Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
1998 Jeep Wrangler TJ Service Manual – PDF DOWNLOAD
Original price was: $86.95.$28.95Current price is: $28.95.
1998 Jeep Wrangler TJ Service Manual – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
1998 Jeep Wrangler TJ Service Manual – PDF DOWNLOAD
DESCRIPTION:
1998 Jeep Wrangler TJ Service Manual – PDF DOWNLOAD
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER
The Vehicle Identification Number (VIN) plate is located on the lower windshield fence near the left A-pillar. The VIN contains 17 characters that provide data concerning the vehicle. Refer to the VIN decoding chart to determine the identification of a vehicle.
The Vehicle Identification Number is also imprinted on the:
† Body Code Plate.
† Vehicle Safety Certification Label.
† Frame rail.
To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Identification Number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation. The formula to use the check digit is not released to the general public.
VEHICLE SAFETY CERTIFICATION LABEL
A vehicle safety certification label (Fig. 1) is attached to every Chrysler Corporation vehicle. The label certifies that the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards. The label also lists:
† Month and year of vehicle manufacture.
† Gross Vehicle Weight Rating (GVWR). The gross front and rear axle weight ratings (GAWR’s) are based on a minimum rim size and maximum cold tire inflation pressure.
† Vehicle Identification Number (VIN).
TABLE OF CONTENTS:
1998 Jeep Wrangler TJ Service Manual – PDF DOWNLOAD
INTRODUCTION........................................................................................... 3 GENERAL INFORMATION................................................................................ 3 VEHICLE IDENTIFICATION NUMBER.................................................................. 3 VEHICLE SAFETY CERTIFICATION LABEL............................................................. 3 VEHICLE IDENTIFICATION NUMBER DECODING CHART............................................... 3 BODY CODE PLATE................................................................................ 4 LOCATION AND DECODING...................................................................... 4 BODY CODE PLATE—LINE 3..................................................................... 4 BODY CODE PLATE—LINE 2..................................................................... 5 BODY CODE PLATE LINE 1..................................................................... 5 VEHICLE DIMENSIONS............................................................................. 5 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS.................................................. 6 INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS.............................................. 6 FASTENER IDENTIFICATION........................................................................ 6 FASTENER IDENTIFICATION.................................................................... 6 INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS.......................................... 6 FASTENER USAGE................................................................................. 6 FASTENER IDENTIFICATION.................................................................... 7 FASTENER STRENGTH.......................................................................... 8 THREADED HOLE REPAIR........................................................................... 9 METRIC SYSTEM.................................................................................. 9 CONVERSION FORMULAS AND EQUIVALENT VALUES.................................................. 9 METRIC CONVERSION.......................................................................... 10 TORQUE REFERENCES.............................................................................. 11 TORQUE SPECIFICATIONS...................................................................... 11 LUBRICATION AND MAINTENANCE............................................................................ 13 GENERAL INFORMATION................................................................................ 13 INTRODUCTION................................................................................... 13 PARTS AND LUBRICANT RECOMMENDATIONS............................................................ 13 INTERNATIONAL SYMBOLS.......................................................................... 13 CLASSIFICATION OF LUBRICANTS................................................................... 13 ENGINE OIL................................................................................. 14 FLUID CAPACITIES............................................................................... 14 FUEL TANK.................................................................................. 14 ENGINE OIL................................................................................. 14 COOLING SYSTEM............................................................................. 14 AUTOMATIC TRANSMISSION..................................................................... 14 MANUAL TRANSMISSION........................................................................ 14 TRANSFER CASE.............................................................................. 14 FRONT AXLE................................................................................. 14 REAR AXLE.................................................................................. 14 GENERAL INFORMATION................................................................................ 15 INTRODUCTION................................................................................... 15 EMISSION CONTROL SYSTEM MAINTENANCE........................................................ 15 UNSCHEDULED INSPECTION......................................................................... 15 SCHEDULE— A.................................................................................... 15 SCHEDULE— B.................................................................................... 16 SERVICE PROCEDURES................................................................................. 20 JUMP STARTING PROCEDURE........................................................................ 20 TO JUMP START A DISABLED VEHICLE:.......................................................... 20 DISCONNECT CABLE CLAMPS AS FOLLOWS:........................................................ 21 TOWING RECOMMENDATIONS......................................................................... 21 SAFETY PRECAUTIONS......................................................................... 21 GROUND CLEARANCE........................................................................... 21 FLAT- BED TOWING RAMP ANGLE................................................................ 21 VEHICLE TOWING................................................................................. 21 TOWING- FRONT END LIFTED (WHEEL LIFT)...................................................... 21 TOWING- REAR END LIFTED (WHEEL LIFT ONLY).................................................. 22 TOWING- FRONT END LIFTED (SLING- TYPE)..................................................... 22 RECREATIONAL TOWING............................................................................ 22 EMERGENCY TOW HOOKS............................................................................ 22 HOISTING RECOMMENDATIONS....................................................................... 22 FLOOR JACK................................................................................. 22 HOIST...................................................................................... 23 DIFFERENTIAL AND DRIVELINE............................................................................. 25 GENERAL INFORMATION................................................................................ 25 PROPELLER SHAFTS............................................................................... 25 PROPELLER SHAFT JOINTS......................................................................... 25 PROPELLER SHAFT JOINT ANGLE.................................................................... 26 LUBRICATION.................................................................................... 26 PRECAUTIONS.................................................................................... 27 DIAGNOSIS AND TESTING.............................................................................. 27 VIBRATION...................................................................................... 27 UNBALANCE...................................................................................... 28 DRIVELINE VIBRATION........................................................................ 28 RUNOUT......................................................................................... 29 RUNOUT SPECIFICATIONS...................................................................... 29 SERVICE PROCEDURES................................................................................. 29 DRIVELINE ANGLE MEASUREMENT PREPARATION........................................................ 29 PROPELLER SHAFT ANGLE MEASUREMENT.............................................................. 30 REMOVAL AND INSTALLATION........................................................................... 31 FRONT PROPELLER SHAFT.......................................................................... 31 REMOVAL.................................................................................... 31 INSTALLATION............................................................................... 31 REAR PROPELLER SHAFT........................................................................... 32 REMOVAL.................................................................................... 32 INSTALLATION............................................................................... 32 DISASSEMBLY AND ASSEMBLY........................................................................... 33 SINGLE CARDAN UNIVERSAL JOINT.................................................................. 33 DISASSEMBLY................................................................................ 33 ASSEMBLY................................................................................... 33 DOUBLE CARDAN JOINT............................................................................ 34 DISASSEMBLY................................................................................ 34 ASSEMBLY................................................................................... 35 CLEANING AND INSPECTION............................................................................ 37 SINGLE AND DOUBLE CARDAN JOINT................................................................. 37 ADJUSTMENTS........................................................................................ 37 AXLE PINION ANGLE ADJUSTMENT................................................................... 37 SPECIFICATIONS..................................................................................... 38 TORQUE......................................................................................... 38 SPECIAL TOOLS...................................................................................... 38 PROPELLER SHAFT................................................................................ 38 GENERAL INFORMATION................................................................................ 39 181 FBI AXLE................................................................................... 39 LUBRICANT SPECIFICATIONS....................................................................... 39 DESCRIPTION AND OPERATION.......................................................................... 40 STANDARD DIFFERENTIAL.......................................................................... 40 DIAGNOSIS AND TESTING.............................................................................. 40 GENERAL INFORMATION............................................................................ 40 GEAR NOISE..................................................................................... 40 BEARING NOISE.................................................................................. 41 LOW SPEED KNOCK................................................................................ 41 FRONT AXLE DIAGNOSIS....................................................................... 42 CONTINUED.................................................................................. 43 VIBRATION...................................................................................... 41 DRIVELINE SNAP................................................................................. 41 SERVICE PROCEDURES ................................................................................ 44 LUBRICANT CHANGE .............................................................................. 44 REMOVAL AND INSTALLATION........................................................................... 44 DRIVE AXLE ASSEMBLY............................................................................ 44 REMOVAL.................................................................................... 44 INSTALLATION............................................................................... 44 AXLE SHAFT—CARDAN U-JOINT...................................................................... 45 REMOVAL.................................................................................... 45 INSTALLATION .............................................................................. 46 PINION SHAFT SEAL.............................................................................. 46 INSTALLATION............................................................................... 46 REMOVAL.................................................................................... 46 COLLAPSIBLE SPACER............................................................................. 47 REMOVAL W/PINION INSTALLED................................................................. 47 REMOVAL W/PINION REMOVED................................................................... 48 INSTALLATION............................................................................... 48 HUB BEARING AND AXLE SHAFT..................................................................... 49 REMOVAL.................................................................................... 49 INSTALLATION............................................................................... 50 STEERING KNUCKLE AND BALL STUDS................................................................ 51 KNUCKLE REMOVAL............................................................................ 51 UPPER BALL STUD REPLACEMENT................................................................ 51 LOWER BALL STUD REPLACEMENT................................................................ 51 KNUCKLE INSTALLATION ...................................................................... 51 AXLE BUSHING REPLACEMENT....................................................................... 51 DIFFERENTIAL................................................................................... 51 REMOVAL.................................................................................... 51 INSTALLATION............................................................................... 54 DIFFERENTIAL SIDE BEARINGS..................................................................... 54 REMOVAL.................................................................................... 54 INSTALLATION............................................................................... 55 AXLE SHAFT OIL SEAL............................................................................ 55 REMOVAL.................................................................................... 55 INSTALLATION............................................................................... 55 RING GEAR...................................................................................... 55 REMOVAL.................................................................................... 55 INSTALLATION............................................................................... 56 PINION GEAR.................................................................................... 56 REMOVAL.................................................................................... 56 INSTALLATION............................................................................... 58 DISASSEMBLY AND ASSEMBLY........................................................................... 60 STANDARD DIFFERENTIAL.......................................................................... 60 DISASSEMBLY................................................................................ 60 ASSEMBLY................................................................................... 61 CLEANING AND INSPECTION............................................................................ 61 CARDAN U-JOINT................................................................................. 61 AXLE COMPONENTS................................................................................ 61 FINAL ASSEMBLY................................................................................. 61 ADJUSTMENTS........................................................................................ 62 PINION GEAR DEPTH.............................................................................. 62 GENERAL INFORMATION........................................................................ 62 PINION DEPTH MEASUREMENT AND ADJUSTMENT.................................................... 62 PINION GEAR DEPTH VARIANCE................................................................. 63 DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH................................................. 64 INTRODUCTION............................................................................... 64 SHIM SELECTION............................................................................. 64 GEAR CONTACT PATTERN ANALYSIS.................................................................. 67 SPECIFICATIONS..................................................................................... 69 181 FBI AXLE................................................................................... 69 181 FBI AXLE................................................................................... 69 SPECIAL TOOLS...................................................................................... 69 181 FBI AXLE................................................................................... 69 GENERAL INFORMATION................................................................................ 73 194 RBI AXLE................................................................................... 73 LUBRICANT SPECIFICATIONS....................................................................... 73 DESCRIPTION AND OPERATION.......................................................................... 74 STANDARD DIFFERENTIAL.......................................................................... 74 TRAC-LOK OPERATION............................................................................. 74 DIAGNOSIS AND TESTING.............................................................................. 75 GENERAL INFORMATION............................................................................ 75 GEAR NOISE..................................................................................... 75 BEARING NOISE.................................................................................. 75 LOW SPEED KNOCK................................................................................ 76 VIBRATION...................................................................................... 76 DRIVELINE SNAP................................................................................. 76 TRAC–LOK DIFFERENTIAL NOISE.................................................................... 76 TRAC LOK TEST ................................................................................. 76 DIAGNOSIS CHART............................................................................ 77 DIAGNOSIS CHART (CONTINUED)................................................................ 78 SERVICE PROCEDURES ................................................................................ 79 LUBRICANT CHANGE .............................................................................. 79 REMOVAL AND INSTALLATION........................................................................... 79 REAR AXLE...................................................................................... 79 REMOVAL.................................................................................... 79 INSTALLATION............................................................................... 79 PINION SHAFT SEAL.............................................................................. 80 REMOVAL.................................................................................... 80 INSTALLATION............................................................................... 80 COLLAPSIBLE SPACER............................................................................. 81 REMOVAL W/PINION INSTALLED................................................................. 81 REMOVAL W/PINION REMOVED................................................................... 81 INSTALLATION............................................................................... 82 AXLE SHAFT..................................................................................... 83 REMOVAL.................................................................................... 83 INSTALLATION............................................................................... 84 AXLE SHAFT SEAL AND BEARING.................................................................... 84 REMOVAL.................................................................................... 84 INSTALLATION............................................................................... 84 DIFFERENTIAL................................................................................... 85 REMOVAL.................................................................................... 85 INSTALLATION............................................................................... 86 DIFFERENTIAL SIDE BEARINGS..................................................................... 87 REMOVAL.................................................................................... 87 INSTALLATION............................................................................... 87 RING GEAR...................................................................................... 88 REMOVAL.................................................................................... 88 INSTALLATION............................................................................... 88 PINION GEAR.................................................................................... 88 REMOVAL.................................................................................... 88 INSTALLATION............................................................................... 89 FINAL ASSEMBLY................................................................................. 91 DISASSEMBLY AND ASSEMBLY........................................................................... 92 STANDARD DIFFERENTIAL.......................................................................... 92 DISASSEMBLY................................................................................ 92 ASSEMBLY................................................................................... 92 TRAC-LOK DIFFERENTIAL.......................................................................... 92 DISASSEMBLY................................................................................ 93 ASSEMBLY................................................................................... 95 CLEANING AND INSPECTION............................................................................ 96 AXLE COMPONENTS................................................................................ 96 TRAC-LOK....................................................................................... 97 PRESOAK PLATES AND DISC.................................................................... 97 ADJUSTMENTS........................................................................................ 97 PINION GEAR DEPTH.............................................................................. 97 GENERAL INFORMATION........................................................................ 97 PINION DEPTH MEASUREMENT AND ADJUSTMENT.................................................... 97 PINION GEAR DEPTH VARIANCE................................................................. 98 DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH................................................. 99 SHIM SELECTION............................................................................. 99 GEAR CONTACT PATTERN ANALYSIS.................................................................. 101 SPECIFICATIONS..................................................................................... 101 194 RBI AXLE................................................................................... 101 194 RBI AXLE................................................................................... 103 SPECIAL TOOLS...................................................................................... 103 194 RBI AXLE................................................................................... 103 GENERAL INFORMATION................................................................................ 107 216 RBI AXLE................................................................................... 107 LUBRICANT SPECIFICATIONS....................................................................... 107 DESCRIPTION AND OPERATION.......................................................................... 108 STANDARD DIFFERENTIAL.......................................................................... 108 TRAC-LOK OPERATION............................................................................. 108 DIAGNOSIS AND TESTING.............................................................................. 109 GENERAL INFORMATION............................................................................ 109 GEAR NOISE..................................................................................... 109 BEARING NOISE.................................................................................. 109 LOW SPEED KNOCK................................................................................ 110 VIBRATION ..................................................................................... 110 DRIVELINE SNAP................................................................................. 110 TRAC–LOK DIFFERENTIAL NOISE.................................................................... 110 TRAC LOK TEST.................................................................................. 110 DIAGNOSIS CHART............................................................................ 111 DIAGNOSIS CHART (CONTINUED)................................................................ 112 SERVICE PROCEDURES REMOVAL AND INSTALLATION........................................................ 113 LUBRICANT CHANGE .............................................................................. 113 REAR AXLE...................................................................................... 113 REMOVAL.................................................................................... 113 INSTALLATION............................................................................... 113 PINION SHAFT SEAL.............................................................................. 114 REMOVAL.................................................................................... 114 INSTALLATION............................................................................... 114 AXLE SHAFT..................................................................................... 115 REMOVAL.................................................................................... 115 INSTALLATION............................................................................... 115 AXLE BEARING AND SEAL ......................................................................... 115 REMOVAL.................................................................................... 115 INSTALLATION............................................................................... 115 DIFFERENTIAL................................................................................... 116 REMOVAL.................................................................................... 116 INSTALLATION............................................................................... 117 DIFFERENTIAL SIDE BEARINGS..................................................................... 118 REMOVAL.................................................................................... 118 INSTALLATION............................................................................... 118 RING GEAR...................................................................................... 118 REMOVAL.................................................................................... 119 INSTALLATION............................................................................... 119 PINION GEAR.................................................................................... 119 REMOVAL.................................................................................... 119 INSTALLATION............................................................................... 121 FINAL ASSEMBLY................................................................................. 122 DISASSEMBLY AND ASSEMBLY........................................................................... 123 STANDARD DIFFERENTIAL.......................................................................... 123 DISASSEMBLY................................................................................ 123 ASSEMBLY................................................................................... 127 TRAC-LOK DIFFERENTIAL.......................................................................... 124 ASSEMBLY................................................................................... 124 DISASSEMBLY................................................................................ 124 CLEANING AND INSPECTION............................................................................ 128 AXLE COMPONENTS................................................................................ 128 TRAC-LOK....................................................................................... 129 PRESOAK PLATES AND DISC.................................................................... 129 ADJUSTMENTS........................................................................................ 129 PINION GEAR DEPTH.............................................................................. 129 GENERAL INFORMATION........................................................................ 129 PINION GEAR DEPTH VARIANCE................................................................. 130 PINION DEPTH MEASUREMENT AND ADJUSTMENT.................................................... 130 DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH................................................. 131 DIFFERENTIAL PRELOAD AND GEAR BACHLASH SHIM SELECTION...................................... 132 GEAR CONTACT PATTERN ANALYSIS.................................................................. 134 SPECIFICATIONS..................................................................................... 136 216 RBI AXLE................................................................................... 136 SPECIAL TOOLS...................................................................................... 136 216 RBI AXLE................................................................................... 136 216 RBI TORQUE................................................................................. 136 BRAKES................................................................................................. 141 GENERAL INFORMATION................................................................................ 142 BRAKE SYSTEM................................................................................... 142 SERVICE WARNINGS & CAUTIONS.................................................................... 142 DESCRIPTION AND OPERATION.......................................................................... 142 BRAKE PEDAL.................................................................................... 142 STOP LAMP SWITCH............................................................................... 142 RED BRAKE WARNING LAMP......................................................................... 142 POWER BRAKE BOOSTER............................................................................ 142 MASTER CYLINDER................................................................................ 143 COMBINATION VALVE.............................................................................. 144 FRONT DISC BRAKES.............................................................................. 144 REAR DRUM BRAKE................................................................................ 144 PARKING BRAKE.................................................................................. 145 PARKING BRAKE OPERATION.................................................................... 145 BRAKE HOSES AND LINES.......................................................................... 146 DIAGNOSIS AND TESTING.............................................................................. 146 BASE BRAKE SYSTEM.............................................................................. 146 PRELIMINARY BRAKE CHECK.................................................................... 146 ROAD TESTING............................................................................... 146 STOP LAMP SWITCH............................................................................... 148 SWITCH CIRCUIT IDENTIFICATION.............................................................. 148 SWITCH CONTINUITY TEST..................................................................... 148 RED BRAKE WARNING LAMP......................................................................... 148 MASTER CYLINDER/POWER BOOSTER.................................................................. 148 POWER BOOSTER VACUUM TEST.................................................................. 149 POWER BOOSTER CHECK VALVE TEST............................................................. 149 COMBINATION VALVE.............................................................................. 149 Metering Valve............................................................................. 149 Pressure Differential Switch............................................................... 