Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
2002 2003 2004 2005 2006 2007 Jeep Liberty KJ JEEP CHEROKEE COMPLETE Service Repair Workshop Manual – PDF DOWNLOAD
$36.95
2002 2003 2004 2005 2006 2007 Jeep Liberty KJ JEEP CHEROKEE COMPLETE Service Repair Manual
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
2002 2003 2004 2005 2006 2007 Jeep Liberty KJ JEEP CHEROKEE COMPLETE Service Repair Workshop Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:2500+
DOWNLOADABLE:YES
FILE TYPE:PDF
2002 2003 2004 2005 2006 2007 JEEP LIBERTY KJ JEEP CHEROKEE COMPLETE SERVICE REPAIR WORKSHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2002 2003 2004 2005 2006 2007 Jeep Liberty KJ JEEP CHEROKEE COMPLETE Service Repair Workshop Manual
MAINTENANCE SCHEDULES – DIESEL ENGINE
There are two maintenance schedules that show the required service for your vehicle. First is Schedule (B(. It is for vehicles that are operated under the conditions that are listed below and at the beginning of the schedule.
- Day or night temperatures are below 32°F (0°C).
- Stop and go driving.
- Extensive engine idling.
- Driving in dusty conditions.
- Short trips of less than 10 miles (16.2 km).
- More than 50% of your driving is at sustained high speeds during hot weather, above 90°F (32°C).
- Trailer towing.
- Taxi, police, or delivery service (commercial service).
- Off-road or desert driving.
NOTE: Most vehicles are operated under the conditions listed for Schedule “B.” Second is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Schedule “B.” Use the schedule that best describes your driving conditions. Where time and mileage are listed, follow the interval that occurs first.
CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.
At Each Stop for Fuel
- Check the engine oil level about 5 minutes after a fully warmed engine is shut off. Checking the oil level while the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only when the level is at or below the ADD or MIN mark.
- Check the windshield washer solvent, add as required.
TABLE OF CONTENTS:
2002 2003 2004 2005 2006 2007 Jeep Liberty KJ JEEP CHEROKEE COMPLETE Service Repair Workshop Manual
MAIN WELCOME PAGE......................................................................................... 0 INSTRUCTIONS.............................................................................................. 0 KJ Powertrain............................................................................................. 0 KJ Diesel Powertrain...................................................................................... 0 KJ Body................................................................................................... 0 KJ Chassis................................................................................................ 0 KJ Diesel Transmission.................................................................................... 0 KJ Service Manual......................................................................................... 1 FOREWORD.............................................................................................. 0 GROUP TAB LOCATOR..................................................................................... 1 in-INTRODUCTION....................................................................................... 2 FASTENER IDENTIFICATION........................................................................... 2 DESCRIPTION................................................................................... 2 FASTENER USAGE.................................................................................... 5 DESCRIPTION................................................................................... 5 INTERNATIONAL SYMBOLS............................................................................. 5 DESCRIPTION................................................................................... 5 METRIC SYSTEM..................................................................................... 5 DESCRIPTION................................................................................... 5 TORQUE REFERENCES................................................................................. 7 DESCRIPTION................................................................................... 7 VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL................................................. 9 DESCRIPTION................................................................................... 9 VEHICLE IDENTIFICATION NUMBER..................................................................... 9 DESCRIPTION................................................................................... 9 VEHICLE CERTIFICATION LABEL....................................................................... 10 DESCRIPTION................................................................................... 10 0-LUBRICATION & MAINTENANCE........................................................................... 12 INTERNATIONAL SYMBOLS............................................................................. 12 DESCRIPTION................................................................................... 12 PARTS & LUBRICANT RECOMMENDATION.................................................................. 12 DESCRIPTION................................................................................... 12 LUBRICANT RECOMMENDATIONS................................................................. 12 Chassis............................................................................... 12 Body.................................................................................. 13 FLUID TYPES............................................................................... 13 API QUALITY CLASSIFICATION ........................................................... 13 GEAR LUBRICANTS....................................................................... 13 FLUID TYPES....................................................................................... 13 DESCRIPTION................................................................................... 13 ENGINE OIL................................................................................ 13 API SERVICE GRADE CERTIFIED........................................................... 13 SAE VISCOSITY......................................................................... 13 ACEA Categories....................................................................... 13 ENERGY CONSERVING OIL................................................................. 13 CONTAINER IDENTIFICATION.............................................................. 14 ENGINE OIL - DIESEL ENGINES............................................................... 14 SAE VISCOSITY GRADE................................................................... 14 ENGINE OIL - DIESEL ENGINES - EXPORT...................................................... 14 SAE VISCOSITY GRADE................................................................... 14 AXLE...................................................................................... 14 MANUAL TRANSMISSION....................................................................... 14 AUTOMATIC TRANSMISSION FLUID.............................................................. 14 FLUID ADDITIVES....................................................................... 15 TRANSFER CASE - NV231..................................................................... 