 LIFTGATE OPENING........................................................... 663 STRUCTURAL ADHESIVE LOCATIONS.................................................. 664 LEFT QUARTER PANEL......................................................... 664 REAR WHEELHOUSE............................................................ 665 ROOF BOWS.................................................................. 666 BODY GAP AND FLUSH MEASUREMENTS................................................ 667 BODY OPENING DIMENSIONS........................................................ 668 WINDSHIELD OPENING......................................................... 668 FRONT DOOR OPENING 2-DOOR.................................................. 669 FRONT DOOR OPENING 4-DOOR.................................................. 670 REAR DOOR OPENING.......................................................... 671 QUARTER WINDOW OPENING 2-DOOR.............................................. 672 QUARTER WINDOW OPENING 4-DOOR.............................................. 673 ENGINE COMPARTMENT......................................................... 674 LIFTGATE OPENING........................................................... 675 TORQUE SPECIFICATIONS.......................................................... 675 SPECIAL TOOLS...................................................................... 676 BODY........................................................................... 676 HEATING AND AIR CONDITIONING............................................................... 677 GENERAL INFORMATION.................................................................... 678 HEATER AND AIR CONDITIONER......................................................... 678 HEATER AND AIR CONDITIONER CONTROL................................................. 678 SERVICE WARNINGS AND PRECAUTIONS................................................... 679 COOLING SYSTEM REQUIREMENTS.................................................... 679 COOLANT PRECAUTIONS............................................................ 680 REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS...................................... 680 DESCRIPTION AND OPERATION.............................................................. 680 ACCUMULATOR........................................................................ 680 BLOWER MOTOR....................................................................... 680 BLOWER MOTOR RESISTOR.............................................................. 681 BLOWER MOTOR SWITCH................................................................ 681 COMPRESSOR......................................................................... 681 BLOWER MOTOR RELAY................................................................. 681 COMPRESSOR CLUTCH.................................................................. 682 CONDENSER.......................................................................... 682 EVAPORATOR COIL.................................................................... 682 FIXED ORIFICE TUBE................................................................. 682 COMPRESSOR CLUTCH RELAY............................................................ 682 HEATER CORE........................................................................ 682 HIGH PRESSURE CUT-OFF SWITCH....................................................... 683 REFRIGERANT........................................................................ 683 HIGH PRESSURE RELIEF VALVE REFRIGERANT LINE........................................ 683 LOW PRESSURE CYCLING CLUTCH SWITCH................................................. 683 REFRIGERANT LINE COUPLER........................................................... 684 REFRIGERANT OIL.................................................................... 684 MANIFOLD GAUGE SET CONNECTIONS................................................. 684 REFRIGERANT SYSTEM SERVICE EQUIPMENT............................................... 684 REFRIGERANT SYSTEM SERVICE PORT.................................................... 684 VACUUM CHECK VALVE................................................................. 685 VACUUM RESERVOIR................................................................... 685 DIAGNOSIS AND TESTING.................................................................. 685 A/C PERFORMANCE.................................................................... 685 HEATER PERFORMANCE................................................................. 689 PREPARATIONS................................................................... 689 MAXIMUM HEATER OUTPUT.......................................................... 689 TEMPERATURE CONTROL............................................................ 689 VACUUM SYSTEM...................................................................... 690 HEATER-A/C CONTROLS............................................................ 690 LOCATING VACUUM LEAKS.......................................................... 690 VACUUM CHECK VALVE............................................................. 690 VIBRATION...................................................................... 691 NOISE.......................................................................... 691 BLOWER MOTOR RELAY................................................................. 691 BLOWER MOTOR....................................................................... 691 RELAY TEST..................................................................... 691 BLOWER MOTOR RESISTOR.............................................................. 694 CIRCUIT TEST................................................................... 694 BLOWER MOTOR SWITCH................................................................ 694 COMPRESSOR......................................................................... 695 COMPRESSOR CLUTCH RELAY............................................................ 695 RELAY TEST..................................................................... 695 COMPRESSOR CLUTCH COIL............................................................. 695 LOW PRESSURE CYCLING CLUTCH SWITCH................................................. 