1998 CHRYSLER VOYAGERS SERVICE MANUAL1998 CHRYSLER VOYAGERS SERVICE MANUAL
DESCRIPTION:
1998 CHRYSLER VOYAGERS SERVICE MANUAL – PDF DOWNLOAD
The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations. This manual does not cover theory of operation, which is addressed in service training material.
Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle. Information in this manual is divided into groups. These groups contain general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components.
To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar after the group title is aligned to a solid tab on the first page of each group. The first page of the group has a contents section that lists major topics within the group. If you are not sure which Group contains the information you need, look up the Component/System in the alphabetical index located in the rear of this manual.
Tightening torques are provided as a specific value throughout this manual. This value represents the midpoint of the acceptable engineering torque range for a given fastener application. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners. When replacing fasteners, always use the same type (part number) fastener as removed.
Chrysler International reserves the right to change testing procedures, specifications, diagnosis, repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
TABLE OF CONTENTS:
1998 CHRYSLER VOYAGERS SERVICE MANUAL – PDF DOWNLOAD
INTRODUCTION NS............................................................................................................................ 4
GENERAL INFORMATION.................................................................................................................... 4
VEHICLE SAFETY CERTIFICATION LABEL................................................................................................. 4
VEHICLE IDENTIFICATION NUMBER...................................................................................................... 4
VIN CHECK DIGIT.................................................................................................................... 4
BODY CODE PLATE.................................................................................................................... 4
LOCATION AND DECODING.......................................................................................................... 4
VIN CODE BREAKDOWN CHART....................................................................................................... 5
BODY CODE PLATE – LINE 3....................................................................................................... 5
BODY CODE PLATE LINE 2......................................................................................................... 6
BODY CODE PLATE LINE 1......................................................................................................... 6
IF TWO BODY CODE PLATES ARE REQUIRED........................................................................................... 6
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS...................................................................................... 7
INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS................................ 7
FASTENER IDENTIFICATION............................................................................................................ 7
FASTENER IDENTIFICATION........................................................................................................ 7
FASTENER IDENTIFICATION........................................................................................................ 8
FASTENER STRENGTH.............................................................................................................. 9
METRIC SYSTEM...................................................................................................................... 10
CONVERSION FORMULAS AND EQUIVALENT VALUES...................................................................................... 10
TORQUE REFERENCES.................................................................................................................. 10
METRIC CONVERSION.............................................................................................................. 11
TORQUE SPECIFICATIONS.......................................................................................................... 12
INTRODUCTION NS/GS......................................................................................................................... 13
GENERAL INFORMATION.................................................................................................................... 13
E- MARK LABEL...................................................................................................................... 13
VEHICLE IDENTIFICATION NUMBER...................................................................................................... 13
VIN CHECK DIGIT................................................................................................................ 13
BODY CODE PLATE.................................................................................................................... 13
LOCATION AND DECODING.......................................................................................................... 13
BODY CODE PLATE— LINE 3........................................................................................................ 13
VIN DECODING INFORMATION....................................................................................................... 14
BODY CODE PLATE— LINE 2........................................................................................................ 14
BODY CODE PLATE LINE 1......................................................................................................... 15
IF TWO BODY CODE PLATES ARE REQUIRED........................................................................................... 15
MANUFACTURER PLATE................................................................................................................. 15
LUBRICATION AND MAINTENANCE................................................................................................................ 17
GENERAL INFORMATION.................................................................................................................... 17
INTRODUCTION....................................................................................................................... 17
PARTS AND LUBRICANT RECOMMENDATIONS............................................................................................... 17
INTERNATIONAL SYMBOLS.............................................................................................................. 17
CLASSIFICATION OF LUBRICANTS....................................................................................................... 17
ENGINE OIL..................................................................................................................... 18
FLUID CAPACITIES................................................................................................................... 18
GENERAL INFORMATION.................................................................................................................... 19
INTRODUCTION....................................................................................................................... 19
UNSCHEDULED INSPECTION............................................................................................................. 19
SCHEDULE – A....................................................................................................................... 19
SCHEDULE – B....................................................................................................................... 20
SERVICE PROCEDURES..................................................................................................................... 23
JUMP STARTING PROCEDURE............................................................................................................ 23
TO JUMP START A DISABLED VEHICLE:.............................................................................................. 23
TOWING RECOMMENDATIONS............................................................................................................. 24
WARNINGS AND CAUTIONS.......................................................................................................... 24
RECOMMENDED TOWING EQUIPMENT................................................................................................... 24
GROUND CLEARANCE............................................................................................................... 24
LOCKED VEHICLE TOWING.......................................................................................................... 24
FLAT TOWING WITH TOW BAR....................................................................................................... 24
FLAT BED TOWING TIE DOWNS...................................................................................................... 24
TOWING—FRONT WHEEL LIFT........................................................................................................ 25
TOWING—REAR WHEEL LIFT......................................................................................................... 25
HOISTING RECOMMENDATIONS........................................................................................................... 25
LUBRICATION AND MAINTENANCE 1.............................................................................................................. 27
GENERAL INFORMATION.................................................................................................................... 27
GENERAL INFORMATION................................................................................................................ 27
ENGINE OIL — GASOLINE ENGINES.................................................................................................. 27
SAE VISCOSITY GRADE........................................................................................................ 27
ENGINE OIL— DIESEL ENGINES..................................................................................................... 27
SAE VISCOSITY GRADE........................................................................................................ 27
MANUAL TRANSMISSION FLUID (A- 558 and A-598 Models)............................................................................ 27
FLUID CAPACITIES............................................................................................................... 27
MAINTENANCE SCHEDULES.................................................................................................................. 28
GENERAL INFORMATION................................................................................................................ 28
MAINTENANCE SCHEDULE........................................................................................................... 28
MAINTENANCE SCHEDULE— DIESEL ENGINE............................................................................................ 28
UNSCHEDULED INSPECTION......................................................................................................... 28
SCHEDULE— A (DIESEL)........................................................................................................... 28
SCHEDULE— B (DIESEL)........................................................................................................... 29
JUMP STARTING, HOISTING AND TOWING..................................................................................................... 31
SERVICE PROCEDURES................................................................................................................. 31
TOWING RECOMMENDATIONS......................................................................................................... 31
WARNINGS AND CAUTIONS...................................................................................................... 31
RECOMMENDED TOWING EQUIPMENT............................................................................................... 31
GROUND CLEARANCE........................................................................................................... 31
LOCKED VEHICLE TOWING...................................................................................................... 31
FLAT TOWING WITH TOW BAR................................................................................................... 31
FLAT BED TOWING TIE DOWNS.................................................................................................. 31
TOWING— FRONT WHEEL LIFT................................................................................................... 32
TOWING— REAR WHEEL LIFT.................................................................................................... 32
TOWING— TOW HOOKS.......................................................................................................... 32
SUSPENSION................................................................................................................................. 33
WHEEL ALIGNMENT........................................................................................................................ 33
DESCRIPTION AND OPERATION.......................................................................................................... 33
GENERAL INFORMATION............................................................................................................ 33
DIAGNOSIS AND TESTING.............................................................................................................. 35
SUSPENSION AND STEERING DIAGNOSIS.............................................................................................. 35
PRE-WHEEL ALIGNMENT INSPECTION................................................................................................. 36
SERVICE PROCEDURES................................................................................................................. 36
WHEEL ALIGNMENT CHECK AND ADJUSTMENT PROCEDURE................................................................................. 36
CASTER AND CAMBER.......................................................................................................... 36
FRONT TOE SETTING PROCEDURE................................................................................................ 39
SPECIFICATIONS..................................................................................................................... 39
ALIGNMENT SPECIFICATIONS....................................................................................................... 39
FRONT SUSPENSION....................................................................................................................... 41
DESCRIPTION AND OPERATION.......................................................................................................... 41
FRONT SUSPENSION DESCRIPTION................................................................................................... 41
SUSPENSION CRADLE (CROSSMEMBER)................................................................................................ 41
Mc PHERSON STRUT ASSEMBLY...................................................................................................... 42
STEERING KNUCKLE............................................................................................................... 42
LOWER CONTROL ARM.............................................................................................................. 42
STABILIZER BAR................................................................................................................. 42
STABILIZER BAR ATTACHING LINK.................................................................................................. 42
HUB AND BEARING ASSEMBLY....................................................................................................... 42
COIL SPRING.................................................................................................................... 43
BALL JOINT..................................................................................................................... 43
WHEEL MOUNTING STUDS........................................................................................................... 43
DIAGNOSIS AND TESTING.............................................................................................................. 43
Mc PHERSON STRUT............................................................................................................... 43
STEERING KNUCKLE .............................................................................................................. 44
LOWER CONTROL ARM.............................................................................................................. 44
BALL JOINT (LOWER)............................................................................................................. 44
STABILIZER BAR................................................................................................................. 44
HUB AND BEARING ASSEMBLY....................................................................................................... 44
SERVICE PROCEDURES................................................................................................................. 44
SUSPENSION CRADLE THREAD REPAIR PROCEDURE..................................................................................... 44
TOOL REQUIREMENT FOR M8x1.25 Thread........................................................................................ 45
TOOL REQUIREMENT FOR M10x1.5 Thread........................................................................................ 45
REMOVAL AND INSTALLATION........................................................................................................... 45
Mc PHERSON STRUT............................................................................................................... 45
REMOVAL.................................................................................................................... 45
INSTALLATION............................................................................................................... 45
STEERING KNUCKLE............................................................................................................... 46
REMOVE..................................................................................................................... 46
INSTALL.................................................................................................................... 49
LOWER CONTROL ARM.............................................................................................................. 51
REMOVE..................................................................................................................... 51
INSTALL.................................................................................................................... 52
BALL JOINT..................................................................................................................... 54
REMOVE..................................................................................................................... 54
INSTALL.................................................................................................................... 54
STABILIZER BAR................................................................................................................. 55
REMOVE..................................................................................................................... 55
INSTALL.................................................................................................................... 56
HUB AND BEARING ASSEMBLY....................................................................................................... 57
REMOVE..................................................................................................................... 57
INSTALL.................................................................................................................... 59
FRONT WHEEL MOUNTING STUDS..................................................................................................... 60
REMOVE..................................................................................................................... 60
INSTALL.................................................................................................................... 60
REAR WHEEL MOUNTING STUDS...................................................................................................... 61
REMOVE..................................................................................................................... 61
INSTALL.................................................................................................................... 61
DISASSEMBLY AND ASSEMBLY........................................................................................................... 62
Mc PHERSON STRUT............................................................................................................... 62
DISASSEMBLY................................................................................................................ 62
ASSEMBLY................................................................................................................... 64
BALL JOINT SEAL BOOT........................................................................................................... 65
REMOVE..................................................................................................................... 65
INSTALL.................................................................................................................... 65
LOWER CONTROL ARM FRONT BUSHING................................................................................................ 66
REMOVE..................................................................................................................... 66
INSTALL.................................................................................................................... 66
LOWER CONTROL ARM REAR BUSHING................................................................................................. 67
REMOVE..................................................................................................................... 67
INSTALL.................................................................................................................... 67
STABILIZER BAR BUSHING......................................................................................................... 67
Disassembly/Assembly....................................................................................................... 67
SPECIFICATIONS..................................................................................................................... 68
FRONT SUSPENSION FASTENER TORQUES.............................................................................................. 68
REAR SUSPENSION........................................................................................................................ 70
SPECIAL TOOLS...................................................................................................................... 69
FRONT SUSPENSION............................................................................................................... 69
GENERAL INFORMATION................................................................................................................ 70
REAR SUSPENSION................................................................................................................ 70
DESCRIPTION AND OPERATION.......................................................................................................... 71
REAR WHEEL ALIGNMENT........................................................................................................... 71
REAR TRACK BAR................................................................................................................. 71
STABILIZER BAR................................................................................................................. 71
SHOCK ABSORBERS (REAR LOAD LEVELING)........................................................................................... 72
REMOVAL AND INSTALLATION........................................................................................................... 72
REAR SPRINGS (FWD)............................................................................................................. 72
REMOVAL.................................................................................................................... 72
FRONT BUSHING REPLACEMENT.................................................................................................. 74
INSTALLATION............................................................................................................... 74
REAR SPRINGS (AWD)............................................................................................................. 75
REMOVE..................................................................................................................... 75
FRONT BUSHING REPLACEMENT.................................................................................................. 76
INSTALL.................................................................................................................... 76
SHOCK ABSORBER................................................................................................................. 77
REMOVE/INSTALL............................................................................................................. 77
REAR TRACK BAR................................................................................................................. 77
REMOVE..................................................................................................................... 77
INSTALL.................................................................................................................... 77
TRACK BAR MOUNT................................................................................................................ 77
REMOVE..................................................................................................................... 77
INSTALLATION............................................................................................................... 78
STABILIZER BAR................................................................................................................. 78
REMOVAL.................................................................................................................... 78
INSPECTION................................................................................................................. 78
INSTALLATION............................................................................................................... 78
JOUNCE BUMPER.................................................................................................................. 78
REMOVAL-STANDARD........................................................................................................... 78
INSTALLATION-STANDARD...................................................................................................... 78
REMOVAL-HEAVY DUTY......................................................................................................... 79
INSTALLATION-HEAVY DUTY ................................................................................................... 79
LEAF SPRING REAR MOUNT......................................................................................................... 79
REMOVE..................................................................................................................... 79
INSTALLATION............................................................................................................... 79
LEAF SPRING FRONT MOUNT........................................................................................................ 79
REMOVE..................................................................................................................... 79
INSTALL.................................................................................................................... 80
SPECIFICATIONS..................................................................................................................... 80
REAR SUSPENSION FASTENER TORQUES............................................................................................... 80
SUSPENSION 1
.............................................................................................................................. 81
SPECIFICATIONS......................................................................................................................... 81
ALIGNMENT SPECIFICATIONS........................................................................................................... 81
BRAKES..................................................................................................................................... 83
GENERAL INFORMATION.................................................................................................................... 83
GENERAL INFORMATION................................................................................................................ 83
GENERAL VEHICLE SERVICE CAUTIONS............................................................................................... 83
BASE BRAKE SYSTEM COMPONENT DESCRIPTION........................................................................................ 83
BASE BRAKE SYSTEM...................................................................................................................... 85
DESCRIPTION AND OPERATION.......................................................................................................... 86
FRONT DISC BRAKE SYSTEM........................................................................................................ 86
REAR DRUM BRAKES............................................................................................................... 87
REAR DISC BRAKES............................................................................................................... 87
PARKING BRAKE SYSTEM OPERATION................................................................................................. 87
PROPORTIONING VALVES........................................................................................................... 87
FIXED PROPORTIONING VALVE.................................................................................................. 87
HEIGHT SENSING PROPORTIONING VALVE......................................................................................... 88
CHASSIS TUBES AND HOSES........................................................................................................ 89
MASTER CYLINDER................................................................................................................ 89
POWER BRAKE VACUUM BOOSTER OPERATION........................................................................................... 90
RED BRAKE WARNING LAMP OPERATION............................................................................................... 90
STOP LAMP SWITCH............................................................................................................... 91
HUB/BEARING REAR WHEEL......................................................................................................... 91
DIAGNOSIS AND TESTING.............................................................................................................. 91
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE............................................................................................. 91
BRAKE SYSTEM DIAGNOSIS CHARTS.................................................................................................. 92
MISCELLANEOUS BRAKE SYSTEM CONDITIONS...................................................................................... 92
RED BRAKE WARNING LAMP FUNCTION............................................................................................ 93
POWER BRAKE SYSTEM DIAGNOSTICS............................................................................................. 94
BRAKE NOISE................................................................................................................ 95
VEHICLE ROAD TEST.......................................................................................................... 95
ADJUSTER REAR DRUM BRAKE (AUTOMATIC)........................................................................................... 96
BRAKE ROTOR.................................................................................................................... 96
CHECKING ROTOR FOR RUNOUT AND THICKNESS.................................................................................... 96
PROPORTIONING VALVES........................................................................................................... 98
FIXED PROPORTIONING VALVE TEST PROCEDURE................................................................................... 98
HEIGHT SENSING PROPORTIONING VALVE......................................................................................... 99
BRAKE FLUID CONTAMINATION ..................................................................................................... 101
RED BRAKE WARNING LAMP TEST.................................................................................................... 101
TRACTION CONTROL LAMP TEST..................................................................................................... 101
STOP LAMP SWITCH TEST PROCEDURE................................................................................................ 101
SERVICE PROCEDURES................................................................................................................. 102
MASTER CYLINDER FLUID LEVEL CHECK.............................................................................................. 102
BLEEDING BASE BRAKE HYDRAULIC SYSTEM........................................................................................... 102
PRESSURE BLEEDING PROCEDURE................................................................................................ 102
BLEEDING WITHOUT A PRESSURE BLEEDER........................................................................................ 103
MASTER CYLINDER BLEEDING PROCEDURE............................................................................................. 104
ROTOR MACHINING (FRONT/REAR)................................................................................................... 104
BRAKE ROTOR MACHINING PROCEDURES........................................................................................... 104
REFACING BRAKE ROTOR....................................................................................................... 105
RESURFACNG BRAKE ROTOR..................................................................................................... 105
ROTOR REFINISHING LIMITS................................................................................................... 106
BRAKE DRUM MACHINING .......................................................................................................... 106
BRAKE TUBE REPAIR PROCEDURE.................................................................................................... 106
DOUBLE INVERTED TUBING FLARES.............................................................................................. 107
ISO TUBING FLARES.......................................................................................................... 107
PARK BRAKE AUTO ADJUSTER MECHANISM RELEASE..................................................................................... 108
REMOVAL AND INSTALLATION........................................................................................................... 109
WHEEL AND TIRE INSTALLATION.................................................................................................... 109
FRONT DISC BRAKE CALIPER....................................................................................................... 109
SERVICE PRECAUTIONS........................................................................................................ 109
REMOVE..................................................................................................................... 109
INSTALL.................................................................................................................... 110
REAR DISC BRAKE CALIPER........................................................................................................ 110
REMOVE..................................................................................................................... 111
INSTALL.................................................................................................................... 111
FRONT DISC BRAKE PADS.......................................................................................................... 112
REMOVE..................................................................................................................... 112
INSTALL.................................................................................................................... 112
REAR DISC BRAKE SHOES.......................................................................................................... 113
REMOVE..................................................................................................................... 113
CALIPER INSPECTION......................................................................................................... 114
INSTALL.................................................................................................................... 114
REAR BRAKE DRUM................................................................................................................ 115
REMOVE..................................................................................................................... 115
INSTALL.................................................................................................................... 115
REAR DRUM BRAKE SHOES.......................................................................................................... 116
REMOVE..................................................................................................................... 116
INSTALL.................................................................................................................... 118
BRAKE SUPPORT PLATE (REAR DRUM BRAKES)......................................................................................... 119
REMOVE..................................................................................................................... 119
INSTALL.................................................................................................................... 121
REAR BRAKE WHEEL CYLINDER...................................................................................................... 121
REMOVE..................................................................................................................... 121
INSTALL.................................................................................................................... 122
HUB/BEARING.................................................................................................................... 122
FRONT WHEEL DRIVE.......................................................................................................... 122
ALL WHEEL DRIVE............................................................................................................ 123
MASTER CYLINDER................................................................................................................ 126
REMOVE..................................................................................................................... 126
BLEEDING MASTER CYLINDER................................................................................................... 127
INSTALL.................................................................................................................... 128
VACUUM BOOSTER 2.4 LITER ENGINE................................................................................................ 129
REMOVE..................................................................................................................... 129
INSTALL.................................................................................................................... 130
VACUUM BOOSTER 3.0 LITER ENGINE................................................................................................ 131
REMOVE..................................................................................................................... 131
INSTALL.................................................................................................................... 133
VACUUM BOOSTER 3.3/3.8 LITER ENGINE............................................................................................ 134
REMOVE..................................................................................................................... 134
INSTALL.................................................................................................................... 136
JUNCTION BLOCK................................................................................................................. 137
REMOVE..................................................................................................................... 137
INSTALL.................................................................................................................... 137
PROPORTIONING VALVE (W/ABS BRAKES)............................................................................................. 138
REMOVE..................................................................................................................... 138
INSTALL.................................................................................................................... 139
PROPORTIONING VALVE (W/O ABS BRAKES)........................................................................................... 139
REMOVE..................................................................................................................... 139
INSTALL.................................................................................................................... 140
HYDRAULIC BRAKE TUBES AND HOSES................................................................................................ 140
PARK BRAKE PEDAL MECHANISM..................................................................................................... 140
REMOVE..................................................................................................................... 140
INSTALL.................................................................................................................... 141
PARK BRAKE SHOES (WITH REAR DISC BRAKES)....................................................................................... 142
REMOVE..................................................................................................................... 142
INSTALL.................................................................................................................... 145
FRONT PARK BRAKE CABLE......................................................................................................... 147
REMOVE..................................................................................................................... 147
INSTALL.................................................................................................................... 147
INTERMEDIATE PARK BRAKE CABLE.................................................................................................. 148
REMOVE..................................................................................................................... 148
INSTALL.................................................................................................................... 148
RIGHT REAR PARK BRAKE CABLE.................................................................................................... 148
REMOVE..................................................................................................................... 148
INSTALL.................................................................................................................... 149
LEFT REAR PARK BRAKE CABLE..................................................................................................... 149
REMOVE..................................................................................................................... 149
INSTALL.................................................................................................................... 150
STOP LAMP SWITCH............................................................................................................... 151
REMOVE..................................................................................................................... 151
INSTALL.................................................................................................................... 151
DISASSEMBLY AND ASSEMBLY........................................................................................................... 151
MASTER CYLINDER TO POWER BRAKE BOOSTER VACUUM SEAL............................................................................. 151
MASTER CYLINDER FLUID RESERVOIR................................................................................................ 152
MASTER CYLINDER FLUID RESERVOIR FILL TUBE...................................................................................... 153
REMOVE..................................................................................................................... 153
INSTALL.................................................................................................................... 153
MASTER CYLINDER BRAKE FLUID LEVEL SWITCH....................................................................................... 153
FRONT DISC BRAKE CALIPER....................................................................................................... 153
CLEANING AND INSPECTION.................................................................................................... 153
CALIPER GUIDE PIN BUSHING SERVICE.......................................................................................... 154
CALIPER DISASSEMBLY........................................................................................................ 155
CALIPER ASSEMBLY........................................................................................................... 157
WHEEL CYLINDER REAR DRUM BRAKE................................................................................................. 158
DISASSEMBLE................................................................................................................ 158
ASSEMBLE................................................................................................................... 158
CLEANING AND INSPECTION............................................................................................................ 158
FRONT DISC BRAKE PAD LINING INSPECTION......................................................................................... 158
REAR DISC BRAKES............................................................................................................... 158
BRAKE PAD LINING WEAR...................................................................................................... 158
CALIPER INSPECTION......................................................................................................... 159
REAR DRUM BRAKE SHOE LINING INSPECTION......................................................................................... 159
REAR DRUM BRAKE WHEEL CYLINDER................................................................................................. 160
BRAKE HOSE AND BRAKE LINES INSPECTION.......................................................................................... 160
REAR WHEEL HUB AND BEARING ASSEMBLY............................................................................................ 160
ADJUSTMENTS........................................................................................................................ 160
STOP LAMP SWITCH............................................................................................................... 160
REAR DRUM BRAKE SHOE ADJUSTMENT................................................................................................ 161
PARK BRAKE SHOES (WITH REAR DISC BRAKES)....................................................................................... 161
PARK BRAKE CABLE ADJUSTMENT.................................................................................................... 163
PROPORTIONING VALVE (HEIGHT SENSING)........................................................................................... 163
SPECIFICATIONS..................................................................................................................... 164
BRAKE FLUID.................................................................................................................... 164
VEHICLE BRAKE SYSTEM COMPONENT SPECIFICATIONS.................................................................................. 164
BRAKE ACTUATION SYSTEM S....................................................................................................... 165
BRAKE FASTENER TORQUE SPECIFICATION............................................................................................ 165
SPECIAL TOOLS...................................................................................................................... 166
SPECIAL TOOLS—BASE BRAKES...................................................................................................... 166
ANTILOCK BRAKE SYSTEM ± TEVES MARK-20.................................................................................................. 167
DESCRIPTION AND OPERATION.......................................................................................................... 167
ANTILOCK BRAKES OPERATION DESCRIPTION.......................................................................................... 167
ABS BRAKES COMPONENT ABBREVIATION LIST......................................................................................... 167
ABS BRAKES OPERATION AND VEHICLE PERFORMANCE................................................................................... 168
NORMAL BRAKING SYSTEM FUNCTION............................................................................................. 168
ABS SYSTEM OPERATION....................................................................................................... 168
VEHICLE HANDLING PERFORMANCE DURING ABS BRAKING............................................................................ 168
NOISE AND BRAKE PEDAL FEEL................................................................................................. 168
TIRE NOISE AND MARKS....................................................................................................... 168
START UP CYCLE............................................................................................................. 168
PREMATURE ABS CYCLING...................................................................................................... 169
ABS BRAKE SYSTEM COMPONENTS.................................................................................................... 169
ABS MASTER CYLINDER AND POWER BRAKE BOOSTER.................................................................................... 169
INTEGRATED CONTROL UNIT (ICU).................................................................................................. 169
INLET VALVES AND SOLENOIDS..................................................................................................... 170
OUTLET VALVES AND SOLENOIDS.................................................................................................... 170
ASR VALVE (ABS WITH TRACTION CONTROL ONLY)..................................................................................... 170
HCU BRAKE FLUID ACCUMULATORS AND NOISE DAMPING CHAMBER......................................................................... 170
HCU PUMP/MOTOR................................................................................................................. 171
ABS FUSES...................................................................................................................... 171
ABS RELAYS..................................................................................................................... 171
PROPORTIONING VALVES........................................................................................................... 171
WHEEL SPEED SENSORS............................................................................................................ 171
CONTROLLER ANTILOCK BRAKES (CAB)............................................................................................... 172
CONTROLLER ANTILOCK BRAKE INPUTS........................................................................................... 173
CONTROLLER ANTILOCK BRAKE OUTPUTS.......................................................................................... 173
ABS WARNING LAMP (YELLOW)...................................................................................................... 173
HYDRAULIC CIRCUITS AND VALVE OPERATION......................................................................................... 174
NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION ............................................................. 174
TEVES MARK 20 ABS CIRCUIT AND SOLENOID VALVE FUNCTION...................................................................... 174
TEVES MARK 20 SECONDARY ABS CIRCUIT AND SOLENOID VALVE FUNCTION............................................................ 174
TEVES MARK 20 ABS WITH TRACTION CONTROL NORMAL BRAKING HYDRAULIC CIRCUIT – SOLENOID AND SHUTTLE VALVE FUNCTION............. 175
TEVES MARK 20 ABS WITH TRACTION CONTROL ABS BRAKING HYDRAULIC CIRCUIT – SOLENOID AND SHUTTLE VALVE FUNCTION................ 175
TEVES MARK 20 ABS WITH TRACTION CONTROL– TRACTION CONTROL HYDRAULIC CIRCUIT – SOLENOID AND SHUTTLE VALVE FUNCTION.......... 177
DIAGNOSIS AND TESTING.............................................................................................................. 177
ABS GENERAL DIAGNOSTICS INFORMATION............................................................................................ 177
ABS WIRING DIAGRAM INFORMATION................................................................................................. 177
ABS DIAGNOSTICS MANUAL......................................................................................................... 178
DRB DIAGNOSTIC SCAN TOOL USAGE................................................................................................. 178
ABS BRAKE DIAGNOSTIC TOOL CONNECTOR ........................................................................................... 178
ABS SYSTEM SELF DIAGNOSTICS.................................................................................................... 178
START-UP CYCLE............................................................................................................. 179
DRIVE-OFF CYCLE............................................................................................................ 179
ONGOING TESTS.............................................................................................................. 179
ABS DIAGNOSTIC TROUBLE CODES................................................................................................... 179
LATCHING VERSUS NON-LATCHING DIAGNOSTIC TROUBLE CODES...................................................................... 179
INTERMITTENT DIAGNOSTIC TROUBLE CODES.......................................................................................... 179
TONEWHEEL INSPECTION........................................................................................................... 180
PROPORTIONING VALVE............................................................................................................ 180
BRAKE FLUID CONTAMINATION...................................................................................................... 180
TEST DRIVING ABS COMPLAINT VEHICLE............................................................................................. 180
ABS SERVICE PRECAUTIONS........................................................................................................ 181
SERVICE PROCEDURES................................................................................................................. 181
BRAKE FLUID LEVEL INSPECTION................................................................................................... 181
BLEEDING TEVES MARK 20 HYDRAULIC SYSTEM........................................................................................ 181
ABS BLEEDING PROCEDURE..................................................................................................... 181
REMOVAL AND INSTALLATION........................................................................................................... 182
ABS GENERAL SERVICE PRECAUTIONS................................................................................................ 182
HYDRAULIC CONTROL UNIT ........................................................................................................ 182
REMOVE..................................................................................................................... 182
INSTALL.................................................................................................................... 184
CONTROLLER ANTILOCK BRAKES (CAB)............................................................................................... 185
REMOVE..................................................................................................................... 185
INSTALL.................................................................................................................... 186
WHEEL SPEED SENSOR (FRONT)..................................................................................................... 187
REMOVE..................................................................................................................... 187
INSTALL.................................................................................................................... 188
WHEEL SPEED SENSOR (REAR FWD).................................................................................................. 188
REMOVE..................................................................................................................... 188
INSTALL.................................................................................................................... 190
WHEEL SPEED SENSOR (REAR AWD).................................................................................................. 190
REMOVE..................................................................................................................... 190
INSTALL.................................................................................................................... 191
TONE WHEEL (REAR FWD).......................................................................................................... 192
REMOVE..................................................................................................................... 192
INSTALL.................................................................................................................... 193
TONE WHEEL (REAR AWD).......................................................................................................... 193
SPECIFICATIONS..................................................................................................................... 194
SPEED SENSOR TONE WHEEL RUNOUT................................................................................................. 194
WHEEL SPEED SENSOR TO TONE WHEEL CLEARANCE..................................................................................... 194
FRONT WHEEL................................................................................................................ 194
REAR WHEEL................................................................................................................. 194
BRAKE FASTENER TORQUE SPECIFICATIONS........................................................................................... 194
BRAKES 1
.................................................................................................................................. 195
GENERAL INFORMATION.................................................................................................................... 195
BASE BRAKE SYSTEM COMPONENT DESCRIPTION............................................................................................ 195
DESCRIPTION AND OPERATION.............................................................................................................. 195
MASTER CYLINDER.................................................................................................................... 195
DIAGNOSIS AND TESTING.................................................................................................................. 195
REAR DRUM BRAKE ADJUSTMENT......................................................................................................... 195
MASTER CYLINDER FLUID LEVEL CHECK.................................................................................................. 196
REMOVAL AND INSTALLATION............................................................................................................... 196
FRONT PARK BRAKE CABLE AND LEVER ASSEMBLY- RHD& LHD VEHICLES....................................................................... 196
REMOVE......................................................................................................................... 196
INSTALL........................................................................................................................ 197
BRAKE PEDAL TORQUE SHAFT ASSEMBLY.................................................................................................. 198
REMOVE......................................................................................................................... 198
INSTALL........................................................................................................................ 198
CLUTCH..................................................................................................................................... 199
GENERAL INFORMATION.................................................................................................................... 199
CLUTCH COMPONENTS.................................................................................................................. 199
CLUTCH CABLE AND PEDAL — LHD................................................................................................... 199
HYDRAULIC LINKAGE AND COMPONENTS — RHD......................................................................................... 200
CLUTCH DISC AND COVER APPLICATION.................................................................................................. 201
CLUTCH REPLACEMENT................................................................................................................. 201
DESCRIPTION AND OPERATION.............................................................................................................. 202
CLUTCH RELEASE SYSTEM.............................................................................................................. 202
CLUTCH CABLE — LHD............................................................................................................. 202
HYDRAULIC CLUTCH — RHD......................................................................................................... 202
CLUTCH PEDAL POSITION SWITCH....................................................................................................... 202
DIAGNOSIS AND TESTING.................................................................................................................. 202
CLUTCH PEDAL POSITION SWITCH....................................................................................................... 202
CLUTCH PEDAL POSITION SWITCH– ELECTRICAL TEST.................................................................................. 202
CLUTCH PEDAL POSITION SWITCH– MECHANICAL TEST.................................................................................. 203
SERVICE DIAGNOSIS– CLUTCH PEDAL POSITION SWITCH................................................................................ 203
CLUTCH DIAGNOSIS................................................................................................................... 204
SERVICE DIAGNOSIS– CLUTCH GRAB/ CHATTER........................................................................................ 204
SERVICE DIAGNOSIS– CLUTCH SLIPS................................................................................................ 204
SERVICE DIAGNOSIS– IMPROPER CLUTCH RELEASE..................................................................................... 205
SERVICE DIAGNOSIS– CLUTCH PEDAL NOISE.......................................................................................... 205
DRIVE PLATE MISALIGNMENT........................................................................................................... 205
CLUTCH COVER AND DISC RUNOUT....................................................................................................... 206
CLUTCH CHATTER COMPLAINTS.......................................................................................................... 206
CLASH– INTO– REVERSE COMPLAINTS.................................................................................................... 206
REMOVAL AND INSTALLATION............................................................................................................... 206
CLUTCH CABLE SYSTEM — LHD.......................................................................................................... 206
REMOVAL........................................................................................................................ 206
INSTALLATION................................................................................................................... 208
CLUTCH PEDAL POSITION SWITCH....................................................................................................... 208
REMOVAL........................................................................................................................ 208
INSTALLATION................................................................................................................... 208
HYDRAULIC CLUTCH LINKAGE SYSTEM — RHD.............................................................................................. 209
REMOVAL........................................................................................................................ 209
INSTALLATION................................................................................................................... 209
QUICK CONNECT COUPLING — RHD....................................................................................................... 210
REMOVAL........................................................................................................................ 210
INSTALLATION................................................................................................................... 210
MASTER CYLINDER SYSTEM — RHD....................................................................................................... 210
REMOVAL........................................................................................................................ 210
INSTALLATION................................................................................................................... 210
SLAVE CYLINDER ASSEMBLY — RHD...................................................................................................... 210
REMOVAL........................................................................................................................ 210
INSTALLATION................................................................................................................... 211
MODULAR CLUTCH ASSEMBLY (2.0L AND 2.4L GASOLINE)................................................................................... 211
CLUTCH ASSEMBLY (2.5L DIESEL)...................................................................................................... 211
REMOVAL........................................................................................................................ 211
INSPECTION..................................................................................................................... 211
INSTALLATION................................................................................................................... 212
CLUTCH RELEASE BEARING AND FORK.................................................................................................... 212
REMOVAL........................................................................................................................ 212
INSTALLATION................................................................................................................... 213
CLEANING AND INSPECTION................................................................................................................ 213
CLUTCH CONTAMINATION............................................................................................................... 213
OIL CONTAMINATION.............................................................................................................. 213
GREASE CONTAMINATION........................................................................................................... 213
ROAD SPLASH/ WATER CONTAMINATION............................................................................................... 213
CLEANING PRECAUTIONS............................................................................................................... 213
ADJUSTMENTS............................................................................................................................ 214
CLUTCH CABLE — LHD................................................................................................................. 214
ADJUSTER MECHANISM FUNCTION CHECK — LHD........................................................................................ 214
CLUTCH PEDAL POSITION SWITCH....................................................................................................... 214
SPECIFICATIONS......................................................................................................................... 214
CLUTCH TIGHTENING REFERENCE........................................................................................................ 214
COOLING SYSTEM............................................................................................................................. 215
GENERAL INFORMATION.................................................................................................................... 215
ACCESSORY DRIVE BELTS.............................................................................................................. 215
COOLING SYSTEM..................................................................................................................... 216
COOLANT RECOVERY SYSTEM (CRS)...................................................................................................... 217
AUTOMATIC TRANSMISSION OIL COOLER 2.4L............................................................................................. 217
ENGINE THERMOSTAT.................................................................................................................. 217
WATER PUMPS........................................................................................................................ 217
COOLANT ........................................................................................................................... 217
RADIATOR........................................................................................................................... 217
RADIATOR PRESSURE CAP.............................................................................................................. 218
ENGINE BLOCK HEATER................................................................................................................ 219
DESCRIPTION AND OPERATION.............................................................................................................. 220