15 TRANSFER CASE - NV241 GENII............................................................... 15 TRANSFER CASE - NV242..................................................................... 15 ENGINE COOLANT............................................................................ 15 COOLANT PERFORMANCE................................................................... 15 POWER STEERING FLUID...................................................................... 16 OPERATION - AUTOMATIC TRANSMISSION FLUID...................................................... 16 FLUID CAPACITIES.................................................................................. 16 SPECIFICATIONS - FLUID CAPACITIES............................................................. 16 MAINTENANCE SCHEDULES............................................................................. 17 DESCRIPTION................................................................................... 17 MAINTENANCE SCHEDULES - GASOLINE ENGINES.................................................. 17 Schedule “B”.......................................................................... 17 Schedule “A”.......................................................................... 21 MAINTENANCE SCHEDULES - DIESEL ENGINE..................................................... 23 Schedule “B”.......................................................................... 23 Schedule “A”.......................................................................... 25 MAINTENANCE SCHEDULES - GASOLINE ENGINES - EXPORT......................................... 25 Schedule “A”.......................................................................... 26 Schedule “B”.......................................................................... 28 DESCRIPTION – DIESEL ENGINES – EXPORT SCHEDULES........................................... 30 Schedule “A”.......................................................................... 31 Schedule “B”.......................................................................... 32 FLUID FILL/CHECK LOCATIONS........................................................................ 34 DESCRIPTION................................................................................... 34 HOISTING.......................................................................................... 34 STANDARD PROCEDURE - HOISTING RECOMMENDATIONS................................................. 34 HOIST..................................................................................... 34 JUMP STARTING..................................................................................... 34 STANDARD PROCEDURE - JUMP STARTING PROCEDURE.................................................. 34 TO JUMP START A DISABLED VEHICLE:......................................................... 35 DISCONNECT CABLE CLAMPS AS FOLLOWS:....................................................... 35 TOWING............................................................................................ 35 STANDARD PROCEDURE - TOWING................................................................... 35 SAFETY PRECAUTIONS........................................................................ 36 TWO-WHEEL-DRIVE VEHICLE TOWING............................................................ 36 TWO WHEEL DRIVE TOWING-REAR END LIFTED.................................................... 36 TWO WHEEL DRIVE TOWING-FRONT END LIFTED................................................... 36 FOUR-WHEEL-DRIVE VEHICLE TOWING........................................................... 36 FOUR WHEEL DRIVE TOWING—REAR END LIFTED................................................... 36 FOUR WHEEL DRIVE TOWING—FRONT END LIFTED.................................................. 37 2-SUSPENSION.......................................................................................... 38 SUSPENSION........................................................................................ 38 DIAGNOSIS AND TESTING - SUSPENSION AND STEERING SYSTEM........................................ 38 WHEEL ALIGNMENT................................................................................... 40 DESCRIPTION................................................................................... 40 OPERATION..................................................................................... 40 STANDARD PROCEDURE............................................................................ 41 STANDARD PROCEDURE - HEIGHT MEASUREMENT................................................... 41 RIDE HEIGHT........................................................................... 41 STANDARD PROCEDURE - CAMBER AND CASTER ADJUSTMENT......................................... 42 STANDARD PROCEDURE - TOE ADJUSTMENT....................................................... 42 STANDARD PROCEDURE - CAMBER, CASTER AND TOE ADJUSTMENT.................................... 42 CASTER................................................................................ 42 CAMBER................................................................................ 43 TOE ADJUSTMENT........................................................................ 43 SPECIFICATIONS................................................................................ 43 ALIGNMENT................................................................................. 43 FRONT................................................................................. 43 REAR.................................................................................. 43 FRONT............................................................................................. 44 DESCRIPTION................................................................................... 44 WARNING....................................................................................... 45 SPECIFICATIONS................................................................................ 45 TORQUE CHART.............................................................................. 45 SPECIAL TOOLS................................................................................. 46 FRONT SUSPENSION.......................................................................... 46 BUSHINGS...................................................................................... 47 REMOVAL................................................................................... 47 REMOVAL - STABILIZER BAR BUSHINGS..................................................... 47 REMOVAL - LOWER CONTROL ARM BUSHING................................................... 47 REMOVAL - CLEVIS BRACKET BUSHING...................................................... 47 REMOVAL - UPPER CONTROL ARM BUSHINGS.................................................. 47 INSTALLATION.............................................................................. 47 INSTALLATION - STABILIZER BAR BUSHINGS................................................ 47 INSTALLATION - LOWER CONTROL ARM BUSHING.............................................. 48 INSTALLATION - CLEVIS BRACKET BUSHING................................................. 48 INSTALLATION - UPPER CONTROL ARM BUSHINGS............................................. 49 HUB / BEARING................................................................................. 49 REMOVAL................................................................................... 49 INSTALLATION.............................................................................. 49 KNUCKLE....................................................................................... 