696 RELAY CIRCUIT TEST............................................................. 696 REFRIGERANT SYSTEM LEAKS........................................................... 696 HIGH PRESSURE CUT-OFF SWITCH....................................................... 696 SYSTEM EMPTY................................................................... 697 REFRIGERANT SYSTEM EVACUATE........................................................ 697 SYSTEM LOW..................................................................... 697 REFRIGERANT SYSTEM CHARGE.......................................................... 697 SERVICE PROCEDURES..................................................................... 697 REFRIGERANT RECOVERY............................................................... 697 REFRIGERANT CHARGE CAPACITY.................................................... 697 REFRIGERANT OIL LEVEL.............................................................. 697 INSTALLATION................................................................... 698 REMOVAL AND INSTALLATION............................................................... 698 REFRIGERANT LINE COUPLER........................................................... 698 REMOVAL........................................................................ 698 HIGH PRESSURE CUT-OFF SWITCH....................................................... 699 REMOVAL........................................................................ 699 L ENGINE....................................................................... 699 INSTALLATION................................................................... 699 SUCTION AND DISCHARGE LINE......................................................... 699 LEFT-HAND DRIVE 4.0L ENGINE.................................................... 700 COMPRESSOR......................................................................... 701 RIGHT-HAND DRIVE 4.0L ENGINE................................................... 701 REMOVAL........................................................................ 701 COMPRESSOR CLUTCH.................................................................. 702 REMOVAL........................................................................ 702 INSTALLATION................................................................... 702 INSPECTION..................................................................... 703 INSTALLATION................................................................... 704 LIQUID LINE........................................................................ 705 CLUTCH BREAK-IN................................................................ 705 COMPRESSOR CLUTCH RELAY............................................................ 705 L ENGINE....................................................................... 705 L ENGINE....................................................................... 706 FIXED ORIFICE TUBE................................................................. 707 LOW PRESSURE CYCLING CLUTCH SWITCH................................................. 707 ACCUMULATOR........................................................................ 708 REMOVAL........................................................................ 708 INSTALLATION................................................................... 708 CONDENSER.......................................................................... 708 L ENGINE....................................................................... 708 L ENGINE....................................................................... 709 VACUUM CHECK VALVE................................................................. 710 VACUUM RESERVOIR................................................................... 710 BLOWER MOTOR....................................................................... 711 REMOVAL........................................................................ 711 HEATER-A/C CONTROL................................................................. 711 REMOVAL........................................................................ 711 INSTALLATION................................................................... 711 INSTALLATION................................................................... 712 TEMPERATURE CONTROL CABLE.......................................................... 712 REMOVAL........................................................................ 712 INSTALLATION................................................................... 713 KICK COVER......................................................................... 713 REMOVAL........................................................................ 713 BLOWER MOTOR RELAY................................................................. 713 INSTALLATION................................................................... 714 MODE DOOR VACUUM ACTUATOR.......................................................... 714 BLOWER MOTOR RESISTOR.............................................................. 714 DEFROST DOOR ACTUATOR.......................................................... 714 FLOOR DOOR ACTUATOR............................................................ 714 PANEL/DEMIST DOOR ACTUATOR..................................................... 715 RECIRCULATION AIR DOOR ACTUATOR................................................ 715 HEATER-A/C HOUSING................................................................. 715 REMOVAL........................................................................ 716 DISASSEMBLY.................................................................... 716 INSTALLATION................................................................... 717 ASSEMBLY....................................................................... 