149 DISC BRAKE ROTOR............................................................................... 150 ROTOR MINIMUM THICKNESS.................................................................... 150 ROTOR RUNOUT............................................................................... 150 ROTOR THICKNESS VARIATION.................................................................. 150 BRAKE DRUM..................................................................................... 150 BRAKE DRUM RUNOUT.......................................................................... 150 PARKING BRAKE.................................................................................. 151 BRAKE LINE AND HOSES........................................................................... 151 BRAKE FLUID CONTAMINATION...................................................................... 151 SERVICE PROCEDURES................................................................................. 151 BRAKE FLUID LEVEL.............................................................................. 151 MASTER CYLINDER BLEEDING....................................................................... 151 BLEEDING PROCEDURE......................................................................... 152 BRAKE BLEEDING................................................................................. 152 MANUAL BLEEDING............................................................................ 152 PRESSURE BLEEDING.......................................................................... 153 DISC ROTOR MACHINING........................................................................... 153 BRAKE DRUM MACHINING........................................................................... 153 BRAKE LINE..................................................................................... 153 FLARING PROCEDURE ......................................................................... 154 REMOVAL AND INSTALLATION........................................................................... 154 STOP LAMP SWITCH............................................................................... 154 REMOVAL.................................................................................... 154 INSTALLATION............................................................................... 154 BRAKE PEDAL.................................................................................... 154 REMOVAL.................................................................................... 154 INSTALLATION............................................................................... 155 COMBINATION VALVE.............................................................................. 155 REMOVAL.................................................................................... 155 INSTALLATION............................................................................... 155 MASTER CYLINDER................................................................................ 156 REMOVAL.................................................................................... 156 INSTALLATION............................................................................... 156 POWER BRAKE BOOSTER............................................................................ 156 REMOVAL.................................................................................... 156 INSTALLATION............................................................................... 157 DISC BRAKE CALIPER............................................................................. 157 REMOVAL.................................................................................... 157 INSTALLATION............................................................................... 158 DISC BRAKE SHOES............................................................................... 159 REMOVAL.................................................................................... 159 INSTALLATION............................................................................... 159 DISC BRAKE ROTOR............................................................................... 159 REMOVAL.................................................................................... 159 INSTALLATION............................................................................... 159 DRUM BRAKE SHOES............................................................................... 160 REMOVAL.................................................................................... 160 INSTALLATION............................................................................... 160 WHEEL CYLINDER................................................................................. 161 REMOVAL.................................................................................... 161 INSTALLATION............................................................................... 161 PARKING BRAKE HAND LEVER....................................................................... 161 REMOVAL.................................................................................... 161 INSTALLATION............................................................................... 161 REAR PARKING BRAKE CABLE....................................................................... 162 REMOVAL.................................................................................... 162 INSTALLATION............................................................................... 162 DISASSEMBLY AND ASSEMBLY........................................................................... 162 MASTER CYLINDER RESERVOIR...................................................................... 162 REMOVAL.................................................................................... 162 INSTALLATION............................................................................... 163 DISC BRAKE CALIPER............................................................................. 163 DISASSEMBLY................................................................................ 163 ASSEMBLY................................................................................... 164 WHEEL CYLINDER................................................................................. 165 DISASSEMBLY................................................................................ 165 ASSEMBLY................................................................................... 166 CLEANING AND INSPECTION............................................................................ 166 CALIPER........................................................................................ 166 CLEANING................................................................................... 166 INSPECTION................................................................................. 166 REAR DRUM BRAKE................................................................................ 166 CLEANING .................................................................................. 166 INSPECTION................................................................................. 166 WHEEL CYLINDER................................................................................. 166 CLEANING................................................................................... 166 INSPECTION................................................................................. 166 ADJUSTMENTS........................................................................................ 167 STOP LAMP SWITCH............................................................................... 167 PARKING BRAKE CABLE TENSIONER.................................................................. 167 ADJUSTMENT................................................................................. 167 REAR DRUM BRAKE................................................................................ 167 ADJUSTMENT WITH BRAKE GAUGE................................................................ 168 ADJUSTMENT WITH ADJUSTING TOOL............................................................. 168 SPECIFICATIONS..................................................................................... 169 BRAKE FLUID.................................................................................... 169 BRAKE COMPONENTS............................................................................... 169 TORQUE CHART................................................................................... 169 SPECIAL TOOLS...................................................................................... 169 BASE BRAKES.................................................................................... 169 GENERAL INFORMATION................................................................................ 170 ANTILOCK BRAKE SYSTEM.......................................................................... 170 DESCRIPTION AND OPERATION.......................................................................... 170 ANTILOCK BRAKE SYSTEM.......................................................................... 170 NORMAL BRAKING............................................................................. 171 ANTILOCK BRAKING........................................................................... 171 CONTROLLER ANTILOCK BRAKES..................................................................... 171 HYDRAULIC CONTROL UNIT......................................................................... 171 Pressure Decrease.......................................................................... 172 Pressure Hold.............................................................................. 172 Pressure Increase.......................................................................... 172 WHEEL SPEED SENSORS AND TONE WHEEL............................................................. 172 SPEED SENSOR AIR GAP....................................................................... 172 COMBINATION VALVE.............................................................................. 172 ACCELERATION SWITCH............................................................................ 173 ABS SYSTEM RELAYS.............................................................................. 173 ABS WARNING LAMP............................................................................... 173 DIAGNOSIS AND TESTING.............................................................................. 173 ANTILOCK BRAKES ............................................................................... 173 SERVICE PROCEDURES................................................................................. 173 BLEEDING ABS BRAKE SYSTEM...................................................................... 173 REMOVAL AND INSTALLATION........................................................................... 174 CONTROLLER ANTILOCK BRAKES..................................................................... 174 REMOVAL.................................................................................... 174 INSTALLATION............................................................................... 174 HYDRAULIC CONTROL UNIT......................................................................... 174 REMOVAL.................................................................................... 174 INSTALLATION............................................................................... 174 FRONT WHEEL SENSOR............................................................................. 174 REMOVAL.................................................................................... 174 INSTALLATION............................................................................... 175 REAR WHEEL SPEED SENSOR........................................................................ 175 REMOVAL.................................................................................... 175 INSTALLATION............................................................................... 176 COMBINATION VALVE.............................................................................. 176 REMOVAL.................................................................................... 176 INSTALLATION............................................................................... 176 ACCELERATION SWITCH............................................................................ 176 REMOVAL.................................................................................... 176 INSTALLATION............................................................................... 176 SPECIFICATIONS..................................................................................... 177 T0RQUE CHART................................................................................... 177 CLUTCH................................................................................................. 179 GENERAL INFORMATION................................................................................ 179 CLUTCH COMPONENTS.............................................................................. 179 HYDRAULIC LINKAGE COMPONENTS............................................................... 179 INSTALLATION METHODS AND PARTS USAGE........................................................... 179 CLUTCH INTERLOCK SAFETY SWITCH BY-PASS......................................................... 179 BY-PASS PROCEDURE.......................................................................... 180 DESCRIPTION AND OPERATION......................................................................... 180 CLUTCH OPERATION............................................................................... 180 DIAGNOSIS AND TESTING.............................................................................. 180 DIAGNOSTIC INFORMATION ........................................................................ 180 CLUTCH CONTAMINATION....................................................................... 182 CLUTCH MISALIGNMENT........................................................................ 182 FLYWHEEL RUNOUT............................................................................ 182 CLUTCH COVER AND DISC RUNOUT............................................................... 182 CLUTCH HOUSING MISALIGNMENT................................................................ 182 INSPECTION AND DIAGNOSIS CHARTS............................................................ 182 DIAGNOSTIC CHART........................................................................... 183 SERVICE PROCEDURES................................................................................. 187 CLUTCH COMPONENT LUBRICATION................................................................... 187 RECOMMENDED LUBRICANTS..................................................................... 187 CLUTCH LINKAGE FLUID........................................................................... 187 CLUTCH FLUID LEVEL............................................................................. 187 FLYWHEEL....................................................................................... 187 REMOVAL AND INSTALLATION........................................................................... 188 CLUTCH COVER AND DISC.......................................................................... 188 REMOVAL.................................................................................... 188 INSTALLATION............................................................................... 188 RELEASE BEARING................................................................................ 189 REMOVAL.................................................................................... 189 INSTALLATION............................................................................... 189 PILOT BEARING.................................................................................. 189 REMOVAL.................................................................................... 189 INSTALLATION............................................................................... 189 CLUTCH HOUSING................................................................................. 190 CLUTCH HYDRAULIC LINKAGE....................................................................... 190 REMOVAL.................................................................................... 190 INSTALLATION............................................................................... 190 CLUTCH PEDAL................................................................................... 191 REMOVAL.................................................................................... 191 INSTALLATION............................................................................... 191 SPECIFICATIONS..................................................................................... 192 TORQUE......................................................................................... 192 COOLING SYSTEM......................................................................................... 193 GENERAL INFORMATION................................................................................ 193 COOLING SYSTEM................................................................................. 193 COMPONENTS................................................................................. 194 COOLING SYSTEM CIRCULATION..................................................................... 194 WATER PUMP..................................................................................... 194 COOLANT........................................................................................ 194 RADIATOR....................................................................................... 194 ACCESSORY DRIVE BELTS.......................................................................... 195 BLOCK HEATER................................................................................... 195 DESCRIPTION AND OPERATION.......................................................................... 195 TRANSMISSION OIL COOLER........................................................................ 195 COOLANT RESERVE/OVERFLOW SYSTEM................................................................ 195 BLOCK HEATER................................................................................... 195 BLOCK HEATER SPECIFICATIONS................................................................ 195 THERMOSTAT..................................................................................... 196 COOLANT PERFORMANCE............................................................................ 196 COOLANT SELECTION AND ADDITIVES................................................................ 196 RADIATOR PRESSURE CAP.......................................................................... 196 WATER PUMP..................................................................................... 197 COOLING SYSTEM HOSES........................................................................... 197 VISCOUS FAN DRIVE.............................................................................. 198 DIAGNOSIS AND TESTING.............................................................................. 199 ON-BOARD DIAGNOSTICS (OBD)..................................................................... 199 COOLING SYSTEM RELATED DIAGNOSTICS......................................................... 199 ACCESSING DIAGNOSTIC TROUBLE CODES......................................................... 199 ACCESSORY DRIVE BELT DIAGNOSIS................................................................. 199 VISUAL DIAGNOSIS........................................................................... 199 NOISE DIAGNOSIS............................................................................ 199 ACCESSORY DRIVE BELT DIAGNOSIS CHART....................................................... 200 PRELIMINARY CHECKS............................................................................. 202 ENGINE COOLING SYSTEM OVERHEATING.......................................................... 202 COOLING SYSTEM DIAGNOSIS....................................................................... 203 COOLING SYSTEM DIAGNOSIS CHART............................................................. 203 RADIATOR COOLANT FLOW CHECK.................................................................... 209 COOLING SYSTEM—TESTING FOR LEAKS............................................................... 209 ULTRAVIOLET LIGHT METHOD................................................................... 209 PRESSURE TESTER METHOD..................................................................... 209 INTERNAL LEAKAGE INSPECTION................................................................ 210 COMBUSTION LEAKAGE TEST (WITHOUT PRESSURE TESTER).......................................... 210 VISCOUS FAN DRIVE.............................................................................. 210 NOISE...................................................................................... 210 LEAKS...................................................................................... 210 TESTING.................................................................................... 210 RADIATOR CAP TO FILLER NECK SEAL— PRESSURE RELIEF CHECK........................................ 211 RADIATOR CAP—PRESSURE TESTING.................................................................. 212 INSPECTION................................................................................. 212 COOLANT—LOW LEVEL AERATION..................................................................... 212 COOLING SYSTEM DEAERATION...................................................................... 212 SERVICE PROCEDURES................................................................................. 212 COOLANT LEVEL—ROUTINE CHECK.................................................................... 212 COOLANT—ADDING ADDITIONAL...................................................................... 212 SERVICE COOLANT LEVEL.......................................................................... 213 COOLING SYSTEM—DRAINING........................................................................ 213 COOLING SYSTEM—REFILLING....................................................................... 213 COOLING SYSTEM—REVERSE FLUSHING................................................................ 213 REVERSE FLUSHING RADIATOR.................................................................. 213 REVERSE FLUSHING ENGINE.................................................................... 214 REMOVAL AND INSTALLATION........................................................................... 214 AUTOMATIC TRANSMISSION OIL COOLER.............................................................. 214 COOLANT RESERVE/OVERFLOW BOTTLE................................................................ 214 REMOVAL/INSTALLATION....................................................................... 214 WATER PUMP..................................................................................... 214 REMOVAL.................................................................................... 214 INSTALLATION............................................................................... 215 THERMOSTAT..................................................................................... 217 REMOVAL.................................................................................... 217 INSTALLATION............................................................................... 217 RADIATOR ...................................................................................... 218 REMOVAL.................................................................................... 218 INSTALLATION............................................................................... 218 BLOCK HEATER................................................................................... 218 REMOVAL.................................................................................... 218 INSTALLATION............................................................................... 218 VISCOUS FAN.................................................................................... 219 REMOVAL.................................................................................... 219 INSTALLATION............................................................................... 220 VISCOUS FAN DRIVE.............................................................................. 220 ACCESSORY DRIVE BELT........................................................................... 220 BELT SCHEMATICS............................................................................ 220 BELT REPLACEMENT........................................................................... 221 CLEANING AND INSPECTION............................................................................ 221 RADIATOR PRESSURE CAP.......................................................................... 221 RADIATOR....................................................................................... 221 COOLING SYSTEM................................................................................. 222 FAN BLADE...................................................................................... 222 COOLING SYSTEM HOSES........................................................................... 222 ADJUSTMENTS........................................................................................ 222 ACCESSORY DRIVE BELT........................................................................... 222 ACCESSOR Y DRIVE BELT TENSION CHAR T....................................................... 222 TORQUE......................................................................................... 223 SPECIFICATIONS..................................................................................... 223 COOLING SYSTEM CAPACITIES...................................................................... 223 ACCESSORY DRIVE BELT TENSION................................................................... 223 SPECIAL TOOLS...................................................................................... 224 COOLING........................................................................................ 224 BATTERY................................................................................................ 225 GENERAL INFORMATION................................................................................ 225 OVERVIEW....................................................................................... 225 INTRODUCTION................................................................................... 225 DESCRIPTION AND OPERATION.......................................................................... 226 BATTERY........................................................................................ 226 BATTERY SIZE AND RATINGS....................................................................... 226 GROUP SIZE................................................................................. 226 COLD CRANKING AMPERAGE..................................................................... 226 RESERVE CAPACITY........................................................................... 226 AMPERE-HOURS............................................................................... 227 BATTERY MOUNTING............................................................................... 227 DIAGNOSIS AND TESTING.............................................................................. 227 BATTERY........................................................................................ 227 ABNORMAL BATTERY DISCHARGING............................................................... 229 BUILT-IN TEST INDICATOR........................................................................ 229 HYDROMETER TEST................................................................................ 229 OPEN-CIRCUIT VOLTAGE TEST...................................................................... 231 LOAD TEST...................................................................................... 232 IGNITION-OFF DRAW TEST......................................................................... 233 DIAGNOSIS.................................................................................. 233 VOLTAGE DROP TEST.............................................................................. 234 SERVICE PROCEDURES................................................................................. 235 BATTERY CHARGING............................................................................... 235 CHARGING A COMPLETELY DISCHARGED BATTERY .................................................. 236 CHARGING TIME REQUIRED..................................................................... 236 REMOVAL AND INSTALLATION........................................................................... 237 BATTERY........................................................................................ 237 SPECIFICATIONS..................................................................................... 239 BATTERY........................................................................................ 239 STARTING SYSTEMS....................................................................................... 241 GENERAL INFORMATION................................................................................ 241 OVERVIEW....................................................................................... 241 INTRODUCTION................................................................................... 241 DESCRIPTION AND OPERATION.......................................................................... 241 STARTING SYSTEM................................................................................ 241 STARTER........................................................................................ 242 STARTER RELAY.................................................................................. 242 DIAGNOSIS AND TESTING.............................................................................. 242 STARTING SYSTEM................................................................................ 242 INSPECTION................................................................................. 243 COLD CRANKING TEST............................................................................. 243 FEED CIRCUIT TEST.............................................................................. 243 CONTROL CIRCUIT TEST........................................................................... 246 RELAY TEST................................................................................. 246 SOLENOID TEST.............................................................................. 246 RELAY CIRCUIT TEST......................................................................... 247 PARK/NEUTRAL POSITION SWITCH TEST.......................................................... 247 CLUTCH PEDAL POSITION SWITCH TEST.......................................................... 247 IGNITION SWITCH TEST....................................................................... 248 STARTER NOISE - 2.5L ENGINE.................................................................... 248 REMOVAL AND INSTALLATION........................................................................... 249 STARTER........................................................................................ 249 2.5L ENGINE................................................................................ 249 4.0L ENGINE................................................................................ 249 STARTER RELAY.................................................................................. 250 SPECIFICATIONS..................................................................................... 250 STARTING SYSTEM................................................................................ 250 CHARGING SYSTEM........................................................................................ 251 GENERAL INFORMATION................................................................................ 251 OVERVIEW....................................................................................... 251 DESCRIPTION AND OPERATION.......................................................................... 251 CHARGING SYSTEM OPERATION...................................................................... 251 GENERATOR...................................................................................... 252 BATTERY TEMPERATURE SENSOR..................................................................... 252 ELECTRONIC VOLTAGE REGULATOR................................................................... 252 DIAGNOSIS AND TESTING.............................................................................. 252 CHARGING SYSTEM................................................................................ 252 INSPECTION................................................................................. 252 CHARGING SYSTEM RESISTANCE TESTS............................................................... 253 PREPARATION................................................................................ 253 TEST....................................................................................... 253 CURRENT OUTPUT TEST............................................................................ 254 PREPARATION................................................................................ 254 TEST 1..................................................................................... 254 TEST 2..................................................................................... 254 RESULTS.................................................................................... 255 BATTERY TEMPERATURE SENSOR..................................................................... 255 ON-BOARD DIAGNOSTIC TEST FOR CHARGING SYSTEM................................................... 255 REMOVAL AND INSTALLATION........................................................................... 256 GENERATOR...................................................................................... 256 REMOVAL.................................................................................... 256 INSTALLATION............................................................................... 257 BATTERY TEMPERATURE SENSOR..................................................................... 257 REMOVAL.................................................................................... 257 INSTALLATION............................................................................... 257 SPECIFICATIONS..................................................................................... 257 GENERATOR RATINGS.............................................................................. 257 TORQUE CHART................................................................................... 257 IGNITION SYSTEM........................................................................................ 259 GENERAL INFORMATION................................................................................ 259 INTRODUCTION................................................................................... 