49 REMOVAL................................................................................... 49 INSTALLATION.............................................................................. 50 LOWER BALL JOINT.............................................................................. 50 DIAGNOSIS AND TESTING - LOWER BALL JOINT.................................................. 50 REMOVAL................................................................................... 50 INSTALLATION.............................................................................. 51 LOWER CONTROL ARM............................................................................. 51 REMOVAL................................................................................... 51 INSTALLATION.............................................................................. 52 SHOCK......................................................................................... 52 REMOVAL................................................................................... 52 REMOVAL - LEFT SIDE................................................................... 52 REMOVAL - RIGHT SIDE.................................................................. 52 INSTALLATION.............................................................................. 53 INSTALLATION - LEFT SIDE.............................................................. 53 INSTALLATION - RIGHT SIDE............................................................. 53 SPRING........................................................................................ 54 REMOVAL................................................................................... 54 INSTALLATION.............................................................................. 54 CLEVIS BRACKET................................................................................ 54 REMOVAL................................................................................... 54 INSTALLATION.............................................................................. 54 STABILIZER BAR................................................................................ 55 REMOVAL................................................................................... 55 INSTALLATION.............................................................................. 55 STABILIZER LINK............................................................................... 55 REMOVAL................................................................................... 55 INSTALLATION.............................................................................. 55 UPPER CONTROL ARM............................................................................. 55 REMOVAL................................................................................... 55 REMOVAL - RIGHT SIDE.................................................................. 55 REMOVAL - LEFT SIDE................................................................... 56 INSTALLATION.............................................................................. 56 INSTALLATION - RIGHT SIDE............................................................. 56 INSTALLATION - LEFT SIDE.............................................................. 56 3-DIFFERENTIAL & DRIVELINE............................................................................ 66 PROPELLER SHAFT................................................................................... 66 DIAGNOSIS AND TESTING......................................................................... 66 PROPELLER SHAFT........................................................................... 66 PROPELLER SHAFT VIBRATION............................................................. 66 BALANCE .............................................................................. 67 RUNOUT................................................................................ 68 STANDARD PROCEDURE............................................................................ 68 PROPELLER SHAFT ANGLE..................................................................... 68 RULES................................................................................. 69 SPECIFICATIONS................................................................................ 70 SPECIAL TOOLS................................................................................. 70 SHAFT-PROPELLER FRONT......................................................................... 70 REMOVAL................................................................................... 70 2.8L DIESEL........................................................................... 70 GAS ENGINES........................................................................... 71 INSTALLATION.............................................................................. 71 2.8L DIESEL........................................................................... 71 GAS ENGINES........................................................................... 71 SHAFT-PROPELLER REAR.......................................................................... 71 REMOVAL................................................................................... 71 INSTALLATION.............................................................................. 72 UNIVERSAL JOINT-SINGLE CARDAN................................................................. 73 DISASSEMBLY - WITH SNAP RINGS............................................................. 73 ASSEMBLY - WITH SNAP RINGS................................................................ 74 HALF SHAFT........................................................................................ 75 CAUTION....................................................................................... 75 DIAGNOSIS AND TESTING......................................................................... 75 HALF SHAFT................................................................................ 75 NOISE/VIBRATION IN TURNS.............................................................. 75 CLUNKING NOISE DURING ACCELERATION.................................................... 75 SHUDDER/VIBRATION DURING ACCELERATION................................................. 75 VIBRATION AT HIGHWAY SPEEDS........................................................... 75 REMOVAL....................................................................................... 75 INSTALLATION.................................................................................. 76 SPECIFICATIONS................................................................................ 77 SPECIAL TOOLS................................................................................. 77 JOINT/BOOT-C/V OUTER.......................................................................... 78 REMOVAL................................................................................... 78 INSTALLATION.............................................................................. 79 JOINT/BOOT-C/V INNER.......................................................................... 81 REMOVAL................................................................................... 81 INSTALLATION.............................................................................. 83 FRONT AXLE - 186FIA............................................................................... 85 DIAGNOSIS AND TESTING......................................................................... 