717 HEATER-A/C HOUSING DOOR............................................................ 718 BLEND-AIR DOOR................................................................. 718 DEFROST DOOR AND CRANK ARM PANEL/DEMIST DOOR AND CRANK ARM..................... 718 RECIRCULATION AIR DOOR......................................................... 719 FLOOR DOOR AND CRANK ARM....................................................... 719 EVAPORATOR COIL.................................................................... 719 PANEL OUTLET DUCTS............................................................. 720 HEATER CORE........................................................................ 720 PANEL OUTLET BARRELS........................................................... 720 DUCTS AND OUTLETS.................................................................. 720 DEMISTER OUTLETS............................................................... 721 DEFROST DUCT/DEMISTER ADAPTER.................................................. 721 CONSOLE REAR DUCT.............................................................. 721 DEMISTER HOSES................................................................. 721 DEMISTER DUCTS................................................................. 721 FLOOR DUCT AND ADAPTER......................................................... 722 EMISSION CONTROL SYSTEMS................................................................... 723 GENERAL INFORMATION.................................................................... 723 SYSTEM DESCRIPTION................................................................. 723 DESCRIPTION AND OPERATION.............................................................. 723 MALFUNCTION INDICATOR LAMP (MIL)................................................... 723 CIRCUIT ACTUATION TEST MODE........................................................ 724 DIAGNOSTIC TROUBLE CODES........................................................... 724 STATE DISPLAY TEST MODE............................................................ 724 BULB CHECK..................................................................... 724 OBTAINING DTC’S USING DRB SCAN TOOL............................................ 724 OBTAINING DTC’S USING VEHICLE ODOMETER......................................... 725 OBTAINING DTC’S USING MIL LAMP................................................. 725 DIAGNOSTIC TROUBLE CODE DESCRIPTIONS........................................... 725 MIL 21—OXYGEN SENSOR (O2S) MONITOR............................................. 729 MONITORED SYSTEMS.................................................................. 729 MIL 21—OXYGEN SENSOR HEATER MONITOR............................................ 730 MIL 64—CATALYST MONITOR........................................................ 730 MIL 43—MISFIRE MONITOR......................................................... 730 MIL 51/52—FUEL SYSTEM MONITOR.................................................. 730 COMPONENT MONITORS................................................................. 731 TRIP DEFINITION.................................................................... 731 NON-MONITORED CIRCUITS............................................................. 731 FUEL PRESSURE.................................................................. 731 SECONDARY IGNITION CIRCUIT..................................................... 731 CYLINDER COMPRESSION........................................................... 732 EXHAUST SYSTEM PCM SYSTEM GROUND............................................... 732 FUEL INJECTOR MECHANICAL MALFUNCTIONS PCM CONNECTOR ENGAGEMENT................. 732 HIGH AND LOW LIMITS................................................................ 732 EXCESSIVE OIL CONSUMPTION...................................................... 732 THROTTLE BODY AIR FLOW......................................................... 732 VACUUM ASSIST.................................................................. 732 LOAD VALUE......................................................................... 732 DESCRIPTION AND OPERATION.............................................................. 733 EVAPORATION (EVAP) CONTROL SYSTEM.................................................. 733 ROLLOVER VALVE..................................................................... 733 DUTY CYCLE EVAP CANISTER PURGE SOLENOID EVAP CANISTER.............................. 733 CRANKCASE VENTILATION SYSTEM....................................................... 734 DIAGNOSIS AND TESTING.................................................................. 735 VACUUM SCHEMATICS.................................................................. 735 REMOVAL AND INSTALLATION............................................................... 735 EVAP CANISTER...................................................................... 735 VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL.................................. 735 REMOVAL........................................................................ 735 INSTALLATION................................................................... 736 INSTALLATION................................................................... 736 ROLLOVER VALVE(S).................................................................. 736 DUTY CYCLE EVAP CANISTER PURGE SOLENOID............................................ 736 REMOVAL........................................................................ 736 SPECIFICATIONS......................................................................... 736 TORQUE CHART....................................................................... 736 DIESEL SUPPLEMENT.......................................................................... 13 FUEL SYSTEM-2.5L DIESEL ENGINE......................................................... 95 GENERAL INFORMATION................................................................ 95 GENERAL INFORMATION............................................................ 95 FUEL SHUTDOWN SOLENOID..................................................... 95 FUEL REQUIREMENTS-2.5L DIESEL.............................................. 95 FUEL DELIVERY SYSTEM-2.5L DIESEL ENGINE............................................ 96 DESCRIPTION AND OPERATION...................................................... 96 INTRODUCTION............................................................... 