WATER PIPES—3.0L ENGINE............................................................................................................ 220
COOLANT PERFORMANCE................................................................................................................ 220
RADIATOR HOSES AND CLAMPS.......................................................................................................... 220
WATER PUMP 2.4L ENGINE ............................................................................................................ 220
WATER PUMP—3.0L ENGINE............................................................................................................. 220
WATER PUMP—3.3/3.8L ENGINES........................................................................................................ 221
DIAGNOSIS AND TESTING.................................................................................................................. 221
ACCESSORY DRIVE BELT............................................................................................................... 221
COOLING SYSTEM DIAGNOSIS........................................................................................................... 222
RADIATOR COOLANT FLOW TEST......................................................................................................... 228
RADIATOR FAN CONTROL............................................................................................................... 228
ELECTRIC FAN MOTOR TEST............................................................................................................ 228
TESTING COOLING SYSTEM FOR LEAKS................................................................................................... 228
RADIATOR FAN OPERATION......................................................................................................... 228
RADIATOR CAP TO FILLER NECK SEAL PRESSURE RELIEF CHECK............................................................................. 229
PRESSURE TESTING RADIATOR CAP...................................................................................................... 229
LOW COOLANT LEVEL AERATION......................................................................................................... 229
DEAERATION......................................................................................................................... 230
TEMPERATURE GAUGE INDICATION....................................................................................................... 230
SERVICE PROCEDURES..................................................................................................................... 230
COOLANT LEVEL CHECK—ROUTINE........................................................................................................ 230
COOLANT—ADDING ADDITIONAL.......................................................................................................... 230
COOLANT LEVEL SERVICE.............................................................................................................. 230
COOLING SYSTEM DRAINING ........................................................................................................... 230
COOLING SYSTEM—REFILLING........................................................................................................... 230
REMOVAL AND INSTALLATION............................................................................................................... 231
WATER PUMP—2.4L ENGINE............................................................................................................. 231
REMOVAL........................................................................................................................ 231
INSTALLATION................................................................................................................... 231
WATER PUMP INLET TUBE—2.4L ENGINE.................................................................................................. 231
REMOVAL........................................................................................................................ 231
INSTALLATION .................................................................................................................. 231
WATER PUMP—3.0L ENGINE............................................................................................................. 232
REMOVAL........................................................................................................................ 232
INSPECTION..................................................................................................................... 232
INSTALLATION................................................................................................................... 233
WATER PUMP—3.3/3.8L ENGINES........................................................................................................ 233
REMOVAL........................................................................................................................ 233
INSTALLATION................................................................................................................... 233
THERMOSTAT—2.4L ENGINE............................................................................................................. 233
REMOVAL........................................................................................................................ 233
INSTALLATION—2.4L ENGINE....................................................................................................... 234
THERMOSTAT—3.0L ENGINE............................................................................................................. 234
REMOVAL........................................................................................................................ 234
INSTALLATION—3.0L ENGINE....................................................................................................... 234
THERMOSTAT—3.3/3.8L ENGINES........................................................................................................ 234
REMOVAL........................................................................................................................ 234
INSTALLATION................................................................................................................... 235
RADIATOR........................................................................................................................... 235
REMOVAL ....................................................................................................................... 235
INSTALLATION................................................................................................................... 235
RADIATOR DRAINCOCK................................................................................................................. 235
REMOVAL........................................................................................................................ 235
INSTALLATION................................................................................................................... 236
FAN MODULE......................................................................................................................... 236
REMOVAL........................................................................................................................ 236
INSTALLATION................................................................................................................... 236
ENGINE BLOCK HEATER................................................................................................................ 237
REMOVAL........................................................................................................................ 237
INSTALLATION................................................................................................................... 237
ACCESSORY DRIVE BELTS—2.4L......................................................................................................... 237
REMOVAL/INSTALLATION-ADJUST.................................................................................................... 237
ACCESSORY DRIVE BELTS—3.0L......................................................................................................... 238
GENERATOR/POWER STEERING PUMP BELT............................................................................................. 238
AIR CONDITIONING BELT.......................................................................................................... 238
ACCESSORY DRIVE BELT—3.3/3.8L...................................................................................................... 238
REMOVE/INSTALL................................................................................................................. 238
CLEANING AND INSPECTION................................................................................................................ 238
WATER PUMP......................................................................................................................... 238
ACCESSORY DRIVE BELT .............................................................................................................. 239
RADIATOR PRESSURE CAP.............................................................................................................. 239
INSPECTION..................................................................................................................... 239
COOLING SYSTEM CLEANING............................................................................................................ 239
REVERSE FLUSHING THE RADIATOR...................................................................................................... 239
REVERSE FLUSHING THE ENGINE........................................................................................................ 239
CHEMICAL CLEANING.................................................................................................................. 239
ADJUSTMENTS............................................................................................................................ 239
PROPER BELT TENSION................................................................................................................ 239
BELT TENSION GAUGE METHOD.......................................................................................................... 240
BELT TENSION CHART................................................................................................................. 240
SPECIFICATIONS......................................................................................................................... 240
COOLING SYSTEM CAPACITY ........................................................................................................... 240
TORQUE CHART....................................................................................................................... 240
SPECIAL TOOLS.......................................................................................................................... 240
COOLING............................................................................................................................ 240
COOLING SYSTEM 1
.......................................................................................................................... 241
GENERAL INFORMATION.................................................................................................................... 241
COOLING SYSTEM — 2.0L GASOLINE..................................................................................................... 241
COOLING SYSTEM — 2.5L VM DIESEL.................................................................................................... 241
COOLANT PRESSURE BOTTLE............................................................................................................ 241
2.5L VM DIESEL................................................................................................................. 241
LOW COOLANT LEVEL SENSOR........................................................................................................... 241
RADIATOR........................................................................................................................... 242
DESCRIPTION AND OPERATION.............................................................................................................. 243
WATER PUMP......................................................................................................................... 243
2.0L GASOLINE.................................................................................................................. 243
2.5L VM DIESEL................................................................................................................. 243
THERMOSTAT OPERATION............................................................................................................... 244
2.5 VM DIESEL.................................................................................................................. 244
PRESSURE/ VENT CAP................................................................................................................. 244
COOLANT PERFORMANCE................................................................................................................ 245
ETHYLENE- GLYCOL MIXTURES...................................................................................................... 245
BELT TENSION....................................................................................................................... 245
AUTOMATIC BELT TENSIONER........................................................................................................... 246
THERMOSTAT......................................................................................................................... 246
DIAGNOSIS...................................................................................................................... 246
TESTING........................................................................................................................ 246
SERVICE PROCEDURES..................................................................................................................... 247
ADDING ADDITIONAL COOLANT.......................................................................................................... 247
2.5L VM DIESEL................................................................................................................. 247
DRAINING COOLING SYSTEM............................................................................................................ 247
2.0L GASOLINE.................................................................................................................. 247
2.5L VM DIESEL................................................................................................................. 247
REFILLING COOLING SYSTEM........................................................................................................... 247
2.0L GASOLINE.................................................................................................................. 247
2.5L VM DIESEL................................................................................................................. 247
REMOVAL AND INSTALLATION............................................................................................................... 247
WATER PUMP — 2.0L GASOLINE......................................................................................................... 247
REMOVAL........................................................................................................................ 247
INSTALLATION................................................................................................................... 248
WATER PUMP — 2.5L VM DIESEL........................................................................................................ 248
REMOVAL........................................................................................................................ 248
INSTALLATION................................................................................................................... 248
ENGINE THERMOSTAT— 2.0L GASOLINE................................................................................................... 249
REMOVAL........................................................................................................................ 249
INSTALLATION................................................................................................................... 249
THERMOSTAT — 2.5L VM DIESEL........................................................................................................ 249
REMOVAL........................................................................................................................ 249
INSTALLATION................................................................................................................... 249
RADIATOR — 2.5L VM DIESEL.......................................................................................................... 249
REMOVAL........................................................................................................................ 249
INSTALLATION................................................................................................................... 250
WATER PUMP BELT — 2.5L VM DIESEL................................................................................................... 250
REMOVAL........................................................................................................................ 250
INSTALLATION................................................................................................................... 250
GENERATOR/ POWER STEERING BELT — 2.5L VM DIESEL.................................................................................... 250
REMOVAL........................................................................................................................ 250
INSTALLATION................................................................................................................... 250
CLEANING AND INSPECTION................................................................................................................ 250
WATER PUMP......................................................................................................................... 250
ADJUSTMENTS............................................................................................................................ 251
BELT TENSION GAUGE METHOD.......................................................................................................... 251
BELT TENSION CHART................................................................................................................. 251
SPECIFICATIONS......................................................................................................................... 252
COOLING SYSTEM CAPACITY TORQUE CHART............................................................................................... 252
SPECIAL TOOLS.......................................................................................................................... 252
COOLING............................................................................................................................ 252
BATTERY.................................................................................................................................... 253
GENERAL INFORMATION.................................................................................................................... 253
INTRODUCTION....................................................................................................................... 253
SAFETY PRECAUTIONS AND WARNINGS.................................................................................................... 253
DESCRIPTION AND OPERATION.............................................................................................................. 253
BATTERY IGNITION OFF DRAW (IOD).................................................................................................... 253
CHARGING TIME REQUIRED............................................................................................................. 254
SIZE OF BATTERY................................................................................................................ 254
BATTERY CHARGING TIMETABLE..................................................................................................... 254
TEMPERATURE.................................................................................................................... 254
CHARGER CAPACITY............................................................................................................... 254
STATE OF CHARGE................................................................................................................ 254
DIAGNOSIS AND TESTING.................................................................................................................. 254
BATTERY BUILT-IN TEST INDICATOR.................................................................................................... 254
USING TEST INDICATOR........................................................................................................... 254
CAUSES OF BATTERY DISCHARGING.................................................................................................. 255
ABNORMAL BATTERY DISCHARGING................................................................................................... 255
BATTERY IGNITION OFF DRAW (IOD).................................................................................................... 255
BATTERY DIAGNOSIS AND TESTING.................................................................................................. 256
BATTERY LOAD TEST.................................................................................................................. 256
BATTERY LOAD TEST TEMPERATURE.................................................................................................. 257
BATTERY OPEN CIRCUIT VOLTAGE TEST.................................................................................................. 258
BATTERY OPEN CIRCUIT VOLTAGE................................................................................................... 258
SERVICE PROCEDURES..................................................................................................................... 258
BATTERY CHARGING................................................................................................................... 258
CHARGING COMPLETELY DISCHARGED BATTERY............................................................................................. 259
BATTERY CHARGING RATE.......................................................................................................... 259
VISUAL INSPECTION.................................................................................................................. 259
REMOVAL AND INSTALLATION............................................................................................................... 260
BATTERY............................................................................................................................ 260
REMOVAL........................................................................................................................ 260
INSTALLATION................................................................................................................... 260
BATTERY TRAY....................................................................................................................... 261
REMOVAL........................................................................................................................ 261
INSTALLATION................................................................................................................... 261
SPECIFICATIONS......................................................................................................................... 262
BATTERY SPECIFICATIONS............................................................................................................. 262
CRANKING RATING.................................................................................................................... 262
RESERVE CAPACITY RATING............................................................................................................ 262
TORQUE............................................................................................................................. 262
BATTERY 1
................................................................................................................................. 263
GENERAL INFORMATION.................................................................................................................... 263
INTRODUCTION....................................................................................................................... 263
SAFETY PRECAUTIONS AND WARNINGS.................................................................................................... 263
DESCRIPTION AND OPERATION.............................................................................................................. 264
BATTERY IGNITION OFF DRAW (IOD).................................................................................................... 264
CHARGING TIME REQUIRED............................................................................................................. 264
SIZE OF BATTERY................................................................................................................ 264
TEMPERATURE.................................................................................................................... 264
CHARGER CAPACITY............................................................................................................... 264
STATE OF CHARGE................................................................................................................ 264
USING HYDROMETER............................................................................................................... 264
DIAGNOSIS AND TESTING.................................................................................................................. 265
BATTERY DISCHARGING................................................................................................................ 265
CAUSE OF BATTERY DISCHARGING................................................................................................... 265
ABNORMAL BATTERY DISCHARGING................................................................................................... 265
BATTERY IGNITION OFF DRAW.......................................................................................................... 265
BATTERY LOAD TEST.................................................................................................................. 267
BATTERY OPEN CIRCUIT VOLTAGE TEST.................................................................................................. 268
SERVICE PROCEDURES..................................................................................................................... 268
BATTERY CHARGING................................................................................................................... 268
CHARGING COMPLETELY DISCHARGED BATTERY............................................................................................. 269
VISUAL INSPECTION.................................................................................................................. 269
REMOVAL AND INSTALLATION............................................................................................................... 270
BATTERY............................................................................................................................ 270
REMOVAL........................................................................................................................ 270
INSTALLATION................................................................................................................... 270
BATTERY TRAY....................................................................................................................... 271
REMOVAL........................................................................................................................ 271
INSTALLATION................................................................................................................... 271
SPECIFICATIONS......................................................................................................................... 271
BATTERY SPECIFICATIONS............................................................................................................. 271
CRANKING RATING................................................................................................................ 271
TORQUE............................................................................................................................. 272
STARTER.................................................................................................................................... 273
GENERAL INFORMATION.................................................................................................................... 273
INTRODUCTION....................................................................................................................... 273
DESCRIPTION AND OPERATION.............................................................................................................. 273
SUPPLY CIRCUIT AND CONTROL CIRCUIT................................................................................................. 273
DIAGNOSIS AND TESTING.................................................................................................................. 273
CONTROL CIRCUIT TEST............................................................................................................... 273
STARTER SOLENOID............................................................................................................... 274
STARTER RELAY.................................................................................................................. 274
RELAY TEST..................................................................................................................... 274
RELAY CIRCUIT TEST............................................................................................................. 274
SAFETY SWITCHES................................................................................................................ 275
IGNITION SWITCH................................................................................................................ 275
BATTERY........................................................................................................................ 275
ALL RELATED WIRING AND CONNECTORS.............................................................................................. 275
FEED CIRCUIT RESISTANCE TEST....................................................................................................... 275
FEED CIRCUIT TEST.................................................................................................................. 276
REMOVAL AND INSTALLATION............................................................................................................... 277
STARTER—2.4L ENGINE................................................................................................................ 277
REMOVAL........................................................................................................................ 277
INSTALLATION................................................................................................................... 278
STARTER—3.0L ENGINE................................................................................................................ 278
REMOVAL........................................................................................................................ 278
INSTALLATION................................................................................................................... 278
STARTER—3.3/3.8L ENGINE............................................................................................................ 278
REMOVAL........................................................................................................................ 278
INSTALLATION................................................................................................................... 278
SPECIFICATIONS......................................................................................................................... 279
STARTER............................................................................................................................ 279
TORQUE............................................................................................................................. 279
STARTING SYSTEM............................................................................................................................ 281
REMOVAL AND INSTALLATION............................................................................................................... 281
STARTER............................................................................................................................ 281
2.0L ENGINE.................................................................................................................... 281
2.4L ENGINE - With Manual Transaxle............................................................................................ 282
2.4L ENGINE - With Automatic Transaxle......................................................................................... 282
3.0L ENGINE.................................................................................................................... 283
3.3/3.8L ENGINE................................................................................................................ 284
2.5L DIESEL ENGINE............................................................................................................. 285
CHARGING SYSTEM............................................................................................................................ 287
GENERAL INFORMATION ................................................................................................................... 287
OVERVIEW .......................................................................................................................... 287
DESCRIPTION AND OPERATION.............................................................................................................. 287
CHARGING SYSTEM OPERATION.......................................................................................................... 287
GENERATOR.......................................................................................................................... 288
BATTERY TEMPERATURE SENSOR......................................................................................................... 288
ELECTRONIC VOLTAGE REGULATOR....................................................................................................... 288
DIAGNOSIS AND TESTING.................................................................................................................. 288
CHARGING SYSTEM.................................................................................................................... 288
INSPECTION..................................................................................................................... 288
CHARGING SYSTEM RESISTANCE TESTS................................................................................................... 290
PREPARATION.................................................................................................................... 290
TEST........................................................................................................................... 290
CURRENT OUTPUT TEST................................................................................................................ 290
PREPARATION.................................................................................................................... 290
CHAR GING SYSTEM TEST.......................................................................................................... 291
OVERCHAR GE TEST............................................................................................................... 292
TEST........................................................................................................................... 293
ON-BOARD DIAGNOSTIC SYSTEM TEST.................................................................................................... 293
GENERAL INFORMATION............................................................................................................ 293
DIAGNOSTIC TROUBLE CODES....................................................................................................... 293
ERASING DIAGNOSTIC TROUBLE CODES............................................................................................... 293
VOLTAGE DROP TEST.............................................................................................................. 294
REMOVAL AND INSTALLATION............................................................................................................... 295
GENERATOR—2.4L ENGINE.............................................................................................................. 295
REMOVAL........................................................................................................................ 295
INSTALLATION................................................................................................................... 295
GENERATOR—3.0L ENGINE.............................................................................................................. 295
REMOVAL........................................................................................................................ 295
INSTALLATION................................................................................................................... 295
GENERATOR—3.3/3.8 L ENGINE......................................................................................................... 296
REMOVAL........................................................................................................................ 296
INSTALLATION................................................................................................................... 296
SPECIFICATIONS......................................................................................................................... 297
GENERATOR.......................................................................................................................... 297
TORQUE............................................................................................................................. 297
IGNITION SYSTEM............................................................................................................................ 299
GENERAL INFORMATION.................................................................................................................... 299
GENERAL INFORMATION................................................................................................................ 299
INTRODUCTION................................................................................................................... 299
POWERTRAIN CONTROL MODULE...................................................................................................... 299
IGNITION SYSTEM................................................................................................................ 300
SPARK PLUGS 2.4/3.0L .......................................................................................................... 300
SPARK PLUGS 3.3/3.8L........................................................................................................... 300
3.3/3.8L SPARK PLUG GAP MEASUREMENT........................................................................................ 301
SPARK PLUG CABLE............................................................................................................... 301
SPARK PLUG CABLES—3.3/3.8L................................................................................................. 302
IGNITION COIL.................................................................................................................. 302
AUTOMATIC SHUTDOWN (ASD) RELAY................................................................................................. 302
CRANKSHAFT POSITION SENSOR..................................................................................................... 303
CAMSHAFT POSITION SENSOR....................................................................................................... 303
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR........................................................................................ 304
ENGINE COOLANT TEMPERATURE (ECT) SENSOR........................................................................................ 304
THROTTLE POSITION SENSOR (TPS)................................................................................................. 305
LOCK KEY CYLINDER.............................................................................................................. 305
KNOCK SENSOR................................................................................................................... 305
DIAGNOSIS AND TESTING.............................................................................................................. 306
TESTING FOR SPARK AT COIL—2.4/3.3/3.8L ENGINES................................................................................. 306
TESTING FOR SPARK AT COIL—3.0L................................................................................................. 306
CHECK COIL TEST—2.4L........................................................................................................... 307
CHECK COIL TEST—3.3/3.8L....................................................................................................... 307
FAILURE TO START TEST.......................................................................................................... 308
IGNITION TIMING PROCEDURE...................................................................................................... 309
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST................................................................................... 309
CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR........................................................................ 309
ENGINE COOLANT TEMPERATURE SENSOR.............................................................................................. 309
INTAKE AIR TEMPERATURE SENSOR.................................................................................................. 309
SPARK PLUG CONDITION........................................................................................................... 309
NORMAL OPERATING CONDITIONS................................................................................................ 309
COLD FOULING (CARBON FOULING).............................................................................................. 309
FUEL FOULING .............................................................................................................. 309
OIL FOULING................................................................................................................ 309
OIL OR ASH ENCRUSTED....................................................................................................... 309
HIGH SPEED MISS............................................................................................................ 310
ELECTRODE GAP BRIDGING .................................................................................................... 310
SCAVENGER DEPOSITS......................................................................................................... 310
CHIPPED ELECTRODE INSULATOR................................................................................................ 310
PREIGNITION DAMAGE......................................................................................................... 310
SPARK PLUG OVERHEATING..................................................................................................... 310
THROTTLE POSITION SENSOR....................................................................................................... 311
SERVICE PROCEDURES................................................................................................................. 311
SPARK PLUG GAP ADJUSTMENT...................................................................................................... 311
POWERTRAIN CONTROL MODULE...................................................................................................... 311
REMOVAL.................................................................................................................... 311
INSTALLATION............................................................................................................... 312
IGNITION TIMING PROCEDURE...................................................................................................... 313
2.4L ENGINE............................................................................................................................ 314
DESCRIPTION AND OPERATION.......................................................................................................... 314
FIRING ORDER—2.4L.............................................................................................................. 314
CRANKSHAFT POSITION SENSOR..................................................................................................... 314
CAMSHAFT POSITION SENSOR....................................................................................................... 315
INTAKE AIR TEMPERATURE SENSOR 2.4L ............................................................................................ 315
REMOVAL AND INSTALLATION........................................................................................................... 316
SPARK PLUG CABLE SERVICE—2.4L.................................................................................................. 316
REMOVAL.................................................................................................................... 316
INSTALLATION............................................................................................................... 316
IGNITION COIL—2.4L............................................................................................................. 316
REMOVAL.................................................................................................................... 316
INSTALLATION............................................................................................................... 316
SPARK PLUG SERVICE............................................................................................................. 316
CRANKSHAFT POSITION SENSOR..................................................................................................... 317
REMOVAL.................................................................................................................... 317
INSTALLATION............................................................................................................... 317
CAMSHAFT POSITION SENSOR....................................................................................................... 317
REMOVAL.................................................................................................................... 317
INSTALLATION............................................................................................................... 317
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR—2.4/3.3/3.8L........................................................................... 318
REMOVAL.................................................................................................................... 318
INSTALLATION............................................................................................................... 318
THROTTLE POSITION SENSOR....................................................................................................... 318
ENGINE COOLANT TEMPERATURE SENSOR—2.4L......................................................................................... 318
REMOVAL.................................................................................................................... 319
INSTALLATION............................................................................................................... 319
KNOCK SENSOR—2.4L.............................................................................................................. 319
REMOVAL.................................................................................................................... 319
INSTALLATION .............................................................................................................. 319
INTAKE AIR TEMPERATURE SENSOR—2.4L............................................................................................. 319
REMOVAL.................................................................................................................... 319
INSTALLATION............................................................................................................... 319
SPECIFICATIONS..................................................................................................................... 320
IGNITION COIL.................................................................................................................. 320
SPARK PLUG..................................................................................................................... 320
TORQUE ........................................................................................................................ 320
SPARK PLUG CABLE RESISTANCE 2.4L............................................................................................... 320
3.0L ENGINE............................................................................................................................ 321
DESCRIPTION AND OPERATION.......................................................................................................... 321
FIRING ORDER—3.0L.............................................................................................................. 321
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR........................................................................................ 321
CAMSHAFT POSITION SENSOR....................................................................................................... 321
REMOVAL AND INSTALLATION........................................................................................................... 322
SPARK PLUG SERVICE............................................................................................................. 322
REMOVAL.................................................................................................................... 322
INSTALLATION............................................................................................................... 322
IGNITION COIL—3.OL................................................................................................................. 322
REMOVAL........................................................................................................................ 322
INSTALLATION................................................................................................................... 322
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR—3.0L................................................................................... 322
REMOVAL.................................................................................................................... 322
INSTALLATION............................................................................................................... 323
ENGINE COOLANT TEMPERATURE SENSOR—3.0L......................................................................................... 323
REMOVAL.................................................................................................................... 323
INSTALLATION............................................................................................................... 323
CRANKSHAFT POSITION SENSOR..................................................................................................... 323
REMOVAL.................................................................................................................... 323
INSTALLATION............................................................................................................... 323
THROTTLE POSITION SENSOR....................................................................................................... 323
DISASSEMBLY AND ASSEMBLY........................................................................................................... 324
DISTRIBUTOR—3.0L............................................................................................................... 324
REMOVAL.................................................................................................................... 324
INSTALLATION............................................................................................................... 324
CLEANING AND INSPECTION............................................................................................................ 324
DISTRIBUTOR CAP................................................................................................................ 324
DISTRIBUTOR ROTOR—3.0L......................................................................................................... 325
SPECIFICATIONS..................................................................................................................... 325
SPARK PLUG..................................................................................................................... 325
TORQUE ........................................................................................................................ 325
SPARK PLUG CABLE RESISTANCE 3.0L............................................................................................... 325
3.3/3.8L ENGINE........................................................................................................................ 326
DESCRIPTION AND OPERATION ......................................................................................................... 326
FIRING ORDER 3.3/3.8L ......................................................................................................... 326
REMOVAL AND INSTALLATION........................................................................................................... 326
SPARK PLUG CABLE SERVICE 3.3/3.8L ENGINES...................................................................................... 326
SPARK PLUG CABLES #3 AND #5.................................................................................................... 327
SPARK PLUG CABLE #1........................................................................................................ 327
SPARK PLUG SERVICE—3.3/3.8L ENGINES............................................................................................ 327
SPARK PLUG #3 AND #5....................................................................................................... 327
SPARK PLUG #1.............................................................................................................. 328
IGNITION COIL.................................................................................................................. 328
REMOVAL.................................................................................................................... 328
INSTALLATION............................................................................................................... 328
CRANKSHAFT POSITION SENSOR..................................................................................................... 328
REMOVAL.................................................................................................................... 328
INSTALLATION............................................................................................................... 328
CAMSHAFT POSITION SENSOR....................................................................................................... 329
REMOVAL.................................................................................................................... 329
INSTALLATION............................................................................................................... 329
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR........................................................................................ 330
REMOVAL.................................................................................................................... 330
INSTALLATION............................................................................................................... 330
ENGINE COOLANT TEMPERATURE SENSOR.............................................................................................. 330
REMOVAL.................................................................................................................... 330
INSTALLATION............................................................................................................... 330
THROTTLE POSITION SENSOR....................................................................................................... 330
KNOCK SENSOR—3.3/3.8L.......................................................................................................... 330
REMOVAL.................................................................................................................... 331
INSTALLATION............................................................................................................... 331
SPECIFICATIONS..................................................................................................................... 331
IGNITION COIL.................................................................................................................. 331
SPARK PLUG..................................................................................................................... 332
TORQUE ........................................................................................................................ 332
SPARK PLUG CABLE RESISTANCE 3.3/3.8L........................................................................................... 332
IGNITION SWITCH AND LOCK CYLINDER...................................................................................................... 333
DESCRIPTION AND OPERATION.......................................................................................................... 333
IGNITION INTERLOCK............................................................................................................. 333
LOCK KEY CYLINDER.............................................................................................................. 333
REMOVAL AND INSTALLATION........................................................................................................... 333
IGNITION SWITCH................................................................................................................ 333
REMOVAL.................................................................................................................... 334
INSTALLATION............................................................................................................... 335
LOCK KEY CYLINDER.............................................................................................................. 336
REMOVAL.................................................................................................................... 336
INSTALLATION............................................................................................................... 336
IGNITION INTERLOCK............................................................................................................. 336
LOCK CYLINDER HOUSING.......................................................................................................... 336
INSTRUMENT PANEL AND SYSTEMS............................................................................................................... 337
GENERAL INFORMATION ................................................................................................................... 337
INTRODUCTION....................................................................................................................... 337
DESCRIPTION AND OPERATION.............................................................................................................. 337
INSTRUMENT CLUSTER ................................................................................................................ 337
DIAGNOSIS AND TESTING.................................................................................................................. 338
DIAGNOSTIC PROCEDURES.............................................................................................................. 338
HEADLAMP SWITCH.................................................................................................................... 338
SELF DIAGNOSTIC TEST............................................................................................................... 338
DIM TEST....................................................................................................................... 338
INSTRUMENT CLUSTER DTC TABLE .................................................................................................. 339
CLUSTER CALIBRATION TABLE...................................................................................................... 339
CALIBRATION TEST............................................................................................................... 339
ODOMETER SEGMENT TEST ......................................................................................................... 339
ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST........................................................................... 339
CONDITIONS..................................................................................................................... 339
INSTRUMENT CLUSTER DIAGNOSIS................................................................................................... 339
SPEEDOMETER DIAGNOSIS.......................................................................................................... 340
TACHOMETER DIAGNOSIS........................................................................................................... 343
FUEL GAUGE DIAGNOSIS........................................................................................................... 345
TEMPERATURE GAUGE DIAGNOSIS.................................................................................................... 347
ODOMETER DIAGNOSIS............................................................................................................. 349
ELECTRONIC GEAR INDICATOR DISPLAY DIAGNOSIS.................................................................................... 351
TRACTION CONTROL SWITCH............................................................................................................ 353
MECHANICAL TRANSMISSION RANGE INDICATOR (PRND21) DIAGNOSIS..................................................................... 353
SWITCH CONTINUITY TABLE........................................................................................................ 353
REMOVAL AND INSTALLATION............................................................................................................... 353
CONVENIENCE BIN - CUP HOLDER....................................................................................................... 353
REMOVAL ....................................................................................................................... 353
INSTALLATION................................................................................................................... 353
CONVENIENCE BIN LAMP............................................................................................................... 353
REMOVAL........................................................................................................................ 353
INSTALLATION .................................................................................................................. 354
CONVENIENCE BIN TRACK ............................................................................................................. 354
REMOVAL ....................................................................................................................... 354
INSTALLATION................................................................................................................... 354
BODY CONTROL MODULE (BCM).......................................................................................................... 354
REMOVAL........................................................................................................................ 354
INSTALLATION................................................................................................................... 355
INSTRUMENT CLUSTER LENS - MECHANICAL TRANSMISSION RANGE INDICATOR (PRND21)......................................................... 355
REMOVAL........................................................................................................................ 355
INSTALLATION................................................................................................................... 355
INSTRUMENT CLUSTER ELECTRONIC ODOMETER AND TRANSMISSION RANGE INDICATOR............................................................ 355
REMOVAL........................................................................................................................ 355
INSTALLATION................................................................................................................... 355
GLOVE BOX.......................................................................................................................... 355
REMOVAL (FIG. 4)............................................................................................................... 355
INSTALLATION................................................................................................................... 355
GLOVE BOX LAMP AND SWITCH.......................................................................................................... 355
REMOVAL........................................................................................................................ 355
INSTALLATION................................................................................................................... 356
GLOVE BOX LOCK STRIKER............................................................................................................. 356
REMOVAL........................................................................................................................ 356
INSTALLATION................................................................................................................... 356
HEADLAMP SWITCH.................................................................................................................... 356
REMOVAL........................................................................................................................ 356
INSTALLATION .................................................................................................................. 356
HEADLAMP SWITCH LAMP(S)............................................................................................................ 357
REMOVAL........................................................................................................................ 357
INSTALLATION................................................................................................................... 357
HVAC CONTROL LAMP ................................................................................................................. 357
REMOVAL ....................................................................................................................... 357
INSTALLATION................................................................................................................... 357
INSTRUMENT CLUSTER BACK PANEL...................................................................................................... 357
REMOVAL........................................................................................................................ 357
INSTALLATION .................................................................................................................. 357
INSTRUMENT CLUSTER BEZEL........................................................................................................... 357
REMOVAL........................................................................................................................ 357
INSTALLATION................................................................................................................... 358
INSTRUMENT CLUSTER LAMPS........................................................................................................... 358
REMOVAL........................................................................................................................ 358
INSTALLATION................................................................................................................... 358
INSTRUMENT CLUSTER LENS............................................................................................................ 358
REMOVAL........................................................................................................................ 358
INSTALLATION................................................................................................................... 358
INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD........................................................................................... 359
REMOVAL........................................................................................................................ 359
INSTALLATION................................................................................................................... 359
INSTRUMENT CLUSTER SUBDIAL......................................................................................................... 359
REMOVAL........................................................................................................................ 359
INSTALLATION................................................................................................................... 359
INSTRUMENT CLUSTER SUBDIAL—MECHANICAL TRANSMISSION RANGE INDICATOR................................................................. 359
REMOVAL........................................................................................................................ 359
INSTALLATION................................................................................................................... 359
INSTRUMENT CLUSTER WITH ELECTRONIC TRANSMISSION RANGE INDICATOR.................................................................... 359
REMOVAL........................................................................................................................ 359
INSTALLATION .................................................................................................................. 359
INSTRUMENT CLUSTER WITH MECHANICAL TRANSMISSION RANGE INDICATOR.................................................................... 360
REMOVAL........................................................................................................................ 360
INSTALLATION................................................................................................................... 360
INSTRUMENT PANEL................................................................................................................... 361
REMOVAL........................................................................................................................ 361
INSTALLATION................................................................................................................... 362
INSTRUMENT PANEL LEFT END COVER.................................................................................................... 363
REMOVAL........................................................................................................................ 363