85 FRONT AXLE - 186FIA....................................................................... 85 GEAR NOISE............................................................................ 85 BEARING NOISE......................................................................... 85 LOW SPEED KNOCK....................................................................... 85 VIBRATION............................................................................. 85 DRIVELINE SNAP........................................................................ 86 REMOVAL....................................................................................... 89 INSTALLATION.................................................................................. 91 ADJUSTMENTS................................................................................... 92 PINION DEPTH MEASUREMENT ................................................................. 93 DIFFERENTIAL SIDE BEARING PRELOAD AND GEAR BACKLASH ...................................... 94 PRELOAD SHIM SELECTION ................................................................... 95 GEAR BACKLASH ............................................................................ 97 GEAR CONTACT PATTERN ..................................................................... 98 DIFFERENTIAL BEARING PRELOAD CHECK ....................................................... 98 SPECIFICATIONS................................................................................ 98 SPECIAL TOOLS................................................................................. 100 COVER-DIFFERENTIAL............................................................................ 103 REMOVAL................................................................................... 103 INSTALLATION.............................................................................. 103 SHAFT-AXLE.................................................................................... 105 REMOVAL................................................................................... 105 INSTALLATION.............................................................................. 105 SEAL-AXLE SHAFT............................................................................... 105 REMOVAL................................................................................... 105 INSTALLATION.............................................................................. 106 BEARING-AXLE.................................................................................. 106 REMOVAL................................................................................... 106 INSTALLATION.............................................................................. 106 SEAL-PINION................................................................................... 107 REMOVAL................................................................................... 107 INSTALLATION.............................................................................. 107 DIFFERENTIAL.................................................................................. 108 REMOVAL................................................................................... 108 DISASSEMBLY............................................................................... 109 ASSEMBLY.................................................................................. 110 INSTALLATION.............................................................................. 110 BEARING-DIFFERENTIAL CASE..................................................................... 111 REMOVAL................................................................................... 111 INSTALLATION.............................................................................. 112 GEAR-PINION/RING.............................................................................. 112 REMOVAL................................................................................... 112 INSTALLATION.............................................................................. 114 REAR AXLE - 8 1/4................................................................................. 117 DIAGNOSIS AND TESTING......................................................................... 117 GEAR NOISE................................................................................ 117 BEARING NOISE............................................................................. 117 LOW SPEED KNOCK........................................................................... 117 VIBRATION................................................................................. 117 DRIVELINE SNAP............................................................................ 118 REMOVAL....................................................................................... 120 INSTALLATION.................................................................................. 121 ADJUSTMENTS................................................................................... 122 PINION DEPTH MEASUREMENT ................................................................. 123 DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH ........................................... 123 GEAR CONTACT PATTERN ..................................................................... 125 SIDE GEAR CLEARANCE ...................................................................... 127 SPECIFICATIONS................................................................................ 128 SPECIAL TOOLS................................................................................. 128 COVER-DIFFERENTIAL............................................................................ 131 REMOVAL................................................................................... 131 INSTALLATION.............................................................................. 131 SHAFT-AXLE.................................................................................... 131 REMOVAL................................................................................... 131 INSTALLATION.............................................................................. 132 SEAL-AXLE SHAFT............................................................................... 132 REMOVAL................................................................................... 132 INSTALLATION.............................................................................. 132 BEARING-AXLE.................................................................................. 133 REMOVAL................................................................................... 133 INSTALLATION.............................................................................. 133 SEAL-PINION................................................................................... 134 REMOVAL................................................................................... 134 INSTALLATION.............................................................................. 134 DIFFERENTIAL.................................................................................. 136 REMOVAL................................................................................... 136 DISASSEMBLY............................................................................... 137 ASSEMBLY.................................................................................. 138 INSTALLATION.............................................................................. 