259 DESCRIPTION AND OPERATION.......................................................................... 259 IGNITION SYSTEM................................................................................ 259 POWERTRAIN CONTROL MODULE...................................................................... 260 DISTRIBUTOR.................................................................................... 260 SPARK PLUGS.................................................................................... 260 SPARK PLUG CABLES.............................................................................. 261 IGNITION COIL.................................................................................. 261 AUTOMATIC SHUTDOWN (ASD) RELAY................................................................. 261 CRANKSHAFT POSITION SENSOR..................................................................... 261 SENSOR OPERATION........................................................................... 261 CAMSHAFT POSITION SENSOR....................................................................... 262 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR ....................................................... 263 ENGINE COOLANT TEMPERATURE SENSOR.............................................................. 263 THROTTLE POSITION SENSOR....................................................................... 263 INTAKE MANIFOLD AIR TEMPERATURE SENSOR......................................................... 263 IGNITION SWITCH AND KEY LOCK CYLINDER.......................................................... 263 DIAGNOSIS AND TESTING.............................................................................. 263 AUTOMATIC SHUTDOWN (ASD) RELAY TEST............................................................ 263 TESTING FOR SPARK AT COIL...................................................................... 263 CHECK COIL TEST................................................................................ 264 FAILURE TO START TEST.......................................................................... 264 IGNITION COIL RESISTANCE................................................................... 264 DISTRIBUTOR CAP................................................................................ 265 DISTRIBUTOR ROTOR.............................................................................. 265 IGNITION TIMING................................................................................ 266 MAP SENSOR..................................................................................... 266 CRANKSHAFT POSITION SENSOR..................................................................... 266 CAMSHAFT POSITION SENSOR....................................................................... 266 ENGINE COOLANT TEMPERATURE SENSOR.............................................................. 267 INTAKE MANIFOLD AIR TEMPERATURE SENSOR......................................................... 267 SPARK PLUG CABLES.............................................................................. 267 TESTING.................................................................................... 267 SPARK PLUG CABLE RESISTANCE................................................................ 268 SPARK PLUG CONDITIONS.......................................................................... 268 NORMAL OPERATING........................................................................... 268 COLD FOULING/CARBON FOULING................................................................ 268 WET FOULING OR GAS FOULING................................................................. 268 OIL OR ASH ENCRUSTED ...................................................................... 268 ELECTRODE GAP BRIDGING..................................................................... 268 SCAVENGER DEPOSITS......................................................................... 268 CHIPPED ELECTRODE INSULATOR................................................................ 269 PREIGNITION DAMAGE......................................................................... 269 SPARK PLUG OVERHEATING..................................................................... 269 REMOVAL AND INSTALLATION........................................................................... 270 SPARK PLUG CABLE REMOVAL....................................................................... 270 SPARK PLUGS.................................................................................... 270 PLUG REMOVAL .............................................................................. 270 PLUG CLEANING.............................................................................. 270 PLUG GAP ADJUSTMENT........................................................................ 270 SPARK PLUG GAP............................................................................. 270 PLUG INSTALLATION.......................................................................... 270 IGNITION COIL.................................................................................. 271 REMOVAL.................................................................................... 271 INSTALLATION............................................................................... 271 AUTOMATIC SHUTDOWN (ASD) RELAY................................................................. 271 REMOVAL.................................................................................... 271 INSTALLATION............................................................................... 271 CRANKSHAFT POSITION SENSOR..................................................................... 272 REMOVAL.................................................................................... 272 INSTALLATION .............................................................................. 272 CAMSHAFT POSITION SENSOR....................................................................... 273 REMOVAL.................................................................................... 273 INSTALLATION............................................................................... 273 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR........................................................ 273 ENGINE COOLANT TEMPERATURE SENSOR.............................................................. 273 THROTTLE POSITION SENSOR....................................................................... 273 INTAKE MANIFOLD AIR TEMPERATURE SENSOR ........................................................ 273 DISTRIBUTOR.................................................................................... 273 REMOVAL—2.5L OR 4.0L ENGINE................................................................ 274 INSTALLATION............................................................................... 275 POWERTRAIN CONTROL MODULE (PCM)................................................................ 277 IGNITION SWITCH AND KEY CYLINDER............................................................... 277 KEY CYLINDER REMOVAL....................................................................... 277 IGNITION SWITCH REMOVAL.................................................................... 277 IGNITION SWITCH INSTALLATION............................................................... 277 KEY CYLINDER INSTALLATION.................................................................. 278 SHIFTER/IGNITION INTERLOCK..................................................................... 278 SPECIFICATIONS..................................................................................... 278 VECI LABEL..................................................................................... 278 IGNITION TIMING................................................................................ 278 ENGINE FIRING ORDER 2.5L 4-CYLINDER ENGINE..................................................... 279 ENGINE FIRING ORDER 4.0L 6-CYLINDER ENGINE..................................................... 279 TORQUE CHART................................................................................... 279 SPARK PLUGS.................................................................................... 279 SPARK PLUG CABLE RESISTANCE.................................................................... 279 IGNITION COIL RESISTANCE....................................................................... 279 INSTRUMENT PANEL SYSTEMS............................................................................... 281 GENERAL INFORMATION................................................................................ 282 INTRODUCTION................................................................................... 282 INSTRUMENT PANEL............................................................................... 282 INSTRUMENT CLUSTER............................................................................. 282 GAUGE.......................................................................................... 283 INDICATOR LAMP................................................................................. 283 FUSEBLOCK MODULE............................................................................... 283 DESCRIPTION AND OPERATION.......................................................................... 283 COOLANT TEMPERATURE GAUGE...................................................................... 283 FUEL GAUGE..................................................................................... 284 ODOMETER AND TRIP ODOMETER..................................................................... 284 OIL PRESSURE GAUGE............................................................................. 284 SPEEDOMETER.................................................................................... 285 TACHOMETER..................................................................................... 285 VOLTMETER...................................................................................... 285 ACCESSORY RELAY................................................................................ 285 AIRBAG INDICATOR LAMP.......................................................................... 285 ANTI-LOCK BRAKE SYSTEM LAMP.................................................................... 286 BRAKE WARNING LAMP............................................................................. 286 CHECK GAUGES LAMP.............................................................................. 286 CIGAR LIGHTER AND POWER OUTLET................................................................. 286 CLUSTER ILLUMINATION LAMP...................................................................... 286 CRUISE-ON INDICATOR LAMP....................................................................... 287 FOUR-WHEEL DRIVE INDICATOR LAMP................................................................ 287 HEADLAMP HIGH BEAM INDICATOR LAMP.............................................................. 287 LOW FUEL WARNING LAMP.......................................................................... 287 MALFUNCTION INDICATOR LAMP..................................................................... 287 SEAT BELT REMINDER LAMP........................................................................ 288 SMART KEY IMMOBILIZER SYSTEM INDICATOR LAMP.................................................... 288 TURN SIGNAL INDICATOR LAMP..................................................................... 288 UPSHIFT INDICATOR LAMP......................................................................... 288 DIAGNOSIS AND TESTING.............................................................................. 288 INSTRUMENT CLUSTER............................................................................. 288 PRELIMINARY DIAGNOSIS ..................................................................... 289 ACTUATOR TEST.............................................................................. 289 COOLANT TEMPERATURE GAUGE...................................................................... 291 FUEL GAUGE ................................................................................... 291 ODOMETER AND TRIP ODOMETER..................................................................... 291 OIL PRESSURE GAUGE............................................................................. 291 SPEEDOMETER.................................................................................... 292 TACHOMETER..................................................................................... 292 VOLTMETER...................................................................................... 292 ACCESSORY RELAY................................................................................ 292 RELAY TEST................................................................................. 292 RELAY CIRCUIT TEST......................................................................... 293 AIRBAG INDICATOR LAMP.......................................................................... 293 ANTI-LOCK BRAKE SYSTEM LAMP.................................................................... 293 BRAKE WARNING LAMP............................................................................. 294 CHECK GAUGES LAMP.............................................................................. 295 CIGAR LIGHTER AND POWER OUTLET................................................................. 295 CLUSTER ILLUMINATION LAMP...................................................................... 295 CRUISE-ON INDICATOR LAMP....................................................................... 296 FOUR-WHEEL DRIVE INDICATOR LAMP................................................................ 296 HEADLAMP HIGH BEAM INDICATOR LAMP.............................................................. 297 LOW FUEL WARNING LAMP.......................................................................... 297 MALFUNCTION INDICATOR LAMP..................................................................... 297 SEAT BELT REMINDER LAMP........................................................................ 298 SMART KEY IMMOBILIZER SYSTEM INDICATOR LAMP.................................................... 298 TURN SIGNAL INDICATOR LAMP..................................................................... 298 UPSHIFT INDICATOR LAMP......................................................................... 298 REMOVAL AND INSTALLATION........................................................................... 299 STEERING COLUMN OPENING COVER.................................................................. 299 KNEE BLOCKER................................................................................... 299 HEADLAMP SWITCH................................................................................ 300 INSTRUMENT PANEL TOP COVER..................................................................... 300 CLUSTER BEZEL.................................................................................. 300 INSTRUMENT CLUSTER............................................................................. 301 CLUSTER COMPONENTS............................................................................. 302 CLUSTER LENS AND ODOMETER RESET KNOB BOOT.................................................. 302 CLUSTER HOOD AND MASK...................................................................... 302 CLUSTER REAR COVER......................................................................... 303 CLUSTER BULB................................................................................... 303 INSTRUMENT PANEL CENTER BEZEL.................................................................. 303 ACCESSORY SWITCH BEZEL......................................................................... 304 ACCESSORY RELAY................................................................................ 304 GLOVE BOX...................................................................................... 304 GLOVE BOX COMPONENTS........................................................................... 305 GLOVE BOX DOOR AND BIN..................................................................... 305 GLOVE BOX CHECK STRAP...................................................................... 305 GLOVE BOX LATCH AND HANDLE................................................................. 306 GLOVE BOX LOCK CYLINDER.................................................................... 306 GLOVE BOX LATCH STRIKER........................................................................ 306 FUSEBLOCK MODULE............................................................................... 306 GRAB HANDLE.................................................................................... 307 GRAB HANDLE BEZEL.............................................................................. 307 INSTRUMENT PANEL ASSEMBLY...................................................................... 307 INSTRUMENT PANEL BASE.......................................................................... 309 AUDIO SYSTEMS.......................................................................................... 311 GENERAL INFORMATION................................................................................ 311 INTRODUCTION................................................................................... 311 DESCRIPTION AND OPERATION.......................................................................... 311 RADIO.......................................................................................... 311 IGNITION-OFF DRAW FUSE......................................................................... 311 SPEAKER ....................................................................................... 311 ANTENNA ....................................................................................... 311 RADIO NOISE SUPPRESSION........................................................................ 312 DIAGNOSIS AND TESTING.............................................................................. 312 AUDIO SYSTEM .................................................................................. 312 RADIO.......................................................................................... 314 SPEAKER........................................................................................ 314 ANTENNA........................................................................................ 315 TEST 1..................................................................................... 315 TEST 2..................................................................................... 315 TEST 3..................................................................................... 315 TEST 4..................................................................................... 315 RADIO FREQUENCY INTERFERENCE................................................................... 316 REMOVAL AND INSTALLATION........................................................................... 316 RADIO.......................................................................................... 316 SPEAKER........................................................................................ 317 INSTRUMENT PANEL........................................................................... 317 SOUND BAR.................................................................................. 318 SOUND BAR...................................................................................... 318 ANTENNA........................................................................................ 318 HORN SYSTEMS........................................................................................... 321 GENERAL INFORMATION................................................................................ 321 INTRODUCTION................................................................................... 321 DESCRIPTION AND OPERATION.......................................................................... 321 HORN RELAY..................................................................................... 321 HORN SWITCH.................................................................................... 321 HORN........................................................................................... 321 DIAGNOSIS AND TESTING.............................................................................. 322 HORN RELAY..................................................................................... 322 RELAY TEST................................................................................. 322 RELAY CIRCUIT TEST......................................................................... 322 HORN SWITCH.................................................................................... 322 HORN........................................................................................... 323 REMOVAL AND INSTALLATION........................................................................... 323 HORN RELAY..................................................................................... 323 HORN SWITCH.................................................................................... 323 HORN........................................................................................... 324 SPEED CONTROL SYSTEM................................................................................... 325 GENERAL INFORMATION................................................................................ 325 INTRODUCTION................................................................................... 325 DESCRIPTION AND OPERATION.......................................................................... 325 SPEED CONTROL SERVO............................................................................ 325 SPEED CONTROL SOLENOID CIRCUITS................................................................ 325 SPEED CONTROL SWITCHES......................................................................... 325 STOP LAMP SWITCH .............................................................................. 326 SERVO CABLE.................................................................................... 326 POWERTRAIN CONTROL MODULE...................................................................... 326 VACUUM RESERVOIR............................................................................... 326 VEHICLE SPEED SENSOR........................................................................... 326 DIAGNOSIS AND TESTING.............................................................................. 326 ROAD TEST...................................................................................... 326 ON-BOARD DIAGNOSTIC TEST FOR SPEED CONTROL SYSTEM.............................................. 326 VEHICLE SPEED SENSOR........................................................................... 327 SPEED CONTROL SWITCHES......................................................................... 327 STOP LAMP SWITCH............................................................................... 327 VACUUM SUPPLY TEST............................................................................. 327 SPEED CONTROL SERVO............................................................................ 327 OVERSHOOT/UNDERSHOOT FOLLOWING SPEED CONTROL SET............................................... 328 REMOVAL AND INSTALLATION........................................................................... 328 SPEED CONTROL SERVO............................................................................ 328 REMOVAL.................................................................................... 328 INSTALLATION............................................................................... 328 SPEED CONTROL SWITCH........................................................................... 329 REMOVAL.................................................................................... 329 INSTALLATION............................................................................... 329 STOP LAMP SWITCH............................................................................... 329 SERVO CABLE.................................................................................... 329 REMOVAL.................................................................................... 329 INSTALLATION............................................................................... 329 VACUUM RESERVOIR............................................................................... 330 REMOVAL.................................................................................... 330 INSTALLATION............................................................................... 330 SPECIFICATIONS..................................................................................... 330 TORQUE CHART................................................................................... 330 TURN SIGNAL AND HAZARD WARNING SYSTEMS................................................................. 331 GENERAL INFORMATION................................................................................ 331 INTRODUCTION................................................................................... 331 DESCRIPTION AND OPERATION.......................................................................... 331 TURN SIGNAL SYSTEM............................................................................. 331 HAZARD WARNING SYSTEM.......................................................................... 331 COMBINATION FLASHER............................................................................ 331 TURN SIGNAL INDICATOR LAMP..................................................................... 333 TURN SIGNAL LAMP............................................................................... 333 DIAGNOSIS AND TESTING.............................................................................. 333 INTRODUCTION................................................................................... 333 TURN SIGNAL AND HAZARD WARNING SYSTEMS......................................................... 333 TURN SIGNAL SWITCH AND HAZARD WARNING SWITCH................................................... 332 MULTI-FUNCTION SWITCH.......................................................................... 334 REMOVAL AND INSTALLATION........................................................................... 334 COMBINATION FLASHER............................................................................ 334 MULTI-FUNCTION SWITCH.......................................................................... 335 WIPER AND WASHER SYSTEMS............................................................................... 337 GENERAL INFORMATION................................................................................ 337 INTRODUCTION................................................................................... 337 DESCRIPTION AND OPERATION.......................................................................... 337 WINDSHIELD WIPER SYSTEM........................................................................ 337 WINDSHIELD WASHER SYSTEM....................................................................... 337 REAR WIPER AND WASHER SYSTEM................................................................... 337 WIPER ARM AND BLADE............................................................................ 338 WIPER LINKAGE AND PIVOT........................................................................ 338 WIPER MOTOR.................................................................................... 338 FRONT...................................................................................... 338 REAR....................................................................................... 338 WIPER SWITCH AND WASHER SWITCH................................................................. 339 FRONT...................................................................................... 339 REAR....................................................................................... 339 WASHER RESERVOIR............................................................................... 339 WASHER PUMP.................................................................................... 339 WASHER NOZZLE AND PLUMBING..................................................................... 339 FRONT...................................................................................... 339 REAR....................................................................................... 340 DIAGNOSIS AND TESTING.............................................................................. 340 WIPER SYSTEM................................................................................... 340 FRONT...................................................................................... 340 REAR....................................................................................... 341 WASHER SYSTEM.................................................................................. 342 FRONT...................................................................................... 342 REAR....................................................................................... 342 WIPER SWITCH AND WASHER SWITCH................................................................. 343 FRONT...................................................................................... 343 REAR....................................................................................... 343 REMOVAL AND INSTALLATION........................................................................... 344 WIPER BLADE.................................................................................... 344 FRONT...................................................................................... 344 REAR....................................................................................... 344 WIPER ARM...................................................................................... 344 FRONT...................................................................................... 344 REAR....................................................................................... 345 WIPER LINKAGE AND PIVOT........................................................................ 345 WIPER MOTOR.................................................................................... 345 FRONT...................................................................................... 345 REAR....................................................................................... 346 WIPER SWITCH AND WASHER SWITCH................................................................. 347 FRONT...................................................................................... 347 REAR....................................................................................... 348 WASHER SYSTEM.................................................................................. 348 WASHER RESERVOIR........................................................................... 348 WASHER PUMP................................................................................ 349 WASHER NOZZLE.............................................................................. 349 CHECK VALVE................................................................................ 350 LAMPS.................................................................................................. 351 LAMP DIAGNOSIS..................................................................................... 351 GENERAL INFORMATION............................................................................ 351 GENERAL INFORMATION........................................................................ 351 SAFETY PRECAUTIONS......................................................................... 351 DIAGNOSIS AND TESTING.......................................................................... 351 DIAGNOSTIC PROCEDURES...................................................................... 351 HEADLAMP................................................................................... 352 HEADLAMP DIAGNOSIS..................................................................... 352 FOG LAMP................................................................................... 353 FOG LAMP DIAGNOSIS..................................................................... 353 DAYTIME RUNNING LAMP....................................................................... 354 DAYTIME RUNNING LAMP DIAGNOSIS......................................................... 354 GENERAL INFORMATION............................................................................ 355 HEADLAMP ALIGNMENT......................................................................... 355 SERVICE PROCEDURES............................................................................. 355 HEADLAMP ALIGNMENT PREPARATION............................................................. 355 ALIGNMENT SCREEN PREPARATION............................................................... 355 HEADLAMP ADJUSTMENT........................................................................ 356 FOG LAMP ADJUSTMENT........................................................................ 356 SPECIAL TOOLS.................................................................................. 357 HEADLAMP ALIGNMENT......................................................................... 357 REMOVAL AND INSTALLATION....................................................................... 358 HEADLAMP BULB.............................................................................. 358 FOG LAMP BULB.............................................................................. 358 REMOVAL ............................................................................... 358 INSTALLATION........................................................................... 358 FRONT PARK/TURN SIGNAL LAMP BULB .......................................................... 358 REMOVAL................................................................................ 358 INSTALLATION........................................................................... 358 SIDE MARKER LAMP BULB...................................................................... 358 REMOVAL................................................................................ 358 INSTALLATION........................................................................... 358 TAIL/TURN SIGNAL/BACK-UP LAMP BULB......................................................... 358 REMOVAL................................................................................ 358 INSTALLATION........................................................................... 359 BACK-UP LAMP BULB.......................................................................... 359 CENTER HIGH MOUNTED STOP LAMP (CHMSL) BULB................................................. 359 REMOVAL................................................................................ 359 INSTALLATION........................................................................... 359 UNDERHOOD LAMP BULB........................................................................ 359 REMOVAL................................................................................ 