INSTALLATION................................................................................................................... 363
INSTRUMENT PANEL LOUVERS........................................................................................................... 363
CENTER LOUVER HOUSING.......................................................................................................... 363
LEFT LOUVER HOUSING............................................................................................................ 363
PASSENGER SIDE LOUVERS......................................................................................................... 364
PASSENGER SIDE LOUVER OUTER HOUSINGS........................................................................................... 364
INSTRUMENT PANEL TOP COVER......................................................................................................... 365
REMOVAL........................................................................................................................ 365
INSTALLATION................................................................................................................... 365
INSTRUMENT PANEL RIGHT END COVER................................................................................................... 365
REMOVAL........................................................................................................................ 365
INSTALLATION................................................................................................................... 366
JUNCTION BLOCK..................................................................................................................... 366
REMOVAL........................................................................................................................ 366
INSTALLATION................................................................................................................... 366
KNEE BLOCKER REINFORCEMENT......................................................................................................... 366
REMOVAL........................................................................................................................ 366
INSTALLATION................................................................................................................... 366
LOWER CONSOLE...................................................................................................................... 366
REMOVAL........................................................................................................................ 366
INSTALLATION................................................................................................................... 367
LOWER INSTRUMENT PANEL............................................................................................................. 367
REMOVAL........................................................................................................................ 367
INSTALLATION .................................................................................................................. 367
LOWER STEERING COLUMN COVER........................................................................................................ 367
REMOVAL........................................................................................................................ 367
INSTALLATION................................................................................................................... 368
MECHANICAL TRANSMISSION RANGE INDICATOR............................................................................................ 368
REMOVAL........................................................................................................................ 368
INSTALLATION .................................................................................................................. 368
MESSAGE CENTER..................................................................................................................... 368
REMOVAL........................................................................................................................ 368
INSTALLATION................................................................................................................... 368
MESSAGE CENTER LAMP................................................................................................................ 368
REMOVAL........................................................................................................................ 368
INSTALLATION................................................................................................................... 368
OUTLET (12 VOLT) BASE.............................................................................................................. 368
REMOVAL ....................................................................................................................... 368
INSTALLATION................................................................................................................... 368
OVER STEERING COLUMN BEZEL......................................................................................................... 368
REMOVAL........................................................................................................................ 368
INSTALLATION................................................................................................................... 369
POWER MIRROR SWITCH................................................................................................................ 370
REMOVAL........................................................................................................................ 370
INSTALLATION................................................................................................................... 370
POWER MIRROR SWITCH LAMP........................................................................................................... 370
REMOVAL........................................................................................................................ 370
INSTALLATION................................................................................................................... 370
RADIO BEZEL AND HVAC CONTROL....................................................................................................... 370
REMOVAL........................................................................................................................ 370
INSTALLATION................................................................................................................... 371
REAR HEATER-A/C SWITCH............................................................................................................. 371
REMOVAL ....................................................................................................................... 371
INSTALLATION................................................................................................................... 371
REAR HEATER-A/C SWITCH LAMP........................................................................................................ 371
REMOVAL........................................................................................................................ 371
INSTALLATION................................................................................................................... 371
TRACTION CONTROL SWITCH............................................................................................................ 371
REMOVAL........................................................................................................................ 371
INSTALLATION................................................................................................................... 371
INSTRUMENT PANEL AND SYSTEMS 1
............................................................................................................ 373
GENERAL INFORMATION.................................................................................................................... 373
INTRODUCTION....................................................................................................................... 373
DESCRIPTION AND OPERATION.............................................................................................................. 373
HEADLAMP AND POWER MIRROR SWITCH LAMP( S).......................................................................................... 373
INSTRUMENT CLUSTER................................................................................................................. 374
DIAGNOSIS AND TESTING.................................................................................................................. 374
DIAGNOSTIC PROCEDURES.............................................................................................................. 374
HEADLAMP SWITCH.................................................................................................................... 374
SELF DIAGNOSTIC TEST............................................................................................................... 375
INSTRUMENT CLUSTER DTC CHART................................................................................................... 375
DIM TEST....................................................................................................................... 375
CLUSTER CALIBRATION TABLE...................................................................................................... 375
CALIBRATION TEST............................................................................................................... 376
ODOMETER SEGMENT TEST.......................................................................................................... 376
CONDITIONS..................................................................................................................... 376
REMOVAL AND INSTALLATION............................................................................................................... 387
CONVENIENCE BIN - CUP HOLDER....................................................................................................... 387
REMOVAL........................................................................................................................ 387
INSTALLATION................................................................................................................... 387
ASH RECEIVER – CONVENIENCE BIN LAMP MODULE......................................................................................... 387
REMOVAL........................................................................................................................ 387
INSTALLATION................................................................................................................... 387
CONVENIENCE BIN.................................................................................................................... 387
REMOVAL........................................................................................................................ 387
INSTALLATION................................................................................................................... 388
BODY CONTROL MODULE (BCM).......................................................................................................... 388
REMOVAL........................................................................................................................ 388
INSTALLATION................................................................................................................... 388
CIGAR LIGHTER BASE................................................................................................................. 388
REMOVAL........................................................................................................................ 388
INSTALLATION................................................................................................................... 388
GLOVE BOX.......................................................................................................................... 389
REMOVAL (FIG. 4)............................................................................................................... 389
INSTALLATION................................................................................................................... 389
GLOVE BOX LAMP AND SWITCH.......................................................................................................... 389
REMOVAL........................................................................................................................ 389
INSTALLATION................................................................................................................... 389
GLOVE BOX LOCK STRIKER............................................................................................................. 389
REMOVAL........................................................................................................................ 389
INSTALLATION................................................................................................................... 389
HEADLAMP SWITCH.................................................................................................................... 390
REMOVAL........................................................................................................................ 390
INSTALLATION................................................................................................................... 390
HEADLAMP SWITCH LAMP( S)........................................................................................................... 390
REMOVAL........................................................................................................................ 390
INSTALLATION................................................................................................................... 390
HVAC CONTROL LAMP.................................................................................................................. 390
REMOVAL........................................................................................................................ 390
INSTALLATION................................................................................................................... 390
INSTRUMENT CLUSTER BACK PANEL...................................................................................................... 390
REMOVAL........................................................................................................................ 390
INSTALLATION................................................................................................................... 390
INSTRUMENT CLUSTER BEZEL........................................................................................................... 390
REMOVAL........................................................................................................................ 390
INSTALLATION................................................................................................................... 391
INSTRUMENT CLUSTER LENS............................................................................................................ 391
REMOVAL........................................................................................................................ 391
INSTALLATION................................................................................................................... 391
INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD........................................................................................... 391
REMOVAL........................................................................................................................ 391
INSTALLATION................................................................................................................... 392
INSTRUMENT CLUSTER SUBDIAL......................................................................................................... 392
REMOVAL........................................................................................................................ 392
INSTALLATION................................................................................................................... 392
INSTRUMENT CLUSTER................................................................................................................. 392
REMOVAL........................................................................................................................ 392
INSTALLATION................................................................................................................... 392
INSTRUMENT PANEL................................................................................................................... 392
REMOVAL........................................................................................................................ 392
INSTALLATION................................................................................................................... 394
INSTRUMENT PANEL LEFT END COVER.................................................................................................... 394
REMOVAL........................................................................................................................ 394
INSTALLATION................................................................................................................... 394
INSTRUMENT PANEL LOUVERS........................................................................................................... 394
CENTER LOUVER HOUSING.......................................................................................................... 394
LEFT LOUVER HOUSING............................................................................................................ 395
PASSENGER SIDE LOUVERS......................................................................................................... 395
PASSENGER SIDE LOUVER OUTER HOUSINGS........................................................................................... 396
INSTRUMENT PANEL TOP COVER......................................................................................................... 396
REMOVAL........................................................................................................................ 396
INSTALLATION................................................................................................................... 397
INSTRUMENT PANEL RIGHT END COVER................................................................................................... 397
REMOVAL........................................................................................................................ 397
INSTALLATION................................................................................................................... 397
JUNCTION BLOCK..................................................................................................................... 397
REMOVAL........................................................................................................................ 397
INSTALLATION................................................................................................................... 397
KNEE BLOCKER REINFORCEMENT......................................................................................................... 397
REMOVAL........................................................................................................................ 397
INSTALLATION................................................................................................................... 398
LOWER CONSOLE...................................................................................................................... 398
REMOVAL........................................................................................................................ 398
INSTALLATION................................................................................................................... 398
LOWER INSTRUMENT PANEL............................................................................................................. 398
REMOVAL........................................................................................................................ 398
INSTALLATION................................................................................................................... 399
LOWER STEERING COLUMN COVER........................................................................................................ 399
REMOVAL........................................................................................................................ 399
INSTALLATION................................................................................................................... 399
MESSAGE CENTER..................................................................................................................... 399
REMOVAL........................................................................................................................ 399
INSTALLATION................................................................................................................... 400
OVER STEERING COLUMN BEZEL......................................................................................................... 400
REMOVAL........................................................................................................................ 400
INSTALLATION................................................................................................................... 400
POWER MIRROR SWITCH................................................................................................................ 400
REMOVAL........................................................................................................................ 400
INSTALLATION................................................................................................................... 400
POWER MIRROR SWITCH LAMP........................................................................................................... 400
REMOVAL........................................................................................................................ 400
INSTALLATION................................................................................................................... 401
RADIO BEZEL AND HVAC CONTROL....................................................................................................... 401
REMOVAL........................................................................................................................ 401
INSTALLATION................................................................................................................... 401
REAR HEATER- A/ C SWITCH........................................................................................................... 401
REMOVAL........................................................................................................................ 401
INSTALLATION................................................................................................................... 401
REAR HEATER- A/ C SWITCH LAMP...................................................................................................... 401
REMOVAL........................................................................................................................ 401
INSTALLATION................................................................................................................... 401
AUDIO SYSTEMS.............................................................................................................................. 403
GENERAL INFORMATION.................................................................................................................... 403
INTRODUCTION ...................................................................................................................... 403
DESCRIPTION AND OPERATION.............................................................................................................. 403
ANTENNA............................................................................................................................ 403
INTERFERENCE ELIMINATION........................................................................................................... 403
RADIOS............................................................................................................................. 403
RADIO IGNITION INTERFERENCE........................................................................................................ 404
CHOKE—INFINITY SPEAKERS............................................................................................................ 404
REMOTE RADIO SWITCHES.............................................................................................................. 405
NAME BRAND SPEAKER RELAY........................................................................................................... 405
DIAGNOSIS AND TESTING.................................................................................................................. 405
ANTENNA............................................................................................................................ 405
TEST 1......................................................................................................................... 405
TEST 2......................................................................................................................... 406
TEST 3......................................................................................................................... 406
TEST 4......................................................................................................................... 406
AUDIO SYSTEM....................................................................................................................... 406
RADIO.............................................................................................................................. 406
AUDIO SYSTEM DIAGNOSIS......................................................................................................... 407
REMOTE RADIO SWITCHES.............................................................................................................. 408
REMOTE RADIO SWITCH TEST....................................................................................................... 408
REMOVAL AND INSTALLATION............................................................................................................... 409
ANTENNA MAST AND CABLE LEAD........................................................................................................ 409
REMOVAL........................................................................................................................ 409
INSTALLATION................................................................................................................... 409
ANTENNA EXTENSION CABLE............................................................................................................ 409
REMOVAL........................................................................................................................ 409
INSTALLATION .................................................................................................................. 409
RADIO/TAPE/CD PLAYER............................................................................................................... 410
REMOVAL........................................................................................................................ 410
INSTALLATION................................................................................................................... 410
INSTRUMENT PANEL SPEAKER........................................................................................................... 410
INSTALLATION................................................................................................................... 410
INSTALLATION................................................................................................................... 410
FRONT DOOR SPEAKER................................................................................................................. 411
REMOVAL........................................................................................................................ 411
INSTALLATION................................................................................................................... 411
REMOTE RADIO SWITCHES.............................................................................................................. 411
REMOVAL........................................................................................................................ 411
INSTALLATION................................................................................................................... 411
QUARTER PANEL SPEAKER ............................................................................................................. 412
REMOVAL ....................................................................................................................... 412
INSTALLATION .................................................................................................................. 412
D PILLAR SPEAKER................................................................................................................... 412
REMOVAL........................................................................................................................ 412
INSTALLATION................................................................................................................... 412
HORNS...................................................................................................................................... 413
DESCRIPTION AND OPERATION ............................................................................................................. 413
INTRODUCTION ...................................................................................................................... 413
DIAGNOSIS AND TESTING.................................................................................................................. 413
HORN............................................................................................................................... 413
HORN RELAY......................................................................................................................... 413
HORNS WILL NOT SOUND............................................................................................................... 414
FUSE BLOWN..................................................................................................................... 414
FUSE OK........................................................................................................................ 414
HORNS SOUND CONTINUOUSLY .......................................................................................................... 415
HORN SYSTEM........................................................................................................................ 415
HORN SYSTEM TEST............................................................................................................... 415
REMOVAL AND INSTALLATION............................................................................................................... 416
HORN SWITCH........................................................................................................................ 416
HORNS.............................................................................................................................. 416
REMOVAL........................................................................................................................ 416
INSTALLATION................................................................................................................... 416
VEHICLE SPEED CONTROL SYSTEM............................................................................................................... 417
GENERAL INFORMATION ................................................................................................................... 417
INTRODUCTION ...................................................................................................................... 417
DESCRIPTION AND OPERATION.............................................................................................................. 417
SPEED CONTROL SERVO................................................................................................................ 417
SPEED CONTROL SWITCHES............................................................................................................. 417
AUTOMATIC SPEED CONTROL OVERSPEED REDUCTION........................................................................................ 418
STOP LAMP SWITCH................................................................................................................... 418
SERVO CABLE........................................................................................................................ 418
POWERTRAIN CONTROL MODULE.......................................................................................................... 418
VACUUM RESERVOIR................................................................................................................... 419
VEHICLE SPEED AND DISTANCE......................................................................................................... 419
DIAGNOSIS AND TESTING.................................................................................................................. 419
ROAD TEST.......................................................................................................................... 419
OVERSHOOT/UNDERSHOOT FOLLOWING SPEED CONTROL SET................................................................................... 419
CHECKING FOR DIAGNOSTIC CODES...................................................................................................... 419
SPEED CONTROL DIAGNOSTIC TROUBLE CODES......................................................................................... 420
SPEED CONTROL SLOWS DOWN BY ITSELF............................................................................................. 420
SPEED CONTROL ELECTRICAL TEST...................................................................................................... 420
SERVO VACUUM TEST.................................................................................................................. 422
SPEED CONTROL SWITCH TEST.......................................................................................................... 422
STOP LAMP SWITCH TEST.............................................................................................................. 422
ELECTRICAL TESTS AT POWERTRAIN CONTROL MODULE...................................................................................... 422
VACUUM SUPPLY TEST................................................................................................................. 424
VEHICLE SPEED SENSOR............................................................................................................... 424
REMOVAL AND INSTALLATION............................................................................................................... 424
SPEED CONTROL SERVO................................................................................................................ 424
REMOVAL........................................................................................................................ 424
INSTALLATION................................................................................................................... 425
SPEED CONTROL SWITCHES............................................................................................................. 425
REMOVAL........................................................................................................................ 425
INSTALLATION................................................................................................................... 425
STOP LAMP SWITCH................................................................................................................... 425
REMOVAL........................................................................................................................ 425
INSTALLATION................................................................................................................... 425
SPEED CONTROL CABLE................................................................................................................ 425
REMOVAL........................................................................................................................ 425
INSTALLATION................................................................................................................... 425
POWERTRAIN CONTROL MODULE.......................................................................................................... 425
VACUUM RESEROIR.................................................................................................................... 426
REMOVAL........................................................................................................................ 426
INSTALLATION................................................................................................................... 426
VEHICLE SPEED SENSOR............................................................................................................... 426
VEHICLE SPEED CONTROL SYSTEM 1
............................................................................................................ 427
GENERAL INFORMATION.................................................................................................................... 427
INTRODUCTION....................................................................................................................... 427
TURN SIGNAL AND FLASHERS................................................................................................................... 429
GENERAL INFORMATION.................................................................................................................... 429
INTRODUCTION....................................................................................................................... 429
COMBINATION FLASHER................................................................................................................ 429
DESCRIPTION AND OPERATION.............................................................................................................. 429
COMBINATION FLASHER FUNCTION....................................................................................................... 429
COMBINATION FLASHER / DAYTIME RUNNING LAMPS (DRL) MODULE........................................................................... 430
DIAGNOSIS AND TESTING.................................................................................................................. 430
TURN SIGNAL MULTI-FUNCTION SWITCH.................................................................................................. 430
TURN SIGNAL MULTI-FUNCTION SWITCH TEST......................................................................................... 431
COMBINATION FLASHER WITH / WITHOUT DAYTIME RUNNING LAMPS MODULE—CIRCUIT DIAGNOSTICS................................................ 431
JUNCTION BLOCK TERMINAL CALL-OUT............................................................................................... 432
JUNCTION BLOCK TERMINAL CALL-OUT WITH DRL...................................................................................... 433
COMBINATION FLASHER DIAGNOSIS.................................................................................................. 434
COMBINATION FLASHER DIAGNOSIS WITH DRL......................................................................................... 436
REMOVAL AND INSTALLATION............................................................................................................... 439
MULTI-FUNCTION SWITCH.............................................................................................................. 439
REMOVAL........................................................................................................................ 439
INSTALLATION................................................................................................................... 439
COMBINATION FLASHER WITH / WITHOUT DRL MODULE...................................................................................... 439
REMOVAL........................................................................................................................ 439
INSTALLATION................................................................................................................... 439
WINDSHIELD WIPERS AND WASHERS.............................................................................................................. 441
WINDSHIELD WIPERS AND WASHER........................................................................................................... 441
GENERAL INFORMATION................................................................................................................ 441
INTRODUCTION................................................................................................................... 441
DIAGNOSIS AND TESTING.............................................................................................................. 441
DIAGNOSTIC PROCEDURES.......................................................................................................... 441
FAILED PARK SWITCH............................................................................................................. 442
WIPER SYSTEM DIAGNOSIS..................................................................................................... 442
MULTI-FUNCTION SWITCH.......................................................................................................... 444
REMOVAL AND INSTALLATION........................................................................................................... 444
MULTI-FUNCTION SWITCH.......................................................................................................... 444
REMOVAL.................................................................................................................... 444
INSTALLATION............................................................................................................... 444
WINDSHIELD WASHER BOTTLE....................................................................................................... 444
REMOVAL.................................................................................................................... 444
INSTALLATION............................................................................................................... 445
WINDSHIELD WIPER BLADE......................................................................................................... 445
REMOVAL.................................................................................................................... 445
INSTALLATION............................................................................................................... 445
WINDSHIELD WIPER BLADE ELEMENT................................................................................................. 446
REMOVAL.................................................................................................................... 446
INSTALLATION............................................................................................................... 446
WINDSHIELD WIPER MOTOR......................................................................................................... 446
REMOVAL.................................................................................................................... 446
INSTALLATION............................................................................................................... 446
WIPER ARM...................................................................................................................... 447
REMOVAL.................................................................................................................... 447
INSTALLATION............................................................................................................... 447
WIPER UNIT..................................................................................................................... 447
REMOVAL.................................................................................................................... 447
INSTALLATION............................................................................................................... 447
WIPER LINKAGE.................................................................................................................. 447
REMOVAL.................................................................................................................... 447
INSTALLATION............................................................................................................... 448
CLEANING AND INSPECTION............................................................................................................ 448
WIPER BLADES................................................................................................................... 448
ADJUSTMENTS........................................................................................................................ 448
WIPER ARM ALIGNMENT............................................................................................................ 448
REAR WIPER AND WASHER.................................................................................................................. 448
DESCRIPTION AND OPERATION ......................................................................................................... 449
INTRODUCTION .................................................................................................................. 449
REAR WINDOW WIPER/WASHER SWITCHES.............................................................................................. 449
DIAGNOSIS AND TESTING.............................................................................................................. 449
DIAGNOSTIC PROCEDURES.......................................................................................................... 449
REMOVAL AND INSTALLATION........................................................................................................... 449
REAR GLASS RUBBER GROMMET...................................................................................................... 449
REMOVAL.................................................................................................................... 449
INSTALLATION............................................................................................................... 449
REAR WINDOW WIPER MOTOR........................................................................................................ 450
REMOVAL.................................................................................................................... 450
INSTALLATION............................................................................................................... 450
REAR WIPER ARM................................................................................................................. 450
REMOVAL.................................................................................................................... 450
INSTALLATION............................................................................................................... 450
REAR WIPER BLADE............................................................................................................... 450
REMOVAL.................................................................................................................... 450
INSTALLATION............................................................................................................... 450
REAR WIPER BLADE ELEMENT....................................................................................................... 450
WIPER AND WASHER SYSTEMS 1
................................................................................................................ 451
HEADLAMP WASHERS....................................................................................................................... 451
GENERAL INFORMATION................................................................................................................ 451
INTRODUCTION................................................................................................................... 451
REMOVAL AND INSTALLATION........................................................................................................... 451
WINDSHIELD/ HEADLAMP WASHER RESERVOIR.......................................................................................... 451
HEADLAMP WASHER NOZZLE......................................................................................................... 451
HEADLAMP WASHER PUMP........................................................................................................... 452
LAMPS...................................................................................................................................... 453
LAMP DIAGNOSIS......................................................................................................................... 453
GENERAL INFORMATION................................................................................................................ 453
GENERAL INFORMATION............................................................................................................ 453
SAFETY PRECAUTIONS............................................................................................................. 453
ELECTRONIC DAYTIME RUNNING LIGHT (DRL)......................................................................................... 453
SYSTEM FUNCTION............................................................................................................ 454
DIAGNOSIS AND TESTING.............................................................................................................. 454
DIAGNOSTIC PROCEDURES.......................................................................................................... 454
HEADLAMP DIAGNOSIS......................................................................................................... 455
FOG LAMP DIAGNOSIS......................................................................................................... 456
HEADLAMP ALIGNMENT..................................................................................................................... 457
GENERAL INFORMATION ............................................................................................................... 457
HEADLAMP ALIGNMENT ............................................................................................................ 457
SERVICE PROCEDURES................................................................................................................. 457
HEADLAMP ALIGNMENT PREPARATION................................................................................................. 457
ADJUSTMENTS........................................................................................................................ 457
HEADLAMP/FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN............................................................................ 457
ALIGNMENT SCREEN PREPARATION............................................................................................... 457
HEADLAMP ADJUSTMENT........................................................................................................ 458
HEADLAMP ADJUSTMENT – TOWN AND COUNTRY..................................................................................... 458
BUBBLE LEVEL CALIBRATION (VERTICAL AIM) ................................................................................... 459
MAGNIFYING WINDOW CALIBRATION (HORIZONTAL AIM)............................................................................. 459
FOG LAMP ALIGNMENT......................................................................................................... 460
REMOVAL AND INSTALLATION........................................................................................................... 461
HEADLAMP BULB.................................................................................................................. 461
REMOVAL.................................................................................................................... 461
INSTALLATION .............................................................................................................. 461
HEADLAMP BULB – TOWN & COUNTRY................................................................................................. 461
HEADLAMP HIGH BEAM......................................................................................................... 461
HEADLAMP LOW BEAM.......................................................................................................... 461
FOG LAMP BULB.................................................................................................................. 462
REMOVAL.................................................................................................................... 462
INSTALLATION............................................................................................................... 462
FOG LAMP BULB – TOWN and COUNTRY............................................................................................... 463
REMOVAL.................................................................................................................... 463
INSTALLATION............................................................................................................... 463
FRONT SIDE MARKER LAMP BULB TOWN and COUNTRY................................................................................... 463
REMOVAL.................................................................................................................... 463
INSTALLATION............................................................................................................... 463
PARKING AND TURN SIGNAL BULB................................................................................................... 463
REMOVAL.................................................................................................................... 463
INSTALLATION............................................................................................................... 463
FRONT PARKING AND TURN SIGNAL LAMP BULB TOWN and COUNTRY .................................................................... 464
REMOVAL ................................................................................................................... 464
INSTALLATION............................................................................................................... 464
TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP BULB.................................................................................. 464
REMOVAL.................................................................................................................... 464
INSTALLATION............................................................................................................... 464
LICENSE PLATE LAMP BULB........................................................................................................ 465
REMOVAL.................................................................................................................... 465
INSTALLATION .............................................................................................................. 465
CENTER HIGH MOUNTED STOP LAMP (CHMSL) BULB..................................................................................... 465
REMOVAL.................................................................................................................... 465
INSTALLATION............................................................................................................... 465
EXTERIOR LAMP SERVICE.................................................................................................................. 466
GENERAL INFORMATION................................................................................................................ 466
HEADLAMP MODULE................................................................................................................ 466
HEADLAMP SWITCH................................................................................................................ 466
HEADLAMP DIMMER SWITCH......................................................................................................... 466
REMOVAL AND INSTALLATION........................................................................................................... 466
HEADLAMP MODULE................................................................................................................ 466
REMOVAL.................................................................................................................... 466
INSTALLATION............................................................................................................... 466
FOG LAMP....................................................................................................................... 466
REMOVAL.................................................................................................................... 466
INSTALLATION............................................................................................................... 467
FOG LAMP – TOWN and COUNTRY.................................................................................................... 467
REMOVAL.................................................................................................................... 467
INSTALLATION............................................................................................................... 467
FRONT SIDE MARKER LAMP TOWN and COUNTRY........................................................................................ 467
REMOVAL.................................................................................................................... 467
INSTALLATION............................................................................................................... 467
FRONT PARKING AND TURN SIGNAL LAMP – TOWN and COUNTRY.......................................................................... 467
REMOVAL.................................................................................................................... 467
INSTALLATION............................................................................................................... 468
TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP....................................................................................... 468
REMOVAL.................................................................................................................... 468
INSTALLATION............................................................................................................... 468
LICENSE PLATE LAMP............................................................................................................. 468
REMOVAL.................................................................................................................... 468
INSTALLATION............................................................................................................... 469
CENTER HIGH MOUNTED STOP LAMP (CHMSL).......................................................................................... 469
REMOVAL.................................................................................................................... 469
INSTALLATION............................................................................................................... 469
INTERIOR LAMPS......................................................................................................................... 470
REMOVAL AND INSTALLATION........................................................................................................... 470
HEADER READING/COURTESY LAMP BULB.............................................................................................. 470
REMOVAL ................................................................................................................... 470
INSTALLATION .............................................................................................................. 470
OVERHEAD CONSOLE READING/COURTESY LAMP......................................................................................... 470
REMOVAL.................................................................................................................... 470
INSTALLATION............................................................................................................... 470
HEADER READING/COURTESY LAMP BULB.............................................................................................. 471
REMOVAL.................................................................................................................... 471
INSTALLATION............................................................................................................... 471
GLOVE BOX LAMP AND SWITCH...................................................................................................... 471
REMOVAL.................................................................................................................... 471
INSTALLATION............................................................................................................... 471
GLOVE BOX LAMP BULB............................................................................................................ 471
REMOVAL.................................................................................................................... 471
INSTALLATION............................................................................................................... 471
IGNITION HALO LAMP BULB........................................................................................................ 471
REMOVAL.................................................................................................................... 471
INSTALLATION............................................................................................................... 472
CONVENIENCE BIN LAMP........................................................................................................... 472
REMOVAL.................................................................................................................... 472
INSTALLATION............................................................................................................... 472
INSTRUMENT PANEL LAMPS AND SWITCHES............................................................................................ 472
DOME LAMP...................................................................................................................... 473
REMOVAL.................................................................................................................... 473
INSTALLATION............................................................................................................... 473
DOME LAMP BULB................................................................................................................. 473
REMOVAL.................................................................................................................... 473
INSTALLATION............................................................................................................... 473
FRONT DOOR COURTESY LAMP....................................................................................................... 473
REMOVAL.................................................................................................................... 473
INSTALLATION............................................................................................................... 474
FRONT DOOR COURTESY LAMP BULB.................................................................................................. 474
REMOVAL.................................................................................................................... 474
INSTALLATION............................................................................................................... 475
RAIL LAMP MODULE BULB.......................................................................................................... 475
REMOVAL.................................................................................................................... 475
INSTALLATION............................................................................................................... 475
LIFTGATE COURTESY LAMP......................................................................................................... 475
REMOVAL.................................................................................................................... 475
INSTALLATION............................................................................................................... 475
LIFTGATE COURTESY LAMP BULB.................................................................................................... 476
REMOVAL.................................................................................................................... 476
INSTALLATION............................................................................................................... 476
BULB APPLICATION....................................................................................................................... 477
GENERAL INFORMATION................................................................................................................ 477
INTRODUCTION................................................................................................................... 477
SPECIFICATIONS..................................................................................................................... 477
EXTERIOR LAMP BULBS............................................................................................................ 477
INTERIOR LAMP BULBS............................................................................................................ 477
LAMPS 1
................................................................................................................................... 479
LAMP DIAGNOSIS......................................................................................................................... 479
GENERAL INFORMATION................................................................................................................ 479
INTRODUCTION................................................................................................................... 479
HEADLAMP LEVELING MOTOR........................................................................................................ 480
DIAGNOSIS AND TESTING.............................................................................................................. 480
DIAGNOSTIC PROCEDURES.......................................................................................................... 480
HEADLAMP DIAGNOSIS......................................................................................................... 480
FOG LAMP DIAGNOSIS......................................................................................................... 481
HEADLAMP LEVELING MOTOR DIAGNOSIS.......................................................................................... 482
SERVICE PROCEDURES................................................................................................................. 483
HEADLAMP ALIGNMENT PREPARATION................................................................................................. 483
ADJUSTMENTS........................................................................................................................ 483
HEADLAMP/ FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN........................................................................... 483
ALIGNMENT SCREEN PREPARATION............................................................................................... 483
HEADLAMP ADJUSTMENT........................................................................................................ 484
FOG LAMP ALIGNMENT......................................................................................................... 485
REMOVAL AND INSTALLATION........................................................................................................... 486
HEADLAMP BULB.................................................................................................................. 486
REMOVAL.................................................................................................................... 486
INSTALLATION............................................................................................................... 486
FRONT TURN SIGNAL LAMP BULB.................................................................................................... 486
REMOVAL.................................................................................................................... 486
INSTALLATION............................................................................................................... 487
CITYLIGHT LAMP BULB............................................................................................................ 487
REMOVAL.................................................................................................................... 487
INSTALLATION............................................................................................................... 487
FOG LAMP BULB.................................................................................................................. 487
REMOVAL.................................................................................................................... 487
INSTALLATION............................................................................................................... 488
SIDE REPEATER LAMP BULB........................................................................................................ 488
REMOVAL.................................................................................................................... 488
INSTALLATION............................................................................................................... 488
TAIL LAMP BULB................................................................................................................. 488
REMOVAL.................................................................................................................... 489
INSTALLATION............................................................................................................... 489
LICENSE PLATE LAMP BULB........................................................................................................ 490
REMOVAL.................................................................................................................... 490
INSTALLATION............................................................................................................... 490
CENTER HIGH MOUNTED STOP LAMP (CHMSL) BULB..................................................................................... 490
REMOVAL.................................................................................................................... 490
INSTALLATION............................................................................................................... 490
LAMP SERVICE........................................................................................................................... 491
GENERAL INFORMATION................................................................................................................ 491
HEADLAMP SWITCH................................................................................................................ 491
HEADLAMP DIMMER SWITCH......................................................................................................... 491
REMOVAL AND INSTALLATION........................................................................................................... 491
HEADLAMP MODULE................................................................................................................ 491