138 DIFFERENTIAL-TRAC-LOK......................................................................... 139 OPERATION................................................................................. 139 DIAGNOSIS AND TESTING..................................................................... 139 DIFFERENTIAL-TRAC-LOK................................................................. 139 DIFFERENTIAL TEST................................................................. 139 BEARING-DIFFERENTIAL CASE..................................................................... 140 REMOVAL................................................................................... 140 INSTALLATION.............................................................................. 140 GEAR-PINION/RING.............................................................................. 140 REMOVAL................................................................................... 140 INSTALLATION.............................................................................. 143 5-BRAKES.............................................................................................. 146 BRAKES - BASE..................................................................................... 146 DESCRIPTION................................................................................... 147 WARNING....................................................................................... 148 DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM..................................................... 148 PRELIMINARY BRAKE CHECK................................................................... 148 ROAD TESTING.............................................................................. 149 BRAKE NOISES.............................................................................. 150 STANDARD PROCEDURE............................................................................ 150 STANDARD PROCEDURE - PRESSURE BLEEDING.................................................... 150 STANDARD PROCEDURE - MANUAL BLEEDING...................................................... 151 SPECIFICATIONS................................................................................ 152 BRAKE COMPONENTS.......................................................................... 152 TORQUE.................................................................................... 152 SPECIAL TOOLS................................................................................. 153 BASE BRAKES............................................................................... 153 BRAKE LINES................................................................................... 153 DESCRIPTION............................................................................... 153 DIAGNOSIS AND TESTING - BRAKE LINE AND HOSES.............................................. 153 STANDARD PROCEDURE........................................................................ 153 STANDARD PROCEDURE - DOUBLE INVERTED FLARING.......................................... 153 STANDARD PROCEDURE - ISO FLARING...................................................... 154 REMOVAL................................................................................... 154 FRONT BRAKE CALIPER HOSE.............................................................. 154 REAR BRAKE HOSE....................................................................... 155 INSTALLATION.............................................................................. 155 FRONT BRAKE CALIPER HOSE.............................................................. 155 INSTALLATION - REAR BRAKE HOSE........................................................ 156 BRAKE PADS / SHOES............................................................................ 156 REMOVAL................................................................................... 156 REMOVAL - FRONT BRAKE PADS............................................................ 156 REMOVAL - REAR DISC BRAKE PADS........................................................ 156 INSTALLATION.............................................................................. 157 INSTALLATION - FRONT BRAKE PADS....................................................... 157 INSTALLATION - REAR DISC BRAKE PADS................................................... 157 DISC BRAKE CALIPERS........................................................................... 158 DESCRIPTION............................................................................... 158 OPERATION................................................................................. 158 REMOVAL................................................................................... 159 FRONT................................................................................. 159 REAR.................................................................................. 159 DISASSEMBLY............................................................................... 159 CLEANING.................................................................................. 160 INSPECTION................................................................................ 160 ASSEMBLY.................................................................................. 161 INSTALLATION.............................................................................. 162 FRONT................................................................................. 162 REAR.................................................................................. 163 DISC BRAKE CALIPER ADAPTER.................................................................... 163 REMOVAL................................................................................... 163 INSTALLATION.............................................................................. 163 ROTORS........................................................................................ 164 DIAGNOSIS AND TESTING..................................................................... 164 DIAGNOSIS AND TESTING - DISC BRAKE ROTOR.............................................. 164 ROTOR MINIMUM THICKNESS........................................................... 164 ROTOR RUNOUT ..................................................................... 164 ROTOR THICKNESS VARIATION ........................................................ 164 DIAGNOSIS AND TESTING - BRAKE DRUM IN HAT ROTOR....................................... 164 BRAKE DRUM RUNOUT................................................................. 164 STANDARD PROCEDURE........................................................................ 165 STANDARD PROCEDURE - DISC BRAKE ROTOR................................................. 165 STANDARD PROCEDURE - BRAKE DRUM IN HAT ROTOR MACHINING................................ 165 REMOVAL................................................................................... 165 FRONT................................................................................. 165 REAR.................................................................................. 165 INSTALLATION.............................................................................. 166 FRONT................................................................................. 166 REAR.................................................................................. 166 BRAKE JUNCTION BLOCK.......................................................................... 166 DESCRIPTION............................................................................... 