359 INSTALLATION........................................................................... 359 DOME LAMP.................................................................................. 360 SOUND BAR DOME LAMP BULB REMOVAL....................................................... 360 SOUND BAR DOME LAMP BULB INSTALLATION.................................................. 360 CARGO AREA DOME LAMP BULB REMOVAL...................................................... 360 CARGO AREA DOME LAMP BULB INSTALLATION................................................. 360 REMOVAL AND INSTALLATION....................................................................... 361 HEADLAMP................................................................................... 361 REMOVAL................................................................................ 361 INSTALLATION........................................................................... 361 FOG LAMP................................................................................... 361 REMOVAL................................................................................ 361 INSTALLATION .......................................................................... 361 FRONT PARK/TURN SIGNAL LAMP................................................................ 362 REMOVAL................................................................................ 362 INSTALLATION........................................................................... 362 SIDE MARKER LAMP........................................................................... 362 REMOVAL................................................................................ 362 INSTALLATION........................................................................... 362 TAIL/STOP/TURN SIGNAL/BACK-UP LAMP......................................................... 362 REMOVAL................................................................................ 362 INSTALLATION .......................................................................... 363 CENTER HIGH MOUNTED STOP LAMP (CHMSL)...................................................... 363 REMOVAL................................................................................ 363 INSTALLATION .......................................................................... 363 UNDERHOOD LAMP............................................................................. 363 REMOVAL................................................................................ 363 INSTALLATION........................................................................... 363 DOME LAMP.................................................................................. 364 SOUND BAR DOME LAMP REMOVAL............................................................ 364 SOUND BAR DOME LAMP INSTALLATION....................................................... 364 CARGO AREA DOME LAMP REMOVAL........................................................... 364 CARGO AREA DOME LAMP INSTALLATION...................................................... 364 GENERAL INFORMATION............................................................................ 365 DAYTIME RUNNING LIGHTS (CANADA ONLY)....................................................... 365 REMOVAL AND INSTALLATION....................................................................... 365 DAYTIME RUNNING LAMP (DRL) MODULE.......................................................... 365 REMOVAL................................................................................ 365 INSTALLATION........................................................................... 365 GENERAL INFORMATION............................................................................ 366 GENERAL INFORMATION........................................................................ 366 SPECIFICATIONS................................................................................. 366 EXTERIOR LAMPS............................................................................. 366 INTERIOR LAMPS............................................................................. 366 LAMPS.................................................................................................. 367 GENERAL INFORMATION................................................................................ 367 GENERAL INFORMATION............................................................................ 367 SAFETY PRECAUTIONS......................................................................... 367 HEADLAMP LEVELING MOTOR........................................................................ 367 DIAGNOSIS AND TESTING.............................................................................. 368 DIAGNOSTIC PROCEDURES.......................................................................... 368 HEADLAMP DIAGNOSIS......................................................................... 368 FOG LAMP DIAGNOSIS......................................................................... 369 HEADLAMP LEVELING MOTOR DIAGNOSIS.......................................................... 370 REMOVAL AND INSTALLATION........................................................................... 371 HEADLAMP BULB.................................................................................. 371 REMOVAL.................................................................................... 371 INSTALLATION............................................................................... 372 CITYLIGHT LAMP BULB............................................................................ 372 REMOVAL.................................................................................... 372 INSTALLATION............................................................................... 372 TAIL LAMP BULB................................................................................. 372 REMOVAL.................................................................................... 372 INSTALLATION............................................................................... 372 REAR FOG LAMP BULB............................................................................. 373 REMOVAL.................................................................................... 373 INSTALLATION............................................................................... 373 LICENSE PLATE LAMP BULB........................................................................ 373 REMOVAL.................................................................................... 373 INSTALLATION............................................................................... 373 CENTER HIGH MOUNTED STOP LAMP (CHMSL) BULB..................................................... 373 REMOVAL.................................................................................... 373 INSTALLATION............................................................................... 373 REMOVAL AND INSTALLATION........................................................................... 374 HEADLAMP ASSEMBLY.............................................................................. 374 REMOVAL.................................................................................... 374 INSTALLATION............................................................................... 374 HEADLAMP LEVELING MOTOR........................................................................ 374 REMOVAL.................................................................................... 374 INSTALLATION............................................................................... 375 TAIL LAMP...................................................................................... 375 REMOVAL.................................................................................... 375 INSTALLATION............................................................................... 375 CENTER HIGH MOUNTED STOP LAMP (CHMSL).......................................................... 375 REMOVAL.................................................................................... 375 INSTALLATION............................................................................... 376 REAR FOG LAMP.................................................................................. 376 REMOVAL.................................................................................... 376 INSTALLATION............................................................................... 376 GENERAL INFORMATION................................................................................ 377 GENERAL INFORMATION............................................................................ 377 SPECIFICATIONS..................................................................................... 377 EXTERIOR LAMPS................................................................................. 377 INTERIOR LAMPS................................................................................. 377 PASSIVE RESTRAINT SYSTEMS.............................................................................. 379 GENERAL INFORMATION................................................................................ 379 INTRODUCTION................................................................................... 379 DESCRIPTION AND OPERATION.......................................................................... 380 AIRBAG MODULE.................................................................................. 380 DRIVER SIDE................................................................................ 380 PASSENGER SIDE............................................................................. 380 STORAGE.................................................................................... 380 IMPACT SENSOR.................................................................................. 381 CLOCKSPRING.................................................................................... 381 AIRBAG CONTROL MODULE.......................................................................... 381 DIAGNOSIS AND TESTING.............................................................................. 381 AIRBAG SYSTEM.................................................................................. 381 SERVICE PROCEDURES................................................................................. 382 AIRBAG SYSTEM.................................................................................. 382 NON-DEPLOYED............................................................................... 382 DEPLOYED................................................................................... 382 CLEANUP PROCEDURE.............................................................................. 382 REMOVAL AND INSTALLATION........................................................................... 383 AIRBAG MODULE.................................................................................. 383 DRIVER SIDE................................................................................ 383 PASSENGER SIDE............................................................................. 383 DRIVER SIDE AIRBAG TRIM COVER AND HORN SWITCH.................................................. 384 PASSENGER SIDE AIRBAG DOOR..................................................................... 386 AIRBAG CONTROL MODULE.......................................................................... 387 CLOCKSPRING.................................................................................... 388 ADJUSTMENTS........................................................................................ 389 CLOCKSPRING CENTERING.......................................................................... 389 SPECIAL TOOLS...................................................................................... 390 STEERING WHEEL................................................................................. 390 ELECTRICALLY HEATED SYSTEMS............................................................................ 391 GENERAL INFORMATION ............................................................................... 391 INTRODUCTION .................................................................................. 391 DESCRIPTION AND OPERATION.......................................................................... 391 REAR GLASS HEATING GRID........................................................................ 391 DEFOGGER SWITCH................................................................................ 391 INSTRUMENT CLUSTER............................................................................. 392 DEFOGGER RELAY................................................................................. 392 DIAGNOSIS AND TESTING.............................................................................. 392 DEFOGGER SYSTEM................................................................................ 392 REAR GLASS HEATING GRID........................................................................ 393 DEFOGGER SWITCH................................................................................ 393 DEFOGGER RELAY................................................................................. 394 RELAY TEST................................................................................. 394 RELAY CIRCUIT TEST......................................................................... 394 INSTRUMENT CLUSTER............................................................................. 394 SERVICE PROCEDURES................................................................................. 395 REAR GLASS HEATING GRID REPAIR................................................................. 395 REMOVAL AND INSTALLATION........................................................................... 396 DEFOGGER SWITCH................................................................................ 396 DEFOGGER RELAY................................................................................. 396 VEHICLE THEFT/SECURITY SYSTEMS......................................................................... 397 GENERAL INFORMATION................................................................................ 397 INTRODUCTION................................................................................... 397 SMART KEY IMMOBILIZER SYSTEM................................................................... 397 DESCRIPTION AND OPERATION.......................................................................... 397 SMART KEY IMMOBILIZER MODULE................................................................... 397 SMART KEY IMMOBILIZER TRANSPONDER.............................................................. 398 SMART KEY IMMOBILIZER SYSTEM INDICATOR LAMP.................................................... 399 DIAGNOSIS AND TESTING.............................................................................. 399 SMART KEY IMMOBILIZER SYSTEM................................................................... 399 SERVICE PROCEDURES................................................................................. 400 SMART KEY IMMOBILIZER SYSTEM TRANSPONDER PROGRAMMING........................................... 400 CUSTOMER LEARN............................................................................. 400 REMOVAL AND INSTALLATION........................................................................... 400 SMART KEY IMMOBILIZER MODULE................................................................... 400 CHIME/BUZZER WARNING SYSTEMS........................................................................... 403 GENERAL INFORMATION................................................................................ 403 INTRODUCTION................................................................................... 403 DESCRIPTION AND OPERATION.......................................................................... 403 INSTRUMENT CLUSTER............................................................................. 403 DRIVER DOOR JAMB SWITCH........................................................................ 403 DRIVER SEAT BELT SWITCH........................................................................ 404 KEY-IN IGNITION SWITCH......................................................................... 404 HEADLAMP SWITCH................................................................................ 404 DIAGNOSIS AND TESTING.............................................................................. 404 DRIVER DOOR JAMB SWITCH........................................................................ 404 DRIVER SEAT BELT SWITCH........................................................................ 404 KEY-IN IGNITION SWITCH......................................................................... 405 HEADLAMP SWITCH................................................................................ 405 INSTRUMENT CLUSTER............................................................................. 405 REMOVAL AND INSTALLATION........................................................................... 406 CHIME WARNING SYSTEM SWITCHES.................................................................. 406 WIRING DIAGRAMS........................................................................................ 407 8W- 01 GENERAL INFORMATION......................................................................... 409 DESCRIPTION AND OPERATION...................................................................... 409 INTRODUCTION............................................................................... 409 CIRCUIT INFORMATION........................................................................ 412 CIRCUIT FUNCTIONS.......................................................................... 412 SECTION IDENTIFICATION..................................................................... 413 SYMBOLS.................................................................................... 413 TERMINOLOGY................................................................................ 415 CONNECTOR INFORMATION...................................................................... 415 IDENTIFICATION......................................................................... 415 LOCATIONS.............................................................................. 415 SPLICE LOCATIONS........................................................................... 415 NOTES, CAUTIONS, and WARNINGS.............................................................. 415 TAKE OUTS.................................................................................. 416 ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES............................................ 416 DIAGNOSIS AND TESTING.......................................................................... 416 TROUBLESHOOTING TOOLS...................................................................... 416 INTERMITTENT AND POOR CONNECTIONS.......................................................... 417 TROUBLESHOOTING TESTS...................................................................... 417 TESTING FOR VOLTAGE POTENTIAL.......................................................... 417 TESTING FOR CONTINUITY................................................................. 417 TESTING FOR A SHORT TO GROUND.......................................................... 418 TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS.......................... 418 TESTING FOR A VOLTAGE DROP............................................................. 418 TROUBLESHOOTING WIRING PROBLEMS............................................................ 418 SERVICE PROCEDURES............................................................................. 418 WIRING REPAIR.............................................................................. 418 TERMINAL/ CONNECTOR REPAIR- MOLEX CONNECTORS............................................... 419 TERMINAL/ CONNECTOR REPAIR— THOMAS AND BETTS CONNECTORS.................................... 419 CONNECTOR REPLACEMENT...................................................................... 419 CONNECTOR AND TERMINAL REPLACEMENT......................................................... 421 TERMINAL REPLACEMENT....................................................................... 421 DIODE REPLACEMENT.......................................................................... 422 SPECIAL TOOLS.................................................................................. 423 WIRING/ TERMINAL........................................................................... 423 8W- 02 COMPONENT INDEX............................................................................. 425 8W- 10 POWER DISTRIBUTION.......................................................................... 427 8W- 11 FUSE BLOCK.................................................................................. 447 8W- 15 GROUND DISTRIBUTION......................................................................... 457 8W- 20 CHARGING SYSTEM............................................................................. 469 8W- 21 STARTING SYSTEM............................................................................. 471 8W- 30 FUEL/ IGNITION SYSTEMS...................................................................... 473 8W- 31 TRANSMISSION CONTROL SYSTEM................................................................. 491 8W- 35 ALL WHEEL ANTI- LOCK BRAKES................................................................. 493 8W- 40 INSTRUMENT CLUSTER.......................................................................... 499 8W- 41 HORN/ CIGAR LIGHTER......................................................................... 509 8W- 42 AIR CONDITIONING- HEATER.................................................................... 511 8W- 43 AIRBAG SYSTEM............................................................................... 515 8W- 44 INTERIOR LIGHTING........................................................................... 517 8W- 47 AUDIO SYSTEMS............................................................................... 523 8W- 48 REAR WINDOW DEFOGGER........................................................................ 527 8W- 50 FRONT LIGHTING.............................................................................. 529 8W- 51 REAR LIGHTING............................................................................... 537 8W- 52 TURN SIGNALS................................................................................ 545 8W- 53 WIPERS...................................................................................... 549 8W- 70 SPLICE INFORMATION.......................................................................... 553 8W- 80 CONNECTOR PIN- OUTS......................................................................... 557 8W- 90 CONNECTOR/ GROUND LOCATIONS................................................................. 595 DESCRIPTION AND OPERATION...................................................................... 595 INTRODUCTION............................................................................... 595 CONNECTOR/ GROUND LOCATIONS (LHD).......................................................... 595 CONNECTOR/ GROUND LOCATIONS (RHD).......................................................... 616 8W- 95 SPLICE LOCATIONS............................................................................ 635 DESCRIPTION AND OPERATION...................................................................... 635 INTRODUCTION............................................................................... 635 SPLICE LOCATIONS (LHD)..................................................................... 635 SPLICE LOCATIONS (RHD)..................................................................... 644 ENGINE................................................................................................. 653 GENERAL INFORMATION................................................................................ 653 FORM-IN-PLACE GASKETS.......................................................................... 653 MOPAR SILICONE RUBBER ADHESIVE SEALANT..................................................... 653 MOPAR GASKET MAKER......................................................................... 653 SURFACE PREPARATION........................................................................ 653 GASKET APPLICATION......................................................................... 653 ENGINE PERFORMANCE............................................................................. 654 HONING CYLINDER BORES.......................................................................... 654 MEASURING WITH PLASTIGAGE...................................................................... 655 CRANKSHAFT MAIN BEARING CLEARANCE.......................................................... 655 CONNECTING ROD BEARING CLEARANCE........................................................... 655 REPAIR DAMAGED OR WORN THREADS................................................................. 656 SERVICE ENGINE ASSEMBLY (SHORT BLOCK) ......................................................... 656 HYDROSTATIC LOCK............................................................................... 656 ENGINE OIL SERVICE............................................................................. 656 ENGINE OIL SPECIFICATION................................................................... 656 API SERVICE GRADE CERTIFIED................................................................ 657 SAE VISCOSITY.............................................................................. 657 ENERGY CONSERVING OIL...................................................................... 657 CRANKCASE OIL LEVEL INSPECTION............................................................. 657 ENGINE OIL CHANGE.......................................................................... 658 ENGINE OIL FILTER CHANGE................................................................... 658 DIAGNOSIS AND TESTING.............................................................................. 659 GENERAL INFORMATION............................................................................ 659 HYDRAULIC TAPPETS.............................................................................. 659 LEAK-DOWN TEST............................................................................. 659 INTAKE MANIFOLD LEAKAGE DIAGNOSIS.............................................................. 660 CYLINDER COMPRESSION PRESSURE TEST............................................................. 660 ENGINE CYLINDER HEAD GASKET FAILURE DIAGNOSIS.................................................. 660 CYLINDER-TO-CYLINDER LEAKAGE TEST.......................................................... 660 CYLINDER-TO-WATER JACKET LEAKAGE TEST...................................................... 660 CYLINDER COMBUSTION PRESSURE LEAKAGE TEST...................................................... 660 CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART....................................... 661 ENGINE OIL LEAK INSPECTION..................................................................... 661 Air Leak Detection Test Method............................................................. 661 INSPECTION FOR REAR SEAL AREA LEAKS........................................................ 661 ENGINE OIL PRESSURE............................................................................ 662 SERVICE DIAGNOSIS—PERFORMANCE.................................................................. 663 ENGINE PERFORMANCE DIAGNOSIS CHART......................................................... 663 SERVICE DIAGNOSIS—MECHANICAL................................................................... 665 ENGINE MECHANICAL DIAGNOSIS CHART.......................................................... 665 DESCRIPTION AND OPERATION.......................................................................... 667 ENGINE DESCRIPTION............................................................................. 667 BUILD DATE CODE............................................................................ 667 LUBRICATION SYSTEM............................................................................. 668 OIL PUMP PRESSURE.............................................................................. 670 OVERSIZE AND UNDERSIZE COMPONENT CODES......................................................... 670 SERVICE PROCEDURES................................................................................. 670 VALVE TIMING................................................................................... 670 PISTON FITTING................................................................................. 670 BORE GAUGE METHOD.......................................................................... 670 PISTON RING FITTING............................................................................ 671 FITTING CONNECTING ROD BEARINGS................................................................ 673 INSPECTION................................................................................. 673 BEARING-TO-JOURNAL CLEARANCE............................................................... 674 CONNECTING ROD BEARING FITTING CHART....................................................... 675 SIDE CLEARANCE MEASUREMENT................................................................. 675 FITTING CRANKSHAFT MAIN BEARINGS............................................................... 675 INSPECTION................................................................................. 675 FITTING BEARINGS (CRANKSHAFT INSTALLED).................................................... 675 MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)......................................... 677 MAIN BEARING FITTING CHART................................................................. 678 REMOVAL AND INSTALLATION........................................................................... 679 ENGINE MOUNTS—FRONT............................................................................ 679 REMOVAL.................................................................................... 679 INSTALLATION............................................................................... 679 ENGINE MOUNT—REAR.............................................................................. 679 REMOVAL.................................................................................... 679 INSTALLATION............................................................................... 680 ENGINE ASSEMBLY................................................................................ 680 REMOVAL.................................................................................... 680 INSTALLATION............................................................................... 681 CYLINDER HEAD COVER............................................................................ 683 REMOVAL.................................................................................... 683 INSTALLATION............................................................................... 683 ROCKER ARMS AND PUSH RODS...................................................................... 683 REMOVAL.................................................................................... 683 INSTALLATION............................................................................... 684 VALVE SPRINGS AND OIL SEALS.................................................................... 684 REMOVAL.................................................................................... 684 INSTALLATION............................................................................... 684 ENGINE CYLINDER HEAD........................................................................... 685 REMOVAL.................................................................................... 685 INSTALLATION............................................................................... 686 VALVES AND VALVE SPRINGS....................................................................... 687 REMOVAL.................................................................................... 687 INSTALLATION............................................................................... 687 HYDRAULIC TAPPETS ............................................................................. 688 REMOVAL ................................................................................... 688 INSTALLATION............................................................................... 688 VIBRATION DAMPER............................................................................... 688 REMOVAL.................................................................................... 688 INSTALLATION............................................................................... 688 TIMING CASE COVER OIL SEAL..................................................................... 688 REMOVAL.................................................................................... 688 INSTALLATION............................................................................... 689 TIMING CASE COVER.............................................................................. 689 REMOVAL.................................................................................... 689 INSTALLATION............................................................................... 689 TIMING CHAIN AND SPROCKETS..................................................................... 690 REMOVAL.................................................................................... 690 INSTALLATION............................................................................... 690 CAMSHAFT....................................................................................... 691 REMOVAL.................................................................................... 691 INSTALLATION............................................................................... 691 CAMSHAFT PIN REPLACEMENT....................................................................... 692 REMOVAL.................................................................................... 692 INSTALLATION............................................................................... 693 CAMSHAFT BEARINGS.............................................................................. 693 CRANKSHAFT MAIN BEARINGS....................................................................... 693 REMOVAL.................................................................................... 693 INSTALLATION............................................................................... 694 OIL PAN........................................................................................ 695 REMOVAL.................................................................................... 695 INSTALLATION............................................................................... 695 OIL PUMP....................................................................................... 696 REMOVAL.................................................................................... 696 INSTALLATION............................................................................... 