REMOVAL.................................................................................................................... 491
INSTALLATION............................................................................................................... 491
HEADLAMP LEVELING MOTOR........................................................................................................ 492
REMOVAL.................................................................................................................... 492
INSTALLATION............................................................................................................... 492
FOG LAMP....................................................................................................................... 492
REMOVAL.................................................................................................................... 492
INSTALLATION............................................................................................................... 492
SIDE REPEATER LAMP............................................................................................................. 492
REMOVAL.................................................................................................................... 492
INSTALLATION............................................................................................................... 492
TAIL LAMP...................................................................................................................... 493
REMOVAL.................................................................................................................... 493
INSTALLATION............................................................................................................... 493
LICENSE PLATE LAMP............................................................................................................. 493
REMOVAL.................................................................................................................... 493
INSTALLATION............................................................................................................... 494
CENTER HIGH MOUNTED STOP LAMP (CHMSL).......................................................................................... 494
REMOVAL.................................................................................................................... 494
INSTALLATION............................................................................................................... 494
BULB APPLICATION....................................................................................................................... 495
GENERAL INFORMATION................................................................................................................ 495
INTRODUCTION................................................................................................................... 495
CLEANING AND INSPECTION............................................................................................................ 495
HEADLAMP CLEANING.............................................................................................................. 495
SPECIFICATIONS..................................................................................................................... 495
EXTERIOR LAMP BULBS............................................................................................................ 495
INTERIOR LAMP BULBS............................................................................................................ 495
RESTRAINT SYSTEM........................................................................................................................... 497
GENERAL INFORMATION.................................................................................................................... 497
WARNINGS AND PRECAUTIONS........................................................................................................... 497
DESCRIPTION AND OPERATION.............................................................................................................. 497
AIRBAG CONTROL MODULE (ACM)........................................................................................................ 497
CLOCKSPRING........................................................................................................................ 498
DRIVER AND PASSENGER AIRBAG MODULES................................................................................................ 498
DIAGNOSIS AND TESTING.................................................................................................................. 498
AIRBAG SYSTEM TEST................................................................................................................. 498
SERVICE PROCEDURES..................................................................................................................... 499
CLEANUP PROCEDURE ................................................................................................................. 499
SERVICE OF DEPLOYED AIRBAG MODULE.............................................................................................. 499
HANDLING AIRBAG MODULE............................................................................................................. 499
DEPLOYED MODULE................................................................................................................ 499
UNDEPLOYED..................................................................................................................... 499
REMOVAL AND INSTALLATION............................................................................................................... 499
AIRBAG CONTROL MODULE.............................................................................................................. 499
REMOVAL........................................................................................................................ 499
INSTALLATION................................................................................................................... 500
CLOCKSPRING........................................................................................................................ 501
REMOVAL........................................................................................................................ 501
INSTALLATION................................................................................................................... 501
DRIVER AIRBAG MODULE............................................................................................................... 501
DEPLOYED MODULE................................................................................................................ 502
UNDEPLOYED..................................................................................................................... 502
PASSENGER AIRBAG................................................................................................................... 502
DEPLOYED MODULE................................................................................................................ 502
UNDEPLOYED..................................................................................................................... 503
ADJUSTMENTS............................................................................................................................ 503
CLOCKSPRING CENTERING PROCEDURE.................................................................................................... 503
ELECTRICALLY HEATED SYSTEMS................................................................................................................ 505
DESCRIPTION AND OPERATION.............................................................................................................. 505
INTRODUCTION....................................................................................................................... 505
HVAC MOUNTED SWITCH................................................................................................................ 505
DIAGNOSIS AND TESTING.................................................................................................................. 506
SYSTEM TEST........................................................................................................................ 506
GRID LINE TEST..................................................................................................................... 506
SERVICE PROCEDURES..................................................................................................................... 507
GRID LINE AND TERMINAL REPAIR...................................................................................................... 507
POWER DOOR LOCKS........................................................................................................................... 509
POWER DOOR LOCKS....................................................................................................................... 509
GENERAL INFORMATION................................................................................................................ 509
INTRODUCTION................................................................................................................... 509
DESCRIPTION AND OPERATION.......................................................................................................... 509
AUTOMATIC DOOR LOCK FEATURE.................................................................................................... 509
DOOR LOCK CIRCUIT PROTECTION................................................................................................... 509
DOOR LOCK INHIBIT FEATURE...................................................................................................... 510
SLIDING DOOR LOCK MEMORY FEATURE............................................................................................... 510
DIAGNOSIS AND TESTING.............................................................................................................. 510
AUTOMATIC DOOR LOCK SYSTEM TEST................................................................................................ 510
DOOR LOCK MOTOR................................................................................................................ 510
DOOR LOCK SWITCH TEST.......................................................................................................... 510
DOOR LOCK SWITCH TEST...................................................................................................... 511
SERVICE PROCEDURES................................................................................................................. 511
AUTOMATIC DOOR LOCKS DISABLE OR ENABLE......................................................................................... 511
REMOVAL AND INSTALLATION........................................................................................................... 511
FRONT DOOR LOCK MOTOR/LATCH.................................................................................................... 511
LIFTGATE LOCK MOTOR............................................................................................................ 511
REMOVAL.................................................................................................................... 511
INSTALLATION............................................................................................................... 511
SLIDING DOOR LOCK CONTACTS..................................................................................................... 511
REMOVAL.................................................................................................................... 511
INSTALLATION............................................................................................................... 511
SLIDING DOOR LOCK MOTOR........................................................................................................ 512
REMOVAL.................................................................................................................... 512
INSTALLATION............................................................................................................... 512
SLIDING DOOR LOCK PLUNGER...................................................................................................... 512
REMOVAL.................................................................................................................... 512
INSTALLATION............................................................................................................... 512
REMOTE KEYLESS ENTRY................................................................................................................... 513
DESCRIPTION AND OPERATION.......................................................................................................... 513
INTRODUCTION................................................................................................................... 513
VEHICLE ACCESS CODE (VAC) PROGRAMMING.......................................................................................... 513
DIAGNOSIS AND TESTING.............................................................................................................. 513
RKE DIAGNOSTICS................................................................................................................ 513
SERVICE PROCEDURES ................................................................................................................ 514
HORN CHIRP DISABLE OR ENABLE .................................................................................................. 514
ADJUSTMENTS........................................................................................................................ 514
PROGRAMMING RKE MODULE......................................................................................................... 514
REMOVAL AND INSTALLATION........................................................................................................... 514
RKE MODULE..................................................................................................................... 514
REMOVAL.................................................................................................................... 514
INSTALLATION............................................................................................................... 514
SPECIFICATIONS..................................................................................................................... 514
RKE TRANSMITTER BATTERY........................................................................................................ 514
RKE TRANSMITTER RANGE.......................................................................................................... 514
VEHICLE THEFT SECURITY SYSTEM.............................................................................................................. 515
GENERAL INFORMATION.................................................................................................................... 515
INTRODUCTION....................................................................................................................... 515
ENABLING....................................................................................................................... 515
DESCRIPTION AND OPERATION.............................................................................................................. 515
ARMING PROCEDURE................................................................................................................... 515
METHOD-A....................................................................................................................... 515
METHOD-B....................................................................................................................... 515
TIME-OUT PERIOD.................................................................................................................... 516
TRIGGERING THE VTSS................................................................................................................ 516
DIAGNOSIS AND TESTING.................................................................................................................. 516
DIAGNOSTIC PROCEDURES.............................................................................................................. 516
REMOVAL AND INSTALLATION............................................................................................................... 516
BODY CONTROL MODULE................................................................................................................ 516
REMOVAL ....................................................................................................................... 516
INSTALLATION................................................................................................................... 516
DOOR LOCK CYLINDER SWITCH.......................................................................................................... 516
REMOVAL........................................................................................................................ 516
INSTALLATION................................................................................................................... 516
FRONT DOOR AJAR (VTSS TRIGGER) SWITCH ............................................................................................. 516
REMOVAL ....................................................................................................................... 516
INSTALLATION................................................................................................................... 517
HOOD AJAR (VTSS TRIGGER) SWITCH.................................................................................................... 517
REMOVAL........................................................................................................................ 517
INSTALLATION................................................................................................................... 517
LIFTGATE AJAR (VTSS TRIGGER) SWITCH................................................................................................ 517
REMOVAL........................................................................................................................ 517
INSTALLATION................................................................................................................... 517
LIFTGATE LOCK CYLINDER SWITCH...................................................................................................... 517
REMOVAL ....................................................................................................................... 517
INSTALLATION................................................................................................................... 517
SLIDING DOOR AJAR (VTSS TRIGGER) SWITCH............................................................................................ 518
REMOVAL........................................................................................................................ 518
INSTALLATION................................................................................................................... 518
VEHICLE THEFT/ SECURITY SYSTEMS............................................................................................................ 519
GENERAL INFORMATION.................................................................................................................... 519
INTRODUCTION....................................................................................................................... 519
SMART KEY IMMOBILIZER SYSTEM....................................................................................................... 519
DESCRIPTION AND OPERATION.............................................................................................................. 519
SMART KEY IMMOBILIZER MODULE....................................................................................................... 519
SMART KEY IMMOBILIZER TRANSPONDER.................................................................................................. 520
SMART KEY IMMOBILIZER SYSTEM INDICATOR LAMP........................................................................................ 521
DIAGNOSIS AND TESTING.................................................................................................................. 521
SMART KEY IMMOBILIZER SYSTEM....................................................................................................... 521
SERVICE PROCEDURES..................................................................................................................... 522
SMART KEY IMMOBILIZER SYSTEM TRANSPONDER PROGRAMMING............................................................................... 522
PROGRAMMING THE SKIM MODULE WITH THE DRBIII.................................................................................... 522
PROGRAMMING IGNITION KEYS WITH THE DRBIII...................................................................................... 522
REMOVAL AND INSTALLATION............................................................................................................... 522
SMART KEY IMMOBILIZER MODULE....................................................................................................... 522
POWER WINDOWS.............................................................................................................................. 525
GENERAL INFORMATION.................................................................................................................... 525
INTRODUCTION....................................................................................................................... 525
DIAGNOSIS AND TESTING.................................................................................................................. 525
POWER VENT WINDOW MOTOR TEST....................................................................................................... 525
POWER WINDOW AND VENT SWITCH TEST.................................................................................................. 526
DRIVER DOOR POWER WINDOW SWITCH TEST........................................................................................... 526
POWER WINDOW MOTOR TEST............................................................................................................ 526
WIRING VOLTAGE TEST................................................................................................................ 527
REMOVAL AND INSTALLATION............................................................................................................... 527
POWER VENT WINDOW MOTOR............................................................................................................ 527
REMOVAL........................................................................................................................ 527
INSTALLATION................................................................................................................... 527
POWER WINDOW SWITCH................................................................................................................ 527
POWER WINDOW MOTOR................................................................................................................. 527
REMOVAL........................................................................................................................ 527
INSTALLATION................................................................................................................... 527
POWER SEATS................................................................................................................................ 529
POWER SEATS............................................................................................................................ 529
GENERAL INFORMATION................................................................................................................ 529
INTRODUCTION................................................................................................................... 529
DIAGNOSIS AND TESTING.............................................................................................................. 529
DIAGNOSTIC PROCEDURES.......................................................................................................... 529
SEAT MOTORS.................................................................................................................... 529
POWER SEAT SWITCH.............................................................................................................. 529
MEMORY SEAT AND MIRROR SYSTEM.......................................................................................................... 531
GENERAL INFORMATION................................................................................................................ 531
INTRODUCTION................................................................................................................... 531
DESCRIPTION AND OPERATION.......................................................................................................... 531
POWER SIDE VIEW MIRROR POSITION SENSING........................................................................................ 531
MEMORY SELECTOR SWITCHES....................................................................................................... 531
DEFINITION OF: MOMENTARILY AND RELEASE..................................................................................... 532
SEAT AND RECLINER SWITCHES..................................................................................................... 532
POSITION SENSING SEAT AND RECLINER POTENTIOMETERS.............................................................................. 532
DIAGNOSIS AND TESTING.............................................................................................................. 532
MEMORY SELECTOR SWITCHES....................................................................................................... 532
SIDE VIEW MIRROR SWITCH STUCK.................................................................................................. 532
DIAGNOSTIC MODE................................................................................................................ 533
MODE 1..................................................................................................................... 533
MIRROR MECHANIZATION TABLE................................................................................................. 533
MODE 2..................................................................................................................... 534
CIRCUIT DESCRIPTION............................................................................................................ 535
SEAT AND RECLINER POSITION SENSING............................................................................................. 537
SERVICE PROCEDURES................................................................................................................. 537
REMOTE KEYLESS ENTRY (RKE) DATA LINK........................................................................................... 537
SEAT ACTUATIONS TABLE...................................................................................................... 538
REMOVAL AND INSTALLATION........................................................................................................... 538
MEMORY SWITCHES................................................................................................................ 538
REMOVAL.................................................................................................................... 538
INSTALLATION............................................................................................................... 538
SEAT TRACK ASSEMBLY............................................................................................................ 538
POWER MIRRORS.............................................................................................................................. 539
GENERAL INFORMATION.................................................................................................................... 539
INTRODUCTION....................................................................................................................... 539
HEATED MIRROR ..................................................................................................................... 539
MEMORY MIRRORS..................................................................................................................... 539
DIAGNOSIS AND TESTING.................................................................................................................. 539
MIRROR MOTOR TEST.................................................................................................................. 539
MIRROR SWITCH TEST................................................................................................................. 539
HEATED MIRROR TEST................................................................................................................. 539
TEST PROCEDURE................................................................................................................. 539
REMOVAL AND INSTALLATION............................................................................................................... 541
POWER MIRROR....................................................................................................................... 541
REMOVAL........................................................................................................................ 541
INSTALLATION................................................................................................................... 541
POWER MIRROR SWITCH................................................................................................................ 541
CHIME WARNING/REMINDER SYSTEM.............................................................................................................. 543
GENERAL INFORMATION.................................................................................................................... 543
INTRODUCTION....................................................................................................................... 543
DIAGNOSIS AND TESTING.................................................................................................................. 543
CHIME SYSTEM DIAGNOSIS............................................................................................................. 543
NO TONE WHEN IGNITION SWITCH IS TURNED ON AND DRIVER’S SEAT BELT IS NOT BUCKLED................................................ 543
NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS TURNED ON..................................................................... 543
FASTEN SEAT BELT LAMP OR TONE CONTINUES FOR MORE THAN 10 SECONDS AFTER SEAT BELTS ARE FASTENED AND DRIVER’S DOOR IS CLOSED..... 543
NO TONE WHEN PARK OR HEADLAMPS ARE ON AND DRIVER’S DOOR IS OPEN................................................................ 543
DOME LAMP ON CHIME................................................................................................................. 544
ENGINE TEMPERATURE CRITICAL CHIME ................................................................................................. 544
EXTERIOR LAMPS ON CHIME............................................................................................................ 544
KEY-IN IGNITION CHIME.............................................................................................................. 544
LOW OIL PRESSURE CHIME OPERATION................................................................................................... 544
SEAT BELT CHIME.................................................................................................................... 544
SEAT BELT LAMP..................................................................................................................... 544
TURN SIGNAL ON CHIME............................................................................................................... 545
WARNING LAMP ANNOUNCEMENT CHIME.................................................................................................... 545
CHIME WARNING/ REMINDER SYSTEM 1
.......................................................................................................... 547
GENERAL INFORMATION.................................................................................................................... 547
INTRODUCTION....................................................................................................................... 547
DIAGNOSIS AND TESTING.................................................................................................................. 547
CATALYST OVERHEAT WARNING CHIME.................................................................................................... 547
CHIME SYSTEM DIAGNOSIS............................................................................................................. 547
NO TONE WHEN IGNITION SWITCH IS TURNED ON AND DRIVER’S SEAT BELT IS NOT BUCKLED................................................ 547
NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS TURNED ON..................................................................... 547
FASTEN SEAT BELT LAMP OR TONE CONTINUES FOR MORE THAN 10 SECONDS AFTER SEAT BELTS ARE FASTENED AND DRIVER’S DOOR IS CLOSED..... 548
NO TONE WHEN PARK OR HEADLAMPS ARE ON AND DRIVER’S DOOR IS OPEN................................................................ 548
DOME LAMP ON CHIME................................................................................................................. 548
ENGINE TEMPERATURE CRITICAL CHIME.................................................................................................. 548
EXTERIOR LAMPS ON CHIME............................................................................................................ 548
KEY- IN IGNITION CHIME............................................................................................................. 548
LOW OIL PRESSURE CHIME OPERATION................................................................................................... 548
SEAT BELT CHIME.................................................................................................................... 549
SEAT BELT LAMP..................................................................................................................... 549
TURN SIGNAL ON CHIME............................................................................................................... 549
WARNING LAMP ANNOUNCEMENT CHIME.................................................................................................... 549
OVERHEAD CONSOLE........................................................................................................................... 551
DESCRIPTION AND OPERATION.............................................................................................................. 551
COMPASS/TEMPERATURE MINI TRIP COMPUTER SELF-DIAGNOSTIC TEST........................................................................ 551
COMPASS MINI-TRIP COMPUTER (CMTC).................................................................................................. 551
THERMOMETER AND COMPASS............................................................................................................ 552
THERMOMETER.................................................................................................................... 552
COMPASS........................................................................................................................ 552
UNIVERSAL TRANSMITTER ............................................................................................................. 552
DIAGNOSIS AND TESTING.................................................................................................................. 553
READING/DOME LAMP DIAGNOSIS........................................................................................................ 553
TRAVELER MESSAGES.................................................................................................................. 553
UNIVERSAL TRANSMITTER.............................................................................................................. 553
SERVICE PROCEDURES..................................................................................................................... 554
COMPASS CALIBRATION PROCEDURE...................................................................................................... 554
COMPASS CALIBRATION PROCEDURE (FAST METHOD)........................................................................................ 554
DEMAGNETIZING PROCEDURE............................................................................................................ 554
UNIVERSAL TRANSMITTER.............................................................................................................. 555
TRAINING....................................................................................................................... 555
ERASING........................................................................................................................ 555
REMOVAL AND INSTALLATION............................................................................................................... 555
AMBIENT TEMPERATURE SENSOR......................................................................................................... 555
REMOVAL........................................................................................................................ 555
INSTALLATION................................................................................................................... 555
COMPASS MINI-TRIP COMPUTER (CMTC) MODULE........................................................................................... 556
REMOVAL........................................................................................................................ 556
INSTALLATION................................................................................................................... 556
COMPASS MINI-TRIP COMPUTER (CMTC) LAMP BULBS....................................................................................... 556
REMOVAL........................................................................................................................ 556
INSTALLATION .................................................................................................................. 556
FRONT HEADER READING/COURTESY LAMP................................................................................................. 556
REMOVAL........................................................................................................................ 556
INSTALLATION................................................................................................................... 556
OVERHEAD CONSOLE................................................................................................................... 556
REMOVAL........................................................................................................................ 556
INSTALLATION................................................................................................................... 556
READING/COURTESY LAMP.............................................................................................................. 556
Removal........................................................................................................................ 556
Installation................................................................................................................... 557
READING/COURTESY LAMP ASSEMBLY..................................................................................................... 557
Removal........................................................................................................................ 557
Installation................................................................................................................... 557
UNIVERSAL TRANSMITTER.............................................................................................................. 557
REMOVAL........................................................................................................................ 557
INSTALLATION................................................................................................................... 558
SPECIAL TOOLS.......................................................................................................................... 559
SPECIAL TOOL....................................................................................................................... 559
WIRING DIAGRAMS............................................................................................................................ 561
8W- 01 GENERAL INFORMATION............................................................................................................. 563
DESCRIPTION AND OPERATION.......................................................................................................... 563
INTRODUCTION................................................................................................................... 563
CIRCUIT INFORMATION............................................................................................................ 566
CIRCUIT FUNCTIONS.............................................................................................................. 566
SECTION IDENTIFICATION......................................................................................................... 567
SYMBOLS........................................................................................................................ 567
TERMINOLOGY.................................................................................................................... 569
CONNECTOR INFORMATION.......................................................................................................... 569
IDENTIFICATION............................................................................................................. 569
LOCATIONS.................................................................................................................. 569
SPLICE LOCATIONS............................................................................................................... 569
NOTES, CAUTIONS, and WARNINGS.................................................................................................. 569
TAKE OUTS...................................................................................................................... 570
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES................................................................................ 570
POSITIVE TEMPERATURE COEFFICIENT............................................................................................... 570
DIAGNOSIS AND TESTING.............................................................................................................. 570
TROUBLESHOOTING TOOLS.......................................................................................................... 570
INTERMITTENT AND POOR CONNECTIONS.............................................................................................. 571
TROUBLESHOOTING TESTS.......................................................................................................... 571
TESTING FOR VOLTAGE POTENTIAL.............................................................................................. 571
TESTING FOR CONTINUITY..................................................................................................... 571
TESTING FOR A SHORT TO GROUND.............................................................................................. 571
TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS.............................................................. 572
TESTING FOR A VOLTAGE DROP................................................................................................. 572
TROUBLESHOOTING WIRING PROBLEMS................................................................................................ 572
SERVICE PROCEDURES................................................................................................................. 572
WIRING REPAIR.................................................................................................................. 572
TERMINAL/ CONNECTOR REPAIR- MOLEX CONNECTORS................................................................................... 573
CONNECTOR REPLACEMENT.......................................................................................................... 573
CONNECTOR AND TERMINAL REPLACEMENT............................................................................................. 574
TERMINAL/ CONNECTOR REPAIR- AUGAT CONNECTORS................................................................................... 574
TERMINAL REPLACEMENT........................................................................................................... 575
DIODE REPLACEMENT.............................................................................................................. 576
SPECIAL TOOLS...................................................................................................................... 576
WIRING/ TERMINAL............................................................................................................... 576
8W- 02 COMPONENT INDEX................................................................................................................. 577
8W- 10 POWER DISTRIBUTION.............................................................................................................. 581
8W- 12 JUNCTION BLOCK.................................................................................................................. 617
8W- 15 GROUND DISTRIBUTION............................................................................................................. 643
8W- 20 CHARGING SYSTEM................................................................................................................. 657
8W- 21 STARTING SYSTEM................................................................................................................. 661
8W- 30 FUEL/ IGNITION SYSTEM........................................................................................................... 665
8W- 31 TRANSMISSION CONTROL SYSTEM..................................................................................................... 705
8W- 33 VEHICLE SPEED CONTROL........................................................................................................... 713
8W- 35 ANTI- LOCK BRAKES............................................................................................................... 719
8W- 39 VEHICLE THEFT SECURITY SYSTEM................................................................................................... 723
8W- 40 INSTRUMENT CLUSTER.............................................................................................................. 729
8W- 41 HORN/ CIGAR LIGHTER/ POWER OUTLET............................................................................................... 741
8W- 42 AIR CONDITIONING- HEATER........................................................................................................ 745
8W- 43 AIRBAG SYSTEM................................................................................................................... 755
8W- 44 INTERIOR LIGHTING............................................................................................................... 759
8W- 45 BODY CONTROL MODULE............................................................................................................. 769
8W- 46 MESSAGE CENTER.................................................................................................................. 779
8W- 47 AUDIO SYSTEM.................................................................................................................... 785
8W- 48 WINDOW DEFOGGERS................................................................................................................ 793
8W- 49 OVERHEAD CONSOLE................................................................................................................ 797
8W- 50 FRONT LIGHTING.................................................................................................................. 801
8W- 51 REAR LIGHTING................................................................................................................... 815
8W- 52 TURN SIGNALS.................................................................................................................... 823
8W- 53 WIPERS.......................................................................................................................... 827
8W- 54 TRAILER TOW..................................................................................................................... 833
8W- 60 POWER WINDOWS................................................................................................................... 837
8W- 61 POWER DOOR LOCKS................................................................................................................ 841
8W- 62 POWER MIRRORS................................................................................................................... 849
8W- 63 POWER SEAT...................................................................................................................... 857
8W- 70 SPLICE INFORMATION.............................................................................................................. 865
8W- 80 CONNECTOR PIN- OUTS............................................................................................................. 877
8W- 90 CONNECTOR/ GROUND LOCATIONS..................................................................................................... 965
DESCRIPTION AND OPERATION.......................................................................................................... 965
INTRODUCTION................................................................................................................... 965
CONNECTOR/ GROUND LOCATIONS.................................................................................................... 965
CONNECTOR/ GROUND LOCATIONS.................................................................................................... 995
8W- 95 SPLICE LOCATIONS................................................................................................................1025
DESCRIPTION AND OPERATION..........................................................................................................1025
INTRODUCTION...................................................................................................................1025
SPLICE LOCATION INDEX..........................................................................................................1025
SPLICE LOCATIONS (RHD).........................................................................................................1039
ENGINE.....................................................................................................................................1051
STANDARD SERVICE PROCEDURES............................................................................................................1051
GENERAL INFORMATION................................................................................................................1051
FORM- IN- PLACE GASKETS........................................................................................................1051
MOPART SILICONE RUBBER ADHESIVE SEALANT....................................................................................1051
MOPART GASKET MAKER........................................................................................................1051
MOPART TORQUE CURE GASKET MAKER............................................................................................1051
GASKET DISASSEMBLY.........................................................................................................1052
SURFACE PREPARATION........................................................................................................1052
FORM- IN- PLACE GASKET APPLICATION.........................................................................................1052
CRANKSHAFT SPROCKET BOLT ACCESS PLUG...........................................................................................1052
ENGINE CORE PLUGS..............................................................................................................1052
REMOVAL....................................................................................................................1052
INSTALLATION...............................................................................................................1052
ENGINE PERFORMANCE.............................................................................................................1052
HONING CYLINDER BORES..........................................................................................................1053
MEASURING MAIN BEARING AND CONNECTING ROD BEARING CLEARANCES...................................................................1053
PREFERRED METHOD...........................................................................................................1053
ALTERNATIVE METHOD.........................................................................................................1054
PLASTIGAGE PROCEDURE.......................................................................................................1054
CONNECTING ROD BEARING CLEARANCE...........................................................................................1054
REPAIR OF DAMAGED OR WORN THREADS..............................................................................................1054
HYDROSTATIC LOCKED ENGINE......................................................................................................1055
ENGINE OIL.....................................................................................................................1055
ENGINE OIL SERVICE.............................................................................................................1055
ENGINE OIL SPECIFICATION...................................................................................................1055
API SERVICE GRADE CERTIFIED................................................................................................1056
SAE VISCOSITY..............................................................................................................1056
ENERGY CONSERVING OIL......................................................................................................1056
CONTAINER IDENTIFICATION...................................................................................................1056
ENGINE OIL CHANGE..........................................................................................................1056
ENGINE DIAGNOSIS.......................................................................................................................1057
DIAGNOSIS AND TESTING..............................................................................................................1057
GENERAL INFORMATION............................................................................................................1057
INTAKE MANIFOLD LEAKAGE DIAGNOSIS..............................................................................................1057
CYLINDER COMPRESSION PRESSURE TEST.............................................................................................1057
CYLINDER COMBUSTION PRESSURE LEAKAGE TEST......................................................................................1058
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS.........................................................................................1058
INSPECTION (ENGINE OIL LEAKS IN GENERAL).......................................................................................1058
INSPECTION FOR REAR SEAL AREA LEAKS........................................................................................1059
ENGINE DIAGNOSIS— PERFORMANCE..................................................................................................1060
ENGINE DIAGNOSIS— MECHANICAL...................................................................................................1062
DESCRIPTION AND OPERATION..........................................................................................................1064
ENGINE IDENTIFICATION..........................................................................................................1064
ENGINE LUBRICATION SYSTEM......................................................................................................1064
OIL PAN....................................................................................................................1064
PRESSURE LUBRICATION.......................................................................................................1064
MAIN/ ROD BEARINGS.........................................................................................................1064
CAMSHAFT/ HYDRAULIC LASH ADJUSTERS.........................................................................................1064
BALANCE SHAFTS.............................................................................................................1065
SPLASH LUBRICATION.........................................................................................................1065
ENGINE COMPONENTS..............................................................................................................1065
DIAGNOSIS AND TESTING..............................................................................................................1066
CHECKING ENGINE OIL PRESSURE...................................................................................................1066
SERVICE PROCEDURES.................................................................................................................1066
FITTING PISTONS................................................................................................................1066
FITTING PISTON RINGS...........................................................................................................1066
PISTON RINGS— INSTALLATION.................................................................................................1067
CYLINDER BORE AND PISTON SPECIFICATION CHART...............................................................................1067
PISTON RING SPECIFICATION CHART............................................................................................1067
FITTING CONNECTING ROD BEARINGS................................................................................................1068
FITTING MAIN BEARINGS..........................................................................................................1069
CRANKSHAFT MAIN BEARINGS...................................................................................................1069
MAIN BEARING INSTALLATION..................................................................................................1069
CRANKSHAFT SPECIFICATION CHART.............................................................................................1069
CRANKSHAFT END PLAY............................................................................................................1070
CRANKSHAFT SPECIFICATION CHART.............................................................................................1070
OPTIONAL CRANKSHAFT END PLAY CHECK.........................................................................................1071
VALVE SERVICE RECONDITION......................................................................................................1071
VALVE REMOVAL..............................................................................................................1071
VALVE INSPECTION...........................................................................................................1071
VALVE GUIDES...............................................................................................................1071
TESTING VALVE SPRINGS......................................................................................................1071
REFACING VALVES AND VALVE SEATS............................................................................................1071
VALVE GUIDE SPECIFICATION CHART............................................................................................1071
VALVE SPECIFICATION CHART..................................................................................................1072
VALVE INSTALLATION.........................................................................................................1073
2.4L ENGINE............................................................................................................................1064
REMOVAL AND INSTALLATION...........................................................................................................1073
ENGINE MOUNT— FRONT............................................................................................................1073
REMOVAL....................................................................................................................1073
INSTALLATION...............................................................................................................1073
ENGINE MOUNT— LEFT.............................................................................................................1074
REMOVAL....................................................................................................................1074
INSTALLATION...............................................................................................................1074
ENGINE MOUNT— RIGHT............................................................................................................1074
REMOVAL....................................................................................................................1074
INSTALLATION...............................................................................................................1074
ENGINE MOUNT— REAR.............................................................................................................1075
REMOVAL....................................................................................................................1075
INSTALLATION...............................................................................................................1075
STRUCTURAL COLLAR..............................................................................................................1075
REMOVAL....................................................................................................................1075
INSTALLATION...............................................................................................................1075
ENGINE ASSEMBLY................................................................................................................1076
REMOVAL....................................................................................................................1076
INSTALLATION...............................................................................................................1076
CYLINDER HEAD COVER............................................................................................................1078
REMOVAL....................................................................................................................1078
INSTALLATION...............................................................................................................1078
CAMSHAFT.......................................................................................................................1078
REMOVAL....................................................................................................................1078
CAMSHAFT END PLAY..........................................................................................................1079
INSTALLATION...............................................................................................................1079
CAMSHAFT FOLLOWER..............................................................................................................1080
REMOVAL....................................................................................................................1080
INSTALLATION...............................................................................................................1080
BALANCE SHAFTS CARRIER ASSEMBLY................................................................................................1080
BALANCE SHAFTS.............................................................................................................1080
BALANCE SHAFT CARRIER......................................................................................................1081
BALANCE SHAFT INSTALLATION.................................................................................................1081
HYDRAULIC LASH ADJUSTER........................................................................................................1083
REMOVAL....................................................................................................................1083
INSTALLATION...............................................................................................................1083
VALVE SPRINGS AND VALVE SEALS IN VEHICLE.......................................................................................1083
REMOVAL....................................................................................................................1083
INSTALLATION...............................................................................................................1083
CYLINDER HEAD..................................................................................................................1084
REMOVAL....................................................................................................................1084
INSTALLATION...............................................................................................................1084
VALVES AND VALVE SPRINGS.......................................................................................................1085
REMOVAL....................................................................................................................1085
INSTALLATION...............................................................................................................1085
VIBRATION DAMPER...............................................................................................................1086
REMOVAL....................................................................................................................1086
INSTALLATION...............................................................................................................1086
TIMING BELT COVER..............................................................................................................1087
FRONT COVER................................................................................................................1087
REAR COVER.................................................................................................................1087
TIMING BELT....................................................................................................................1087
REMOVAL....................................................................................................................1087
INSTALLATION...............................................................................................................1089
TIMING BELT TENSIONER ASSEMBLY.................................................................................................1090
REMOVAL....................................................................................................................1090
INSTALLATION...............................................................................................................1090
CAMSHAFT OIL SEAL— FRONT.......................................................................................................1091
REMOVAL....................................................................................................................1091
INSTALLATION...............................................................................................................1091
CRANKSHAFT OIL SEAL— FRONT.....................................................................................................1092
REMOVAL....................................................................................................................1092
INSTALLATION...............................................................................................................1092
CRANKSHAFT OIL SEAL— REAR......................................................................................................1093
REMOVAL....................................................................................................................1093
INSTALLATION...............................................................................................................1094
OIL PAN........................................................................................................................1095
REMOVAL....................................................................................................................1095
INSTALLATION...............................................................................................................1095
CRANKSHAFT.....................................................................................................................1096
REMOVAL....................................................................................................................1096
INSTALLATION...............................................................................................................1096
OIL FILTER.....................................................................................................................1097
OIL PUMP.......................................................................................................................1097
REMOVAL....................................................................................................................1097
INSTALLATION...............................................................................................................1098
PISTON AND CONNECTING ROD......................................................................................................1099
REMOVAL....................................................................................................................1099
INSTALLATION...............................................................................................................1099
DISASSEMBLY AND ASSEMBLY...........................................................................................................1100
OIL PUMP.......................................................................................................................1100
DISASSEMBLY................................................................................................................1100
ASSEMBLY...................................................................................................................1101
CLEANING AND INSPECTION............................................................................................................1101
CYLINDER HEAD..................................................................................................................1101
CLEANING...................................................................................................................1101
INSPECTION.................................................................................................................1101
VALVE GUIDES...............................................................................................................1101
VALVE AND VALVE SPRING.........................................................................................................1101
VALVES.....................................................................................................................1101
VALVE GUIDE SPECIFICATION CHART............................................................................................1101
VALVE SPRINGS..............................................................................................................1102