166 OPERATION................................................................................. 166 PROPORTIONING VALVE................................................................... 166 DIAGNOSIS AND TESTING - PROPORTIONING VALVE............................................... 166 REMOVAL................................................................................... 167 INSTALLATION.............................................................................. 167 PEDAL......................................................................................... 167 DESCRIPTION............................................................................... 167 OPERATION................................................................................. 168 REMOVAL................................................................................... 168 INSTALLATION.............................................................................. 168 POWER BRAKE BOOSTER........................................................................... 168 DESCRIPTION............................................................................... 168 OPERATION................................................................................. 169 DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER..................................... 169 POWER BOOSTER VACUUM TEST............................................................. 169 POWER BOOSTER CHECK VALVE TEST........................................................ 170 REMOVAL................................................................................... 170 LEFT HAND DRIVE (LHD)................................................................. 170 RIGHT HAND DRIVE (RHD)................................................................ 171 INSTALLATION.............................................................................. 171 LEFT HAND DRIVE (LHD)................................................................. 171 RIGHT HAND DRIVE (RHD)................................................................ 172 MASTER CYLINDER............................................................................... 173 DESCRIPTION............................................................................... 173 OPERATION................................................................................. 173 DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER..................................... 173 POWER BOOSTER VACUUM TEST............................................................. 173 POWER BOOSTER CHECK VALVE TEST........................................................ 173 STANDARD PROCEDURE - MASTER CYLINDER BLEEDING............................................. 173 REMOVAL................................................................................... 174 INSTALLATION.............................................................................. 175 FLUID......................................................................................... 175 DIAGNOSIS AND TESTING..................................................................... 175 BRAKE FLUID CONTAMINATION............................................................. 175 STANDARD PROCEDURE - MASTER CYLINDER FLUID LEVEL.......................................... 175 SPECIFICATIONS............................................................................ 175 BRAKE FLUID........................................................................... 175 FLUID RESERVOIR............................................................................... 176 REMOVAL................................................................................... 176 INSTALLATION.............................................................................. 176 SUPPORT PLATE................................................................................. 176 REMOVAL................................................................................... 176 INSTALLATION.............................................................................. 177 PARKING BRAKE................................................................................. 177 DESCRIPTION............................................................................... 177 OPERATION................................................................................. 177 ADJUSTMENTS............................................................................... 178 ADJUSTMENT - LOCK OUT................................................................. 178 CABLES........................................................................................ 178 REMOVAL................................................................................... 178 INSTALLATION.............................................................................. 179 LEVER......................................................................................... 180 REMOVAL................................................................................... 180 INSTALLATION.............................................................................. 181 SHOES......................................................................................... 181 DESCRIPTION............................................................................... 181 OPERATION................................................................................. 181 REMOVAL................................................................................... 181 CLEANING - REAR DRUM IN HAT BRAKE......................................................... 182 INSPECTION - REAR DRUM IN HAT BRAKE....................................................... 182 INSTALLATION.............................................................................. 183 ADJUSTMENTS............................................................................... 183 ADJUSTMENT - WITH ADJUSTING TOOL...................................................... 183 ADJUSTMENT - REAR DRUM IN HAT PARK BRAKE (ROTOR REMOVED).............................. 184 BRAKES - ABS...................................................................................... 186 DESCRIPTION................................................................................... 186 ANTILOCK BRAKING SYSTEM................................................................... 186 ELECTRONIC BRAKE DISTRIBUTION............................................................. 186 OPERATION..................................................................................... 186 ANTILOCK BRAKING SYSTEM................................................................... 186 ELECTRONIC BRAKE DISTRIBUTION............................................................. 187 DIAGNOSIS AND TESTING - ANTILOCK BRAKING SYSTEM............................................... 187 STANDARD PROCEDURE - ABS BRAKE BLEEDING....................................................... 187 SPECIFICATIONS................................................................................ 187 ELECTRICAL.................................................................................... 188 DESCRIPTION............................................................................... 188 OPERATION................................................................................. 188 FRONT WHEEL SPEED SENSOR...................................................................... 188 REMOVAL................................................................................... 188 INSTALLATION.............................................................................. 