96 FUEL SYSTEM PRESSURE WARNING............................................... 96 FUEL TANK.................................................................. 96 FUEL TANK MODULE........................................................... 97 FUEL GAUGE SENDING UNIT.................................................... 97 FUEL FILTER/WATER SEPARATOR................................................ 97 FUEL SHUTDOWN SOLENOID..................................................... 97 FUEL INJECTION PUMP........................................................ 98 FUEL INJECTORS............................................................. 98 FUEL TUBES/LINES/HOSES AND CLAMPS-LOW-PRESSURE TYPE........................ 99 QUICK-CONNECT FITTINGS-LOW PRESSURE TYPE................................... 99 HIGH-PRESSURE FUEL LINES................................................... 100 FUEL DRAIN TUBES........................................................... 100 FUEL HEATER................................................................ 100 FUEL HEATER RELAY.......................................................... 101 DIAGNOSIS AND TESTING.......................................................... 101 GENERAL INFORMATION........................................................ 101 VISUAL INSPECTION.......................................................... 101 AIR IN FUEL SYSTEM......................................................... 104 FUEL HEATER RELAY TEST..................................................... 104 FUEL INJECTOR TEST......................................................... 104 FUEL INJECTOR / NEEDLE MOVEMENT SENSOR TEST................................ 105 FUEL INJECTION PUMP TEST................................................... 105 FUEL SUPPLY RESTRICTIONS................................................... 105 LOW-PRESSURE LINES..................................................... 105 HIGH-PRESSURE LINES.................................................... 105 FUEL SHUTDOWN SOLENOID TEST................................................ 106 HIGH-PRESSURE FUEL LINE LEAK TEST.......................................... 106 SERVICE PROCEDURES............................................................. 106 AIR BLEED PROCEDURES....................................................... 106 AIR BLEEDING AT FUEL FILTER............................................ 106 FUEL INJECTION PUMP BLEEDING........................................... 106 HIGH-PRESSURE FUEL LINE BLEEDING....................................... 107 FUEL INJECTION PUMP TIMING................................................. 107 REMOVAL AND INSTALLATION....................................................... 107 ACCELERATOR PEDAL.......................................................... 107 REMOVAL................................................................ 107 INSTALLATION........................................................... 107 AIR CLEANER ELEMENT........................................................ 107 REMOVAL................................................................ 107 INSTALLATION........................................................... 107 FUEL DRAIN TUBES........................................................... 108 FUEL FILTER/WATER SEPARATOR................................................ 108 DRAINING WATER FROM FILTER BOWL........................................ 108 FUEL FILTER REMOVAL.................................................... 109 FUEL FILTER INSTALLATION............................................... 109 FUEL HEATER................................................................ 109 FUEL HEATER RELAY.......................................................... 109 FUEL LEVEL SENSOR.......................................................... 109 REMOVAL................................................................ 109 FUEL INJECTION PUMP........................................................ 109 REMOVAL................................................................ 109 INSTALLATION/ADJUSTING PUMP TIMING..................................... 111 FUEL INJECTORS............................................................. 113 REMOVAL................................................................ 113 INSTALLATION........................................................... 114 FUEL TANK.................................................................. 114 REMOVAL................................................................ 114 INSTALLATION........................................................... 115 FUEL RESERVOIR MODULE...................................................... 115 REMOVAL................................................................ 115 INSTALLATION........................................................... 115 HIGH-PRESSURE LINES........................................................ 116 REMOVAL................................................................ 116 INSTALLATION........................................................... 116 SPECIFICATIONS................................................................. 116 FUEL TANK CAPACITY......................................................... 116 IDLE SPEED................................................................. 116 FUEL INJECTOR FIRING SEQUENCE.............................................. 116 FUEL SYSTEM PRESSURE....................................................... 116 FUEL INJECTION SYSTEM-2.5L DIESEL ENGINE........................................... 117 GENERAL INFORMATION............................................................ 117 INTRODUCTION............................................................... 117 DESCRIPTION AND OPERATION...................................................... 118 POWERTRAIN CONTROL MODULE (PCM)............................................ 118 BOOST / PRESSURE SENSOR.................................................... 119 VEHICLE THEFT ALARM........................................................ 119 BATTERY VOLTAGE-PCM INPUT.................................................. 119 SENSOR RETURN-ECM/PCM INPUT (ANALOG GROUND)................................ 119 IGNITION CIRCUIT SENSE-MSA/PCM INPUT....................................... 