CRANKSHAFT.....................................................................................................................1102
OIL PUMP.......................................................................................................................1102
CYLINDER BLOCK.................................................................................................................1104
CYLINDER BORE INSPECTION...................................................................................................1104
ADJUSTMENTS........................................................................................................................1104
ENGINE MOUNTS..................................................................................................................1104
ENGINE MOUNT INSULATOR ADJUSTMENT..........................................................................................1104
CYLINDER BORE AND PISTON SPECIFICATION CHART...............................................................................1104
SPECIFICATIONS.....................................................................................................................1105
2.4L ENGINE....................................................................................................................1105
TORQUE CHART 2.4L..............................................................................................................1107
SPECIAL TOOLS......................................................................................................................1108
2.4L ENGINE....................................................................................................................1108
3.0L ENGINE............................................................................................................................1111
DESCRIPTION AND OPERATION..........................................................................................................1111
ENGINE IDENTIFICATION NUMBER...................................................................................................1111
ENGINE LUBRICATION.............................................................................................................1111
ENGINE COMPONENTS..............................................................................................................1111
DIAGNOSIS AND TESTING..............................................................................................................1112
CHECKING ENGINE OIL PRESSURE...................................................................................................1112
SERVICE PROCEDURES.................................................................................................................1112
AUTO LASH ADJUSTER.............................................................................................................1112
FUNCTION CHECK.............................................................................................................1112
FITTING CONNECTING ROD BEARINGS................................................................................................1113
CONNECTING ROD CLEARANCE...................................................................................................1113
CONNECTING ROD SIDE CLEARANCE..............................................................................................1113
FITTING MAIN BEARING...........................................................................................................1113
INSPECTION.................................................................................................................1113
CRANKSHAFT OIL CLEARANCE— MECHANICAL MEASUREMENT...........................................................................1113
PLASTIGAGE MEASUREMENT.....................................................................................................1113
CONNECTING ROD SPECIFICATION CHART.........................................................................................1113
CRANKSHAFT BEARING INSTALLATION............................................................................................1114
CRANKSHAFT SPECIFICATION CHART.............................................................................................1114
CHECKING CRANKSHAFT END PLAY...................................................................................................1115
CRANKSHAFT SIZE CLASSIFICATION CHART.......................................................................................1115
CRANKSHAFT SPECIFICATION CHART.............................................................................................1115
VALVE SERVICE RECONDITION......................................................................................................1116
VALVES.....................................................................................................................1116
VALVE SEAT.................................................................................................................1117
INSTALLATION...............................................................................................................1117
VALVE SPECIFICATION CHART..................................................................................................1117
REMOVAL AND INSTALLATION...........................................................................................................1118
ENGINE MOUNTS..................................................................................................................1118
RIGHT SIDE MOUNT...........................................................................................................1118
FRONT MOUNT................................................................................................................1118
LEFT SIDE MOUNT............................................................................................................1118
REAR MOUNT.................................................................................................................1119
ENGINE MOUNT RUBBER INSULATORS.............................................................................................1119
ENGINE ASSEMBLY................................................................................................................1119
REMOVAL....................................................................................................................1119
INSTALLATION...............................................................................................................1120
CYLINDER HEAD COVER............................................................................................................1120
REMOVAL....................................................................................................................1120
INSTALLATION...............................................................................................................1121
CAMSHAFT.......................................................................................................................1121
REMOVAL....................................................................................................................1121
CAMSHAFT INSPECTION........................................................................................................1121
CAMSHAFT INSTALL...........................................................................................................1121
ROCKER ARMS....................................................................................................................1122
INSTALL ROCKER ARM SHAFT ASSEMBLY..........................................................................................1122
CAMSHAFT SEAL..................................................................................................................1122
CAMSHAFT END SEAL (PLUG)— IN VEHICLE SERVICE...............................................................................1122
CAMSHAFT OIL SEAL PLUG— OUT OF VEHICLE SERVICE.............................................................................1123
CAMSHAFT END SEAL (PLUG) SERVICE — OUT OF VEHICLE SERVICE..................................................................1123
CYLINDER HEAD..................................................................................................................1124
REMOVAL....................................................................................................................1124
INSTALLATION...............................................................................................................1124
TIMING BELT....................................................................................................................1125
REMOVAL....................................................................................................................1125
CAMSHAFT SPROCKETS.........................................................................................................1126
TIMING BELT TENSIONER......................................................................................................1126
INSTALLATION— TIMING BELT..................................................................................................1126
OIL PAN........................................................................................................................1127
PISTON AND CONNECTING ROD......................................................................................................1128
FITTING PISTONS............................................................................................................1128
FITTING PISTON RINGS.......................................................................................................1129
PISTON RINGS— INSTALLATION.................................................................................................1129
PISTON RING SPECIFICATION CHART............................................................................................1129
CRANKSHAFT.....................................................................................................................1131
REMOVAL....................................................................................................................1131
CRANKSHAFT BEARINGS— INSTALLATION..........................................................................................1132
REAR CRANKSHAFT SEAL...........................................................................................................1133
REAR CRANKSHAFT SEAL RETAINER..............................................................................................1133
FRONT CRANKSHAFT OIL SEAL......................................................................................................1133
OIL PUMP.......................................................................................................................1134
REMOVAL....................................................................................................................1134
INSTALLATION...............................................................................................................1134
OIL FILTER AND ADAPTOR.........................................................................................................1134
DISASSEMBLY AND ASSEMBLY...........................................................................................................1135
ROCKER ARMS AND SHAFTS.........................................................................................................1135
ROCKER ARM SHAFTS..........................................................................................................1135
REASSEMBLE.................................................................................................................1135
ASSEMBLE ROCKER ASSEMBLY...................................................................................................1135
CLEANING AND INSPECTION............................................................................................................1136
TIMING BELT....................................................................................................................1136
INSPECTION.................................................................................................................1136
CYLINDER HEAD..................................................................................................................1136
CLEANING AND INSPECTION....................................................................................................1136
CYLINDER BORE..................................................................................................................1137
INSPECTION.................................................................................................................1137
OIL PUMP.......................................................................................................................1137
OIL RELIEF PLUNGER.........................................................................................................1138
ADJUSTMENTS........................................................................................................................1138
ENGINE MOUNTS..................................................................................................................1138
ENGINE MOUNT INSULATOR ADJUSTMENT..........................................................................................1138
SPECIFICATIONS.....................................................................................................................1139
3.0L ENGINE....................................................................................................................1139
TORQUE CHART 3.0L..............................................................................................................1140
SPECIAL TOOLS......................................................................................................................1141
3.0L ENGINE....................................................................................................................1141
3.3/3.8L ENGINE........................................................................................................................1143
DESCRIPTION AND OPERATION..........................................................................................................1143
ENGINE IDENTIFICATION..........................................................................................................1143
ENGINE LUBRICATION SYSTEM......................................................................................................1143
ENGINE COMPONENTS..............................................................................................................1143
DIAGNOSIS AND TESTING..............................................................................................................1144
HYDRAULIC TAPPETS..............................................................................................................1144
PRELIMINARY STEP TO CHECKING THE HYDRAULIC TAPPETS.........................................................................1145
OIL LEVEL TOO HIGH.........................................................................................................1145
OIL LEVEL TOO LOW..........................................................................................................1145
VALVE TRAIN NOISE DIAGNOSIS................................................................................................1145
CHECKING ENGINE OIL PRESSURE...................................................................................................1146
SERVICE PROCEDURES.................................................................................................................1146
VALVE TIMING...................................................................................................................1146
MEASURING TIMING CHAIN FOR STRETCH.............................................................................................1146
FITTING PISTONS AND RINGS......................................................................................................1147
FITTING PISTONS............................................................................................................1147
FITTING RINGS..............................................................................................................1147
FITTING CONNECTING ROD BEARINGS................................................................................................1147
CYLINDER BORE AND PISTON SPECIFICATION CHART...............................................................................1147
FITTING MAIN BEARINGS..........................................................................................................1148
CRANKSHAFT OIL CLEARANCE...................................................................................................1148
PISTON RING SPECIFICATION CHART............................................................................................1148
PLASTIGAGE (OIL CLEARANCE) MEASUREMENT.....................................................................................1149
CRANKSHAFT END PLAY............................................................................................................1149
DIAL INDICATOR METHOD......................................................................................................1149
CONNECTING ROD SPECIFICATION CHART.........................................................................................1149
CRANKSHAFT SPECIFICATION CHART.............................................................................................1149
FEELER GAUGE METHOD........................................................................................................1150
VALVE SERVICE RECONDITION......................................................................................................1150
VALVE INSPECTION...........................................................................................................1150
REFACING VALVES AND VALVE SEATS............................................................................................1151
VALVE GUIDE SPECIFICATION CHART............................................................................................1151
VALVE SPECIFICATION CHART..................................................................................................1151
TESTING VALVE SPRINGS......................................................................................................1152
REMOVAL AND INSTALLATION...........................................................................................................1152
WIPER UNIT.....................................................................................................................1152
ENGINE MOUNTS..................................................................................................................1152
RIGHT SIDE MOUNT...........................................................................................................1152
FRONT MOUNT................................................................................................................1153
LEFT SIDE MOUNT............................................................................................................1153
REAR MOUNT.................................................................................................................1153
ENGINE MOUNT RUBBER INSULATORS.............................................................................................1154
ENGINE ASSEMBLY................................................................................................................1154
REMOVAL....................................................................................................................1154
INSTALLATION...............................................................................................................1155
CRANKSHAFT DAMPER..............................................................................................................1156
REMOVAL....................................................................................................................1156
INSTALLATION...............................................................................................................1156
ROCKER ARMS AND SHAFT ASSEMBLY.................................................................................................1156
REMOVAL....................................................................................................................1156
INSTALLATION...............................................................................................................1156
VALVE STEM SEALS OR SPRINGS, CYLINDER HEAD NOT REMOVED.........................................................................1156
CYLINDER HEAD COVER............................................................................................................1157
REMOVAL....................................................................................................................1157
INSTALLATION...............................................................................................................1157
CYLINDER HEAD..................................................................................................................1158
REMOVAL....................................................................................................................1158
INSTALLATION...............................................................................................................1158
INTAKE MANIFOLD SEALING....................................................................................................1159
VALVES AND VALVE SPRINGS.......................................................................................................1159
REMOVAL....................................................................................................................1159
VALVE INSTALLATION.........................................................................................................1160
TAPPET REMOVAL.................................................................................................................1160
INSTALLATION...............................................................................................................1160
TIMING CHAIN COVER.............................................................................................................1161
REMOVAL....................................................................................................................1161
INSTALLATION...............................................................................................................1161
TIMING CHAIN...................................................................................................................1162
REMOVAL....................................................................................................................1162
INSTALLATION...............................................................................................................1162
CAMSHAFT.......................................................................................................................1163
REMOVAL— ENGINE REMOVED FROM VEHICLE.......................................................................................1163
INSTALLATION...............................................................................................................1163
CAMSHAFT BEARINGS..............................................................................................................1164
REMOVAL....................................................................................................................1164
INSTALLATION...............................................................................................................1164
OIL PAN........................................................................................................................1164
REMOVAL....................................................................................................................1164
INSTALLATION...............................................................................................................1164
PISTON AND CONNECTING ROD......................................................................................................1165
REMOVAL....................................................................................................................1165
INSTALLING PISTON AND CONNECTING ROD ASSEMBLY..............................................................................1165
CRANKSHAFT.....................................................................................................................1166
MAIN BEARINGS..............................................................................................................1166
CRANKSHAFT MAIN JOURNALS...................................................................................................1166
REMOVAL....................................................................................................................1166
INSTALLATION...............................................................................................................1167
CRANKSHAFT OIL SEAL— FRONT.....................................................................................................1167
REMOVAL....................................................................................................................1167
INSTALLATION...............................................................................................................1167
CRANKSHAFT OIL SEAL— REAR......................................................................................................1168
REMOVAL....................................................................................................................1168
INSTALLATION...............................................................................................................1168
REAR CRANKSHAFT SEAL RETAINER..............................................................................................1168
OIL FILTER.....................................................................................................................1169
ENGINE OIL GALLERY PLUGS.......................................................................................................1169
REMOVAL....................................................................................................................1169
INSTALLATION...............................................................................................................1169
DISASSEMBLY AND ASSEMBLY...........................................................................................................1169
OIL PUMP.......................................................................................................................1169
DISASSEMBLY................................................................................................................1169
OIL PUMP ASSEMBLY..........................................................................................................1170
HYDRAULIC TAPPETS..............................................................................................................1170
DISASSEMBLY................................................................................................................1170
ASSEMBLY...................................................................................................................1170
CLEANING AND INSPECTION............................................................................................................1170
CYLINDER HEAD..................................................................................................................1170
OIL PAN........................................................................................................................1171
OIL PUMP.......................................................................................................................1171
INSPECTION AND REPAIR......................................................................................................1171
ENGINE BLOCK AND BORE..........................................................................................................1171
CLEANING AND INSPECTION....................................................................................................1171
CYLINDER BORE INSPECTION...................................................................................................1172
ADJUSTMENTS........................................................................................................................1173
ENGINE MOUNTS..................................................................................................................1173
ENGINE MOUNT INSULATOR ADJUSTMENT..........................................................................................1173
SPECIFICATIONS.....................................................................................................................1173
3.3/ 3.8L ENGINE...............................................................................................................1173
CYLINDER BORE AND PISTON SPECIFICATION CHART...............................................................................1173
TORQUE CHART...................................................................................................................1176
SPECIAL TOOLS......................................................................................................................1177
3.3/ 3.8L ENGINE...............................................................................................................1177
ENGINE 1
..................................................................................................................................1179
2.0L SOHC ENGINE.......................................................................................................................1179
DESCRIPTION AND OPERATION..........................................................................................................1179
ENGINE IDENTIFICATION..........................................................................................................1179
GENERAL SPECIFICATION..........................................................................................................1180
ENGINE LUBRICATION SYSTEM......................................................................................................1180
ENGINE LUBRICATION.........................................................................................................1180
PRESSURE LUBRICATION.......................................................................................................1180
MAIN/ ROD BEARINGS.........................................................................................................1180
CAMSHAFT/ HYDRAULIC LASH ADJUSTERS.........................................................................................1180
SPLASH LUBRICATION.........................................................................................................1181
ENGINE COMPONENTS..............................................................................................................1181
DIAGNOSIS AND TESTING..............................................................................................................1181
CHECKING ENGINE OIL PRESSURE...................................................................................................1181
SERVICE PROCEDURES.................................................................................................................1182
CYLINDER BORE AND PISTON SIZING................................................................................................1182
SIZING PISTONS.............................................................................................................1182
CYLINDER BORE AND PISTON SPECIFICATION CHART...............................................................................1182
FITTING PISTON RINGS...........................................................................................................1182
FITTING CONNECTING RODS........................................................................................................1183
PISTON RING SPECIFICATION CHART............................................................................................1183
CONNECTING ROD SPECIFICATION CHART.........................................................................................1184
FITTING CRANKSHAFT BEARINGS....................................................................................................1184
CRANKSHAFT END PLAY............................................................................................................1184
DIAL INDICATOR METHOD......................................................................................................1184
REMOVAL AND INSTALLATION...........................................................................................................1184
CYLINDER HEAD COVER............................................................................................................1184
REMOVAL....................................................................................................................1184
INSTALLATION...............................................................................................................1184
CRANKSHAFT SPECIFICATION CHART.............................................................................................1184
SPARK PLUG TUBE................................................................................................................1185
SPARK PLUG TUBE SEALS......................................................................................................1185
CAMSHAFT.......................................................................................................................1185
REMOVAL....................................................................................................................1185
INSTALLATION...............................................................................................................1186
ROCKER ARM/ HYDRAULIC LASH ADJUSTER............................................................................................1186
REMOVAL....................................................................................................................1186
INSTALLATION...............................................................................................................1187
HYDRAULIC LASH ADJUSTER NOISE..............................................................................................1188
VALVE SEALS AND SPRINGS IN VEHICLE.............................................................................................1188
REMOVAL....................................................................................................................1188
INSTALLATION...............................................................................................................1188
CYLINDER HEAD..................................................................................................................1188
REMOVAL....................................................................................................................1188
INSTALLATION...............................................................................................................1189
TIMING BELT COVER..............................................................................................................1189
REMOVAL....................................................................................................................1189
INSTALLATION...............................................................................................................1190
CAMSHAFT OIL SEAL..............................................................................................................1190
REMOVAL....................................................................................................................1190
INSTALLATION...............................................................................................................1191
TIMING BELT SYSTEM.............................................................................................................1191
CHECKING BELT TIMING— COVER INSTALLED......................................................................................1191
REMOVAL— TIMING BELT.......................................................................................................1191
CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE AND BELT INSTALLATION —SOHC ENGINE................................................1192
TIMING BELT w/AUTO TENIONER IF EQUIPPED....................................................................................1194
OIL PAN........................................................................................................................1195
REMOVAL....................................................................................................................1195
INSTALLATION...............................................................................................................1196
FRONT CRANKSHAFT OIL SEAL......................................................................................................1196
REMOVAL....................................................................................................................1196
INSTALLATION...............................................................................................................1197
CRANKSHAFT OIL SEAL— REAR......................................................................................................1198
REMOVAL....................................................................................................................1198
INSTALLATION...............................................................................................................1198
CRANKSHAFT.....................................................................................................................1199
REMOVAL....................................................................................................................1199
CRANKSHAFT MAIN BEARINGS LOCATION..........................................................................................1200
CRANKSHAFT MAIN JOURNALS INSPECTION........................................................................................1200
INSTALLATION...............................................................................................................1200
OIL FILTER ADAPTER.............................................................................................................1202
REMOVE AND INSTALL.........................................................................................................1202
OIL FILTER.....................................................................................................................1202
REMOVE AND INSTALL.........................................................................................................1202
OIL PUMP.......................................................................................................................1203
REMOVAL....................................................................................................................1203
INSTALLATION...............................................................................................................1203
PISTON AND CONNECTING ROD......................................................................................................1203
REMOVAL....................................................................................................................1203
PISTON RING— REMOVAL.......................................................................................................1203
PISTON RINGS— INSTALLATION.................................................................................................1204
PISTON AND ROD —INSTALLATION...............................................................................................1206
VIBRATION DAMPER...............................................................................................................1206
REMOVAL....................................................................................................................1206
INSTALLATION...............................................................................................................1207
FEELER GAGE METHOD.............................................................................................................1184
DISASSEMBLY AND ASSEMBLY...........................................................................................................1207
OIL PUMP.......................................................................................................................1207
VALVE SERVICE WITH THE CYLINDER HEAD REMOVED...................................................................................1207
REMOVAL....................................................................................................................1207
VALVE INSPECTION...........................................................................................................1207
VALVE GUIDES...............................................................................................................1207
TESTING VALVE SPRINGS......................................................................................................1207
VALVE GUIDE SPECIFICATION CHART............................................................................................1208
REFACING VALVES AND VALVE SEATS............................................................................................1208
VALVE SPECIFICATION CHART..................................................................................................1209
CLEANING...................................................................................................................1209
VALVE INSTALLATION.........................................................................................................1209
CLEANING AND INSPECTION............................................................................................................1210
CYLINDER HEAD AND CAMSHAFT JOURNALS............................................................................................1210
INSPECTING CYLINDER HEAD...................................................................................................1210
CLEANING...................................................................................................................1210
OIL PUMP.......................................................................................................................1210
CYLINDER BLOCK AND BORE........................................................................................................1212
CYLINDER BORE INSPECTION...................................................................................................1212
CYLINDER BORE AND PISTON SPECIFICATION CHART...............................................................................1212
SPECIFICATIONS.....................................................................................................................1212
ENGINE 2.0L SOHC...............................................................................................................1212
TORQUE CHART 2.0L SOHC.........................................................................................................1214
SPECIAL TOOLS......................................................................................................................1214
ENGINE 2.0L SOHC...............................................................................................................1214
2.5L VM DIESEL.........................................................................................................................1218
GENERAL INFORMATION................................................................................................................1218
GENERAL SPECIFICATION..........................................................................................................1218
ENGINE IDENTIFICATION..........................................................................................................1219
DESCRIPTION AND OPERATION..........................................................................................................1219
LUBRICATION SYSTEM.............................................................................................................1219
DIAGNOSIS AND TESTING..............................................................................................................1221
ENGINE DIAGNOSIS— PERFORMANCE..................................................................................................1221
ENGINE DIAGNOSIS— MECHANICAL...................................................................................................1222
ENGINE DIAGNOSIS— MECHANICAL CONT..........................................................................................1223
ENGINE DIAGNOSIS— MECHANICAL CONT..........................................................................................1224
HYDRAULIC TAPPETS..............................................................................................................1225
OIL LEVEL HIGH.............................................................................................................1225
OIL LEVEL LOW..............................................................................................................1225
TAPPET NOISE DIAGNOSIS.....................................................................................................1225
SERVICE PROCEDURES.................................................................................................................1225
CHECKING OIL LEVEL.............................................................................................................1225
CHANGING ENGINE OIL AND FILTER.................................................................................................1225
ENGINE OIL CHANGE..........................................................................................................1226
ENGINE OIL.................................................................................................................1226
ENGINE OIL FILTER CHANGE...................................................................................................1226
TIMING PROCEDURE...............................................................................................................1227
VALVE AND SEAT REFACING........................................................................................................1227
VALVE REFACING.............................................................................................................1227
VALVE SEAT REFACING........................................................................................................1227
VALVE STAND DOWN...........................................................................................................1228
VALVE GUIDE HEIGHT.........................................................................................................1228
VALVE STEM- TO- GUIDE CLEARANCE MEASUREMENT................................................................................1228
FITTING PISTON RING............................................................................................................1228
CRANKSHAFT END PLAY............................................................................................................1228
REMOVAL AND INSTALLATION...........................................................................................................1229
ENGINE MOUNT— FRONT............................................................................................................1229
ENGINE MOUNT— RIGHT............................................................................................................1229
MOUNT— LEFT SIDE...............................................................................................................1229
ENGINE MOUNT— REAR.............................................................................................................1230
ENGINE ASSEMBLY................................................................................................................1231
REMOVAL....................................................................................................................1231
CYLINDER HEAD COVER............................................................................................................1232
REMOVAL....................................................................................................................1232
INSTALLATION...............................................................................................................1232
ROCKER ARMS AND PUSH RODS......................................................................................................1232
REMOVAL....................................................................................................................1232
INSTALLATION...............................................................................................................1232
VALVE SPRINGS— CYLINDER HEAD NOT REMOVED.......................................................................................1233
REMOVAL....................................................................................................................1233
INSTALLATION...............................................................................................................1233
CYLINDER HEAD..................................................................................................................1233
REMOVAL....................................................................................................................1233
CYLINDER HEAD GASKET.......................................................................................................1235
INSTALLATION CYLINDER HEAD.................................................................................................1236
VALVES AND VALVE SPRINGS— HEAD OFF.............................................................................................1238
REMOVAL....................................................................................................................1238
INSTALLATION...............................................................................................................1238
HYDRAULIC TAPPETS..............................................................................................................1238
REMOVAL....................................................................................................................1238
INSTALLATION...............................................................................................................1238
VIBRATION DAMPER...............................................................................................................1239
REMOVAL....................................................................................................................1239
INSTALLATION...............................................................................................................1239
TIMING GEAR COVER OIL SEAL.....................................................................................................1239
REMOVAL....................................................................................................................1239
INSTALLATION...............................................................................................................1239
INJECTION PUMP.................................................................................................................1239
TIMING GEAR COVER..............................................................................................................1239
REMOVAL....................................................................................................................1239
INSTALLATION...............................................................................................................1240
CAMSHAFT.......................................................................................................................1240
REMOVAL....................................................................................................................1240
THRUST PLATE INSPECTION....................................................................................................1241
INSTALLATION...............................................................................................................1241
CAMSHAFT BEARINGS..............................................................................................................1241
REMOVAL....................................................................................................................1241
INSTALLATION...............................................................................................................1241
CRANKSHAFT MAIN BEARINGS.......................................................................................................1241
REMOVAL....................................................................................................................1241
INSTALLATION...............................................................................................................1242
OIL PAN........................................................................................................................1244
REMOVAL....................................................................................................................1244
INSTALLATION...............................................................................................................1245
OIL PUMP.......................................................................................................................1245
REMOVAL....................................................................................................................1245
INSTALLATION...............................................................................................................1245
OIL PUMP PRESSURE RELIEF VALVE.................................................................................................1245
REMOVAL....................................................................................................................1245
INSTALLATION...............................................................................................................1245
OIL FILTER ADAPTER AND OIL COOLER..............................................................................................1246
REMOVAL....................................................................................................................1246
INSTALLATION...............................................................................................................1246
VACUUM PUMP....................................................................................................................1246
REMOVAL....................................................................................................................1246
INSTALLATION...............................................................................................................1246
PISTONS AND CONNECTING ROD.....................................................................................................1246
REMOVAL....................................................................................................................1246
PISTON PIN— REMOVAL........................................................................................................1247
PISTON RING— REMOVAL.......................................................................................................1248
FITTING PISTON RINGS.......................................................................................................1248
PISTON RINGS— INSTALLATION.................................................................................................1248
PISTON PIN— INSTALLATION...................................................................................................1249
PISTON— INSTALLATION.......................................................................................................1249
CYLINDER LINER.................................................................................................................1250
REMOVAL....................................................................................................................1250
INSTALLATION...............................................................................................................1250
CRANKSHAFT— REMOVAL............................................................................................................1250
REAR CRANKSHAFT OIL SEAL.......................................................................................................1250
REMOVAL....................................................................................................................1250
INSTALLATION...............................................................................................................1251
DISASSEMBLY AND ASSEMBLY...........................................................................................................1251
HYDRAULIC TAPPETS..............................................................................................................1251
DISASSEMBLE AND ASSEMBLE...................................................................................................1251
CLEANING AND INSPECTION............................................................................................................1252
CYLINDER HEAD COVERS...........................................................................................................1252
ROCKER ARMS AND PUSH RODS......................................................................................................1252
CLEANING...................................................................................................................1252
INSPECTION.................................................................................................................1252
CYLINDER HEAD..................................................................................................................1253
CLEANING...................................................................................................................1253
INSPECTION.................................................................................................................1253
VALVE GUIDE HEIGHT.........................................................................................................1253
VALVE STEM- TO- GUIDE CLEARANCE MEASUREMENT................................................................................1253
TIMING GEAR COVER..............................................................................................................1253
VALVES AND VALVE SPRINGS.......................................................................................................1254
VALVE CLEANING.............................................................................................................1254
INSPECTION.................................................................................................................1254
HYDRAULIC TAPPETS..............................................................................................................1254
OIL PUMP.......................................................................................................................1254
CLEANING...................................................................................................................1254
INSPECTION.................................................................................................................1254
PISTON AND CONNECTING ROD......................................................................................................1254
PISTONS....................................................................................................................1254
CONNECTING ROD.............................................................................................................1255
PISTON PIN.................................................................................................................1255
CRANKSHAFT.....................................................................................................................1255
CRANKSHAFT JOURNALS........................................................................................................1255
BEARING- TO- JOURNAL CLEARANCE.............................................................................................1255
CRANKSHAFT MAIN BEARING........................................................................................................1255
INSPECTION.................................................................................................................1255
OIL PAN........................................................................................................................1256
CYLINDER LINER.................................................................................................................1256
INSPECTION.................................................................................................................1256
SPECIFICATIONS.....................................................................................................................1256
2.5L VM DIESEL.................................................................................................................1256
SPECIAL TOOLS......................................................................................................................1259
2.5L VM DIESEL.................................................................................................................1259
TORQUE.........................................................................................................................1258
EXHAUST SYSTEM AND INTAKE MANIFOLD.........................................................................................................1263
GENERAL INFORMATION....................................................................................................................1263
EXHAUST SYSTEM.....................................................................................................................1263
CATALYTIC CONVERTERS...............................................................................................................1263
EXHAUST GAS RECIRCULATION (EGR)....................................................................................................1264
HEAT SHIELDS.......................................................................................................................1264
EXHAUST FLEX- JOINT COUPLING.......................................................................................................1264
DESCRIPTION AND OPERATION..............................................................................................................1265
INTAKE/ EXHAUST MANIFOLD— 2.4L ENGINE..............................................................................................1265
INTAKE/ EXHAUST MANIFOLD— 3.0L ENGINE..............................................................................................1265
INTAKE/ EXHAUST MANIFOLD— 3.3/ 3.8L ENGINES........................................................................................1265
DIAGNOSIS AND TESTING..................................................................................................................1265
EXHAUST SYSTEM.....................................................................................................................1265
REMOVAL AND INSTALLATION...............................................................................................................1266
EXHAUST PIPES, MUFFLERS AND TAILPIPES..............................................................................................1266
REMOVAL........................................................................................................................1266
INSTALLATION...................................................................................................................1266
UPPER INTAKE MANIFOLD— 2.4L ENGINE.................................................................................................1266
REMOVAL........................................................................................................................1266
INSTALLATION...................................................................................................................1268
INTAKE MANIFOLD LOWER— 2.4L ENGINE.................................................................................................1268
REMOVAL........................................................................................................................1268
INSTALLATION...................................................................................................................1269
EXHAUST MANIFOLD— 2.4L ENGINE......................................................................................................1270
REMOVAL........................................................................................................................1270
INSTALLATION...................................................................................................................1270
INTAKE MANIFOLD— 3.0L ENGINE.......................................................................................................1270
REMOVAL........................................................................................................................1270
INSTALLATION...................................................................................................................1272
EXHAUST MANIFOLD— 3.0L ENGINE......................................................................................................1273
REMOVAL........................................................................................................................1273
INSTALLATION...................................................................................................................1273
INTAKE MANIFOLD— 3.3/ 3.8L ENGINE..................................................................................................1274
REMOVAL........................................................................................................................1274
INSTALLATION...................................................................................................................1276
EXHAUST MANIFOLDS— 3.3/ 3.8L ENGINE................................................................................................1278
REMOVAL........................................................................................................................1278
INSTALLATION...................................................................................................................1278
CLEANING AND INSPECTION................................................................................................................1279
INTAKE MANIFOLD....................................................................................................................1279
INSPECTION.....................................................................................................................1279
CLEANING.......................................................................................................................1279
EXHAUST MANIFOLD...................................................................................................................1279
INSPECTION.....................................................................................................................1279
CLEANING.......................................................................................................................1279
SPECIFICATIONS.........................................................................................................................1280
TORQUE CHART.......................................................................................................................1280
FRAME AND BUMPERS..........................................................................................................................1281
BUMPERS AND FASCIA.....................................................................................................................1281
REMOVAL AND INSTALLATION...........................................................................................................1281
FRONT BUMPER FASCIA............................................................................................................1281
REMOVAL....................................................................................................................1281
INSTALLATION...............................................................................................................1281
FRONT BUMPER REINFORCEMENT.....................................................................................................1281
REMOVAL....................................................................................................................1281
INSTALLATION...............................................................................................................1282
REAR BUMPER FASCIA.............................................................................................................1282
REMOVAL....................................................................................................................1282
INSTALLATION...............................................................................................................1282
REAR BUMPER REINFORCEMENT......................................................................................................1282
REMOVAL....................................................................................................................1282
INSTALLATION...............................................................................................................1282
FRAME..................................................................................................................................1283
REMOVAL AND INSTALLATION...........................................................................................................1283
FRONT CROSSMEMBER..............................................................................................................1283
REMOVAL....................................................................................................................1283
INSTALLATION...............................................................................................................1284
FRONT CROSSMEMBER MOUNT BUSHINGS...............................................................................................1285
REMOVAL....................................................................................................................1285
INSTALLATION...............................................................................................................1285
SPECIFICATIONS.....................................................................................................................1285
FRAME AND BODY OPENING DIMENSIONS..............................................................................................1285
VEHICLE PREPARATION........................................................................................................1285
FRAME AND BUMPERS 1
.......................................................................................................................1293
FRAME..................................................................................................................................1293
REMOVAL AND INSTALLATION...........................................................................................................1293
FRONT TOW HOOK BRACKET.........................................................................................................1293
REMOVAL....................................................................................................................1293
INSTALLATION...............................................................................................................1293
REAR TOW HOOK BRACKET..........................................................................................................1293
REMOVAL....................................................................................................................1293
INSTALLATION...............................................................................................................1294
FUEL SYSTEM................................................................................................................................1295
GENERAL INFORMATION....................................................................................................................1295
GENERAL INFORMATION................................................................................................................1295
INTRODUCTION...................................................................................................................1295