188 REAR WHEEL SPEED SENSOR....................................................................... 189 REMOVAL................................................................................... 189 INSTALLATION.............................................................................. 189 HCU (HYDRAULIC CONTROL UNIT).................................................................. 189 DESCRIPTION............................................................................... 189 OPERATION................................................................................. 189 PRESSURE DECREASE..................................................................... 190 PRESSURE HOLD......................................................................... 190 PRESSURE INCREASE..................................................................... 190 REMOVAL................................................................................... 190 DISASSEMBLY............................................................................... 190 ASSEMBLY.................................................................................. 191 INSTALLATION.............................................................................. 192 6-CLUTCH.............................................................................................. 194 CLUTCH............................................................................................ 194 WARNING....................................................................................... 194 DIAGNOSIS AND TESTING......................................................................... 194 CLUTCH.................................................................................... 194 CLUTCH CONTAMINATION.................................................................. 194 IMPROPER RELEASE OR CLUTCH ENGAGEMENT................................................. 195 CLUTCH MISALIGNMENT................................................................... 195 PRESSURE PLATE AND DISC RUNOUT........................................................ 195 FLYWHEEL RUNOUT....................................................................... 195 DIAGNOSIS CHART....................................................................... 195 SPECIFICATIONS................................................................................ 198 CLUTCH DISC....................................................................................... 199 REMOVAL....................................................................................... 199 INSTALLATION.................................................................................. 199 GAS ENGINES............................................................................... 199 2.8L DIESEL............................................................................... 200 CLUTCH RELEASE BEARING............................................................................ 201 REMOVAL....................................................................................... 201 INSTALLATION.................................................................................. 201 FLYWHEEL.......................................................................................... 201 DESCRIPTION................................................................................... 201 STANDARD FLYWHEEL ........................................................................ 201 DUAL MASS FLYWHEEL ....................................................................... 202 DIAGNOSIS AND TESTING......................................................................... 202 FLYWHEEL.................................................................................. 202 PILOT BEARING..................................................................................... 202 REMOVAL....................................................................................... 202 INSTALLATION.................................................................................. 202 LINKAGE........................................................................................... 203 REMOVAL....................................................................................... 203 INSTALLATION.................................................................................. 203 MASTER CYLINDER................................................................................... 204 INSPECTION.................................................................................... 204 CLUTCH PEDAL...................................................................................... 204 REMOVAL....................................................................................... 204 INSTALLATION.................................................................................. 205 CLUTCH SWITCH OVERRIDE RELAY...................................................................... 205 DESCRIPTION................................................................................... 205 OPERATION..................................................................................... 205 REMOVAL....................................................................................... 205 INSTALLATION.................................................................................. 205 CLUTCH PEDAL POSITION SWITCH...................................................................... 206 DESCRIPTION................................................................................... 206 OPERATION..................................................................................... 206 DIAGNOSIS AND TESTING......................................................................... 206 CLUTCH PEDAL POSITION SWITCH.............................................................. 206 7-COOLING............................................................................................. 208 COOLING........................................................................................... 208 DESCRIPTION................................................................................... 208 2.4L ENGINE............................................................................... 208 3.7L ENGINE............................................................................... 208 2.8L DIESEL ENGINE........................................................................ 208 COOLING SYSTEM COMPONENTS............................................................. 208 COOLING SYSTEM ROUTING - 3.7L ENGINE...................................................... 209 HOSE CLAMPS............................................................................... 209 OPERATION..................................................................................... 210 COOLING SYSTEM............................................................................ 210 HOSE CLAMPS............................................................................... 210 DIAGNOSIS AND TESTING......................................................................... 210 ON-BOARD DIAGNOSTICS (OBD)................................................................ 210 COOLING SYSTEM RELATED DIAGNOSTICS.................................................... 210 ACCESSING DIAGNOSTIC TROUBLE CODES.................................................... 210 ERASING TROUBLE CODES................................................................. 210 PRELIMINARY CHECKS........................................................................ 