119 IGNITION CIRCUIT SENSE-PCM INPUT........................................... 120 POWER GROUND............................................................... 120 NEEDLE MOVEMENT OR INSTRUMENTED FIRST INJECTOR-ECM INPUT................... 120 FUEL INJECTOR SENSOR-GROUND................................................ 120 ENGINE COOLANT TEMPERATURE SENSOR-ECM/PCM INPUT............................ 120 ENGINE SPEED/CRANK POSITION SENSOR-ECM INPUT............................... 120 AIR CONDITIONING (A/C) CONTROLS-ECM INPUTS................................. 121 BRAKE SWITCH-ECM INPUT..................................................... 121 DATA LINK CONNECTOR-PCM AND ECM INPUT AND OUTPUT........................... 121 VEHICLE SPEED SENSOR-ECM INPUT............................................. 121 SPEED CONTROL-ECM INPUT.................................................... 122 ASD RELAY-ECM INPUT........................................................ 122 FIVE VOLT POWER-ECM/PCM OUTPUT............................................. 122 ENGINE COOLANT GAUGE-PCM OUTPUT............................................ 122 ENGINE OIL PRESSURE GAUGE-PCM OUTPUT....................................... 122 GLOW PLUG LAMP-PCM OUTPUT.................................................. 122 SPEED CONTROL-PCM OUTPUTS.................................................. 122 AIR CONDITIONING RELAY-ECM OUTPUT.......................................... 122 TIMING SOLENOID-ECM OUTPUT................................................. 123 TACHOMETER-PCM OUTPUT...................................................... 123 GLOW PLUG RELAY-ECM OUTPUT................................................. 123 GLOW PLUGS................................................................. 124 ELECTRIC VACUUM MODULATOR (EVM)-ECM OUTPUT................................. 124 DIAGNOSIS AND TESTING.......................................................... 124 DIESEL DIAGNOSTICS......................................................... 124 ASD RELAY TEST............................................................. 124 ENGINE SPEED SENSOR TEST................................................... 124 ENGINE COOLANT TEMPERATURE SENSOR TEST..................................... 124 GLOW PLUG TEST............................................................. 125 GLOW PLUG RELAY TEST....................................................... 126 RELAYS-OPERATION/TESTING................................................... 126 OPERATION.............................................................. 126 TESTING................................................................ 127 BOOST / PRESSURE SENSOR.................................................... 127 VEHICLE SPEED SENSOR TEST.................................................. 128 DIAGNOSTIC TROUBLE CODES................................................... 128 REMOVAL AND INSTALLATION....................................................... 128 ASD RELAY.................................................................. 128 A/C CLUTCH RELAY........................................................... 128 ENGINE SPEED SENSOR........................................................ 128 REMOVAL................................................................ 128 INSTALLATION........................................................... 128 ENGINE COOLANT TEMPERATURE SENSOR.......................................... 128 REMOVAL................................................................ 128 INSTALLATION........................................................... 128 GLOW PLUGS................................................................. 128 REMOVAL................................................................ 128 INSTALLATION........................................................... 129 GLOW PLUG RELAY............................................................ 129 REMOVAL................................................................ 129 INSTALLATION........................................................... 129 POWERTRAIN CONTROL MODULE (PCM)............................................ 129 REMOVAL................................................................ 129 INSTALLATION........................................................... 130 VEHICLE SPEED SENSOR....................................................... 130 REMOVAL................................................................ 130 INSTALLATION........................................................... 130 SPECIFICATIONS................................................................. 131 GLOW PLUG CURRENT DRAW..................................................... 131 TORQUE CHART-2.5L DIESEL................................................... 131 LUBRICATION AND MAINTENANCE............................................................ 13 GENERAL INFORMATION................................................................ 13 SPECIFICATIONS................................................................. 13 ENGINE OIL-DIESEL ENGINES.................................................. 13 SAE VISCOSITY GRADE.................................................... 13 FLUID CAPACITIES........................................................... 13 FUEL TANK.............................................................. 13 ENGINE OIL............................................................. 13 COOLING SYSTEM......................................................... 13 MANUAL TRANSMISSION.................................................... 13 TRANSFER CASE.......................................................... 13 FRONT AXLE............................................................. 13 REAR AXLE.............................................................. 13 MAINTENANCE SCHEDULE............................................................... 14 GENERAL INFORMATION............................................................ 14 MAINTENANCE SCHEDULE-DIESEL ENGINE......................................... 