PCM REPLACEMENT................................................................................................................1295
FUEL REQUIREMENTS..............................................................................................................1295
GASOLINE/ OXYGENATE BLENDS.....................................................................................................1296
E- 85 GENERAL INFORMATION......................................................................................................1296
ETHANOL FUEL (E- 85)...........................................................................................................1296
FUEL REQUIREMENTS..............................................................................................................1296
STARTING.......................................................................................................................1296
CRUISING RANGE.................................................................................................................1297
REPLACEMENT PARTS..............................................................................................................1297
FUEL DELIVERY SYSTEM...................................................................................................................1298
DESCRIPTION AND OPERATION..........................................................................................................1298
FUEL DELIVERY SYSTEM...........................................................................................................1298
FUEL PUMP MODULE...............................................................................................................1298
ELECTRIC FUEL PUMP.........................................................................................................1298
FUEL PUMP ELECTRICAL CONTROL...............................................................................................1299
ELECTRICAL PUMP REPLACEMENT................................................................................................1299
FUEL LEVEL SENSOR..............................................................................................................1299
FUEL PRESSURE REGULATOR........................................................................................................1299
FUEL INJECTORS.................................................................................................................1299
FUEL TANK......................................................................................................................1299
PRESSURE- VACUUM FILLER CAP....................................................................................................1300
QUICK- CONNECT FITTINGS........................................................................................................1300
DIAGNOSIS AND TESTING..............................................................................................................1300
FUEL PUMP PRESSURE TEST 2.4/ 3.3/ 3.8L.........................................................................................1300
FUEL PRESSURE BELOW SPECIFICATIONS.........................................................................................1302
FUEL LEVEL SENSOR..............................................................................................................1303
FUEL INJECTORS.................................................................................................................1303
SERVICE PROCEDURES.................................................................................................................1305
FUEL SYSTEM PRESSURE RELEASE PROCEDURE— 2.4/ 3.3/ 3.8L.........................................................................1305
FUEL SYSTEM PRESSURE RELEASE PROCEDURE— 3.0L ENGINE............................................................................1305
HOSES AND CLAMPS...............................................................................................................1306
QUICK- CONNECT FITTINGS........................................................................................................1306
REMOVAL....................................................................................................................1306
INSTALLATION...............................................................................................................1306
REMOVAL AND INSTALLATION...........................................................................................................1306
FUEL FILTER....................................................................................................................1306
REMOVAL....................................................................................................................1307
INSTALLATION...............................................................................................................1307
FUEL PUMP MODULE...............................................................................................................1307
REMOVAL....................................................................................................................1307
INSTALLATION...............................................................................................................1308
FUEL PRESSURE REGULATOR........................................................................................................1308
REMOVAL....................................................................................................................1308
INSTALLATION...............................................................................................................1308
FUEL PUMP INLET STRAINER.......................................................................................................1309
REMOVAL....................................................................................................................1309
INSTALLATION...............................................................................................................1309
FUEL LEVEL SENSOR..............................................................................................................1309
REMOVAL....................................................................................................................1309
INSTALLATION...............................................................................................................1310
FUEL TANK......................................................................................................................1311
REMOVAL....................................................................................................................1311
INSTALLATION...............................................................................................................1312
FUEL INJECTOR RAIL— 2.4L.......................................................................................................1312
REMOVAL....................................................................................................................1312
INSTALLATION...............................................................................................................1313
FUEL INJECTOR RAIL— 3.0L.......................................................................................................1313
REMOVAL....................................................................................................................1313
INSTALLATION...............................................................................................................1315
FUEL INJECTOR RAIL— 3.3/ 3.8L..................................................................................................1315
REMOVAL....................................................................................................................1315
INSTALLATION...............................................................................................................1317
FUEL INJECTOR— 2.4L............................................................................................................1318
REMOVAL....................................................................................................................1318
INSTALLATION...............................................................................................................1319
FUEL INJECTORS— 3.0L...........................................................................................................1319
REMOVAL....................................................................................................................1319
INSTALLATION...............................................................................................................1319
FUEL INJECTOR— 3.3/ 3.8L.......................................................................................................1320
REMOVAL....................................................................................................................1320
INSTALLATION...............................................................................................................1320
ACCELERATOR PEDAL..............................................................................................................1320
REMOVAL....................................................................................................................1320
INSTALLATION...............................................................................................................1320
THROTTLE CABLE.................................................................................................................1321
REMOVAL....................................................................................................................1321
INSTALLATION...............................................................................................................1321
SPECIFICATIONS.....................................................................................................................1322
TORQUE.........................................................................................................................1322
FUEL TANK CAPACITY.............................................................................................................1322
FUEL INJECTION SYSTEM..................................................................................................................1323
GENERAL INFORMATION................................................................................................................1324
INTRODUCTION...................................................................................................................1324
MODES OF OPERATION.............................................................................................................1324
IGNITION SWITCH ON (ZERO RPM) MODE.........................................................................................1324
ENGINE START- UP MODE......................................................................................................1324
ENGINE WARM- UP MODE.......................................................................................................1325
CRUISE OR IDLE MODE........................................................................................................1325
ACCELERATION MODE..........................................................................................................1325
DECELERATION MODE..........................................................................................................1325
WIDE OPEN THROTTLE (WOT) MODE..............................................................................................1325
IGNITION SWITCH OFF MODE...................................................................................................1326
DESCRIPTION AND OPERATION..........................................................................................................1326
SYSTEM DIAGNOSIS...............................................................................................................1326
CCD BUS........................................................................................................................1326
POWERTRAIN CONTROL MODULE (PCM)................................................................................................1326
AIR CONDITIONING PRESSURE TRANSDUCER— PCM INPUT................................................................................1327
AIR CONDITIONING SWITCH SENSE— PCM INPUT.......................................................................................1327
AUTOMATIC SHUTDOWN (ASD) SENSE— PCM INPUT......................................................................................1327
BATTERY VOLTAGE— PCM INPUT.....................................................................................................1327
BRAKE SWITCH— PCM INPUT........................................................................................................1327
CAMSHAFT POSITION SENSOR— PCM INPUT............................................................................................1327
3.3/ 3.8L..................................................................................................................1327
2.4L.......................................................................................................................1328
CRANKSHAFT POSITION SENSOR— PCM INPUT..........................................................................................1329
3.0/ 3.3/ 3.8L.............................................................................................................1329
2.4L.......................................................................................................................1330
ENGINE COOLANT TEMPERATURE SENSOR— PCM INPUT...................................................................................1330
3.0/ 3.3/ 3.8L.............................................................................................................1331
2.4L.......................................................................................................................1331
HEATED OXYGEN SENSOR (O2S SENSOR)— PCM INPUT...................................................................................1331
UPSTREAM HEATED OXYGEN SENSOR..............................................................................................1332
DOWNSTREAM HEATED OXYGEN SENSOR............................................................................................1332
KNOCK SENSOR— PCM INPUT........................................................................................................1332
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— PCM INPUT.............................................................................1333
SPEED CONTROL— PCM INPUT.......................................................................................................1333
TRANSAXLE PARK/ NEUTRAL SWITCH— PCM INPUT......................................................................................1334
THROTTLE POSITION SENSOR (TPS)— PCM INPUT......................................................................................1334
VEHICLE SPEED AND DISTANCE— PCM INPUT..........................................................................................1335
INTAKE AIR TEMPERATURE SENSOR— PCM INPUT (2.4L ONLY)...........................................................................1335
AIR CONDITIONING (A/ C) CLUTCH RELAY— PCM OUTPUT...............................................................................1335
GENERATOR FIELD— PCM OUTPUT....................................................................................................1336
AUTOMATIC SHUTDOWN RELAY— PCM OUTPUT...........................................................................................1336
FUEL PUMP RELAY— PCM OUTPUT....................................................................................................1336
STARTER RELAY— PCM OUTPUT......................................................................................................1336
IDLE AIR CONTROL MOTOR— PCM OUTPUT.............................................................................................1336
DUTY CYCLE EVAP CANISTER PURGE SOLENOID— PCM OUTPUT............................................................................1337
PROPORTIONAL PURGE SOLENOID....................................................................................................1337
ELECTRONIC EGR TRANSDUCER SOLENOID— PCM OUTPUT.................................................................................1337
DATA LINK CONNECTOR— PCM OUTPUT................................................................................................1338
AUTOMATIC TRANSAXLE CONTROL MODULE— PCM OUTPUT.................................................................................1338
FUEL INJECTORS— PCM OUTPUT.....................................................................................................1338
IGNITION COIL— PCM OUTPUT......................................................................................................1339
TORQUE CONVERTER CLUTCH SOLENOID— PCM OUTPUT...................................................................................1340
MALFUNCTION INDICATOR (CHECK ENGINE) LAMP— PCM OUTPUT..........................................................................1340
SOLID STATE FAN RELAY— PCM OUTPUT..............................................................................................1340
SPEED CONTROL SOLENOIDS— PCM OUTPUT............................................................................................1340
TACHOMETER— PCM OUTPUT.........................................................................................................1341
THROTTLE BODY..................................................................................................................1341
DIAGNOSIS AND TESTING..............................................................................................................1341
VISUAL INSPECTION— 2.4L ENGINE.................................................................................................1341
VISUAL INSPECTION— 3.0L ENGINE.................................................................................................1346
VISUAL INSPECTION— 3.3/ 3.8L ENGINES...........................................................................................1349
ASD AND FUEL PUMP RELAYS.......................................................................................................1353
OPERATION..................................................................................................................1353
TESTING....................................................................................................................1354
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR........................................................................................1354
HEATED OXYGEN SENSOR...........................................................................................................1355
KNOCK SENSOR...................................................................................................................1355
CAMSHAFT AND CRANKSHAFT POSITION SENSOR........................................................................................1355
ENGINE COOLANT TEMPERATURE SENSOR..............................................................................................1355
THROTTLE POSITION SENSOR.......................................................................................................1356
THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE.................................................................................1356
REMOVAL AND INSTALLATION...........................................................................................................1358
THROTTLE BODY..................................................................................................................1358
REMOVAL....................................................................................................................1358
INSTALLATION...............................................................................................................1358
FUEL PUMP RELAY................................................................................................................1358
AUTOMATIC SHUTDOWN (ASD) RELAY.................................................................................................1358
THROTTLE POSITION SENSOR.......................................................................................................1359
REMOVAL....................................................................................................................1359
INSTALLATION...............................................................................................................1359
IDLE AIR CONTROL MOTOR.........................................................................................................1359
REMOVAL....................................................................................................................1359
INSTALLATION...............................................................................................................1360
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— 2.4/ 3.3/ 3.8L........................................................................1360
REMOVAL....................................................................................................................1360
INSTALLATION...............................................................................................................1360
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— 3.0L..................................................................................1360
REMOVAL....................................................................................................................1360
INSTALLATION...............................................................................................................1360
PROPORTIONAL PURGE SOLENOID VALVE..............................................................................................1360
REMOVAL....................................................................................................................1360
INSTALLATION...............................................................................................................1360
POWERTRAIN CONTROL MODULE......................................................................................................1361
REMOVAL....................................................................................................................1361
INSTALLATION...............................................................................................................1362
CRANKSHAFT POSITION SENSOR.....................................................................................................1362
CAMSHAFT POSITION SENSOR.......................................................................................................1362
UPSTREAM OXYGEN SENSOR.........................................................................................................1362
REMOVAL....................................................................................................................1362
INSTALLATION...............................................................................................................1363
DOWNSTREAM OXYGEN SENSOR.......................................................................................................1363
REMOVAL....................................................................................................................1363
INSTALLATION...............................................................................................................1364
KNOCK SENSOR...................................................................................................................1364
AIR CLEANER ELEMENT............................................................................................................1364
REMOVAL....................................................................................................................1364
INSTALLATION...............................................................................................................1364
ENGINE COOLANT TEMPERATURE SENSOR— 2.4L........................................................................................1364
REMOVAL....................................................................................................................1365
INSTALLATION...............................................................................................................1365
ENGINE COOLANT TEMPERATURE SENSOR— 3.0L........................................................................................1365
REMOVAL....................................................................................................................1365
INSTALLATION...............................................................................................................1365
ENGINE COOLANT TEMPERATURE SENSOR— 3.3/ 3.8L...................................................................................1365
REMOVAL....................................................................................................................1365
INSTALLATION...............................................................................................................1365
INTAKE AIR TEMPERATURE SENSOR— 2.4L............................................................................................1366
REMOVAL....................................................................................................................1366
INSTALLATION...............................................................................................................1366
SPECIFICATIONS.....................................................................................................................1366
TORQUE.........................................................................................................................1366
SPECIAL TOOLS......................................................................................................................1366
FUEL...........................................................................................................................1366
FUEL SYSTEM— 2.5L DIESEL ENGINE/ 2.0L GAS ENGINE...........................................................................................1369
GENERAL INFORMATION....................................................................................................................1369
GENERAL INFORMATION................................................................................................................1369
INTRODUCTION— 2.5L DIESEL......................................................................................................1369
INTRODUCTION— 2.0L ENGINE......................................................................................................1370
FUEL REQUIREMENTS— 2.5L DIESEL.................................................................................................1370
FUEL REQUIREMENTS— 2.0L ENGINE.................................................................................................1370
GASOLINE/ OXYGENATE BLENDS.....................................................................................................1370
FUEL DELIVERY SYSTEM - 2.5L DIESEL ENGINE..............................................................................................1371
DESCRIPTION AND OPERATION..........................................................................................................1371
INTRODUCTION...................................................................................................................1371
FUEL SYSTEM PRESSURE WARNING...................................................................................................1371
FUEL TANK......................................................................................................................1371
FUEL TANK MODULE...............................................................................................................1372
FUEL GAUGE SENDING UNIT........................................................................................................1372
FUEL FILTER/ WATER SEPARATOR...................................................................................................1372
FUEL SHUTDOWN SOLENOID.........................................................................................................1373
FUEL INJECTION PUMP............................................................................................................1373
FUEL INJECTORS.................................................................................................................1374
FUEL TUBES/ LINES/ HOSES AND CLAMPS— LOW-PRESSURE TYPE.........................................................................1374
QUICK- CONNECT FITTINGS— LOW PRESSURE TYPE.....................................................................................1375
HIGH- PRESSURE FUEL LINES......................................................................................................1375
FUEL DRAIN TUBES...............................................................................................................1375
FUEL HEATER....................................................................................................................1376
FUEL HEATER RELAY..............................................................................................................1376
WASTEGATE (TURBOCHARGER).......................................................................................................1376
DIAGNOSIS AND TESTING..............................................................................................................1377
GENERAL INFORMATION............................................................................................................1377
VISUAL INSPECTION..............................................................................................................1377
AIR IN FUEL SYSTEM.............................................................................................................1379
FUEL HEATER RELAY TEST.........................................................................................................1380
FUEL INJECTOR TEST.............................................................................................................1380
FUEL INJECTOR SENSOR TEST......................................................................................................1380
FUEL INJECTION PUMP TEST.......................................................................................................1380
FUEL SUPPLY RESTRICTIONS.......................................................................................................1381
LOW– PRESSURE LINES........................................................................................................1381
HIGH– PRESSURE LINES.......................................................................................................1381
FUEL SHUTDOWN SOLENOID TEST....................................................................................................1381
HIGH- PRESSURE FUEL LINE LEAK TEST.............................................................................................1382
WASTEGATE (TURBOCHARGER).......................................................................................................1382
SERVICE PROCEDURES.................................................................................................................1382
AIR BLEED PROCEDURES...........................................................................................................1382
AIR BLEEDING AT FUEL FILTER................................................................................................1382
FUEL INJECTION PUMP BLEEDING...............................................................................................1383
HIGH– PRESSURE FUEL LINE BLEEDING..........................................................................................1383
FUEL INJECTION PUMP TIMING.....................................................................................................1383
REMOVAL AND INSTALLATION...........................................................................................................1384
ACCELERATOR PEDAL..............................................................................................................1384
REMOVAL....................................................................................................................1384
INSTALLATION...............................................................................................................1384
AIR CLEANER ELEMENT............................................................................................................1384
REMOVAL....................................................................................................................1384
INSTALLATION...............................................................................................................1384
FUEL DRAIN TUBES...............................................................................................................1384
FUEL FILTER/ WATER SEPARATOR...................................................................................................1384
DRAINING WATER FROM FILTER BOWL............................................................................................1384
FUEL FILTER REMOVAL........................................................................................................1385
FUEL FILTER INSTALLATION...................................................................................................1385
FUEL HEATER....................................................................................................................1385
FUEL HEATER RELAY..............................................................................................................1385
FUEL LEVEL SENSOR..............................................................................................................1386
REMOVAL....................................................................................................................1386
INSTALLATION...............................................................................................................1387
FUEL INJECTION PUMP............................................................................................................1387
REMOVAL....................................................................................................................1387
INSTALLATION/ ADJUSTING PUMP TIMING........................................................................................1389
FUEL INJECTORS.................................................................................................................1390
REMOVAL....................................................................................................................1390
INSTALLATION...............................................................................................................1391
FUEL SHUTDOWN SOLENOID.........................................................................................................1391
REMOVAL....................................................................................................................1391
INSTALLATION...............................................................................................................1391
FUEL TANK......................................................................................................................1391
REMOVAL....................................................................................................................1391
INSTALLATION...............................................................................................................1392
FUEL RESERVOIR MODULE..........................................................................................................1393
REMOVAL....................................................................................................................1393
INSTALLATION...............................................................................................................1393
HIGH- PRESSURE LINES...........................................................................................................1394
REMOVAL....................................................................................................................1394
INSTALLATION...............................................................................................................1394
SPECIFICATIONS.....................................................................................................................1395
FUEL TANK CAPACITY.............................................................................................................1395
IDLE SPEED.....................................................................................................................1395
FUEL INJECTOR FIRING SEQUENCE..................................................................................................1395
FUEL SYSTEM PRESSURE...........................................................................................................1395
FUEL DELIVERY SYSTEM-2.0L ENGINE.......................................................................................................1396
DESCRIPTION AND OPERATION..........................................................................................................1396
FUEL DELIVERY SYSTEM...........................................................................................................1396
FUEL PUMP MODULE...............................................................................................................1396
ELECTRIC FUEL PUMP.............................................................................................................1396
FUEL LEVEL SENSOR..............................................................................................................1396
FUEL PRESSURE REGULATOR........................................................................................................1396
FUEL INJECTORS.................................................................................................................1396
FUEL TANK......................................................................................................................1396
PRESSURE- VACUUM FILLER CAP— 2.0L ENGINE.......................................................................................1396
QUICK- CONNNECT FITTINGS— 2.0L ENGINE..........................................................................................1396
DIAGNOSIS AND TESTING..............................................................................................................1396
FUEL PUMP PRESSURE TEST— 2.0L ENGINE...........................................................................................1396
FUEL LEVEL SENSOR— 2.0L ENGINE.................................................................................................1396
FUEL INJECTORS— 2.0L ENGINE....................................................................................................1397
SERVICE PROCEDURES.................................................................................................................1397
FUEL SYSTEM PRESSURE RELEASE PROCEDURE— 2.0L ENGINE............................................................................1397
HOSES AND CLAMPS— 2.0L ENGINE..................................................................................................1397
QUICK- CONNNECT FITTINGS— 2.0L ENGINE..........................................................................................1397
REMOVAL AND INSTALLATION...........................................................................................................1397
FUEL FILTER— 2.0L ENGINE.......................................................................................................1397
FUEL PUMP MODULE— 2.0L ENGINE..................................................................................................1397
FUEL PRESSURE REGULATOR— 2.0L ENGINE...........................................................................................1397
FUEL PRESSURE REGULATOR— 2.0L ENGINE...........................................................................................1397
FUEL LEVEL SENSOR— 2.0L ENGINE.................................................................................................1398
FUEL TANK— 2.0L ENGINE.........................................................................................................1398
FUEL INJECTORS.................................................................................................................1398
REMOVAL....................................................................................................................1398
INSTALLATION...............................................................................................................1398
ACCELERATOR PEDAL..............................................................................................................1399
TORQUE SPECIFICATION...........................................................................................................1399
FUEL INJECTION SYSTEM-2.0L ENGINE......................................................................................................1400
GENERAL INFORMATION................................................................................................................1400
INTRODUCTION— 2.0L ENGINE......................................................................................................1400
MODES OF OPERATION— 2.0L ENGINE................................................................................................1400
DESCRIPTION AND OPERATION..........................................................................................................1401
SYSTEM DIAGNOSIS— 2.0L ENGINE..................................................................................................1401
POWERTRAIN CONTROL MODULE— 2.0L ENGINE.........................................................................................1401
AIR CONDITIONING PRESSURE TRANSDUCER— PCM INPUT— 2.0L ENGINE...................................................................1401
AIR CONDITIONING SWITCH SENSE— PCM INPUT— 2.0L ENGINE..........................................................................1401
AUTOMATIC SHUTDOWN (ASD) SENSE— PCM INPUT— 2.0L ENGINE.........................................................................1401
BATTERY VOLTAGE— PCM INPUT— 2.0L ENGINE........................................................................................1401
CAMSHAFT POSITION SENSOR— PCM INPUT— 2.0L ENGINE...............................................................................1401
CRANKSHAFT POSITION SENSOR— PCM INPUT— 2.0L ENGINE.............................................................................1401
ENGINE COOLANT TEMPERATURE SENSOR— PCM INPUT— 2.0L ENGINE......................................................................1401
HEATED OXYGEN SENSOR— PCM INPUT— 2.0L ENGINE...................................................................................1401
KNOCK SENSOR— PCM INPUT— 2.0L ENGINE...........................................................................................1402
MANIFOLD ABSOLUTE PRESSURE (MAP SENSOR)— PCM INPUT— 2.0L ENGINE................................................................1402
SPEED CONTROL— PCM INPUT— 2.0L ENGINE..........................................................................................1402
THROTTLE POSITION SENSOR/ IDLE AIR CONTROL MOTOR— PCM INPUT— 2.0L ENGINE.......................................................1403
AIR CONDITIONING (A/ C) RELAY— PCM OUTPUT— 2.0L ENGINE.........................................................................1403
GENERATOR FIELD— PCM OUTPUT— 2.0L ENGINE.......................................................................................1403
AUTOMATIC SHUTDOWN RELAY— PCM OUTPUT— 2.0L ENGINE..............................................................................1403
FUEL PUMP RELAY— PCM OUTPUT— 2.0L ENGINE.......................................................................................1403
STARTER RELAY— PCM OUTPUT— 2.0L ENGINE.........................................................................................1403
IDLE AIR CONTROL MOTOR— PCM OUTPUT— 2.0L ENGINE................................................................................1403
ELECTRONIC EGR TRANSDUCER— PCM OUTPUT— 2.0L ENGINE.............................................................................1403
DATA LINK CONNECTOR— PCM OUTPUT— 2.0L ENGINE...................................................................................1403
FUEL INJECTORS— PCM OUTPUT— 2.0L ENGINE........................................................................................1403
IGNITION COIL— PCM OUTPUT— 2.0L ENGINE.........................................................................................1404
MALFUNCTION INDICATOR (CHECK ENGINE) LAMP— PCM OUTPUT— 2.0L ENGINE.............................................................1404
RADIATOR FAN CONTROL MODULE— PCM OUTPUT— 2.0L ENGINE...........................................................................1404
SPEED CONTROL SOLENOIDS— PCM OUTPUT— 2.0L ENGINE...............................................................................1404
TACHOMETER— PCM OUTPUT— 2.0L ENGINE............................................................................................1404
THROTTLE BODY— 2.0L ENGINE.....................................................................................................1404
DIAGNOSIS AND TESTING..............................................................................................................1404
VISUAL INSPECTION— SOHC........................................................................................................1404
ASD AND FUEL PUMP RELAYS— 2.0L ENGINE..........................................................................................1407
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— 2.0L ENGINE...........................................................................1407
KNOCK SENSOR— 2.0L ENGINE......................................................................................................1408
CAMSHAFT AND CRANKSHAFT POSITION SENSOR........................................................................................1408
ENGINE COOLANT TEMPERATURE SENSOR..............................................................................................1408
THROTTLE POSITION SENSOR.......................................................................................................1408
THROTTLE BODY MINIMUM AIR FLOW.................................................................................................1409
SPECIFICATIONS.....................................................................................................................1410
TORQUE.........................................................................................................................1410
FUEL INJECTION SYSTEM - 2.5L DIESEL ENGINE.............................................................................................1411
GENERAL INFORMATION................................................................................................................1411
INTRODUCTION...................................................................................................................1411
DESCRIPTION AND OPERATION..........................................................................................................1412
POWERTRAIN CONTROL MODULE (PCM)................................................................................................1412
BOOST PRESSURE SENSOR..........................................................................................................1413
VEHICLE THEFT ALARM............................................................................................................1413
BATTERY VOLTAGE— PCM INPUT.....................................................................................................1413
SENSOR RETURN— PCM INPUT (ANALOG GROUND).......................................................................................1413
SIGNAL GROUND— PCM INPUT.......................................................................................................1413
IGNITION CIRCUIT SENSE— PCM INPUT..............................................................................................1413
START SIGNAL— PCM INPUT........................................................................................................1413
POWER GROUND...................................................................................................................1413
NEEDLE MOVEMENT OR INSTRUMENTED FIRST INJECTOR— PCM INPUT......................................................................1413
FUEL INJECTOR SENSOR— GROUND...................................................................................................1414
ENGINE COOLANT TEMPERATURE SENSOR— PCM INPUT...................................................................................1414
ENGINE SPEED SENSOR— PCM INPUT.................................................................................................1414
AIR CONDITIONING (A/ C) CONTROLS— PCM INPUTS...................................................................................1415
BRAKE SWITCH— PCM INPUT........................................................................................................1415
DATA LINK CONNECTOR— PCM INPUT AND OUTPUT......................................................................................1415
VEHICLE SPEED SENSOR— PCM INPUT................................................................................................1415
SPEED CONTROL— PCM INPUTS......................................................................................................1416
DIESEL PCM RELAY— PCM INPUT....................................................................................................1416
FIVE VOLT POWER— PCM OUTPUT....................................................................................................1416
ENGINE COOLANT GAUGE— PCM OUTPUT...............................................................................................1416
ENGINE OIL PRESSURE GAUGE— PCM OUTPUT..........................................................................................1416
GLOW PLUG LAMP— PCM OUTPUT.....................................................................................................1416
SPEED CONTROL— PCM OUTPUTS.....................................................................................................1416
AIR CONDITIONING RELAY— PCM OUTPUT.............................................................................................1416
FUEL TIMING SOLENOID— PCM OUTPUT...............................................................................................1416
TACHOMETER— PCM OUTPUT.........................................................................................................1417
GLOW PLUG RELAY— PCM OUTPUT....................................................................................................1417
GLOW PLUGS.....................................................................................................................1417
GLOW PLUG CONTROL..........................................................................................................1417
EXHAUST GAS RECIRCULATION (EGR) SOLENOID— PCM OUTPUT...........................................................................1418
DIAGNOSIS AND TESTING..............................................................................................................1418
DIESEL DIAGONSTICS.............................................................................................................1418
DIESEL PCM RELAY TEST..........................................................................................................1418
ENGINE SPEED SENSOR TEST.......................................................................................................1418
ENGINE COOLANT TEMPERATURE SENSOR TEST.........................................................................................1418
SENSOR RESISTANCE (OHMS)...................................................................................................1418
GLOW PLUG TEST.................................................................................................................1419
GLOW PLUG RELAY TEST...........................................................................................................1419
RELAYS— OPERATION/ TESTING.....................................................................................................1420
OPERATION..................................................................................................................1420
GLOW PLUG CONTROL..........................................................................................................1420
TESTING....................................................................................................................1421
BOOST PRESSURE SENSOR..........................................................................................................1421
VEHICLE SPEED SENSOR TEST......................................................................................................1421
DIAGNOSTIC TROUBLE CODES.......................................................................................................1421
REMOVAL AND INSTALLATION...........................................................................................................1421
DIESEL PCM RELAY...............................................................................................................1421
A/ C CLUTCH RELAY..............................................................................................................1421
ENGINE SPEED SENSOR............................................................................................................1421
REMOVAL....................................................................................................................1421
INSTALLATION...............................................................................................................1422
ENGINE COOLANT TEMPERATURE SENSOR..............................................................................................1422
REMOVAL....................................................................................................................1422
INSTALLATION...............................................................................................................1422
GLOW PLUGS.....................................................................................................................1422
REMOVAL....................................................................................................................1422
INSTALLATION...............................................................................................................1423
GLOW PLUG RELAY................................................................................................................1423
REMOVAL....................................................................................................................1423
INSTALLATION...............................................................................................................1423
POWERTRAIN CONTROL MODULE (PCM)................................................................................................1423
REMOVAL....................................................................................................................1423
INSTALLATION...............................................................................................................1423
VEHICLE SPEED SENSOR...........................................................................................................1423
REMOVAL....................................................................................................................1424
INSTALLATION...............................................................................................................1424
SPECIFICATIONS.....................................................................................................................1424
GLOW PLUG CURRENT DRAW.........................................................................................................1424
TORQUE CHART— 2.5L DIESEL......................................................................................................1425
STEERING...................................................................................................................................1427
GENERAL INFORMATION....................................................................................................................1427
GENERAL INFORMATION................................................................................................................1427
STEERING SYSTEM AND COMPONENT DESCRIPTION......................................................................................1427
DIAGNOSIS AND TESTING..............................................................................................................1428
STEERING SYSTEM DIAGNOSIS CHARTS...............................................................................................1428
STEERING NOISE.............................................................................................................1428
BINDING STICKING SEIZED SHAKE SHUDDER VIBRATION............................................................................1430
LOW ASSIST, NO ASSIST, HARD STEERING POOR RETURN TO CENTER.................................................................1431
LOOSE STEERING.............................................................................................................1432
VEHICLE LEADS TO THE SIDE POWER STEERING FLUID LEAK........................................................................1433
FOAMY OR MILKY POWER STEERING FLUID........................................................................................1434
POWER STEERING PUMP....................................................................................................................1435
DESCRIPTION AND OPERATION..........................................................................................................1435
POWER STEERING PUMP OPERATION..................................................................................................1435
DIAGNOSIS AND TESTING..............................................................................................................1435
POWER STEERING PUMP FLOW RATE AND PRESSURE TEST................................................................................1435
POWER STEERING PUMP FLOW AND PRESSURE TEST PROCEDURE.......................................................................1436
SERVICE PROCEDURES.................................................................................................................1436
POWER STEERING SYSTEM FLUID LEVEL CHECK........................................................................................1436
POWER STEERING PUMP INITIAL OPERATION..........................................................................................1436
REMOVAL AND INSTALLATION...........................................................................................................1437
2.4 LITER POWER STEERING PUMP..................................................................................................1437
REMOVE.....................................................................................................................1437
INSTALL....................................................................................................................1439
3.0 LITER POWER STEERING PUMP..................................................................................................1439
REMOVE.....................................................................................................................1439
INSTALL....................................................................................................................1441
3.3/ 3.8 LITER POWER STEERING PUMP.............................................................................................1442
REMOVE.....................................................................................................................1442
INSTALL....................................................................................................................1443
POWER STEERING FLUID RESERVOIR TO PUMP SUPPLY HOSE.............................................................................1444
REMOVE.....................................................................................................................1444
INSTALL....................................................................................................................1445
POWER STEERING FLUID PRESSURE HOSE.............................................................................................1445
REMOVE.....................................................................................................................1445
INSTALL....................................................................................................................1446
POWER STEERING FLUID RETURN HOSE...............................................................................................1447
REMOVE.....................................................................................................................1447
INSTALL....................................................................................................................1447
REMOTE POWER STEERING FLUID RESERVOIR..........................................................................................1448
REMOVE.....................................................................................................................1448
INSTALL....................................................................................................................1448
DISASSEMBLY AND ASSEMBLY...........................................................................................................1449
POWER STEERING PUMP PULLEY.....................................................................................................1449
DISASSEMBLY................................................................................................................1449
ASSEMBLY...................................................................................................................1449
POWER STEERING PUMP FLOW CONTROL VALVE SEAL....................................................................................1449
DISASSEMBLE................................................................................................................1449
ASSEMBLE...................................................................................................................1450
SPECIFICATIONS.....................................................................................................................1450
POWER STEERING SYSTEM SPECIFICATIONS...........................................................................................1450
POWER STEERING PUMP FASTENER TORQUE SPECIFICATIONS.............................................................................1450
SPECIAL TOOLS......................................................................................................................1451
POWER STEERING PUMP............................................................................................................1451
POWER STEERING GEAR....................................................................................................................1452
DESCRIPTION AND OPERATION..........................................................................................................1452
STEERING GEAR OPERATION DESCRIPTION............................................................................................1452
DIAGNOSIS AND TESTING..............................................................................................................1453
POWER STEERING GEAR............................................................................................................1453
POWER STEERING PUMP FLOW AND PRESSURE TEST PROCEDURE.......................................................................1453
REMOVAL AND INSTALLATION...........................................................................................................1453
STEERING GEAR..................................................................................................................1453
REMOVE.....................................................................................................................1453
INSTALL....................................................................................................................1456
DISASSEMBLY AND ASSEMBLY...........................................................................................................1457
STEERING GEAR INNER TIE ROD BOOT...............................................................................................1457
DISASSEMBLE................................................................................................................1457
ASSEMBLE...................................................................................................................1458
OUTER TIE ROD END..............................................................................................................1459
DISASSEMBLE................................................................................................................1459
ASSEMBLE...................................................................................................................1460
SPECIFICATIONS.....................................................................................................................1460
STEERING GEAR FASTENER TORQUE SPECIFICATIONS...................................................................................1460
SPECIAL TOOLS......................................................................................................................1461
POWER STEERING GEAR............................................................................................................1461
STEERING COLUMN........................................................................................................................1462
DESCRIPTION AND OPERATION..........................................................................................................1462
STEERING COLUMN DESCRIPTION....................................................................................................1462
DIAGNOSIS AND TESTING..............................................................................................................1464
STEERING COLUMN................................................................................................................1464
SERVICE PROCEDURES.................................................................................................................1464
STEERING COLUMN SERVICE PROCEDURE WARNINGS.....................................................................................1464
REMOVAL AND INSTALLATION...........................................................................................................1464
STEERING COLUMN ASSEMBLY.......................................................................................................1464
REMOVE.....................................................................................................................1464
INSTALL....................................................................................................................1469
SPECIFICATIONS.....................................................................................................................1471
STEERING COLUMN FASTENER TORQUE SPECIFICATIONS.................................................................................1471
POWER STEERING - 2.5L VM DIESEL
...........................................................................................................1473
POWER STEERINGÐ 2.5L VM DIESEL.........................................................................................................1473
GENERAL INFORMATION................................................................................................................1473
POWER STEERING PUMP............................................................................................................1473
STEERING GEAR OPERATION— RHD & LHD VEHICLES....................................................................................1473
POWER STEERING GEAR............................................................................................................1473
SERVICE PROCEDURES.................................................................................................................1473
POWER STEERING PUMP – INITIAL OPERATION........................................................................................1473
REMOVAL AND INSTALLATION...........................................................................................................1474
POWER STEERING PUMP— 2.5L DIESEL...............................................................................................1474
REMOVAL....................................................................................................................1474
INSTALLATION...............................................................................................................1474
TRANSAXLE AND POWER TRANSFER UNIT..........................................................................................................1475
GENERAL INFORMATION....................................................................................................................1476
31TH TRANSAXLE.....................................................................................................................1476
FLUID LEVEL AND CONDITION..........................................................................................................1476
SELECTION OF LUBRICANT.............................................................................................................1477
SPECIAL ADDITIVES..................................................................................................................1477
DESCRIPTION AND OPERATION..............................................................................................................1477
TORQUE CONVERTER CLUTCH............................................................................................................1477
HYDRAULIC CONTROL SYSTEM...........................................................................................................1477
PRESSURE SUPPLY SYSTEM.............................................................................................................1477
PRESSURE REGULATING VALVES.........................................................................................................1477
FLOW CONTROL VALVES................................................................................................................1477
CLUTCHES, BAND SERVOS, AND ACCUMULATOR.............................................................................................1477
GEARSHIFT AND PARKING LOCK CONTROLS................................................................................................1478
TORQUE CONVERTER CLUTCH SOLENOID WIRING CONNECTOR..................................................................................1478
GOVERNOR...........................................................................................................................1478
DIAGNOSIS AND TESTING..................................................................................................................1478
THREE SPEED TRANSAXLE DIAGNOSIS AND TESTS..........................................................................................1478
31TH HYDRAULIC TROUBLE CODE CHARTS.............................................................................................1478
ROAD TEST..........................................................................................................................1478
HYDRAULIC PRESSURE TESTS...........................................................................................................1487
TEST ONE (SELECTOR IN 1).......................................................................................................1487
TEST TWO (SELECTOR IN 2).......................................................................................................1487
TEST THREE (SELECTOR IN D).....................................................................................................1487
TEST FOUR (SELECTOR IN REVERSE)................................................................................................1488
TEST RESULT INDICATIONS........................................................................................................1488