697 PISTONS AND CONNECTING RODS.................................................................... 697 REMOVAL.................................................................................... 697 INSTALLATION............................................................................... 697 REAR MAIN OIL SEALS............................................................................ 698 REMOVAL.................................................................................... 698 INSTALLATION............................................................................... 698 DISASSEMBLY AND ASSEMBLY........................................................................... 698 VALVE SERVICE.................................................................................. 698 VALVE REFACING............................................................................. 699 VALVE SEAT REFACING........................................................................ 699 VALVE STEM OIL SEAL REPLACEMENT............................................................ 699 VALVE GUIDES............................................................................... 699 VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT.................................................. 699 CYLINDER BLOCK................................................................................. 700 DISASSEMBLY................................................................................ 700 ASSEMBLY................................................................................... 700 CLEANING AND INSPECTION............................................................................ 701 ROCKER ARMS AND PUSH RODS ..................................................................... 701 CLEANING .................................................................................. 701 INSPECTION................................................................................. 701 HYDRAULIC TAPPETS.............................................................................. 701 CLEANING................................................................................... 701 INSPECTION................................................................................. 701 ENGINE CYLINDER HEAD........................................................................... 701 CLEANING................................................................................... 701 INSPECTION................................................................................. 701 CYLINDER BLOCK................................................................................. 701 CLEANING................................................................................... 701 INSPECTION—CYLINDER BORE................................................................... 702 HONING—CYLINDER BORE....................................................................... 702 SPECIFICATIONS..................................................................................... 703 2.5L ENGINE.................................................................................... 703 2.5L Engine Description.................................................................... 703 2.5L Engine Specifications................................................................. 703 2.5L TORQUE SPECIFICATIONS..................................................................... 705 SPECIAL TOOLS...................................................................................... 706 2.5L ENGINE.................................................................................... 706 DESCRIPTION AND OPERATION.......................................................................... 707 ENGINE DESCRIPTION............................................................................. 707 LUBRICATION SYSTEM............................................................................. 708 OIL PUMP PRESSURE.............................................................................. 708 OVERSIZE AND UNDERSIZE COMPONENT CODES......................................................... 708 SERVICE PROCEDURES................................................................................. 708 VALVE TIMING................................................................................... 708 PISTON FITTING................................................................................. 710 BORE GAGE METHOD........................................................................... 710 PISTON RING FITTING............................................................................ 711 FITTING CONNECTING ROD BEARINGS................................................................ 712 INSPECTION................................................................................. 712 SIDE CLEARANCE MEASUREMENT................................................................. 714 FITTING CRANKSHAFT MAIN BEARINGS............................................................... 714 INSPECTION................................................................................. 714 FITTING BEARINGS (CRANKSHAFT INSTALLED).................................................... 715 MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)......................................... 717 MAIN BEARING FITTING CHART................................................................. 717 REMOVAL AND INSTALLATION........................................................................... 718 ENGINE MOUNTS—FRONT............................................................................ 718 REMOVAL.................................................................................... 718 INSTALLATION............................................................................... 718 ENGINE MOUNT—REAR.............................................................................. 718 REMOVAL.................................................................................... 719 INSTALLATION............................................................................... 719 ENGINE ASSEMBLY................................................................................ 720 REMOVAL.................................................................................... 720 INSTALLATION............................................................................... 721 ENGINE CYLINDER HEAD COVER..................................................................... 722 REMOVAL.................................................................................... 722 INSTALLATION............................................................................... 722 ROCKER ARMS AND PUSH RODS...................................................................... 723 REMOVAL ................................................................................... 723 INSTALLATION............................................................................... 723 VALVE STEM SEAL AND SPRING..................................................................... 723 REMOVAL.................................................................................... 724 INSTALLATION............................................................................... 724 ENGINE CYLINDER HEAD........................................................................... 724 REMOVAL.................................................................................... 724 INSTALLATION............................................................................... 725 CYLINDER HEAD BOLTS........................................................................ 725 VALVES AND VALVE SPRINGS....................................................................... 726 REMOVAL.................................................................................... 726 INSTALLATION............................................................................... 726 HYDRAULIC TAPPETS.............................................................................. 726 REMOVAL.................................................................................... 726 INSTALLATION............................................................................... 726 VIBRATION DAMPER............................................................................... 727 REMOVAL.................................................................................... 727 INSTALLATION............................................................................... 727 TIMING CASE COVER.............................................................................. 727 REMOVAL.................................................................................... 727 INSTALLATION............................................................................... 727 TIMING CHAIN AND SPROCKETS..................................................................... 728 REMOVAL.................................................................................... 728 INSTALLATION............................................................................... 728 CAMSHAFT....................................................................................... 729 REMOVAL.................................................................................... 729 INSTALLATION............................................................................... 729 CAMSHAFT PIN REPLACEMENT....................................................................... 730 REMOVAL.................................................................................... 730 CAMSHAFT BEARINGS.......................................................................... 731 INSTALLATION............................................................................... 731 OIL PAN........................................................................................ 732 REMOVAL.................................................................................... 732 INSTALLATION............................................................................... 732 OIL PUMP ...................................................................................... 733 REMOVAL.................................................................................... 733 INSTALLATION............................................................................... 733 CRANKSHAFT MAIN BEARINGS....................................................................... 733 REMOVAL.................................................................................... 733 INSTALLATION............................................................................... 734 PISTONS AND CONNECTING RODS.................................................................... 735 REMOVAL.................................................................................... 735 INSTALLATION............................................................................... 735 REAR MAIN OIL SEALS............................................................................ 736 REMOVAL.................................................................................... 736 INSTALLATION............................................................................... 737 TIMING CASE COVER OIL SEAL..................................................................... 737 REMOVAL.................................................................................... 737 INSTALLATION............................................................................... 737 DISASSEMBLY AND ASSEMBLY........................................................................... 738 VALVE SERVICE.................................................................................. 738 VALVE REFACING............................................................................. 738 VALVE SEAT REFACING........................................................................ 738 VALVE STEM OIL SEAL REPLACEMENT............................................................ 738 VALVE GUIDES............................................................................... 738 VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT.................................................. 739 VALVE SPRING TENSION TEST.................................................................. 739 CYLINDER BLOCK................................................................................. 740 DISASSEMBLY................................................................................ 740 ASSEMBLY................................................................................... 740 CLEANING AND INSPECTION............................................................................ 740 ENGINE CYLINDER HEAD........................................................................... 740 CLEANING................................................................................... 740 INSPECTION................................................................................. 740 ROCKER ARMS AND PUSH RODS...................................................................... 740 CLEANING................................................................................... 740 INSPECTION................................................................................. 740 HYDRAULIC TAPPETS.............................................................................. 740 CLEANING................................................................................... 740 INSPECTION................................................................................. 740 CYLINDER BLOCK................................................................................. 741 CLEANING................................................................................... 741 INSPECTION—CYLINDER BORE................................................................... 741 HONING—CYLINDER BORE....................................................................... 741 SPECIFICATIONS..................................................................................... 742 4.0L ENGINE SPECIFICATIONS..................................................................... 742 4.0L Engine Description.................................................................... 742 4.0L Engine Specifications................................................................. 742 4.0L TORQUE SPECIFICATIONS..................................................................... 744 TORQUE SPECIFICATIONS...................................................................... 744 SPECIAL TOOLS...................................................................................... 745 4.0L ENGINE.................................................................................... 745 EXHAUST SYSTEM AND INTAKE MANIFOLD..................................................................... 747 GENERAL INFORMATION................................................................................ 747 EXHAUST SYSTEM................................................................................. 747 CATALYTIC CONVERTER............................................................................ 749 EXHAUST HEAT SHIELDS........................................................................... 749 DIAGNOSIS AND TESTING.............................................................................. 749 EXHAUST SYSTEM................................................................................. 749 EXHAUST SYSTEM DIAGNOSIS CHART............................................................. 749 REMOVAL AND INSTALLATION........................................................................... 750 EXHAUST PIPE................................................................................... 750 REMOVAL.................................................................................... 750 INSTALLATION............................................................................... 750 MUFFLER AND TAILPIPE ASSEMBLY.................................................................. 750 REMOVAL.................................................................................... 751 INSTALLATION............................................................................... 751 INTAKE MANIFOLD—2.5L ENGINE.................................................................... 752 REMOVAL.................................................................................... 752 INSTALLATION............................................................................... 753 INTAKE MANIFOLD—4.0L ENGINE.................................................................... 753 REMOVAL.................................................................................... 753 INSTALLATION............................................................................... 754 EXHAUST MANIFOLD—2.5L ENGINE................................................................... 754 REMOVAL.................................................................................... 754 INSTALLATION............................................................................... 755 EXHAUST MANIFOLD—4.0L ENGINE................................................................... 755 SPECIFICATIONS..................................................................................... 755 TORQUE SPECIFICATIONS.......................................................................... 755 FRAME AND BUMPERS...................................................................................... 757 REMOVAL AND INSTALLATION........................................................................... 757 FRONT TOW HOOK................................................................................. 757 REMOVAL.................................................................................... 757 INSTALLATION............................................................................... 757 FRONT BUMPER EXTENSION......................................................................... 757 REMOVAL.................................................................................... 757 INSTALLATION............................................................................... 757 FRONT BUMPER................................................................................... 758 REMOVAL.................................................................................... 758 INSTALLATION............................................................................... 758 REAR BUMPER.................................................................................... 758 REMOVAL.................................................................................... 758 INSTALLATION............................................................................... 758 REAR BUMPER EXTENSION.......................................................................... 758 REMOVAL.................................................................................... 758 INSTALLATION............................................................................... 758 GENERAL INFORMATION................................................................................ 759 GENERAL INFORMATION............................................................................ 759 SERVICE PROCEDURES................................................................................. 760 FRAME SERVICE.................................................................................. 760 SAFETY PRECAUTIONS AND WARNINGS............................................................ 760 FRAME STRAIGHTENING........................................................................ 760 FRAME REPAIRS.............................................................................. 760 FRAME FASTENERS............................................................................ 761 REMOVAL AND INSTALLATION........................................................................... 761 TRANSFER CASE SKID PLATE....................................................................... 761 REMOVAL.................................................................................... 761 INSTALLATION............................................................................... 761 FUEL TANK SKID PLATE........................................................................... 762 REMOVAL.................................................................................... 762 INSTALLATION............................................................................... 762 SPECIFICATIONS..................................................................................... 763 VEHICLE DIMENSIONS............................................................................. 763 WINDSHIELD OPENING......................................................................... 763 DOOR OPENING............................................................................... 763 QUARTER WINDOW OPENING..................................................................... 764 ENGINE COMPARTMENT......................................................................... 765 TAILGATE AND LIFTGATE OPENING.............................................................. 765 FRAME SIDE VIEW............................................................................ 767 FRAME TOP VIEW............................................................................. 768 TORQUE SPECIFICATIONS.......................................................................... 769 FRAME AND BUMPERS...................................................................................... 771 REMOVAL AND INSTALLATION........................................................................... 771 EMERGENCY TOE EYE.............................................................................. 771 REMOVAL.................................................................................... 771 INSTALLATION............................................................................... 771 FRONT BUMPER EXTENSIONS........................................................................ 771 REMOVAL.................................................................................... 771 INSTALLATION............................................................................... 771 FRONT LICENSE PLATE BRACKET.................................................................... 772 REMOVAL.................................................................................... 772 INSTALLATION............................................................................... 772 REAR LICENSE PLATE BRACKET..................................................................... 772 REMOVAL.................................................................................... 772 INSTALLATION............................................................................... 772 FUEL SYSTEM............................................................................................ 773 GENERAL INFORMATION................................................................................ 773 GENERAL INFORMATION............................................................................ 773 INTRODUCTION............................................................................... 773 FUEL REQUIREMENTS.......................................................................... 773 GASOLINE/ OXYGENATE BLENDS................................................................. 773 FUEL DELIVERY SYSTEM............................................................................... 775 DESCRIPTION AND OPERATION...................................................................... 775 FUEL DELIVERY SYSTEM....................................................................... 775 FUEL PUMP MODULE........................................................................... 776 FUEL PUMP.................................................................................. 776 FUEL GAUGE SENDING UNIT.................................................................... 776 FUEL FILTER/ FUEL PRESSURE REGULATOR....................................................... 776 FUEL TANK.................................................................................. 777 ROLLOVER VALVE( S)......................................................................... 777 FUEL INJECTORS............................................................................. 777 FUEL RAIL/ FUEL DAMPER— 2.5L ENGINE........................................................ 778 FUEL RAIL— 4.0L ENGINE..................................................................... 778 FUEL TANK FILLER TUBE CAP.................................................................. 778 QUICK- CONNECT FITTINGS.................................................................... 778 DIAGNOSIS AND TESTING.......................................................................... 779 FUEL PUMP PRESSURE TEST— ALL ENGINES WITH PRESSURE TEST PORT............................... 779 FUEL PUMP CAPACITY TEST.................................................................... 779 FUEL PRESSURE LEAK DOWN TEST............................................................... 780 FUEL PUMP AMPERAGE TEST.................................................................... 781 FUEL GAUGE SENDING UNIT.................................................................... 782 FUEL INJECTOR TEST......................................................................... 783 SERVICE PROCEDURES............................................................................. 783 FUEL SYSTEM PRESSURE RELEASE PROCEDURE..................................................... 783 FUEL TUBES/ LINES/ HOSES AND CLAMPS........................................................ 783 QUICK- CONNECT FITTINGS.................................................................... 784 SINGLE- TAB TYPE....................................................................... 784 TWO- TAB TYPE FITTING.................................................................. 785 PLASTIC RETAINER RING TYPE FITTING..................................................... 785 LATCH CLIP FITTING (FUEL LINE- TO- FUEL RAIL).......................................... 786 REMOVAL AND INSTALLATION....................................................................... 787 FUEL FILTER/ FUEL PRESSURE REGULATOR....................................................... 787 REMOVAL................................................................................ 787 INSTALLATION........................................................................... 788 FUEL PUMP MODULE........................................................................... 788 REMOVAL................................................................................ 788 INSTALLATION........................................................................... 788 FUEL PUMP INLET FILTER..................................................................... 789 REMOVAL................................................................................ 789 INSTALLATION........................................................................... 789 FUEL GAUGE SENDING UNIT.................................................................... 789 REMOVAL................................................................................ 789 INSTALLATION........................................................................... 789 FUEL INJECTOR RAIL— 2.5L ENGINE............................................................ 790 REMOVAL................................................................................ 790 INSTALLATION........................................................................... 790 FUEL INJECTOR RAIL— 4.0L ENGINE............................................................ 791 REMOVAL................................................................................ 791 INSTALLATION........................................................................... 791 FUEL INJECTORS............................................................................. 792 REMOVAL................................................................................ 792 INSTALLATION........................................................................... 792 FUEL TANK.................................................................................. 792 REMOVAL................................................................................ 792 INSTALLATION........................................................................... 793 FUEL TANK FILLER TUBE CAP.................................................................. 794 ACCELERATOR PEDAL.......................................................................... 794 REMOVAL................................................................................ 794 INSTALLATION........................................................................... 794 THROTTLE CABLE............................................................................. 794 REMOVAL................................................................................ 794 INSTALLATION........................................................................... 794 SPECIFICATIONS................................................................................. 795 VECI LABEL................................................................................. 795 FUEL TANK CAPACITY FUEL SYSTEM PRESSURE.................................................... 795 TORQUE CHART............................................................................... 795 FUEL INJECTION SYSTEM.............................................................................. 796 GENERAL INFORMATION............................................................................ 797 INTRODUCTION............................................................................... 797 MODES OF OPERATION......................................................................... 797 IGNITION SWITCH (KEY- ON) MODE......................................................... 797 ENGINE START- UP MODE.................................................................. 798 ENGINE WARM- UP MODE................................................................... 798 IDLE MODE.............................................................................. 798 CRUISE MODE............................................................................ 798 ACCELERATION MODE...................................................................... 799 DECELERATION MODE...................................................................... 799 WIDE OPEN THROTTLE MODE................................................................ 799 IGNITION SWITCH OFF MODE............................................................... 799 DESCRIPTION AND OPERATION...................................................................... 799 POWERTRAIN CONTROL MODULE (PCM)............................................................ 799 AIR CONDITIONING (A/ C) CONTROLS— PCM INPUT................................................ 800 AUTOMATIC SHUTDOWN (ASD) RELAY SENSE— PCM INPUT............................................ 801 BATTERY TEMPERATURE SENSOR— PCM INPUT...................................................... 801 BATTERY VOLTAGE— PCM INPUT................................................................. 801 BRAKE SWITCH— PCM INPUT.................................................................... 801 FIVE VOLT SENSOR SUPPLY— PRIMARY........................................................... 801 FIVE VOLT SENSOR SUPPLY— SECONDARY......................................................... 801 FUEL LEVEL SENSOR— PCM INPUT............................................................... 801 CAMSHAFT POSITION SENSOR— PCM INPUT........................................................ 802 CRANKSHAFT POSITION SENSOR— PCM INPUT...................................................... 802 ENGINE COOLANT TEMPERATURE SENSOR— PCM INPUT............................................... 802 GENERATOR OUTPUT— PCM INPUT................................................................ 802 OXYGEN SENSOR (O2S)— PCM INPUT............................................................. 803 UPSTREAM HEATED OXYGEN SENSOR.......................................................... 803 DOWNSTREAM HEATED OXYGEN SENSOR........................................................ 803 IGNITION CIRCUIT SENSE— PCM INPUT.......................................................... 803 INTAKE MANIFOLD AIR TEMPERATURE SENSOR— PCM INPUT.......................................... 804 LEAK DETECTION PUMP (SWITCH) SENSE— PCM INPUT.............................................. 804 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— PCM INPUT......................................... 804 OIL PRESSURE SENSOR— PCM INPUT............................................................. 804 POWER GROUND............................................................................... 804 POWER STEERING PRESSURE SWITCH— PCM INPUT.................................................. 804 SENSOR RETURN— PCM INPUT................................................................... 805 SIGNAL GROUND— PCM INPUT................................................................... 805 SPEED CONTROL SWITCHES— PCM INPUT.......................................................... 805 TRANSMISSION PARK/ NEUTRAL SWITCH— PCM INPUT............................................... 805 THROTTLE POSITION SENSOR (TPS)— PCM INPUT.................................................. 805 VEHICLE SPEED AND DISTANCE SENSOR— PCM INPUT............................................... 806 AIR CONDITIONING (A/ C) CLUTCH RELAY— PCM OUTPUT........................................... 806 AUTO SHUTDOWN (ASD) RELAY— PCM OUTPUT...................................................... 806 CCD BUS (+/-) CIRCUITS- PCM OUTPUTS........................................................ 806 DATA LINK CONNECTOR— PCM INPUT AND OUTPUT.................................................. 806 DUTY CYCLE EVAP PURGE SOLENOID VALVE- PCM OUTPUT........................................... 807 FUEL INJECTORS— PCM OUTPUT................................................................. 807 FUEL PUMP RELAY- PCM OUTPUT................................................................ 807 GENERATOR FIELD SOURCE (+)— PCM OUTPUT..................................................... 807 GENERATOR FIELD DRIVER (-)— PCM OUTPUT..................................................... 807 IDLE AIR CONTROL (IAC) MOTOR— PCM OUTPUT................................................... 807 IGNITION COIL— PCM OUTPUT.................................................................. 808 LEAK DETECTION PUMP— PCM OUTPUT............................................................ 808 MALFUNCTION INDICATOR LAMP— PCM OUTPUT..................................................... 808 SPEED CONTROL SOLENOIDS— PCM OUTPUT........................................................ 808 TACHOMETER— PCM OUTPUT..................................................................... 808 THROTTLE BODY.............................................................................. 808 DIAGNOSIS AND TESTING.......................................................................... 808 VISUAL INSPECTION.......................................................................... 808 ASD AND FUEL PUMP RELAYS................................................................... 811 OPERATION.............................................................................. 812 TESTING................................................................................ 