14 AT EACH STOP FOR FUEL OR SCHEDULED SERVICE STOP........................ 14 SCHEDULE-A................................................................. 14 SCHEDULE-B................................................................. 15 EXHAUST SYSTEM AND TURBOCHARGER........................................................ 23 GENERAL INFORMATION................................................................ 23 EXHAUST SYSTEM................................................................. 23 EXHAUST HEAT SHIELDS........................................................... 23 REMOVAL AND INSTALLATION........................................................... 24 EXHAUST PIPE................................................................... 24 REMOVAL.................................................................... 24 INSTALLATION............................................................... 24 MUFFLER AND EXHAUST TAILPIPE................................................... 24 REMOVAL.................................................................... 24 INSTALLATION............................................................... 24 EXHAUST MANIFOLD AND TURBOCHARGER (LHD)........................................ 25 REMOVAL.................................................................... 25 Cleaning................................................................... 26 INSTALLATION............................................................... 26 EXHAUST MANIFOLD AND TURBOCHARGER (RHD)........................................ 27 REMOVAL.................................................................... 27 Cleaning................................................................... 29 INSTALLATION............................................................... 29 INTAKE MANIFOLD................................................................ 32 REMOVAL.................................................................... 32 CLEANING................................................................... 32 INSTALLATION............................................................... 32 SPECIFICATIONS..................................................................... 32 TORQUE SPECIFICATIONS.......................................................... 32 STEERING............................................................................... 163 TRANSMISSION AND TRANSFER CASE......................................................... 529 AX15 MANUAL TRANSMISSION........................................................... 529 GENERAL INFORMATION............................................................ 529 AX 15 MANUAL TRANSMISSION.................................................. 529 TRANSMISSION IDENTIFICATION................................................ 530 TRANSMISSION SHIFT PATTERN................................................. 530 TRANSMISSION LUBRICANT..................................................... 530 TRANSMISSION SWITCH AND PLUG LOCATIONS..................................... 530 TRANSMISSION GEAR RATIOS................................................... 531 TRANSMISSION ASSEMBLY INFORMATION.......................................... 531 DIAGNOSIS AND TESTING.......................................................... 531 LOW LUBRICANT LEVEL........................................................ 531 HARD SHIFTING.............................................................. 531 TRANSMISSION NOISE......................................................... 531 REMOVAL AND INSTALLATION....................................................... 531 TRANSMISSION............................................................... 531 REMOVAL................................................................ 531 INSTALLATION........................................................... 532 SPECIFICATIONS................................................................. 534 TORQUE..................................................................... 534 NV231 TRANSFER CASE................................................................ 535 GENERAL INFORMATION............................................................ 535 NV231 TRANSFER CASE........................................................ 535 OPERATING RANGES....................................................... 535 SHIFT MECHANISM........................................................ 535 TRANSFER CASE IDENTIFICATION............................................... 535 RECOMMENDED LUBRICANT AND FILL LEVEL....................................... 535 DIAGNOSIS AND TESTING.......................................................... 536 NV231 DIAGNOSIS............................................................ 536 REMOVAL AND INSTALLATION....................................................... 537 TRANSFER CASE.............................................................. 537 REMOVAL................................................................ 537 INSTALLATION........................................................... 537 SHIFT LEVER................................................................ 537 REMOVAL................................................................ 537 INSTALLATION........................................................... 537 SPEEDOMETER................................................................ 537 REMOVAL................................................................ 537 INSTALLATION AND INDEXING.............................................. 538 FRONT OUTPUT SHAFT SEAL.................................................... 539 REMOVAL................................................................ 539 INSTALLATION........................................................... 539 REAR RETAINER BUSHING AND SEAL............................................. 539 REMOVAL................................................................ 539 INSTALLATION........................................................... 540 SPECIFICATIONS................................................................. 540 TORQUE..................................................................... 540 SPECIAL TOOLS.................................................................. 540 SPECIAL TOOLS-NV231........................................................ 540
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