GOVERNOR PRESSURE..............................................................................................................1489
THROTTLE PRESSURE..............................................................................................................1489
CLUTCH AND SERVO AIR PRESSURE TESTS................................................................................................1489
FRONT CLUTCH...................................................................................................................1489
REAR CLUTCH....................................................................................................................1489
KICKDOWN SERVO (FRONT).........................................................................................................1489
LOW AND REVERSE SERVO (REAR)...................................................................................................1489
FLUID LEAKAGE- TRANSAXLE TORQUE CONVERTER HOUSING AREA.............................................................................1489
TORQUE CONVERTER LEAKAGE.......................................................................................................1489
SERVICE PROCEDURES.....................................................................................................................1490
FLUID AND FILTER CHANGE............................................................................................................1490
30,000 MILE TRANSAXLE OIL CHANGE...............................................................................................1490
SEVERE USAGE SERVICE...........................................................................................................1491
FLUID DRAIN AND REFILL.............................................................................................................1492
ALUMINUM THREAD REPAIR.............................................................................................................1492
FLUSHING COOLERS AND TUBES.........................................................................................................1492
COOLER FLUSH USING TOOL 6906A..................................................................................................1492
OIL PUMP VOLUME CHECK..............................................................................................................1493
REMOVAL AND INSTALLATION...............................................................................................................1493
VEHICLE SPEED SENSOR PINION GEAR...................................................................................................1493
REMOVAL........................................................................................................................1493
INSTALLATION...................................................................................................................1493
PARK/ NEUTRAL STARTING AND BACK- UP LAMP SWITCH....................................................................................1493
TEST...........................................................................................................................1493
REMOVAL........................................................................................................................1493
INSTALLATION...................................................................................................................1493
TRANSAXLE AND TORQUE CONVERTER REMOVAL.............................................................................................1494
REMOVAL........................................................................................................................1494
INSTALLATION...................................................................................................................1494
FRONT PUMP OIL SEAL................................................................................................................1495
REMOVAL........................................................................................................................1495
INSTALLATION...................................................................................................................1495
DISASSEMBLY AND ASSEMBLY...............................................................................................................1495
TRANSAXLE..........................................................................................................................1495
DISASSEMBLY....................................................................................................................1495
ASSEMBLY.......................................................................................................................1501
VALVE BODY RECONDITION.............................................................................................................1501
OIL PUMP- RECONDITION..............................................................................................................1505
FRONT CLUTCH- RECONDITION..........................................................................................................1506
INSPECTION.....................................................................................................................1506
DISASSEMBLY....................................................................................................................1506
ASSEMBLY.......................................................................................................................1507
REAR CLUTCH- RECONDITION...........................................................................................................1507
INSPECTION.....................................................................................................................1507
DISASSEMBLY....................................................................................................................1507
ASSEMBLY.......................................................................................................................1507
FRONT PLANETARY & ANNULUS GEAR-RECONDITION.........................................................................................1509
LOW/ REVERSE (REAR) SERVO- RECONDITION.............................................................................................1510
DISASSEMBLY ASSEMBLY...........................................................................................................1510
ACCUMULATOR- RECONDITION...........................................................................................................1510
DISASSEMBLY....................................................................................................................1510
ASSEMBLY.......................................................................................................................1511
KICKDOWN SERVO (CONTROLLED LOAD) -RECONDITION......................................................................................1511
DISASSEMBLY ASSEMBLY...........................................................................................................1511
TRANSFER SHAFT REPAIR..............................................................................................................1512
DISASSEMBLY....................................................................................................................1512
DETERMINING SHIM THICKNESS.....................................................................................................1516
ASSEMBLY.......................................................................................................................1516
PARKING PAWL.......................................................................................................................1516
DISASSEMBLY ASSEMBLY...........................................................................................................1516
OUTPUT SHAFT REPAIR................................................................................................................1517
DETERMINING SHIM THICKNESS.....................................................................................................1519
DIFFERENTIAL REPAIR................................................................................................................1520
DETERMINING SHIM THICKNESS.....................................................................................................1524
CLEANING AND INSPECTION................................................................................................................1524
VALVE BODY.........................................................................................................................1524
ADJUSTMENTS............................................................................................................................1525
GEARSHIFT CABLE ADJUSTMENT.........................................................................................................1525
THROTTLE PRESSURE LINKAGE ADJUSTMENT...............................................................................................1525
ROD ADJUSTMENT PROCEDURE.......................................................................................................1525
BAND ADJUSTMENT....................................................................................................................1525
KICKDOWN BAND (FRONT)..........................................................................................................1525
LOW/ REVERSE BAND (REAR).......................................................................................................1526
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS.............................................................................................1526
LINE PRESSURE..................................................................................................................1526
THROTTLE PRESSURE..............................................................................................................1526
BEARING ADJUSTMENT PROCEDURES......................................................................................................1526
OUTPUT SHAFT BEARING...............................................................................................................1526
DIFFERENTIAL BEARING...............................................................................................................1527
TRANSFER SHAFT BEARING.............................................................................................................1528
DIFFERENTIAL BEARING SHIM CHART................................................................................................1528
SCHEMATICS AND DIAGRAMS................................................................................................................1530
31TH TRANSAXLE HYDRAULIC SCHEMATIC.................................................................................................1530
SPECIFICATIONS.........................................................................................................................1538
31TH AUTOMATIC TRANSAXLE...........................................................................................................1538
31TH TORQUE SPECIFICATIONS.........................................................................................................1539
SPECIAL TOOLS..........................................................................................................................1540
31TH AUTOMATIC TRANSAXLE...........................................................................................................1540
GENERAL INFORMATION....................................................................................................................1545
41TE FOUR SPEED AUTOMATIC TRANSAXLE................................................................................................1545
TRANSAXLE IDENTIFICATION.......................................................................................................1545
OPERATION......................................................................................................................1546
FLUID LEVEL AND CONDITION..........................................................................................................1546
SELECTION OF LUBRICANT.............................................................................................................1546
SPECIAL ADDITIVES..................................................................................................................1546
DESCRIPTION AND OPERATION..............................................................................................................1546
CLUTCH AND GEAR....................................................................................................................1546
HYDRAULICS.........................................................................................................................1547
SOLENOIDS..........................................................................................................................1547
SENSORS............................................................................................................................1547
ELECTRONICS........................................................................................................................1547
ADAPTIVE CONTROLS..................................................................................................................1547
TORQUE MANAGEMENT..................................................................................................................1548
ON- BOARD DIAGNOSTICS..............................................................................................................1548
TRANSMISSION CONTROL MODULE........................................................................................................1548
GEARSHIFT AND PARKING LOCK CONTROLS................................................................................................1548
TRANSMISSION RANGE SENSOR..........................................................................................................1548
SHIFT POSITION INDICATOR...........................................................................................................1548
DIAGNOSIS AND TESTING..................................................................................................................1549
41TE TRANSAXLE GENERAL DIAGNOSIS...................................................................................................1549
ROAD TEST..........................................................................................................................1549
HYDRAULIC PRESSURE TESTS...........................................................................................................1549
TEST ONE- SELECTOR IN LOW......................................................................................................1550
TEST TWO- SELECTOR IN DRIVE....................................................................................................1550
TEST THREE- OVERDRIVE CLUTCH CHECK.............................................................................................1550
TEST FOUR- SELECTOR IN CIRCLE DRIVE, OVERDRIVE GEAR............................................................................1550
TEST FIVE- SELECTOR IN CIRCLE DRIVE, OVERDRIVE.................................................................................1550
TEST SIX- SELECTOR IN REVERSE..................................................................................................1550
TEST RESULT INDICATIONS........................................................................................................1551
CLUTCH AIR PRESSURE TESTS..........................................................................................................1551
OVERDRIVE CLUTCH...............................................................................................................1551
REVERSE CLUTCH.................................................................................................................1552
2/ 4 CLUTCH....................................................................................................................1552
LOW/ REVERSE CLUTCH............................................................................................................1552
UNDERDRIVE CLUTCH..............................................................................................................1552
FLUID LEAKAGE- TORQUE CONVERTER HOUSING AREA.......................................................................................1552
TORQUE CONVERTER LEAKAGE.......................................................................................................1552
SHIFT POSITION INDICATOR...........................................................................................................1552
SERVICE PROCEDURES.....................................................................................................................1553
FLUID AND FILTER CHANGE............................................................................................................1553
30,000 MILE TRANSAXLE OIL CHANGE...............................................................................................1553
SEVERE USAGE SERVICE...........................................................................................................1554
FLUID DRAIN AND REFILL.............................................................................................................1555
ALUMINUM THREAD REPAIR.............................................................................................................1555
FLUSHING COOLERS AND TUBES.........................................................................................................1555
COOLER FLUSH USING TOOL 6906A..................................................................................................1556
OIL PUMP VOLUME CHECK..............................................................................................................1556
TRANSAXLE QUICK LEARN PROCEDURE....................................................................................................1556
PINION FACTOR PROCEDURE............................................................................................................1557
REMOVAL AND INSTALLATION...............................................................................................................1557
GEARSHIFT CABLE....................................................................................................................1557
REMOVAL........................................................................................................................1557
INSTALLATION...................................................................................................................1557
ADJUSTMENT.....................................................................................................................1558
MANUAL VALVE LEVER (SHIFT LEVER)...................................................................................................1558
REMOVAL........................................................................................................................1558
INSTALLATION...................................................................................................................1558
SOLENOID ASSEMBLY- REPLACE.........................................................................................................1559
TRANSMISSION RANGE SENSOR..........................................................................................................1559
REMOVAL........................................................................................................................1559
INSTALLATION...................................................................................................................1560
SPEED SENSOR- INPUT................................................................................................................1560
SPEED SENSOR- OUTPUT...............................................................................................................1560
TRANSMISSION CONTROL MODULE........................................................................................................1561
REMOVAL........................................................................................................................1561
INSTALLATION...................................................................................................................1561
VALVE BODY.........................................................................................................................1562
REMOVAL........................................................................................................................1562
INSTALLATION...................................................................................................................1563
TRANSAXLE..........................................................................................................................1563
REMOVAL........................................................................................................................1563
INSTALLATION...................................................................................................................1565
OIL PUMP SEAL......................................................................................................................1566
REMOVAL .......................................................................................................................1566
INSTALLATION...................................................................................................................1566
DISASSEMBLY AND ASSEMBLY...............................................................................................................1566
VALVE BODY RECONDITION.............................................................................................................1566
TRANSAXLE DISASSEMBLE..............................................................................................................1569
OIL PUMP INSPECTION............................................................................................................1572
INPUT CLUTCHES- RECONDITION........................................................................................................1584
DISASSEMBLY....................................................................................................................1584
ASSEMBLY.......................................................................................................................1589
TRANSAXLE ASSEMBLE.................................................................................................................1596
OUTPUT GEAR BEARING ADJUSTMENT.................................................................................................1599
OUTPUT GEAR BEARING SHIM CHART.................................................................................................1600
TRANSFER SHAFT BEARING.........................................................................................................1603
TRANSFER SHAFT BEARING SHIM CHART..............................................................................................1604
LOW/ REVERSE REACTION PLATE CHART..............................................................................................1607
DETERMINING No. 4 THRUST PLATE THICKNESS INPUT SHAFT END PLAY.................................................................1608
NO. 4 THRUST PLATE CHART.......................................................................................................1610
DIFFERENTIAL REPAIR................................................................................................................1613
DISASSEMBLE....................................................................................................................1613
CHECKING SIDE GEAR END PLAY....................................................................................................1615
ASSEMBLE.......................................................................................................................1615
DIFFERENTIAL SERVICE TOOLS.....................................................................................................1615
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT........................................................................................1616
DIFFERENTIAL BEARING SHIM CHART................................................................................................1617
CLEANING AND INSPECTION................................................................................................................1618
CLEANING VALVE BODY................................................................................................................1618
ADJUSTMENTS............................................................................................................................1618
GEARSHIFT CABLE ADJUSTMENT.........................................................................................................1618
SCHEMATICS AND DIAGRAMS................................................................................................................1619
41TE TRANSAXLE HYDRAULIC SCHEMATICS................................................................................................1619
SPECIFICATIONS.........................................................................................................................1632
41TE AUTOMATIC TRANSAXLE...........................................................................................................1632
41TE TORQUE SPECIFICATIONS.........................................................................................................1632
SPECIAL TOOLS..........................................................................................................................1633
41TE AUTOMATIC TRANSAXLE...........................................................................................................1633
GENERAL INFORMATION....................................................................................................................1639
POWER TRANSFER UNIT................................................................................................................1639
DIAGNOSIS AND TESTING..................................................................................................................1639
SEAL IDENTIFICATION................................................................................................................1639
FLUID LEAK DIAGNOSIS...............................................................................................................1641
REMOVAL AND INSTALLATION...............................................................................................................1641
POWER TRANSFER UNIT (P. T. U.).....................................................................................................1641
REMOVAL........................................................................................................................1641
INSTALLATION...................................................................................................................1643
END COVER SEAL.....................................................................................................................1643
INPUT SHAFT SEAL...................................................................................................................1643
REMOVAL........................................................................................................................1643
INSTALLATION...................................................................................................................1644
DIFFERENTIAL CARRIER SEAL..........................................................................................................1644
REMOVAL........................................................................................................................1644
INSTALLATION...................................................................................................................1645
REAR COVER O- RING.................................................................................................................1645
REMOVAL........................................................................................................................1645
INSTALLATION...................................................................................................................1645
POWER TRANSFER UNIT OUTPUT SEAL....................................................................................................1645
REMOVAL........................................................................................................................1646
INSTALLATION...................................................................................................................1647
INPUT SHAFT COVER SEAL.............................................................................................................1648
REMOVAL........................................................................................................................1648
INSTALLATION...................................................................................................................1648
HALF SHAFT INNER SEAL..............................................................................................................1649
REMOVAL........................................................................................................................1649
INSTALLATION...................................................................................................................1650
INPUT SHAFT END SEAL...............................................................................................................1651
REMOVAL........................................................................................................................1651
INSTALLATION...................................................................................................................1651
OUTER HALF SHAFT SEAL..............................................................................................................1651
REMOVAL........................................................................................................................1652
INSTALLATION...................................................................................................................1652
END COVER BALL BEARING.............................................................................................................1652
REMOVAL........................................................................................................................1652
INSTALLATION...................................................................................................................1653
ADJUSTMENTS............................................................................................................................1654
OUTPUT FLANGE SHIM SELECTION.......................................................................................................1654
SPECIFICATIONS.........................................................................................................................1654
TORQUE.............................................................................................................................1654
SPECIAL TOOLS..........................................................................................................................1655
SDP POWER TRANSFER UNIT............................................................................................................1655
A– 598 MANUAL TRANSAXLE....................................................................................................................1657
GENERAL INFORMATION....................................................................................................................1658
A- 598 MANUAL TRANSAXLE............................................................................................................1658
A- 558 MANUAL TRANSAXLE— RHD VEHICLES..............................................................................................1658
TRANSAXLE IDENTIFICATION INFORMATION...............................................................................................1658
TRANSAXLE IDENTIFICATION INFORMATION— RHD VEHICLES.................................................................................1658
SELECTION OF LUBRICANT.............................................................................................................1658
SELECTION OF LUBRICANT— RHD VEHICLES...............................................................................................1658
SPECIAL ADDITIVES..................................................................................................................1658
SPECIAL ADDITIVES— RHD VEHICLES....................................................................................................1659
GEAR RATIOS........................................................................................................................1659
GEAR RATIOS— RHD VEHICLES..........................................................................................................1659
GEARSHIFT PATTERN..................................................................................................................1659
GEARSHIFT PATTERN— RHD VEHICLES....................................................................................................1659
DESCRIPTION AND OPERATION..............................................................................................................1659
GEARSHIFT LEVERS...................................................................................................................1659
AXLE SEALS.........................................................................................................................1659
DIAGNOSIS AND TESTING..................................................................................................................1659
COMMON PROBLEM CAUSES..............................................................................................................1659
HARD SHIFTING......................................................................................................................1660
NOISY OPERATION....................................................................................................................1660
SLIPS OUT OF GEAR..................................................................................................................1660
LOW LUBRICANT LEVEL................................................................................................................1660
CLUTCH PROBLEMS....................................................................................................................1660
SERVICE PROCEDURES.....................................................................................................................1660
FLUID DRAIN AND FILL...............................................................................................................1660
TRANSAXLE FLUID DRAIN..........................................................................................................1660
TRANSAXLE FLUID FILL...........................................................................................................1660
FLUID DRAIN AND FILL— RHD VEHICLES.................................................................................................1660
TRANSAXLE FLUID DRAIN..........................................................................................................1660
TRANSAXLE FLUID FILL...........................................................................................................1660
REMOVAL AND INSTALLATION...............................................................................................................1661
GEARSHIFT KNOB.....................................................................................................................1661
REMOVAL........................................................................................................................1661
INSTALLATION...................................................................................................................1661
GEARSHIFT BOOT.....................................................................................................................1661
REMOVAL........................................................................................................................1661
INSTALLATION...................................................................................................................1661
GEARSHIFT BOOT.....................................................................................................................1661
REMOVAL........................................................................................................................1661
INSTALLATION...................................................................................................................1661
GEARSHIFT CABLES...................................................................................................................1661
REMOVAL........................................................................................................................1661
INSTALLATION...................................................................................................................1663
GEARSHIFT CABLES— RHD VEHICLES.....................................................................................................1663
REMOVAL........................................................................................................................1663
INSTALLATION...................................................................................................................1663
GEARSHIFT MECHANISM REPLACEMENT....................................................................................................1663
REMOVAL........................................................................................................................1663
INSTALLATION...................................................................................................................1664
GEARSHIFT MECHANISM REPLACEMENT— RHD VEHICLES......................................................................................1664
REMOVAL........................................................................................................................1664
INSTALLATION...................................................................................................................1665
VEHICLE SPEED SENSOR DRIVE GEAR....................................................................................................1665
REMOVAL........................................................................................................................1665
INSTALLATION...................................................................................................................1665
BACK- UP LAMP SWITCH...............................................................................................................1665
REMOVAL........................................................................................................................1665
INSTALLATION...................................................................................................................1666
CRANKSHAFT POSITION SENSOR — 2.5L VM DIESEL........................................................................................1666
REMOVAL........................................................................................................................1667
INSTALLATION...................................................................................................................1667
CROSSOVER LEVER....................................................................................................................1667
REMOVAL........................................................................................................................1667
INSTALLATION...................................................................................................................1667
SELECTOR LEVER.....................................................................................................................1667
REMOVAL........................................................................................................................1667
INSTALLATION...................................................................................................................1667
AXLE SEALS.........................................................................................................................1667
EXTENSION HOUSING AXLE SEAL....................................................................................................1667
DIFFERENTIAL BEARING RETAINER AXLE SEAL........................................................................................1668
SHIFT SHAFT SEALS..................................................................................................................1668
REMOVAL........................................................................................................................1668
INSTALLATION...................................................................................................................1668
TRANSAXLE..........................................................................................................................1668
REMOVAL........................................................................................................................1668
INSTALLATION...................................................................................................................1670
INPUT SHAFT FRONT BEARING RETAINER.................................................................................................1671
REMOVAL........................................................................................................................1671
INSTALLATION...................................................................................................................1671
INPUT SHAFT SEAL...................................................................................................................1672
REMOVAL........................................................................................................................1672
INSTALLATION...................................................................................................................1672
A- 558 TRANSAXLE ASSEMBLY— RHD VEHICLES............................................................................................1672
REMOVAL........................................................................................................................1672
INSTALLATION...................................................................................................................1675
DISASSEMBLY AND ASSEMBLY...............................................................................................................1676
TRANSAXLE..........................................................................................................................1676
DISASSEMBLY....................................................................................................................1676
ASSEMBLY.......................................................................................................................1684
INPUT SHAFT........................................................................................................................1688
DISASSEMBLY....................................................................................................................1688
ASSEMBLY.......................................................................................................................1688
INTERMEDIATE SHAFT.................................................................................................................1689
DISASSEMBLY....................................................................................................................1689
ASSEMBLY.......................................................................................................................1693
DIFFERENTIAL.......................................................................................................................1695
DIFFERENTIAL BEARINGS..........................................................................................................1695
RING GEAR......................................................................................................................1698
DIFFERENTIAL GEARS.............................................................................................................1698
SYNCHRONIZER.......................................................................................................................1699
DISASSEMBLY....................................................................................................................1700
ASSEMBLY.......................................................................................................................1700
SHIFT COVER........................................................................................................................1701
DISASSEMBLY....................................................................................................................1701
ASSEMBLY.......................................................................................................................1703
TRANSAXLE CASE.....................................................................................................................1704
INTERMEDIATE SHAFT FRONT BEARING CUP...........................................................................................1704
INPUT SHAFT FRONT BEARING......................................................................................................1705
SHIFT RAIL BUSHINGS............................................................................................................1707
REVERSE SHIFT LEVER............................................................................................................1708
CLEANING AND INSPECTION................................................................................................................1708
TRANSAXLE..........................................................................................................................1708
SYNCHRONIZER.......................................................................................................................1708
CLEAN..........................................................................................................................1708
INSPECT........................................................................................................................1708
ADJUSTMENTS............................................................................................................................1708
GEARSHIFT CROSSOVER CABLE..........................................................................................................1708
GEARSHIFT CROSSOVER CABLE..........................................................................................................1711
BEARING ADJUSTMENT PROCEDURE.......................................................................................................1712
GENERAL RULES ON SERVICING BEARINGS............................................................................................1713
INTERMEDIATE SHAFT BEARING PRELOAD.................................................................................................1713
SPECIFICATIONS.........................................................................................................................1715
A- 598 (T- 750) MANUAL TRANSAXLE...................................................................................................1715
NV T750 (A- 598) MANUAL TRANSAXLE FLUID FILL...................................................................................1715
A- 558 MANUAL TRANSAXLE— RHD VEHICLES..............................................................................................1715
SPECIAL TOOLS..........................................................................................................................1716
A- 558 MANUAL TRANSAXLE FLUID FILL.................................................................................................1716
A- 598 (T- 750) MANUAL TRANSAXLE ..................................................................................................1716
A- 558 MANUAL TRANSAXLE RHD VEHICLES..............................................................................................1716
TIRES AND WHEELS...........................................................................................................................1719
DESCRIPTION AND OPERATION..............................................................................................................1719
TIRE INFORMATION...................................................................................................................1719
TIRE IDENTIFICATION............................................................................................................1719
TIRE CHAINS....................................................................................................................1719
RADIAL-PLY TIRES...................................................................................................................1720
SPARE TIRE (TEMPORARY).............................................................................................................1720
TIRE INFLATION PRESSURES...........................................................................................................1720
TIRE PRESSURE FOR HIGH-SPEED DRIVING...............................................................................................1721
REPLACEMENT TIRES..................................................................................................................1721
DIAGNOSIS AND TESTING..................................................................................................................1721
PRESSURE GAUGES....................................................................................................................1721
TREAD WEAR INDICATORS..............................................................................................................1721
TIRE WEAR PATTERNS.................................................................................................................1722
TIRE NOISE OR VIBRATION............................................................................................................1722
LEAD CORRECTION CHART..............................................................................................................1722
LEAD CORRECTION CHART..........................................................................................................1723
SERVICE PROCEDURES.....................................................................................................................1724
TIRE AND WHEEL ROTATION (NON-DIRECTIONAL THREAD PATTERN)...........................................................................1724
REPAIRING TIRE LEAKS...............................................................................................................1724
TIRE AND WHEEL MATCH MOUNTING......................................................................................................1724
CLEANING AND INSPECTION................................................................................................................1725
CLEANING TIRES.....................................................................................................................1725
SPECIFICATIONS.........................................................................................................................1726
TIRE SPECIFICATIONS................................................................................................................1726
DESCRIPTION AND OPERATION..............................................................................................................1727
WHEEL INFORMATION..................................................................................................................1727
DIAGNOSIS AND TESTING..................................................................................................................1727
WHEEL INSPECTION...................................................................................................................1727
TIRE AND WHEEL RUNOUT..............................................................................................................1728
METHOD 1 (RELOCATE WHEEL ON HUB)...............................................................................................1728
METHOD 2 (RELOCATE TIRE ON WHEEL)..............................................................................................1728
SERVICE PROCEDURES.....................................................................................................................1729
WHEEL INSTALLATION.................................................................................................................1729
TIRE AND WHEEL BALANCE.............................................................................................................1729
SPECIFICATIONS.........................................................................................................................1730
WHEEL SPECIFICATIONS...............................................................................................................1730
BODY.......................................................................................................................................1731
GENERAL INFORMATION....................................................................................................................1731
SAFETY PRECAUTIONS AND WARNINGS....................................................................................................1731
GENERAL INFORMATION....................................................................................................................1732
PAINT CODE.........................................................................................................................1732
BASE COAT/ CLEAR COAT FINISH.......................................................................................................1732
WET SANDING, BUFFING, AND POLISHING................................................................................................1732
PAINTED SURFACE TOUCH- UP..........................................................................................................1732
TOUCH- UP PROCEDURE............................................................................................................1732
AFTERMARKET PAINT REPAIR PRODUCTS..................................................................................................1733
EXTERIOR COLORS................................................................................................................1733
INTERIOR COLORS................................................................................................................1733
DESCRIPTION AND OPERATION..............................................................................................................1734
SAFETY PRECAUTIONS.................................................................................................................1734
REMOVAL AND INSTALLATION...............................................................................................................1734
WINDSHIELD.........................................................................................................................1734
WINDSHIELD REMOVAL – EXTERIOR METHOD...........................................................................................1734
WINDSHIELD REMOVAL – INTERIOR METHOD...........................................................................................1735
WINDSHIELD INSTALLATION........................................................................................................1735
BODY SIDE/ SLIDING DOOR STATIONARY GLASS...........................................................................................1736
REMOVAL........................................................................................................................1736
INSTALLATION...................................................................................................................1736
REAR WINDOW........................................................................................................................1737
REAR WINDOW REMOVAL – EXTERIOR METHOD..........................................................................................1737
REAR WINDOW REMOVAL – INTERIOR METHOD..........................................................................................1737
REAR WINDOW INSTALLATION.......................................................................................................1737
REMOVAL AND INSTALLATION...............................................................................................................1739
ARM REST...........................................................................................................................1739
REMOVAL........................................................................................................................1739
INSTALLATION...................................................................................................................1739
BENCH SEAT BACK COVER..............................................................................................................1739
REMOVAL........................................................................................................................1739
INSTALLATION...................................................................................................................1739
BENCH SEAT BACK HINGE..............................................................................................................1739
REMOVAL........................................................................................................................1739
INSTALLATION...................................................................................................................1740
SYNCHRONIZING CABLE ADJUSTMENT.................................................................................................1740
BENCH SEAT BACK HINGE COVERS.......................................................................................................1740
REMOVAL........................................................................................................................1740
INSTALLATION...................................................................................................................1740
BENCH SEAT RISER – FIRST REAR......................................................................................................1741
REMOVAL........................................................................................................................1741
INSTALLATION...................................................................................................................1741
BENCH SEAT RISER – SECOND REAR.....................................................................................................1741
REMOVAL........................................................................................................................1741
INSTALLATION...................................................................................................................1741
BENCH SEAT TRACK – SECOND REAR.....................................................................................................1741
REMOVAL........................................................................................................................1741
INSTALLATION...................................................................................................................1741
BUCKET SEAT BACK...................................................................................................................1742
REMOVAL........................................................................................................................1742
INSTALLATION...................................................................................................................1742
BUCKET SEAT BACK ASSIST STRAP......................................................................................................1742
REMOVAL........................................................................................................................1742
INSTALLATION...................................................................................................................1742
BUCKET SEAT CUSHION PAN............................................................................................................1742
REMOVAL........................................................................................................................1742
INSTALLATION...................................................................................................................1743
BUCKET SEAT CUSHION SIDE COVER.....................................................................................................1743
REMOVAL........................................................................................................................1743
INSTALLATION...................................................................................................................1743
BUCKET SEAT RECLINER – MANUAL......................................................................................................1743
REMOVAL........................................................................................................................1743
INSTALLATION...................................................................................................................1743
BUCKET SEAT RECLINER – POWER.......................................................................................................1744
REMOVAL........................................................................................................................1744
INSTALLATION...................................................................................................................1744
BUCKET SEAT RISER – MANUAL TRACK...................................................................................................1744
REMOVAL........................................................................................................................1744
INSTALLATION...................................................................................................................1744
BUCKET SEAT TRACK – MANUAL.........................................................................................................1744
REMOVAL........................................................................................................................1744
INSTALLATION...................................................................................................................1744
BUCKET SEAT TRACK – POWER..........................................................................................................1744
REMOVAL........................................................................................................................1744
INSTALLATION...................................................................................................................1745
BUCKET SEAT TRACK FRONT COVER – POWER..............................................................................................1745
REMOVAL........................................................................................................................1745
INSTALLATION...................................................................................................................1745
BUCKET SEAT TRACK REAR COVER – POWER...............................................................................................1745
REMOVAL........................................................................................................................1745
INSTALLATION...................................................................................................................1745
CHILD RESTRAINT SEAT MODULE........................................................................................................1746
REMOVAL........................................................................................................................1746
INSTALLATION...................................................................................................................1746
HEAD RESTRAINT – BENCH SEAT........................................................................................................1746
REMOVAL........................................................................................................................1746
INSTALLATION...................................................................................................................1747
HEAD RESTRAINT – BUCKET SEAT.......................................................................................................1747
REMOVAL........................................................................................................................1747
INSTALLATION...................................................................................................................1748
HEAD RESTRAINT SLEEVE..............................................................................................................1748
REMOVAL........................................................................................................................1748
INSTALLATION...................................................................................................................1748
HEATED SEAT HEATING ELEMENT........................................................................................................1748
HEATED SEAT MODULE.................................................................................................................1748
REMOVAL........................................................................................................................1748
INSTALLATION...................................................................................................................1749
HEATED SEAT SWITCH.................................................................................................................1749
REMOVAL........................................................................................................................1749
INSTALLATION...................................................................................................................1749
MECHANICAL LUMBAR HANDLE ASSEMBLY..................................................................................................1749
REMOVAL........................................................................................................................1749
INSTALLATION...................................................................................................................1749
PLASTIC GROCERY BAG RETAINER.......................................................................................................1749
REMOVAL........................................................................................................................1749
INSTALLATION...................................................................................................................1749
POWER SEAT SWITCH..................................................................................................................1750
REMOVAL........................................................................................................................1750
INSTALLATION...................................................................................................................1750
RECLINER HANDLE – MANUAL...........................................................................................................1750
REMOVAL........................................................................................................................1750
INSTALLATION...................................................................................................................1750
UNDER SEAT STORAGE BIN.............................................................................................................1750
REMOVAL........................................................................................................................1750
INSTALLATION...................................................................................................................1750
UNDER SEAT STORAGE BIN GUIDE.......................................................................................................1751
REMOVAL........................................................................................................................1751
INSTALLATION...................................................................................................................1751
UNDER SEAT STORAGE BIN LOCK/ LATCH.................................................................................................1751
REMOVAL........................................................................................................................1751
INSTALLATION...................................................................................................................1751
DIAGNOSIS AND TESTING..................................................................................................................1753
WATER LEAKS........................................................................................................................1753
VISUAL INSPECTION BEFORE WATER LEAK TESTS......................................................................................1753
WATER LEAK TESTS...............................................................................................................1753
WATER LEAK DETECTION...........................................................................................................1753
WIND NOISE.........................................................................................................................1754
VISUAL INSPECTION BEFORE TESTS.................................................................................................1754
SERVICE PROCEDURES.....................................................................................................................1754
HEAT STAKING.......................................................................................................................1754
REMOVAL AND INSTALLATION...............................................................................................................1755
A- PILLAR LOWER EXTENSION TRIM.....................................................................................................1755
REMOVAL........................................................................................................................1755
INSTALLATION...................................................................................................................1755
A- PILLAR TRIM PANEL...............................................................................................................1755
REMOVAL........................................................................................................................1755
INSTALLATION...................................................................................................................1755
COWL COVER.........................................................................................................................1755
REMOVAL........................................................................................................................1755
INSTALLATION...................................................................................................................1755
COWL TRIM..........................................................................................................................1755
REMOVAL........................................................................................................................1755
INSTALLATION...................................................................................................................1756
FLOOR CARPET.......................................................................................................................1756
REMOVAL........................................................................................................................1756
INSTALLATION...................................................................................................................1756
FRONT DOOR.........................................................................................................................1757
REMOVAL........................................................................................................................1757
INSTALLATION...................................................................................................................1757