812 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST............................................... 812 OXYGEN (O2S) SENSORS....................................................................... 813 CAMSHAFT AND CRANKSHAFT POSITION SENSORS................................................... 814 ENGINE COOLANT TEMPERATURE SENSOR.......................................................... 814 IDLE AIR CONTROL (IAC) MOTOR............................................................... 814 INTAKE MANIFOLD AIR TEMPERATURE SENSOR..................................................... 814 SENSOR RESISTANCE (OHMS)— COOLANT TEMPERATURE SENSOR/ INTAKE AIR TEMPERATURE SENSOR.... 814 POWER STEERING PRESSURE SWITCH............................................................. 815 2.5L 4– Cylinder Engine Only........................................................... 815 VEHICLE SPEED SENSOR....................................................................... 815 THROTTLE POSITION SENSOR (TPS)............................................................. 815 REMOVAL AND INSTALLATION....................................................................... 816 AUTOMATIC SHUTDOWN (ASD) RELAY............................................................. 816 REMOVAL................................................................................ 816 INSTALLATION........................................................................... 816 FUEL PUMP RELAY............................................................................ 816 REMOVAL................................................................................ 816 INSTALLATION........................................................................... 816 THROTTLE BODY.............................................................................. 816 REMOVAL................................................................................ 816 INSTALLATION........................................................................... 817 THROTTLE POSITION SENSOR (TPS)............................................................. 817 REMOVAL................................................................................ 817 INSTALLATION........................................................................... 817 IDLE AIR CONTROL (IAC) MOTOR............................................................... 817 REMOVAL................................................................................ 817 INSTALLATION........................................................................... 817 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR.................................................... 818 REMOVAL................................................................................ 818 INSTALLATION........................................................................... 818 DUTY CYCLE EVAP CANISTER PURGE SOLENOID.................................................... 818 POWERTRAIN CONTROL MODULE (PCM)............................................................ 818 REMOVAL................................................................................ 818 INSTALLATION........................................................................... 818 POWER STEERING PRESSURE SWITCH— 2.5L ENGINE................................................ 818 REMOVAL................................................................................ 819 INSTALLATION........................................................................... 819 CRANKSHAFT POSITION SENSOR................................................................. 819 CAMSHAFT POSITION SENSOR................................................................... 819 OXYGEN SENSOR.............................................................................. 819 REMOVAL................................................................................ 819 INSTALLATION........................................................................... 820 AIR CLEANER ELEMENT........................................................................ 820 REMOVAL................................................................................ 820 INSTALLATION........................................................................... 820 ENGINE COOLANT TEMPERATURE SENSOR.......................................................... 820 REMOVAL................................................................................ 820 INSTALLATION........................................................................... 820 INTAKE MANIFOLD AIR TEMPERATURE SENSOR..................................................... 821 REMOVAL................................................................................ 821 INSTALLATION........................................................................... 821 VEHICLE SPEED SENSOR....................................................................... 821 REMOVAL................................................................................ 821 INSTALLATION........................................................................... 822 SPECIFICATIONS................................................................................. 822 VECI LABEL................................................................................. 822 TORQUE CHART............................................................................... 822 SPECIAL TOOLS.................................................................................. 822 FUEL SYSTEM................................................................................ 822 FUEL SYSTEM............................................................................................ 825 GENERAL INFORMATION................................................................................ 825 INTRODUCTION................................................................................... 825 FUEL REQUIREMENTS— LEADED FUEL VEHICLES........................................................ 825 STEERING............................................................................................... 827 GENERAL INFORMATION................................................................................ 827 STEERING SYSTEM................................................................................ 827 DIAGNOSIS AND TESTING.............................................................................. 828 POWER STEERING SYSTEM DIAGNOSIS CHARTS......................................................... 828 STEERING NOISE............................................................................. 828 BINDING AND STICKING....................................................................... 828 INSUFFICIENT ASST. OR POOR RETURN TO CENTER................................................ 829 LOOSE STEERING AND VEHICLE LEAD............................................................ 829 DESCRIPTION AND OPERATION.......................................................................... 830 POWER STEERING PUMP............................................................................ 830 DIAGNOSIS AND TESTING.............................................................................. 830 PUMP FLOW RATE AND PRESSURE.................................................................... 830 FLOW AND PRESSURE TEST..................................................................... 830 PUMP LEAKAGE DIAGNOSIS......................................................................... 831 SERVICE PROCEDURES................................................................................. 831 POWER STEERING PUMP - INITIAL OPERATION........................................................ 831 PUMP SPECIFICATIONS........................................................................ 831 REMOVAL AND INSTALLATION........................................................................... 832 POWER STEERING PUMP............................................................................ 832 REMOVAL.................................................................................... 832 INSTALLATION............................................................................... 832 PUMP REMOTE RESERVOIR – 2.5L................................................................... 832 REMOVAL.................................................................................... 832 INSTALLATION............................................................................... 833 DISASSEMBLY AND ASSEMBLY........................................................................... 833 PUMP PULLEY.................................................................................... 833 DISASSEMBLY................................................................................ 833 ASSEMBLY................................................................................... 833 PUMP RESERVOIR................................................................................. 833 DISASSEMBLY................................................................................ 833 ASSEMBLY................................................................................... 834 FLOW CONTROL VALVE............................................................................. 834 DISASSEMBLY................................................................................ 834 ASSEMBLY................................................................................... 834 SPECIFICATIONS..................................................................................... 834 TORQUE CHART................................................................................... 834 SPECIAL TOOLS...................................................................................... 835 POWER STEERING PUMP............................................................................ 835 DESCRIPTION AND OPERATION.......................................................................... 836 POWER STEERING GEAR............................................................................ 836 DIAGNOSIS AND TESTING.............................................................................. 836 POWER STEERING GEAR LEAKAGE DIAGNOSIS.......................................................... 836 REMOVAL AND INSTALLATION........................................................................... 837 POWER STEERING GEAR............................................................................ 837 REMOVAL.................................................................................... 837 INSTALLATION............................................................................... 838 DISASSEMBLY AND ASSEMBLY........................................................................... 838 HOUSING END PLUG............................................................................... 838 DISASSEMBLY................................................................................ 838 ASSEMBLY................................................................................... 838 PITMAN SHAFT/ SEALS/ BEARING................................................................... 838 DISASSEMBLY................................................................................ 838 ASSEMBLY................................................................................... 839 SPOOL VALVE.................................................................................... 839 DISASSEMBLY................................................................................ 839 ASSEMBLY................................................................................... 841 RACK PISTON AND WORM SHAFT..................................................................... 842 DISASSEMBLY................................................................................ 842 ASSEMBLY................................................................................... 843 ADJUSTMENTS........................................................................................ 844 STEERING GEAR.................................................................................. 844 WORM THRUST BEARING PRELOAD................................................................ 844 OVER-CENTER................................................................................ 844 SPECIFICATIONS..................................................................................... 846 POWER STEERING GEAR............................................................................ 846 TORQUE CHART................................................................................... 846 SPECIAL TOOLS...................................................................................... 846 POWER STEERING GEAR............................................................................ 846 DESCRIPTION AND OPERATION.......................................................................... 847 MANUAL STEERING GEAR........................................................................... 847 DIAGNOSIS AND TESTING.............................................................................. 848 MANUAL STEERING SYSTEM......................................................................... 848 REMOVAL AND INSTALLATION........................................................................... 848 MANUAL STEERING GEAR........................................................................... 848 REMOVAL.................................................................................... 848 INSTALLATION............................................................................... 849 DISASSEMBLY AND ASSEMBLY........................................................................... 849 PITMAN SHAFT, SEAL AND COVER................................................................... 849 DISASSEMBLY................................................................................ 849 ASSEMBLY................................................................................... 849 WORM SHAFT AND BALL NUT........................................................................ 850 DISASSEMBLY................................................................................ 850 ASSEMBLY................................................................................... 851 WORM BEARING ADJUSTER.......................................................................... 852 DISASSEMBLY................................................................................ 852 ASSEMBLY................................................................................... 852 ADJUSTMENTS........................................................................................ 852 WORM BEARING PRELOAD........................................................................... 852 OVER- CENTER PRELOAD........................................................................... 852 SPECIFICATIONS..................................................................................... 853 MANUAL STEERING GEAR........................................................................... 853 TORQUE CHART................................................................................... 853 SPECIAL TOOLS...................................................................................... 853 MANUAL STEERING GEAR........................................................................... 853 GENERAL INFORMATION................................................................................ 854 STEERING COLUMN................................................................................ 854 SERVICE PRECAUTIONS........................................................................ 854 REMOVAL AND INSTALLATION........................................................................... 855 STEERING COLUMN................................................................................ 855 REMOVAL.................................................................................... 855 INSTALLATION............................................................................... 856 SPECIFICATIONS..................................................................................... 857 TORQUE CHART................................................................................... 857 GENERAL INFORMATION................................................................................ 858 STEERING LINKAGE............................................................................... 858 SERVICE PROCEDURES................................................................................. 858 STEERING LINKAGE............................................................................... 858 REMOVAL AND INSTALLATION........................................................................... 858 TIE ROD........................................................................................ 858 REMOVAL.................................................................................... 858 INSTALLATION............................................................................... 859 PITMAN ARM..................................................................................... 859 REMOVAL.................................................................................... 859 INSTALLATION............................................................................... 859 DRAG LINK...................................................................................... 859 REMOVAL.................................................................................... 859 INSTALLATION............................................................................... 859 STEERING DAMPENER.............................................................................. 859 REMOVAL.................................................................................... 859 INSTALLATION............................................................................... 860 SPECIFICATIONS..................................................................................... 860 TORQUE CHART................................................................................... 860 SPECIAL TOOLS...................................................................................... 860 STEERING LINKAGE............................................................................... 860 SUSPENSION............................................................................................. 861 GENERAL INFORMATION................................................................................ 861 WHEEL ALIGNMENT................................................................................ 861 DIAGNOSIS AND TESTING.............................................................................. 863 SUSPENSION AND STEERING SYSTEM................................................................. 863 SERVICE PROCEDURES................................................................................. 863 PRE-ALIGNMENT.................................................................................. 863 WHEEL ALIGNMENT................................................................................ 863 CAMBER..................................................................................... 863 CASTER..................................................................................... 863 TOE POSITION............................................................................... 864 SPECIFICATIONS..................................................................................... 864 ALIGNMENT SPECIFICATIONS....................................................................... 864 DESCRIPTION AND OPERATION.......................................................................... 865 FRONT SUSPENSION............................................................................... 865 DIAGNOSIS AND TESTING.............................................................................. 866 SHOCK DIAGNOSIS................................................................................ 866 REMOVAL AND INSTALLATION........................................................................... 866 SHOCK ABSORBER................................................................................. 866 REMOVAL.................................................................................... 866 INSTALLATION............................................................................... 866 COIL SPRING.................................................................................... 866 REMOVAL.................................................................................... 866 INSTALLATION............................................................................... 866 STEERING KNUCKLE............................................................................... 867 LOWER SUSPENSION ARM........................................................................... 867 REMOVAL.................................................................................... 867 INSTALLATION............................................................................... 867 UPPER SUSPENSION ARM........................................................................... 867 REMOVAL.................................................................................... 867 INSTALLATION............................................................................... 867 AXLE BUSHING................................................................................... 868 REMOVAL.................................................................................... 868 INSTALLATION............................................................................... 868 STABILIZER BAR................................................................................. 868 REMOVAL.................................................................................... 868 INSTALLATION............................................................................... 868 TRACK BAR...................................................................................... 869 REMOVAL.................................................................................... 869 INSTALLATION............................................................................... 869 HUB BEARING.................................................................................... 869 REMOVAL.................................................................................... 869 INSTALLATION............................................................................... 869 WHEEL MOUNTING STUDS........................................................................... 870 REMOVAL.................................................................................... 870 INSTALLATION............................................................................... 870 SPECIFICATIONS..................................................................................... 870 TORQUE CHART................................................................................... 870 SPECIAL TOOLS...................................................................................... 871 FRONT SUSPENSION............................................................................... 871 DESCRIPTION AND OPERATION.......................................................................... 872 REAR SUSPENSION................................................................................ 872 DIAGNOSIS AND TESTING.............................................................................. 872 SHOCK DIAGNOSIS................................................................................ 872 REMOVAL AND INSTALLATION........................................................................... 873 SHOCK ABSORBER................................................................................. 873 REMOVAL.................................................................................... 873 INSTALLATION............................................................................... 873 COIL SPRING.................................................................................... 873 REMOVAL.................................................................................... 873 INSTALLATION .............................................................................. 873 LOWER SUSPENSION ARM........................................................................... 873 REMOVAL.................................................................................... 873 INSTALLATION............................................................................... 873 UPPER SUSPENSION ARM........................................................................... 874 REMOVAL.................................................................................... 874 INSTALLATION............................................................................... 874 STABILIZER BAR................................................................................. 874 REMOVAL.................................................................................... 874 INSTALLATION............................................................................... 874 TRACK BAR...................................................................................... 874 REMOVAL.................................................................................... 874 INSTALLATION............................................................................... 875 SPECIFICATIONS..................................................................................... 875 TORQUE CHART................................................................................... 875 TRANSMISSION AND TRANSFER CASE......................................................................... 877 GENERAL INFORMATION................................................................................ 877 AX5 MANUAL TRANSMISSION........................................................................ 877 TRANSMISSION IDENTIFICATION.................................................................... 877 GEAR RATIOS.................................................................................... 878 RECOMMENDED LUBRICANT.......................................................................... 878 TRANSMISSION ASSEMBLY INFORMATION.............................................................. 878 DIAGNOSIS AND TESTING.............................................................................. 878 LOW LUBRICANT LEVEL............................................................................ 878 HARD SHIFTING.................................................................................. 879 TRANSMISSION NOISE............................................................................. 880 REMOVAL AND INSTALLATION........................................................................... 880 TRANSMISSION................................................................................... 880 REMOVAL.................................................................................... 880 INSTALLATION............................................................................... 881 FRONT BEARING RETAINER SEAL.................................................................... 882 REMOVAL.................................................................................... 882 INSTALLATION............................................................................... 882 EXTENSION HOUSING SEAL......................................................................... 883 REMOVAL ................................................................................... 883 INSTALLATION .............................................................................. 883 ADAPTER HOUSING SEAL........................................................................... 883 REMOVAL.................................................................................... 883 INSTALLATION............................................................................... 883 DISASSEMBLY AND ASSEMBLY........................................................................... 884 ADAPTER/EXTENSION HOUSING AND FRONT BEARING RETAINER........................................... 884 DISASSEMBLY................................................................................ 884 ASSEMBLY................................................................................... 886 SHIFT MECHANISM AND GEARTRAIN.................................................................. 891 DISASSEMBLY................................................................................ 891 ASSEMBLY................................................................................... 897 COUNTERSHAFT................................................................................... 902 DISASSEMBLY................................................................................ 902 ASSEMBLY................................................................................... 902 INPUT SHAFT.................................................................................... 902 DISASSEMBLY................................................................................ 902 ASSEMBLY................................................................................... 903 OUTPUT SHAFT................................................................................... 904 DISASSEMBLY................................................................................ 904 ASSEMBLY................................................................................... 905 SEMI-SYNCHRONIZED REVERSE IDLER GEAR........................................................... 908 DISASSEMBLY................................................................................ 908 ASSEMBLY................................................................................... 908 CLEANING AND INSPECTION............................................................................ 909 AX5 MANUAL TRANSMISSION COMPONENTS............................................................. 909 GENERAL INFORMATION........................................................................ 909 GEAR CASE, ADAPTER/EXTENSION HOUSING, INTERMEDIATE PLATE................................... 909 OUTPUT SHAFT............................................................................... 909 COUNTERSHAFT............................................................................... 910 GEAR AND SYNCHRONIZER...................................................................... 910 SPECIFICATIONS..................................................................................... 911 TORQUE......................................................................................... 911 SPECIAL TOOLS...................................................................................... 912 AX5............................................................................................ 912 GENERAL INFORMATION................................................................................ 914 AX15 MANUAL TRANSMISSION....................................................................... 914 TRANSMISSION IDENTIFICATION.................................................................... 914 TRANSMISSION GEAR RATIOS....................................................................... 914 RECOMMENDED LUBRICANT.......................................................................... 914 TRANSMISSION ASSEMBLY INFORMATION.............................................................. 914 DIAGNOSIS AND TESTING.............................................................................. 914 LOW LUBRICANT LEVEL............................................................................ 914 HARD SHIFTING.................................................................................. 915 TRANSMISSION NOISE............................................................................. 916 REMOVAL AND INSTALLATION........................................................................... 916 TRANSMISSION................................................................................... 916 REMOVAL.................................................................................... 916 INSTALLATION............................................................................... 918 FRONT BEARING RETAINER SEAL.................................................................... 919 REMOVAL.................................................................................... 919 INSTALLATION............................................................................... 919 EXTENSION HOUSING SEAL ........................................................................ 920 REMOVAL ................................................................................... 920 INSTALLATION .............................................................................. 920 ADAPTER HOUSING SEAL........................................................................... 920 REMOVAL.................................................................................... 920 INSTALLATION............................................................................... 920 DISASSEMBLY AND ASSEMBLY........................................................................... 921 ADAPTER/EXTENSION HOUSING AND FRONT BEARING RETAINER........................................... 921 DISASSEMBLY................................................................................ 921 ASSEMBLY................................................................................... 925 SHIFT MECHANISM AND GEARTRAIN.................................................................. 929 DISASSEMBLY................................................................................ 929 ASSEMBLY................................................................................... 936 COUNTERSHAFT................................................................................... 941 DISASSEMBLY................................................................................ 941 ASSEMBLY................................................................................... 941 INPUT SHAFT.................................................................................... 941 DISASSEMBLY................................................................................ 941 ASSEMBLY................................................................................... 942 OUTPUT SHAFT................................................................................... 942 DISASSEMBLY................................................................................ 943 ASSEMBLY................................................................................... 944 CLEANING AND INSPECTION............................................................................ 947 AX15 MANUAL TRANSMISSION COMPONENTS............................................................ 947 GENERAL INFORMATION........................................................................ 947 GEAR CASE, ADAPTER/EXTENSION HOUSING, INTERMEDIATE PLATE................................... 947 OUTPUT SHAFT............................................................................... 947 COUNTERSHAFT............................................................................... 948 GEAR AND SYNCHRONIZER...................................................................... 948 SPECIFICATIONS..................................................................................... 949 TORQUE......................................................................................... 949 SPECIAL TOOLS...................................................................................... 949 AX15........................................................................................... 949 GENERAL INFORMATION................................................................................ 952 30/32RH AUTOMATIC TRANSMISSION................................................................. 952 TRANSMISSION IDENTIFICATION.................................................................... 954 RECOMMENDED FLUID.............................................................................. 954 EFFECTS OF INCORRECT FLUID LEVEL............................................................... 954 CAUSES OF BURNT FLUID.......................................................................... 954 FLUID CONTAMINATION............................................................................ 954 TORQUE CONVERTER—ELECTRONIC CLUTCH............................................................. 954 TRANSMISSION GEAR RATIOS....................................................................... 955 GEARSHIFT MECHANISM............................................................................ 955 DESCRIPTION AND OPERATION.......................................................................... 955 HYDRAULIC CONTROL SYSTEM....................................................................... 955 PRESSURE SUPPLY............................................................................ 955 Pressure Regulation........................................................................ 955 Flow Control And Lubrication............................................................... 955 Clutch/Band Application.................................................................... 956 CONVERTER CLUTCH ENGAGEMENT.................................................................... 956 CONVERTER DRAINBACK VALVE...................................................................... 956 BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM................................................... 956 DIAGNOSIS AND TESTING.............................................................................. 956 AUTOMATIC TRANSMISSION DIAGNOSIS............................................................... 956 PRELIMINARY DIAGNOSIS.......................................................................... 956 VEHICLE IS DRIVEABLE....................................................................... 956 VEHICLE IS DISABLED........................................................................ 956 PARK/NEUTRAL POSITION SWITCH................................................................... 957 SWITCH TEST................................................................................ 957 GEARSHIFT CABLE................................................................................ 957 THROTTLE VALVE CABLE........................................................................... 958 ROAD TESTING................................................................................... 958 ANALYZING ROAD TEST............................................................................ 958 HYDRAULIC PRESSURE TEST........................................................................ 958 Pressure Test Por t Locations.............................................................. 959 PRESSURE TEST PROCEDURE.................................................................... 959 CONVERTER STALL TEST........................................................................... 960 STALL TEST PROCEDURE....................................................................... 960 STALL TEST ANALYSIS............................................................................ 961 Stall Speed Too High....................................................................... 961 Stall Speed Low............................................................................ 961 Stall Speed Nor mal But Acceleration Poor.................................................. 961 Conver ter Noise During Test............................................................... 961 AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION............................................. 961 Front Clutch Air Test...................................................................... 961 Rear Clutch Air Test....................................................................... 961 Front Ser vo Apply Air Test ............................................................... 961 Rear Ser vo Air Test....................................................................... 961 CONVERTER HOUSING FLUID LEAK DIAGNOSIS......................................................... 961 CONVERTER HOUSING AREA LEAK CORRECTION..................................................... 962 TORQUE CONVERTER LEAK POINTS............................................................... 962 DIAGNOSIS CHARTS............................................................................... 962 DIAGNOSIS CHART............................................................................ 963 SERVICE PROCEDURES................................................................................. 970 FLUID LEVEL CHECK.............................................................................. 970 FLUID LEVEL CHECK PROCEDURE................................................................ 970 FLUID AND FILTER REPLACEMENT................................................................... 970 REMOVAL.................................................................................... 970 INSPECTION................................................................................. 971 CLEANING................................................................................... 971 INSTALLATION............................................................................... 971 TRANSMISSION FILL PROCEDURE.................................................................... 971 CONVERTER DRAINBACK CHECK VALVE SERVICE........................................................ 971 COOLER FLUSH USING TOOL 6906............................................................... 972 OIL COOLER FLOW CHECK.......................................................................... 972 FLUSHING COOLERS AND TUBES..................................................................... 972 ALUMINUM THREAD REPAIR......................................................................... 973 REMOVAL AND INSTALLATION........................................................................... 973 TRANSMISSION................................................................................... 973 REMOVAL.................................................................................... 973 INSTALLATION............................................................................... 974 TORQUE CONVERTER............................................................................... 975 REMOVAL.................................................................................... 975 INSTALLATION............................................................................... 975 EXTENSION HOUSING ............................................................................. 976 REMOVAL.................................................................................... 976 INSTALLATION............................................................................... 976 SPEEDOMETER ADAPTER............................................................................ 976 REMOVAL.................................................................................... 976 INSTALLATION............................................................................... 977 PARK/NEUTRAL POSITION SWITCH................................................................... 978 REMOVAL.................................................................................... 978 INSTALLATION............................................................................... 978 GEARSHIFT CABLE................................................................................ 978 REMOVAL.................................................................................... 978 INSTALLATION............................................................................... 978 BRAKE TRANSMISSION SHIFT INTERLOCK............................................................. 978 REMOVAL.................................................................................... 978 INSTALLATION............................................................................... 978 VALVE BODY..................................................................................... 979 REMOVAL.................................................................................... 979 OUTPUT SHAFT REAR BEARING...................................................................... 980 REMOVAL.................................................................................... 980 INSTALLATION............................................................................... 980 INSTALLATION............................................................................... 980 GOVERNOR AND PARK GEAR......................................................................... 981 REMOVAL.................................................................................... 981 INSTALLATION............................................................................... 981 PARK LOCK...................................................................................... 982 REMOVAL.................................................................................... 982 INSTALLATION............................................................................... 982 DISASSEMBLY AND ASSEMBLY........................................................................... 982 GOVERNOR AND PARK GEAR......................................................................... 982 DISASSEMBLY................................................................................ 982 ASSEMBLY................................................................................... 983 VALVE BODY..................................................................................... 983 DISASSEMBLY................................................................................ 983 ASSEMBLY................................................................................... 986 TRANSMISSION................................................................................... 991 DISASSEMBLY................................................................................ 991 ASSEMBLY................................................................................... 996 OVERRUNNING CLUTCH/LOW-REVERSE DRUM............................................................1001 DISASSEMBLY................................................................................1001 ASSEMBLY...................................................................................1002 FRONT SERVO PISTON.............................................................................1002 DISASSEMBLY................................................................................1002 ASSEMBLY...................................................................................1002 REAR SERVO PISTON..............................................................................1002 DISASSEMBLY................................................................................1002 ASSEMBLY...................................................................................1002 OIL PUMP AND REACTION SHAFT SUPPORT............................................................1003 DISASSEMBLY................................................................................1003 ASSEMBLY...................................................................................1005 FRONT CLUTCH...................................................................................1006 DISASSEMBLY................................................................................1006 ASSEMBLY...................................................................................1006 REAR CLUTCH....................................................................................1008 DISASSEMBLY................................................................................1008 ASSEMBLY...................................................................................1009 PLANETARY GEARTRAIN/OUTPUT SHAFT...............................................................1011 DISASSEMBLY................................................................................1011 ASSEMBLY...................................................................................1012 CLEANING AND INSPECTION............................................................................1015 GOVERNOR AND PARK GEAR.........................................................................1015 EXTENSION HOUSING AND PARK LOCK................................................................1017 VALVE BODY.....................................................................................1017 TRANSMISSION...................................................................................1019 OVERRUNNING CLUTCH/LOW-REVERSE DRUM/OVERDRIVE PISTON RETAINER..................................1019 FRONT SERVO....................................................................................1019 REAR SERVO.....................................................................................1020 OIL PUMP AND REACTION SHAFT SUPPORT............................................................1020 FRONT CLUTCH...................................................................................1020 REAR CLUTCH....................................................................................1021 PLANETARY GEARTRAIN/OUTPUT SHAFT...............................................................1021 ADJUSTMENTS........................................................................................1021 GEARSHIFT CABLE................................................................................1021 Gearshift Adjustment Procedure.............................................................1021 BRAKE TRANSMISSION SHIFT INTERLOCK CABLE ADJUSTMENT............................................1022 TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT...................................................1022 Checking Throttle Valve Cable Adjustment...................................................1022 Throttle Valve Cable Adjustment Procedure..................................................1023 FRONT BAND ADJUSTMENT..........................................................................1023 REAR BAND ADJUSTMENT...........................................................................1024 VALVE BODY.....................................................................................1024 CONTROL PRESSURE ADJUSTMENTS...............................................................1024 SCHEMATICS AND DIAGRAMS............................................................................1026 HYDRAULIC SCHEMATICS...........................................................................1026 SPECIFICATIONS.....................................................................................1038 30/32RH AUTOMATIC TRANSMISSION.................................................................1038 GENERAL....................................................................................1038 THRUST WASHER/SPACER/SNAP RING DIMENSIONS..................................................1038 PRESSURE TEST—ALL..........................................................................1039 TORQUE.........................................................................................1039 SPECIAL TOOLS......................................................................................1039 30/32RH TRANSMISSIONS..........................................................................1039 GENERAL INFORMATION................................................................................1044 NV231 TRANSFER CASE............................................................................1044 OPERATING RANGES...........................................................................1044 SHIFT MECHANISM............................................................................1044 TRANSFER CASE IDENTIFICATION...................................................................1044 RECOMMENDED LUBRICANT AND FILL LEVEL...........................................................1044 DIAGNOSIS AND TESTING..............................................................................1045 NV231 DIAGNOSIS................................................................................1045 REMOVAL AND INSTALLATION...........................................................................1046 TRANSFER CASE..................................................................................1046 REMOVAL....................................................................................1046 INSTALLATION...............................................................................1046 SHIFT LEVER....................................................................................1046 REMOVAL....................................................................................1046 INSTALLATION...............................................................................1046 SPEEDOMETER....................................................................................1046 REMOVAL....................................................................................1046 INSTALLATION AND INDEXING..................................................................1048 FRONT OUTPUT SHAFT SEAL........................................................................1048 REMOVAL....................................................................................1048 INSTALLATION...............................................................................1048 DISASSEMBLY AND ASSEMBLY...........................................................................1048 NV231 TRANSFER CASE ...........................................................................1048 DISASSEMBLY ...............................................................................1048 CLEANING AND INSPECTION............................................................................1064 NV231 TRANSFER CASE............................................................................1064 MAINSHAFT/SPROCKET/HUB INSPECTION..........................................................1064 INPUT GEAR AND PLANETARY CARRIER...........................................................1064 SHIFT FORKS/HUBS/SLEEVES...................................................................1064 REAR RETAINER/BEARING/ SEAL/SLINGER/ BOOT..................................................1065 REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN.........................................................1066 LOW RANGE ANNULUS GEAR.....................................................................1066 FRONT-REAR CASES AND FRONT RETAINER........................................................1066 OIL PUMP/OIL PICKUP........................................................................1066 ADJUSTMENTS........................................................................................1066 SHIFT LINKAGE ADJUSTMENT.......................................................................1066 SPECIFICATIONS.....................................................................................1068 TORQUE.........................................................................................1068 SPECIAL TOOLS......................................................................................1068 SPECIAL TOOLS—NV231............................................................................1068 TIRES AND WHEELS.......................................................................................1071 DESCRIPTION AND OPERATION..........................................................................1071 TIRE INFORMATION...............................................................................1071 TIRE CHAINS................................................................................1071 RADIAL-PLY TIRES...............................................................................1072 SPARE TIRE–TEMPORARY...........................................................................1072 TIRE INFLATION PRESSURES.......................................................................1072 TIRE PRESSURE FOR HIGH SPEED OPERATION.........................................................1073 REPLACEMENT TIRES..............................................................................1073 DIAGNOSIS AND TESTING..............................................................................1073 PRESSURE GAUGES................................................................................1073 TREAD WEAR INDICATORS..........................................................................1073 TIRE WEAR PATTERNS.............................................................................1073 TIRE NOISE OR VIBRATION........................................................................1074 SERVICE PROCEDURES.................................................................................1074 ROTATION.......................................................................................1074 MATCH MOUNTING.................................................................................1074 REPAIRING LEAKS................................................................................1075 CLEANING AND INSPECTION............................................................................1076 CLEANING TIRES.................................................................................1076 DESCRIPTION AND OPERATION .........................................................................1077 WHEEL .........................................................................................1077 DIAGNOSIS AND TESTING..............................................................................1077 WHEEL INSPECTION...............................................................................1077 TIRE AND WHEEL RUNOUT..........................................................................1077 METHOD 1 (RELOCATE WHEEL ON HUB)...........................................................1078 METHOD 2 (RELOCATE TIRE ON WHEEL)..........................................................1078 SERVICE PROCEDURES.................................................................................1078 WHEEL INSTALLATION.............................................................................1078 WHEEL REPLACEMENT..........................................................................1079 TIRE AND WHEEL BALANCE.........................................................................1079 SPECIFICATIONS.....................................................................................1080 TORQUE CHART...................................................................................1080 BODY...................................................................................................1081 GENERAL INFORMATION................................................................................1081 SAFETY PRECAUTIONS AND WARNINGS................................................................1081 GENERAL INFORMATION................................................................................1082 PAINT CODE.....................................................................................1082 BASE COAT/CLEAR COAT FINISH....................................................................1082 FINESSE SANDING, BUFFING, AND POLISHING........................................................1082 PAINTED SURFACE TOUCH-UP.......................................................................1082 TOUCH-UP PROCEDURE.........................................................................1082 AFTERMARKET PAINT REPAIR PRODUCTS..............................................................1083 EXTERIOR COLOR.............................................................................1083 HARD TOP...................................................................................1083 INTERIOR COLOR.............................................................................1083 SERVICE PROCEDURES.................................................................................1084 HARD TOP REPAIR................................................................................1084 HARD TOP HOLE REPAIR.......................................................................1084 FRACTURE REPAIR............................................................................1084 GENERAL INFORMATION................................................................................1085 SAFETY PRECAUTIONS.............................................................................1085 REMOVAL AND INSTALLATION...........................................................................1085 WINDSHIELD.....................................................................................1085 REMOVAL....................................................................................1085 INSTALLATION...............................................................................1086 QUARTER GLASS..................................................................................1086 REMOVAL....................................................................................1086 INSTALLATION...............................................................................1087 REMOVAL AND INSTALLATION...........................................................................1088 BUCKET SEATBACK................................................................................1088 REMOVAL....................................................................................1088 INSTALLATION...............................................................................1088 BUCKET SEATBACK COVER..........................................................................1089 REMOVAL....................................................................................1089 INSTALLATION...............................................................................1089 BUCKET SEAT CUSHION COVER......................................................................1089 REMOVAL....................................................................................1089 INSTALLATION...............................................................................1089 REAR SEATBACK..................................................................................1090 REMOVAL....................................................................................1090 INSTALLATION...............................................................................1090 REAR SEATBACK COVER............................................................................1090 REMOVAL....................................................................................1090 INSTALLATION...............................................................................1090 REAR SEAT CUSHION COVER........................................................................1091 REMOVAL....................................................................................1091 INSTALLATION...............................................................................1091 INDEX..........................................................................................1092 SERVICE PROCEDURES ................................................................................1093 BODY LUBRICATION ..............................................................................1093 REMOVAL AND INSTALLATION...........................................................................1093 RADIATOR GRILLE PANEL..........................................................................1093 REMOVAL....................................................................................1093 INSTALLATION...............................................................................1093 HOOD...........................................................................................1094 REMOVAL....................................................................................1094 INSTALLATION...............................................................................1094 HOOD INSULATION PANEL .........................................................................1095 REMOVAL ...................................................................................1095 INSTALLATION ..............................................................................1095 HOOD HINGE.....................................................................................1095 REMOVAL....................................................................................1095 INSTALLATION...............................................................................1095 HOOD SAFETY LATCH..............................................................................1095 REMOVAL....................................................................................1095 INSTALLATION...............................................................................1095 COWL WEATHERSTRIP..............................................................................1095 REMOVAL....................................................................................1095 INSTALLATION...............................................................................1095 COWL GRILLE AND SCREEN ........................................................................1096 REMOVAL ...................................................................................1096 INSTALLATION...............................................................................1096 WINDSHIELD FRAME...............................................................................1096 REMOVAL....................................................................................1096 INSTALLATION...............................................................................1096 WINDSHIELD FRAME WEATHERSTRIP..................................................................1096 UPPER FRAME WEATHERSTRIP REMOVAL...........................................................1096 UPPER FRAME WEATHERSTRIP INSTALLATION......................................................1096 LOWER FRAME WEATHERSTRIP REMOVAL...........................................................1097 LOWER FRAME WEATHERSTRIP INSTALLATION......................................................1097 WINDSHIELD HINGE...............................................................................1097 REMOVAL....................................................................................1097 INSTALLATION...............................................................................1097 BODY DECALS....................................................................................1098 REMOVAL....................................................................................1098 INSTALLATION...............................................................................1098 SIDE VIEW MIRROR...............................................................................1099 REMOVAL....................................................................................1099 INSTALLATION...............................................................................1099 FENDER FLARE...................................................................................1099 REMOVAL....................................................................................1099 INSTALLATION...............................................................................1099 FRONT FENDER...................................................................................1099 RIGHT FENDER REMOVAL.......................................................................1099 RIGHT FENDER INSTALLATION..................................................................1100 LEFT FENDER REMOVAL .......................................................................1101 LEFT FENDER INSTALLATION...................................................................1101 BODY SIDE MOLDING..............................................................................1101 REMOVAL....................................................................................1101 INSTALLATION ..............................................................................1101 SIDE STEP......................................................................................1101 REMOVAL....................................................................................1101 INSTALLATION...............................................................................1101 FULL DOOR TRIM PANEL...........................................................................1102 REMOVAL....................................................................................1102 INSTALLATION...............................................................................1102 FULL DOOR......................................................................................1102 REMOVAL....................................................................................1102 INSTALLATION...............................................................................1102 FULL DOOR HINGE................................................................................1102 REMOVAL....................................................................................1102 INSTALLATION...............................................................................1103 FULL DOOR OUTSIDE RELEASE HANDLE...............................................................1103 REMOVAL....................................................................................1103 INSTALLATION...............................................................................1104 FULL DOOR LOCK CYLINDER........................................................................1104 REMOVAL....................................................................................1104 INSTALLATION...............................................................................1104 FULL DOOR LATCH................................................................................1104 REMOVAL....................................................................................1104 INSTALLATION...............................................................................1105 FULL DOOR LATCH STRIKER........................................................................1105 REMOVAL....................................................................................1105 INSTALLATION...............................................................................1105 FULL DOOR INSIDE HANDLE ACTUATOR...............................................................1105 REMOVAL....................................................................................1105 INSTALLATION...............................................................................1105 FULL DOOR GLASS................................................................................1106 REMOVAL....................................................................................1106 