FRONT DOOR APPLIQUE................................................................................................................1758
REMOVAL........................................................................................................................1758
INSTALLATION...................................................................................................................1758
FRONT DOOR CHECK STRAP.............................................................................................................1758
REMOVAL........................................................................................................................1758
INSTALLATION...................................................................................................................1759
FRONT DOOR FRAME CLOSEOUT MOLDINGS.................................................................................................1759
REMOVAL – A- PILLAR, HEADER, OR B- PILLAR......................................................................................1759
INSTALLATION – A- PILLAR, HEADER, OR B- PILLAR.................................................................................1759
FRONT DOOR GLASS...................................................................................................................1759
REMOVAL........................................................................................................................1759
INSTALLATION...................................................................................................................1759
FRONT DOOR GLASS RUN WEATHER- STRIP................................................................................................1760
REMOVAL........................................................................................................................1760
INSTALLATION...................................................................................................................1760
FRONT DOOR HINGE...................................................................................................................1760
REMOVAL........................................................................................................................1761
INSTALLATION...................................................................................................................1761
FRONT DOOR INNER BELT MOLDING......................................................................................................1761
REMOVAL........................................................................................................................1761
INSTALLATION...................................................................................................................1761
FRONT DOOR LATCH...................................................................................................................1761
REMOVAL........................................................................................................................1761
INSTALLATION...................................................................................................................1762
FRONT DOOR LATCH STRIKER...........................................................................................................1762
REMOVAL........................................................................................................................1762
INSTALLATION...................................................................................................................1762
FRONT DOOR LOCK CYLINDER...........................................................................................................1762
REMOVAL........................................................................................................................1762
INSTALLATION...................................................................................................................1763
FRONT DOOR OUTER BELT MOLDING......................................................................................................1763
REMOVAL........................................................................................................................1763
INSTALLATION...................................................................................................................1763
FRONT DOOR OUTSIDE HANDLE..........................................................................................................1763
REMOVAL........................................................................................................................1763
INSTALLATION...................................................................................................................1764
FRONT DOOR REFLECTOR...............................................................................................................1764
REMOVAL........................................................................................................................1764
INSTALLATION...................................................................................................................1764
FRONT DOOR SILL PLATE..............................................................................................................1764
REMOVAL........................................................................................................................1764
INSTALLATION...................................................................................................................1764
FRONT DOOR TRIM PANEL..............................................................................................................1764
REMOVAL........................................................................................................................1764
INSTALLATION...................................................................................................................1765
FRONT DOOR WEATHER- STRIP..........................................................................................................1766
REMOVAL........................................................................................................................1766
INSTALLATION...................................................................................................................1766
FRONT DOOR WINDOW CRANK............................................................................................................1766
REMOVAL........................................................................................................................1766
INSTALLATION...................................................................................................................1766
FRONT DOOR WINDOW REGULATOR........................................................................................................1766
REMOVAL........................................................................................................................1766
INSTALLATION...................................................................................................................1767
FRONT SEAT.........................................................................................................................1767
REMOVAL........................................................................................................................1767
INSTALLATION...................................................................................................................1767
FRONT WHEELHOUSE SPLASH SHIELD.....................................................................................................1767
REMOVAL........................................................................................................................1767
INSTALLATION...................................................................................................................1767
FUEL FILL DOOR BLOCKER LATCH.......................................................................................................1768
REMOVAL........................................................................................................................1768
INSTALLATION...................................................................................................................1768
FUEL FILL DOOR BLOCKER LATCH STRIKER...............................................................................................1768
REMOVAL........................................................................................................................1768
INSTALLATION...................................................................................................................1768
FUEL FILL DOOR BLOCKER LOCKOUT LINK................................................................................................1768
REMOVAL........................................................................................................................1768
INSTALLATION...................................................................................................................1769
FUEL FILLER HOUSING – WITH BLOCKER LATCH...........................................................................................1769
REMOVAL........................................................................................................................1769
INSTALLATION...................................................................................................................1769
GRILLE.............................................................................................................................1769
REMOVAL........................................................................................................................1769
INSTALLATION...................................................................................................................1769
HEADLINING......................................................................................................................... 0
REMOVAL........................................................................................................................1769
INSTALLATION...................................................................................................................1770
HOOD...............................................................................................................................1770
REMOVAL........................................................................................................................1770
INSTALLATION...................................................................................................................1770
HOOD HINGE.........................................................................................................................1771
REMOVAL........................................................................................................................1771
INSTALLATION................................................................................................................... 0
ADJUSTMENTS............................................................................................................................1810
SLIDING DOOR ADJUSTMENTS...........................................................................................................1810
PRELIMINARY CHECKS.............................................................................................................1810
UP/ DOWN ADJUSTMENT............................................................................................................1810
FORE/ AFT ADJUSTMENT...........................................................................................................1810
SEAL COMPRESSION...............................................................................................................1811
STABILIZER ADJUSTMENT..........................................................................................................1812
BODY 1
....................................................................................................................................1813
REMOVAL AND INSTALLATION...............................................................................................................1813
HEAD RESTRAINT.....................................................................................................................1813
REMOVAL........................................................................................................................1813
INSTALLATION...................................................................................................................1813
HEAD RESTRAINT ESCUTCHEON..........................................................................................................1813
REMOVAL........................................................................................................................1813
INSTALLATION...................................................................................................................1813
HEAD RESTRAINT SLEEVE..............................................................................................................1814
REMOVAL........................................................................................................................1814
INSTALLATION...................................................................................................................1814
BENCH SEAT BACK COVER..............................................................................................................1814
REMOVAL........................................................................................................................1814
INSTALLATION...................................................................................................................1814
REMOVAL AND INSTALLATION...............................................................................................................1815
GEARSHIFT CONSOLE..................................................................................................................1815
REMOVAL........................................................................................................................1815
INSTALLATION...................................................................................................................1815
LIFTGATE CHMSL ACCESS PANEL........................................................................................................1815
REMOVAL........................................................................................................................1815
INSTALLATION...................................................................................................................1816
HEATING AND AIR CONDITIONING...............................................................................................................1817
GENERAL INFORMATION....................................................................................................................1818
INTRODUCTION.......................................................................................................................1818
SAFETY PRECAUTIONS AND WARNINGS....................................................................................................1818
DESCRIPTION AND OPERATION..............................................................................................................1818
AIR DISTRIBUTION DUCTS.............................................................................................................1818
A/ C PRESSURE TRANSDUCER...........................................................................................................1818
A/ C SERVICE PORTS.................................................................................................................1818
REAR BLOWER SPEED SWITCH...........................................................................................................1819
COMPRESSOR HIGH-PRESSURE RELIEF VALVE..............................................................................................1819
CONDENSATE DRAIN...................................................................................................................1819
ENGINE COOLING SYSTEM REQUIREMENTS.................................................................................................1819
EVAPORATOR PROBE...................................................................................................................1819
HANDLING TUBING AND FITTINGS.......................................................................................................1819
HVAC CONTROL MODULE................................................................................................................1820
SIDE DOOR HEATER A/ C OUTLETS......................................................................................................1820
SIDE WINDOW DEMISTER...............................................................................................................1820
SYSTEM AIRFLOW.....................................................................................................................1820
SYSTEM OIL LEVEL...................................................................................................................1821
REFRIGERANT OIL LEVEL CHECK....................................................................................................1821
SERVICING REFRIGERANT OIL LEVEL................................................................................................1822
DIAGNOSIS AND TESTING..................................................................................................................1822
ACTUATOR CALIBRATION/ DIAGNOSTICS AND COOLDOWN TEST................................................................................1822
GENERAL INFORMATION............................................................................................................1822
ACTUATOR CALIBRATION...........................................................................................................1822
REFRIGERANT OIL CAPACITIES.....................................................................................................1822
DIAGNOSTICS....................................................................................................................1823
COOLDOWN TEST..................................................................................................................1823
CALIBRATION/ COOLDOWN LED DISPLAY CODES........................................................................................1823
CALIBRATION/ DIAGNOSTICS TEST ENTRY............................................................................................1823
CALIBRATION/ COOLDOWN LED DISPLAY CODES........................................................................................1823
COOLDOWN TEST ENTRY............................................................................................................1824
CALIBRATION DIAGNOSTICS AND COOLDOWN ABORT.....................................................................................1824
EEPROM DATA....................................................................................................................1824
ACTUATOR CALIBRATION AND DIAGNOSTICS...........................................................................................1824
FAIL CODES/ LEVEL DISPLAY......................................................................................................1825
WIPE BUTTON LED................................................................................................................1825
LEVEL 1– FAILURE CODE VALUES (INTERMITTENT WIPE BUTTON LED)....................................................................1825
TEMPERATURE AND MODE POTENTIOMETER DIAGNOSTICS.................................................................................1825
POTENTIOMETER VS. POSITION AND FLASH RATE......................................................................................1825
EVAPORATOR PROBE TEMPERATURE DIAGNOSTICS.......................................................................................1825
HVAC CONTROL DIAGNOSTIC CONDITIONS.................................................................................................1825
A/ C PERFORMANCE TEST..............................................................................................................1828
PERFORMANCE TEST PROCEDURE.....................................................................................................1828
A/ C PRESSURE TRANSDUCER...........................................................................................................1828
A/ C PERFORMANCE TEMPERATURES..................................................................................................1828
A/ C PRESSURE TRANSDUCER VOLTAGE...............................................................................................1829
BLOWER MOTOR AND WHEEL ASSEMBLY....................................................................................................1829
VIBRATION AND/ OR NOISE DIAGNOSIS..............................................................................................1829
COMPRESSOR NOISE DIAGNOSIS.........................................................................................................1829
COMPRESSOR CLUTCH/ COIL............................................................................................................1829
TESTS..........................................................................................................................1829
EXPANSION VALVE....................................................................................................................1829
TESTS..........................................................................................................................1829
HEATER PERFORMANCE TEST............................................................................................................1831
PRE-DIAGNOSTIC PREPARATIONS....................................................................................................1831
MAXIMUM HEATER OUTPUT: TEST AND ACTION.........................................................................................1831
TEMPERATURE REFERENCE TABLE....................................................................................................1831
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW.........................................................................1831
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT................................................................................1831
TEMPERATURE CONTROL............................................................................................................1832
SYSTEM CHARGE LEVEL TEST...........................................................................................................1832
SERVICE PROCEDURES.....................................................................................................................1832
R-134a REFRIGERANT.................................................................................................................1832
CHARGING REFRIGERANT SYSTEM........................................................................................................1833
EVACUATING REFRIGERANT SYSTEM......................................................................................................1834
THERMOCOUPLE PROBE.................................................................................................................1835
STICKING HVAC CONTROL MODULE PUSH BUTTONS..........................................................................................1835
SYSTEM LEAK CHECKING...............................................................................................................1835
EMPTY REFRIGERANT SYSTEM LEAK TEST.............................................................................................1835
LOW REFRIGERANT LEVEL LEAK TEST................................................................................................1835
REMOVAL AND INSTALLATION...............................................................................................................1836
A/ C PRESSURE TRANSDUCER...........................................................................................................1836
REMOVAL........................................................................................................................1836
INSTALLATION...................................................................................................................1836
A/ C SERVICE PORTS.................................................................................................................1836
REMOVAL........................................................................................................................1836
INSTALLATION...................................................................................................................1836
BLEND-AIR DOOR ACTUATOR............................................................................................................1836
REMOVAL........................................................................................................................1836
INSTALLATION...................................................................................................................1836
BLOWER MOTOR AND WHEEL ASSEMBLY....................................................................................................1837
REMOVAL........................................................................................................................1837
INSTALLATION...................................................................................................................1837
BLOWER MOTOR RESISTOR BLOCK........................................................................................................1837
REMOVAL........................................................................................................................1837
INSTALLATION...................................................................................................................1838
BLOWER MOTOR WHEEL.................................................................................................................1838
COMPRESSOR.........................................................................................................................1839
REMOVAL........................................................................................................................1839
INSTALLATION...................................................................................................................1839
COMPRESSOR CLUTCH/ COIL............................................................................................................1839
REMOVAL........................................................................................................................1839
INSTALLATION...................................................................................................................1841
CLUTCH BREAK-IN................................................................................................................1841
CONDENSER ASSEMBLY.................................................................................................................1841
REMOVAL........................................................................................................................1841
INSTALLATION...................................................................................................................1842
DISCHARGE LINE.....................................................................................................................1842
REMOVAL........................................................................................................................1842
INSTALLATION...................................................................................................................1843
EVAPORATOR PROBE...................................................................................................................1843
REMOVAL........................................................................................................................1843
INSTALLATION...................................................................................................................1843
EXPANSION VALVE....................................................................................................................1844
REMOVAL........................................................................................................................1844
INSTALLATION...................................................................................................................1844
FILTER-DRIER ASSEMBLY..............................................................................................................1844
REMOVAL........................................................................................................................1844
INSTALLATION...................................................................................................................1845
HEATER A/ C UNIT HOUSING...........................................................................................................1845
REMOVAL........................................................................................................................1845
INSTALLATION...................................................................................................................1846
HEATER CORE........................................................................................................................1846
REMOVAL........................................................................................................................1846
INSTALLATION...................................................................................................................1847
HEATER HOSES.......................................................................................................................1847
REMOVAL........................................................................................................................1847
INSTALLATION...................................................................................................................1848
LIQUID LINE........................................................................................................................1848
REMOVAL........................................................................................................................1848
INSTALLATION...................................................................................................................1848
MODE DOOR ACTUATOR.................................................................................................................1848
REMOVAL........................................................................................................................1848
INSTALLATION...................................................................................................................1848
SIDE WINDOW DEMISTER DUCTS.........................................................................................................1849
LEFT SIDE......................................................................................................................1849
RIGHT SIDE.....................................................................................................................1849
SUCTION LINE.......................................................................................................................1849
REMOVAL........................................................................................................................1849
INSTALLATION...................................................................................................................1849
RECIRC DOOR ACTUATOR...............................................................................................................1850
REMOVAL........................................................................................................................1850
INSTALLATION...................................................................................................................1850
DISASSEMBLY AND ASSEMBLY...............................................................................................................1850
HEATER A/ C UNIT RECONDITION.......................................................................................................1850
DISASSEMBLY - EVAPORATOR HOUSING...............................................................................................1850
ASSEMBLY - EVAPORATOR HOUSING..................................................................................................1851
DISASSEMBLY - DISTRIBUTION HOUSING.............................................................................................1851
ASSEMBLY - DISTRIBUTION HOUSING................................................................................................1856
GENERAL INFORMATION....................................................................................................................1857
INTRODUCTION.......................................................................................................................1857
DESCRIPTION AND OPERATION..............................................................................................................1857
REAR BLOWER RESISTOR BLOCK.........................................................................................................1857
REAR HEATER AND A/ C LINES.........................................................................................................1857
SYSTEM OPERATION...................................................................................................................1857
DIAGNOSIS AND TESTING..................................................................................................................1859
DIAGNOSTIC PROCEDURES..............................................................................................................1859
REMOVAL AND INSTALLATION...............................................................................................................1859
AIR DISTRIBUTION DUCT- A/ C........................................................................................................1859
REMOVAL........................................................................................................................1859
INSTALLATION...................................................................................................................1859
AIR DISTRIBUTION DUCT- HEATER......................................................................................................1859
REMOVAL........................................................................................................................1859
INSTALLATION...................................................................................................................1859
EVAPORATOR AND EXPANSION VALVE.....................................................................................................1860
REMOVAL........................................................................................................................1860
INSTALLATION...................................................................................................................1860
REAR AIR CONDITIONING LINES........................................................................................................1861
REMOVAL........................................................................................................................1861
INSTALLATION...................................................................................................................1861
REAR HEATER A/ C AIR OUTLETS.......................................................................................................1861
REMOVAL........................................................................................................................1861
INSTALLATION...................................................................................................................1861
REAR HEATER- A/ C AUXILIARY CONDENSER..............................................................................................1861
REMOVAL........................................................................................................................1861
INSTALLATION...................................................................................................................1861
REAR HEATER A/ C BLOWER MOTOR......................................................................................................1862
REMOVAL........................................................................................................................1862
INSTALLATION...................................................................................................................1862
REAR HEATER- A/ C CONTROL ILLUMINATION BULB........................................................................................1862
REMOVAL........................................................................................................................1862
INSTALLATION...................................................................................................................1862
REAR HEATER A/ C UNIT..............................................................................................................1862
REMOVAL........................................................................................................................1862
INSTALLATION...................................................................................................................1863
REAR HEATER CORE...................................................................................................................1864
REMOVAL........................................................................................................................1864
INSTALLATION...................................................................................................................1864
REAR HEATER LINES..................................................................................................................1865
REMOVAL........................................................................................................................1865
INSTALLATION...................................................................................................................1865
MODE DOOR..........................................................................................................................1865
REMOVAL........................................................................................................................1865
INSTALLATION...................................................................................................................1865
MODE DOOR ACTUATOR.................................................................................................................1865
REMOVAL........................................................................................................................1865
INSTALLATION...................................................................................................................1865
HEATING AND AIR CONDITIONING 1
............................................................................................................1867
GENERAL INFORMATION....................................................................................................................1867
INTRODUCTION.......................................................................................................................1867
SAFETY PRECAUTIONS AND WARNINGS....................................................................................................1868
DESCRIPTION AND OPERATION..............................................................................................................1868
AIR DISTRIBUTION DUCTS.............................................................................................................1868
A/ C PRESSURE TRANSDUCER...........................................................................................................1868
A/ C SERVICE PORTS.................................................................................................................1868
COMPRESSOR.........................................................................................................................1868
COMPRESSOR HIGH- PRESSURE RELIEF VALVE.............................................................................................1869
CONDENSATE DRAIN...................................................................................................................1869
ENGINE COOLING SYSTEM REQUIREMENTS.................................................................................................1869
EVAPORATOR PROBE...................................................................................................................1869
HANDLING TUBING AND FITTINGS.......................................................................................................1869
HVAC CONTROL MODULE................................................................................................................1869
SIDE DOOR HEATER A/ C OUTLETS......................................................................................................1870
SIDE WINDOW DEMISTER...............................................................................................................1870
SYSTEM AIRFLOW.....................................................................................................................1870
SYSTEM OIL LEVEL...................................................................................................................1870
REFRIGERANT OIL LEVEL CHECK....................................................................................................1871
REFRIGERANT OIL CAPACITIES.....................................................................................................1871
SERVICING REFRIGERANT OIL LEVEL................................................................................................1871
DIAGNOSIS AND TESTING..................................................................................................................1871
ACTUATOR CALIBRATION/ DIAGNOSTICS AND COOLDOWN TEST................................................................................1871
GENERAL INFORMATION............................................................................................................1871
ACTUATOR CALIBRATION...........................................................................................................1871
REFRIGERANT OIL CAPACITIES.....................................................................................................1871
DIAGNOSTICS....................................................................................................................1872
COOLDOWN TEST..................................................................................................................1872
CALIBRATION/ COOLDOWN LED DISPLAY CODES........................................................................................1872
CALIBRATION/ DIAGNOSTICS TEST ENTRY............................................................................................1872
COOLDOWN TEST ENTRY............................................................................................................1873
CALIBRATION DIAGNOSTICS AND COOLDOWN ABORT.....................................................................................1873
EEPROM DATA....................................................................................................................1873
ACTUATOR CALIBRATION AND DIAGNOSTICS...........................................................................................1873
FAIL CODES/ LEVEL DISPLAY......................................................................................................1874
TEMPERATURE AND MODE POTENTIOMETER DIAGNOSTICS.................................................................................1874
EVAPORATOR PROBE TEMPERATURE DIAGNOSTICS.......................................................................................1874
WIPE BUTTON LED................................................................................................................1874
LEVEL 1– FAILURE CODE VALUES (INTERMITTENT WIPE BUTTON LED)....................................................................1874
POTENTIOMETER VS. POSITION AND FLASH RATE......................................................................................1874
HVAC CONTROL DIAGNOSTIC CONDITIONS.................................................................................................1875
A/ C PERFORMANCE TEST..............................................................................................................1877
PERFORMANCE TEST PROCEDURE.....................................................................................................1877
A/ C PRESSURE TRANSDUCER...........................................................................................................1877
BLOWER MOTOR AND WHEEL ASSEMBLY....................................................................................................1878
VIBRATION AND/ OR NOISE DIAGNOSIS..............................................................................................1878
COMPRESSOR NOISE DIAGNOSIS.........................................................................................................1878
COMPRESSOR CLUTCH/ COIL............................................................................................................1878
TESTS..........................................................................................................................1878
EXPANSION VALVE....................................................................................................................1880
TESTS..........................................................................................................................1880
HEATER PERFORMANCE TEST............................................................................................................1880
PRE- DIAGNOSTIC PREPARATIONS...................................................................................................1880
MAXIMUM HEATER OUTPUT: TEST AND ACTION.........................................................................................1880
TEMPERATURE REFERENCE CHART....................................................................................................1880
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW.........................................................................1881
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT................................................................................1881
TEMPERATURE CONTROL............................................................................................................1881
SYSTEM CHARGE LEVEL TEST...........................................................................................................1881
SERVICE PROCEDURES.....................................................................................................................1882
R-134a REFRIGERANT.................................................................................................................1882
CHARGING REFRIGERANT SYSTEM........................................................................................................1883
EVACUATING REFRIGERANT SYSTEM......................................................................................................1883
THERMOCOUPLE PROBE.................................................................................................................1884
STICKING HVAC CONTROL MODULE PUSH BUTTONS..........................................................................................1884
SYSTEM LEAK CHECKING...............................................................................................................1885
EMPTY REFRIGERANT SYSTEM LEAK TEST.............................................................................................1885
LOW REFRIGERANT LEVEL LEAK TEST................................................................................................1885
REMOVAL AND INSTALLATION...............................................................................................................1885
A/ C PRESSURE TRANSDUCER...........................................................................................................1885
REMOVAL........................................................................................................................1885
INSTALLATION...................................................................................................................1885
A/ C SERVICE PORTS.................................................................................................................1885
REMOVAL........................................................................................................................1886
INSTALLATION...................................................................................................................1886
BLEND- AIR DOOR ACTUATOR...........................................................................................................1886
REMOVAL........................................................................................................................1886
INSTALLATION...................................................................................................................1886
BLOWER MOTOR AND WHEEL ASSEMBLY....................................................................................................1886
REMOVAL........................................................................................................................1886
INSTALLATION...................................................................................................................1887
BLOWER MOTOR RESISTOR BLOCK........................................................................................................1887
REMOVAL........................................................................................................................1887
INSTALLATION...................................................................................................................1888
BLOWER MOTOR WHEEL.................................................................................................................1888
COMPRESSOR (2.5L TURBO DIESEL).....................................................................................................1888
REMOVAL........................................................................................................................1888
INSTALLATION...................................................................................................................1888
CONDENSER ASSEMBLY.................................................................................................................1889
REMOVAL........................................................................................................................1889
INSTALLATION...................................................................................................................1889
DISCHARGE LINE.....................................................................................................................1889
REMOVAL........................................................................................................................1889
INSTALLATION...................................................................................................................1889
EVAPORATOR PROBE...................................................................................................................1890
REMOVAL........................................................................................................................1890
INSTALLATION...................................................................................................................1891
EXPANSION VALVE....................................................................................................................1891
REMOVAL........................................................................................................................1891
INSTALLATION...................................................................................................................1891
FILTER- DRIER ASSEMBLY.............................................................................................................1892
REMOVAL........................................................................................................................1892
INSTALLATION...................................................................................................................1892
HEATER A/ C UNIT HOUSING...........................................................................................................1892
REMOVAL........................................................................................................................1892
INSTALLATION...................................................................................................................1892
HEATER CORE........................................................................................................................1892
REMOVAL........................................................................................................................1892
INSTALLATION...................................................................................................................1894
HEATER HOSES.......................................................................................................................1894
REMOVAL........................................................................................................................1894
INSTALLATION...................................................................................................................1894
LIQUID LINE........................................................................................................................1894
REMOVAL........................................................................................................................1894
INSTALLATION...................................................................................................................1894
MODE DOOR ACTUATOR.................................................................................................................1895
REMOVAL........................................................................................................................1895
INSTALLATION...................................................................................................................1895
SIDE WINDOW DEMISTER DUCTS.........................................................................................................1895
LEFT SIDE......................................................................................................................1895
RIGHT SIDE.....................................................................................................................1895
SUCTION LINE.......................................................................................................................1895
REMOVAL........................................................................................................................1895
INSTALLATION...................................................................................................................1896
RECIRC DOOR ACTUATOR...............................................................................................................1896
REMOVAL........................................................................................................................1896
INSTALLATION...................................................................................................................1896
DISASSEMBLY AND ASSEMBLY...............................................................................................................1896
HEATER A/ C UNIT RECONDITION.......................................................................................................1896
DISASSEMBLY— EVAPORATOR HOUSING................................................................................................1896
ASSEMBLY— EVAPORATOR HOUSING...................................................................................................1898
DISASSEMBLY— DISTRIBUTION HOUSING..............................................................................................1898
ASSEMBLY— DISTRIBUTION HOUSING.................................................................................................1902
EMISSION CONTROL SYSTEMS...................................................................................................................1905
GENERAL INFORMATION....................................................................................................................1905
SYSTEM DESCRIPTION.................................................................................................................1905
DESCRIPTION AND OPERATION..............................................................................................................1905
MALFUNCTION INDICATOR LAMP (MIL)...................................................................................................1905
STATE DISPLAY TEST MODE............................................................................................................1906
STATE DISPLAY INPUTS AND OUTPUTS...............................................................................................1906
STATE DISPLAY SENSORS..........................................................................................................1906
CIRCUIT ACTUATION TEST MODE........................................................................................................1907
DIAGNOSTIC TROUBLE CODES...........................................................................................................1907
BULB CHECK.....................................................................................................................1907
OBTAINING DTC’S USING DRB SCAN TOOL............................................................................................1907
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS...........................................................................................1908
MONITORED SYSTEMS..................................................................................................................1912
HEX 66, and 7A—OXYGEN SENSOR (O2S) MONITOR.....................................................................................1912
HEX 67, 69, 7C, and 7D—OXYGEN SENSOR HEATER MONITOR............................................................................1912
HEX 2E—EGR MONITOR.............................................................................................................1912
HEX 6A,6B, 6C, 6D, 6E, AE, and AF—MISFIRE MONITOR..............................................................................1913
HEX 76, 77, 78, and 79—FUEL SYSTEM MONITOR.....................................................................................1913
HEX 70, and B4 CATALYST MONITOR ...............................................................................................1913
HEX A0, A1, B7, and B8 LEAK DETECTION PUMP MONITOR.............................................................................1913
TRIP DEFINITION....................................................................................................................1914
COMPONENT MONITORS.................................................................................................................1914
NON-MONITORED CIRCUITS.............................................................................................................1915
FUEL PRESSURE .................................................................................................................1915
SECONDARY IGNITION CIRCUIT.....................................................................................................1915
CYLINDER COMPRESSION...........................................................................................................1915
EXHAUST SYSTEM.................................................................................................................1915
FUEL INJECTOR MECHANICAL MALFUNCTIONS..........................................................................................1915
EXCESSIVE OIL CONSUMPTION......................................................................................................1915
THROTTLE BODY AIR FLOW.........................................................................................................1915
VACUUM ASSIST..................................................................................................................1915
PCM SYSTEM GROUND..............................................................................................................1915
PCM CONNECTOR ENGAGEMENT.......................................................................................................1915
HIGH AND LOW LIMITS................................................................................................................1915
LOAD VALUE.........................................................................................................................1916
DESCRIPTION AND OPERATION..............................................................................................................1917
EVAPORATION CONTROL SYSTEM.........................................................................................................1917
ROLLOVER VALVE.....................................................................................................................1917
EVAPORATIVE (EVAP) CANISTER........................................................................................................1917
PROPORTIONAL PURGE SOLENOID........................................................................................................1917
PRESSURE-VACUUM FILLER CAP.........................................................................................................1918
LEAK DETECTION PUMP................................................................................................................1918
POSITIVE CRANKCASE VENTILATION (PCV) SYSTEMS.......................................................................................1919
PCV VALVE......................................................................................................................1919
CRANKCASE VENT FILTER..............................................................................................................1920
VEHICLE EMISSION CONTROL INFORMATION LABEL.........................................................................................1920
DIAGNOSIS AND TESTING..................................................................................................................1920
LEAK DETECTION PUMP................................................................................................................1920
PCV VALVE TEST.....................................................................................................................1920
ROLLOVER VALVES....................................................................................................................1921
REMOVAL AND INSTALLATION...............................................................................................................1920
LEAK DETECTION PUMP REPLACEMENT....................................................................................................1920
REMOVAL........................................................................................................................1920
INSTALLATION...................................................................................................................1921
DESCRIPTION AND OPERATION..............................................................................................................1922
GENERAL INFORMATION................................................................................................................1922
DIAGNOSIS AND TESTING..................................................................................................................1923
EGR SYSTEM ON-BOARD DIAGNOSTICS....................................................................................................1923
EGR SYSTEM TEST....................................................................................................................1923
EGR GAS FLOW TEST..................................................................................................................1924
EGR VALVE LEAKAGE TEST.............................................................................................................1924
EGR VALVE CONTROL (TRANSDUCER) TEST................................................................................................1925
TESTING ELECTRICAL SOLENOID PORTION OF VALVE...................................................................................1925
TESTING VACUUM TRANSDUCER PORTION OF VALVE.....................................................................................1925
REMOVAL AND INSTALLATION...............................................................................................................1925
EGR VALVE SERVICE—3.0L ENGINES.....................................................................................................1925
REMOVAL........................................................................................................................1925
INSTALLATION...................................................................................................................1925
EGR VALVE SERVICE—3.3/3.8L ENGINES.................................................................................................1926
REMOVAL........................................................................................................................1926
INSTALLATION ..................................................................................................................1926
EGR TUBE SERVICE—3.0L ENGINES......................................................................................................1926
REMOVAL........................................................................................................................1926
INSTALLATION...................................................................................................................1926
EGR TUBE SERVICE—3.3/3.8L ENGINES..................................................................................................1926
REMOVAL........................................................................................................................1926
INSTALLATION...................................................................................................................1927
SPECIAL TOOLS..........................................................................................................................1927
EMISSION CONTROL SYSTEM............................................................................................................1927
EMISSION CONTROL SYSTEM 1
.................................................................................................................1929
GENERAL INFORMATION....................................................................................................................1929
SYSTEM DESCRIPTION 2.5L DIESEL ENGINE.............................................................................................1929
MONITORED CIRCUITS.............................................................................................................1929
NON– MONITORED CIRCUITS........................................................................................................1929
HIGH AND LOW LIMITS............................................................................................................1930
DESCRIPTION AND OPERATION..............................................................................................................1930
DIAGNOSTIC TROUBLE CODES...........................................................................................................1930
ACCESSING DIAGNOSTIC TROUBLE CODES.............................................................................................1930
ERASING TROUBLE CODES..........................................................................................................1930
DESCRIPTION AND OPERATION..............................................................................................................1933
VACUUM HOSE ROUTING SCHEMATIC......................................................................................................1933
EXHAUST GAS RECIRCULATION (EGR) SYSTEM.............................................................................................1933
GENERAL INFORMATION............................................................................................................1933
EGR SYSTEM OPERATION...........................................................................................................1933
DIAGNOSIS AND TESTING..................................................................................................................1934
EGR GAS FLOW TEST..................................................................................................................1934
ELECTRIC VACUUM MODULATOR (EVM) TEST...............................................................................................1935
VACUUM TEST....................................................................................................................1935
REMOVAL AND INSTALLATION...............................................................................................................1935
EGR VALVE..........................................................................................................................1935
REMOVAL........................................................................................................................1935
INSTALLATION...................................................................................................................1935
EGR TUBE...........................................................................................................................1935
REMOVAL........................................................................................................................1935
INSTALLATION...................................................................................................................1935
ELECTRIC VACUUM MODULATOR (EVM)....................................................................................................1935
REMOVAL........................................................................................................................1936
INSTALLATION...................................................................................................................1936
SPECIFICATIONS.........................................................................................................................1936
TORQUE CHART— 2.5L DIESEL..........................................................................................................1936
GENERAL INFORMATION....................................................................................................................1937
GENERAL INFORMATION................................................................................................................1937
POSITIVE CRANKCASE VENTILATION SYSTEM (PCV) SYSTEM— 2.0L ENGINE....................................................................1937
REMOVAL AND INSTALLATION...............................................................................................................1937
EGR VALVE..........................................................................................................................1937
REMOVAL........................................................................................................................1937
INSTALLATION...................................................................................................................1938
EGR TUBE...........................................................................................................................1938
REMOVAL........................................................................................................................1938
INSTALLATION...................................................................................................................1938
TORQUE.............................................................................................................................1938
PLEASE NOTE:
This is the SAME MANUAL used by the dealerships to diagnose your vehicle
No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
SK
✹
What Our Customers Say
★★★★★Live reviews from customers
Loading customer reviews...
🌟 Related Products
Discover more professional manuals for your equipment