INSTALLATION...............................................................................1106 FULL DOOR INNER BELT WEATHERSTRIP..............................................................1106 FULL DOOR OUTER BELT SEAL......................................................................1106 REMOVAL....................................................................................1106 INSTALLATION...............................................................................1106 FULL DOOR GLASS RUN CHANNEL WEATHERSTRIP.......................................................1107 REMOVAL....................................................................................1107 INSTALLATION ..............................................................................1107 FULL DOOR WEATHERSTRIP.........................................................................1107 REMOVAL....................................................................................1107 INSTALLATION...............................................................................1107 FULL DOOR WINDOW REGULATOR ....................................................................1108 REMOVAL ...................................................................................1108 INSTALLATION...............................................................................1108 HALF DOOR TRIM PANEL...........................................................................1108 REMOVAL....................................................................................1108 INSTALLATION...............................................................................1108 HALF DOOR......................................................................................1108 REMOVAL....................................................................................1108 INSTALLATION ..............................................................................1108 HALF DOOR HINGE................................................................................1108 HALF DOOR OUTSIDE HANDLE ......................................................................1109 REMOVAL....................................................................................1109 INSTALLATION...............................................................................1109 HALF DOOR LOCK CYLINDER........................................................................1109 REMOVAL....................................................................................1109 INSTALLATION ..............................................................................1109 HALF DOOR LATCH................................................................................1109 REMOVAL ...................................................................................1109 INSTALLATION...............................................................................1109 HALF DOOR LATCH STRIKER........................................................................1110 REMOVAL....................................................................................1110 INSTALLATION...............................................................................1110 HALF DOOR INSIDE HANDLE ACTUATOR...............................................................1110 REMOVAL....................................................................................1110 INSTALLATION ..............................................................................1110 HALF DOOR WEATHERSTRIP.........................................................................1110 REMOVAL....................................................................................1110 INSTALLATION...............................................................................1110 HALF DOOR WINDOW...............................................................................1111 REMOVAL....................................................................................1111 INSTALLATION...............................................................................1111 HARD TOP.......................................................................................1111 REMOVAL....................................................................................1111 INSTALLATION...............................................................................1112 HARD TOP AIR EXHAUSTER.........................................................................1112 REMOVAL....................................................................................1112 INSTALLATION...............................................................................1112 SOFT TOP.......................................................................................1112 REMOVAL....................................................................................1112 INSTALLATION...............................................................................1112 SOFT TOP FABRIC................................................................................1113 REMOVAL....................................................................................1113 INSTALLATION...............................................................................1113 HARD/SOFT TOP LATCH............................................................................1113 REMOVAL....................................................................................1113 INSTALLATION...............................................................................1113 DOOR OPENING FRAME.............................................................................1114 REMOVAL....................................................................................1114 INSTALLATION...............................................................................1114 FRONT SHOULDER/LAP BELT AND BUCKLE.............................................................1114 FRONT SHOULDER/LAP BELT AND RETRACTOR REMOVAL..............................................1114 FRONT SHOULDER/LAP BELT AND RETRACTOR INSTALLATION.........................................1114 FRONT SEAT BELT BUCKLE REMOVAL.............................................................1114 FRONT SEAT BELT BUCKLE INSTALLATION........................................................1114 REAR SHOULDER/LAP BELT AND BUCKLE..............................................................1115 SEAT/LAP BELT AND RETRACTOR REMOVAL........................................................1115 SEAT/LAP BELT AND RETRACTOR INSTALLATION...................................................1115 REAR BUCKLE REMOVAL........................................................................1116 REAR BUCKLE INSTALLATION...................................................................1116 BUCKET SEAT....................................................................................1116 REMOVAL....................................................................................1116 INSTALLATION...............................................................................1116 MINI FLOOR CONSOLE.............................................................................1116 REMOVAL....................................................................................1116 INSTALLATION...............................................................................1117 FULL FLOOR CONSOLE.............................................................................1117 REMOVAL....................................................................................1117 INSTALLATION ..............................................................................1117 CONSOLE LOCK CYLINDER..........................................................................1117 REMOVAL....................................................................................1117 INSTALLATION...............................................................................1117 SHIFT BOOT.....................................................................................1118 REMOVAL....................................................................................1118 INSTALLATION...............................................................................1118 REAR SEAT......................................................................................1118 REMOVAL....................................................................................1118 INSTALLATION...............................................................................1119 ADD-A-TRUNK....................................................................................1119 REMOVAL....................................................................................1119 INSTALLATION...............................................................................1119 FRONT CARPET...................................................................................1119 REMOVAL....................................................................................1119 INSTALLATION...............................................................................1119 CENTER CARPET..................................................................................1119 REMOVAL....................................................................................1119 INSTALLATION...............................................................................1119 CARGO AREA CARPET..............................................................................1119 REMOVAL ...................................................................................1119 INSTALLATION...............................................................................1119 WHEELHOUSE CARPET..............................................................................1119 REMOVAL....................................................................................1119 INSTALLATION...............................................................................1120 SPORT BAR......................................................................................1120 REMOVAL....................................................................................1120 INSTALLATION...............................................................................1121 REAR VIEW MIRROR...............................................................................1122 REMOVAL....................................................................................1122 INSTALLATION...............................................................................1122 REARVIEW MIRROR SUPPORT BRACKET................................................................1122 INSTALLATION...............................................................................1122 SUNVISOR.......................................................................................1122 REMOVAL....................................................................................1122 INSTALLATION...............................................................................1122 WHEELHOUSE SPLASH SHIELD.......................................................................1123 REMOVAL....................................................................................1123 INSTALLATION...............................................................................1123 LIFTGATE GLASS SUPPORT CYLINDER................................................................1123 REMOVAL....................................................................................1123 INSTALLATION...............................................................................1123 LIFTGATE GLASS.................................................................................1123 REMOVAL....................................................................................1123 INSTALLATION...............................................................................1124 LIFTGATE GLASS HINGE...........................................................................1124 REMOVAL....................................................................................1124 INSTALLATION...............................................................................1124 LIFTGATE GLASS WEATHERSTRIP....................................................................1124 SPARE TIRE CARRIER.............................................................................1124 REMOVAL....................................................................................1124 INSTALLATION...............................................................................1124 LICENSE PLATE BRACKET..........................................................................1125 REMOVAL....................................................................................1125 INSTALLATION...............................................................................1125 TAILGATE.......................................................................................1125 REMOVAL....................................................................................1125 INSTALLATION...............................................................................1125 TAILGATE HINGE.................................................................................1126 REMOVAL....................................................................................1126 INSTALLATION...............................................................................1126 TAILGATE OUTSIDE HANDLE........................................................................1126 REMOVAL....................................................................................1126 INSTALLATION...............................................................................1126 TAILGATE LOCK CYLINDER.........................................................................1126 REMOVAL....................................................................................1126 INSTALLATION...............................................................................1126 TAILGATE LATCH.................................................................................1126 REMOVAL....................................................................................1126 INSTALLATION...............................................................................1127 TAILGATE LATCH STRIKER.........................................................................1127 REMOVAL....................................................................................1127 INSTALLATION...............................................................................1127 TAILGATE WEATHERSTRIP AND CHANNEL..............................................................1127 REMOVAL....................................................................................1127 INSTALLATION...............................................................................1127 ADJUSTMENTS........................................................................................1128 HOOD ADJUSTMENT................................................................................1128 DOOR ADJUSTMENT................................................................................1128 TAILGATE ADJUSTMENT............................................................................1128 SPECIFICATIONS.....................................................................................1129 BODY LUBRICANTS................................................................................1129 TORQUE SPECIFICATIONS..........................................................................1129 SPECIAL TOOLS......................................................................................1130 BODY...........................................................................................1130 HEATING AND AIR CONDITIONING...........................................................................1131 GENERAL INFORMATION................................................................................1132 HEATER AND AIR CONDITIONER.....................................................................1132 HEATER AND AIR CONDITIONER CONTROL.............................................................1132 SERVICE WARNINGS AND PRECAUTIONS...............................................................1133 COOLING SYSTEM REQUIREMENTS................................................................1133 REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS..................................................1134 DESCRIPTION AND OPERATION..........................................................................1134 ACCUMULATOR....................................................................................1134 BLOWER MOTOR...................................................................................1135 BLOWER MOTOR RELAY.............................................................................1135 BLOWER MOTOR RESISTOR..........................................................................1135 BLOWER MOTOR SWITCH............................................................................1135 COMPRESSOR.....................................................................................1135 COMPRESSOR CLUTCH..............................................................................1136 COMPRESSOR CLUTCH RELAY........................................................................1136 CONDENSER......................................................................................1136 EVAPORATOR COIL................................................................................1136 FIXED ORIFICE TUBE ............................................................................1137 HEATER CORE....................................................................................1137 HIGH PRESSURE CUT-OFF SWITCH...................................................................1137 HIGH PRESSURE RELIEF VALVE.....................................................................1137 LOW PRESSURE CYCLING CLUTCH SWITCH.............................................................1137 REFRIGERANT....................................................................................1138 REFRIGERANT LINE...............................................................................1138 REFRIGERANT LINE COUPLER.......................................................................1138 REFRIGERANT OIL................................................................................1139 REFRIGERANT SYSTEM SERVICE EQUIPMENT...........................................................1139 MANIFOLD GAUGE SET CONNECTIONS.............................................................1139 REFRIGERANT SYSTEM SERVICE PORT................................................................1140 VACUUM CHECK VALVE.............................................................................1140 VACUUM RESERVOIR...............................................................................1140 DIAGNOSIS AND TESTING..............................................................................1140 A/C PERFORMANCE................................................................................1140 HEATER PERFORMANCE.............................................................................1144 MAXIMUM HEATER OUTPUT......................................................................1144 TEMPERATURE CONTROL........................................................................1144 VACUUM SYSTEM..................................................................................1144 VACUUM CHECK VALVE.........................................................................1145 HEATER-A/C CONTROLS........................................................................1145 LOCATING VACUUM LEAKS......................................................................1145 BLOWER MOTOR...................................................................................1148 VIBRATION..................................................................................1148 NOISE......................................................................................1148 BLOWER MOTOR RELAY.............................................................................1148 RELAY TEST.................................................................................1148 RELAY CIRCUIT TEST.........................................................................1148 BLOWER MOTOR RESISTOR..........................................................................1149 BLOWER MOTOR SWITCH............................................................................1149 COMPRESSOR.....................................................................................1150 COMPRESSOR CLUTCH COIL.........................................................................1150 COMPRESSOR CLUTCH RELAY........................................................................1151 RELAY TEST.................................................................................1151 RELAY CIRCUIT TEST.........................................................................1151 HIGH PRESSURE CUT-OFF SWITCH...................................................................1151 LOW PRESSURE CYCLING CLUTCH SWITCH.............................................................1151 REFRIGERANT SYSTEM LEAKS.......................................................................1152 SYSTEM EMPTY...............................................................................1152 SYSTEM LOW.................................................................................1152 SERVICE PROCEDURES.................................................................................1152 REFRIGERANT RECOVERY...........................................................................1152 REFRIGERANT SYSTEM EVACUATE....................................................................1152 REFRIGERANT SYSTEM CHARGE......................................................................1153 REFRIGERANT CHARGE CAPACITY................................................................1153 REFRIGERANT OIL LEVEL..........................................................................1153 REMOVAL AND INSTALLATION...........................................................................1153 REFRIGERANT LINE COUPLER.......................................................................1153 REMOVAL ...................................................................................1154 INSTALLATION...............................................................................1154 HIGH PRESSURE CUT-OFF SWITCH...................................................................1154 REMOVAL....................................................................................1154 INSTALLATION...............................................................................1154 SUCTION AND DISCHARGE LINE.....................................................................1155 REMOVAL....................................................................................1155 INSTALLATION...............................................................................1155 COMPRESSOR.....................................................................................1156 REMOVAL....................................................................................1156 INSTALLATION...............................................................................1158 COMPRESSOR CLUTCH..............................................................................1156 REMOVAL ...................................................................................1156 INSPECTION.................................................................................1158 INSTALLATION...............................................................................1158 CLUTCH BREAK-IN............................................................................1159 COMPRESSOR CLUTCH RELAY........................................................................1159 LIQUID LINE....................................................................................1159 REMOVAL....................................................................................1160 INSTALLATION...............................................................................1160 FIXED ORIFICE TUBE.............................................................................1160 REMOVAL....................................................................................1160 INSTALLATION...............................................................................1160 LOW PRESSURE CYCLING CLUTCH SWITCH.............................................................1161 REMOVAL....................................................................................1161 INSTALLATION...............................................................................1162 ACCUMULATOR....................................................................................1161 REMOVAL....................................................................................1161 INSTALLATION...............................................................................1162 CONDENSER......................................................................................1162 REMOVAL....................................................................................1162 INSTALLATION...............................................................................1162 VACUUM CHECK VALVE.............................................................................1163 VACUUM RESERVOIR...............................................................................1164 BLOWER MOTOR...................................................................................1164 REMOVAL....................................................................................1164 INSTALLATION...............................................................................1164 HEATER-A/C CONTROL.............................................................................1164 REMOVAL....................................................................................1165 INSTALLATION...............................................................................1165 BLOWER MOTOR SWITCH............................................................................1165 TEMPERATURE CONTROL CABLE......................................................................1166 REMOVAL....................................................................................1166 INSTALLATION...............................................................................1166 BLOWER MOTOR RELAY.............................................................................1167 KICK COVER.....................................................................................1167 REMOVAL....................................................................................1167 INSTALLATION...............................................................................1167 BLOWER MOTOR RESISTOR..........................................................................1167 MODE DOOR VACUUM ACTUATOR......................................................................1168 DEFROST DOOR ACTUATOR......................................................................1168 FLOOR DOOR ACTUATOR........................................................................1169 PANEL/DEMIST DOOR ACTUATOR.................................................................1169 RECIRCULATION AIR DOOR ACTUATOR............................................................1169 HEATER-A/C HOUSING.............................................................................1169 REMOVAL....................................................................................1169 DISASSEMBLY................................................................................1170 ASSEMBLY...................................................................................1171 INSTALLATION...............................................................................1171 HEATER-A/C HOUSING DOOR........................................................................1172 BLEND-AIR DOOR.............................................................................1172 PANEL/DEMIST DOOR AND LEVER................................................................1172 DEFROST DOOR AND LEVER.....................................................................1173 FLOOR DOOR AND LEVER.......................................................................1173 RECIRCULATION AIR DOOR.....................................................................1173 EVAPORATOR COIL................................................................................1173 HEATER CORE....................................................................................1174 DEFROST/DEMIST DUCT........................................................................1175 DEMISTER HOSES.............................................................................1175 FLOOR DUCT.................................................................................1175 FRESH AIR DUCT AND COLLAR..................................................................1175 PANEL DUCTS................................................................................1175 PANEL OUTLET BARRELS.......................................................................1175 DUCTS AND OUTLETS..............................................................................1174 EMISSION CONTROL SYSTEMS...............................................................................1177 GENERAL INFORMATION................................................................................1177 SYSTEM DESCRIPTION.............................................................................1177 DESCRIPTION AND OPERATION..........................................................................1178 MALFUNCTION INDICATOR LAMP (MIL)...............................................................1178 STATE DISPLAY TEST MODE........................................................................1178 CIRCUIT ACTUATION TEST MODE....................................................................1178 DIAGNOSTIC TROUBLE CODES.......................................................................1178 OBTAINING DIAGNOSTIC TROUBLE CODES.........................................................1179 DIAGNOSTIC TROUBLE CODE DESCRIPTIONS.......................................................1179 MONITORED SYSTEMS..............................................................................1183 OXYGEN SENSOR (O2S) MONITOR................................................................1183 OXYGEN SENSOR HEATER MONITOR...............................................................1183 LEAK DETECTION PUMP MONITOR (IF EQUIPPED)..................................................1183 MISFIRE MONITOR............................................................................1184 FUEL SYSTEM MONITOR........................................................................1184 CATALYST MONITOR...........................................................................1184 TRIP DEFINITION................................................................................1185 COMPONENT MONITORS.............................................................................1185 NON-MONITORED CIRCUITS.........................................................................1185 FUEL PRESSURE..............................................................................1186 SECONDARY IGNITION CIRCUIT.................................................................1186 CYLINDER COMPRESSION.......................................................................1186 EXHAUST SYSTEM.............................................................................1186 FUEL INJECTOR MECHANICAL MALFUNCTIONS......................................................1186 EXCESSIVE OIL CONSUMPTION..................................................................1186 THROTTLE BODY AIR FLOW.....................................................................1186 VACUUM ASSIST .............................................................................1186 PCM SYSTEM GROUND..........................................................................1186 PCM CONNECTOR ENGAGEMENT ..................................................................1186 HIGH AND LOW LIMITS............................................................................1186 LOAD VALUE.....................................................................................1186 DESCRIPTION AND OPERATION..........................................................................1187 EVAPORATION CONTROL SYSTEM.....................................................................1187 ROLLOVER VALVE.................................................................................1187 EVAP CANISTER..................................................................................1188 DUTY CYCLE EVAP CANISTER PURGE SOLENOID........................................................1188 LEAK DETECTION PUMP (LDP)......................................................................1188 CRANKCASE VENTILATION SYSTEM...................................................................1188 VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL..............................................1190 DIAGNOSIS AND TESTING..............................................................................1190 VACUUM SCHEMATICS..............................................................................1190 LEAK DETECTION PUMP (LDP)......................................................................1190 REMOVAL AND INSTALLATION...........................................................................1190 EVAP CANISTER..................................................................................1190 REMOVAL....................................................................................1191 INSTALLATION...............................................................................1191 EVAP CANISTER PURGE SOLENOID...................................................................1191 REMOVAL....................................................................................1191 INSTALLATION...............................................................................1191 ROLLOVER VALVE.................................................................................1191 LEAK DETECTION PUMP (LDP)......................................................................1191 INSTALLATION...............................................................................1191 REMOVAL....................................................................................1191 SPECIFICATIONS.....................................................................................1192 TORQUE CHART...................................................................................1192 EMISSION CONTROL SYSTEMS...............................................................................1193 DESCRIPTION AND OPERATION..........................................................................1193 DIAGNOSTIC TROUBLE CODES.......................................................................1193 OBTAINING DIAGNOSTIC TROUBLE CODES.........................................................1193 DIAGNOSTIC TROUBLE CODE DESCRIPTIONS.......................................................1194
Contact us: [email protected]
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.V