210 ENGINE COOLING SYSTEM OVERHEATING..................................................... 210 COOLING SYSTEM LEAKS...................................................................... 211 ULTRAVIOLET LIGHT METHOD.............................................................. 211 PRESSURE TESTER METHOD................................................................ 211 INTERNAL LEAKAGE INSPECTION........................................................... 211 COMBUSTION LEAKAGE TEST - WITHOUT PRESSURE TESTER..................................... 212 COOLING SYSTEM DIAGNOSIS CHART - GAS ENGINE............................................... 213 COOLING SYSTEM DIAGNOSIS CHART - DIESEL ENGINE............................................ 219 COOLING SYSTEM FLOW CHECK - DIESEL ENGINE................................................. 224 COOLING SYSTEM AERATION................................................................... 224 STANDARD PROCEDURE............................................................................ 224 DRAINING COOLING SYSTEM................................................................... 224 REFILLING COOLING SYSTEM.................................................................. 225 COOLING SYSTEM - REVERSE FLUSHING......................................................... 225 CHEMICAL CLEANING..................................................................... 225 REVERSE FLUSHING RADIATOR............................................................. 225 REVERSE FLUSHING ENGINE............................................................... 226 INSPECTION.................................................................................... 226 SPECIFICATIONS................................................................................ 226 FILL VOLUMES.............................................................................. 226 TORQUE.................................................................................... 226 SPECIAL TOOLS................................................................................. 227 COOLING................................................................................... 227 ACCESSORY DRIVE................................................................................... 228 DIAGNOSIS AND TESTING - SERPENTINE DRIVE BELT DIAGNOSIS....................................... 228 BELT TENSIONERS............................................................................... 230 DESCRIPTION............................................................................... 230 OPERATION................................................................................. 230 REMOVAL................................................................................... 230 2.4L ENGINE........................................................................... 230 3.7L ENGINE........................................................................... 231 2.8L DIESEL........................................................................... 231 INSTALLATION.............................................................................. 231 2.4L ENGINE........................................................................... 231 3.7L ENGINE........................................................................... 232 2.8L DIESEL........................................................................... 232 DRIVE BELTS................................................................................... 232 DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT.............................................. 232 VISUAL DIAGNOSIS...................................................................... 232 NOISE DIAGNOSIS....................................................................... 232 REMOVAL................................................................................... 234 2.4L ENGINE........................................................................... 234 3.7L ENGINE........................................................................... 235 2.8L DIESEL........................................................................... 235 INSTALLATION.............................................................................. 235 2.4L ENGINE........................................................................... 235 3.7L ENGINE........................................................................... 236 2.8L DIESEL........................................................................... 237 IDLER PULLEY.................................................................................. 238 REMOVAL................................................................................... 238 INSTALLATION.............................................................................. 238 2.8L DIESEL........................................................................... 238 ENGINE............................................................................................ 239 COOLANT....................................................................................... 240 DESCRIPTION............................................................................... 240 HOAT COOLANT.......................................................................... 240 COOLANT PERFORMANCE............................................................... 240 COOLANT SELECTION AND ADDITIVES................................................... 241 ENGINE COOLANT........................................................................ 241 ETHYLENE-GLYCOL MIXTURES.......................................................... 241 PROPYLENE-GLYCOL MIXTURES......................................................... 241 OPERATION................................................................................. 241 COOLANT RECOVERY CONTAINER.................................................................... 242 DESCRIPTION............................................................................... 242 COOLANT RECOVERY PRESSURE SYSTEM - 3.7L/2.8L DIESEL................................... 242 COOLANT RECOVERY NON-PRESSURE SYSTEM - 2.4L........................................... 242 OPERATION................................................................................. 242 COOLANT RECOVERY PRESSURE SYSTEM - 3.7L/2.8L DIESEL................................... 242 COOLANT RECOVERY NON-PRESSURE SYSTEM - 2.4L........................................... 242 REMOVAL................................................................................... 243 PRESSURE SYSTEM - 3.7L/2.8L DIESEL.................................................... 243 NON-PRESSURE SYSTEM - 2.4L............................................................ 243 INSTALLATION.............................................................................. 243 PRESSURE SYSTEM - 3.7L/2.8L DIESEL.................................................... 243 NON-PRESSURE SYSTEM - 2.4L............................................................ 243 COOLANT SYSTEM HOSES-2.8L DIESEL.............................................................. 244 REMOVAL................................................................................... 244 UPPER RADIATOR HOSE - 2.8L DIESEL..................................................... 244 HEATER CORE HOSES - 2.8L DIESEL....................................................... 244 INSTALLATION.............................................................................. 244 UPPER RADIATOR HOSE - 2.8L DIESEL..................................................... 244 HEATER CORE HOSES - 2.8L DIESEL....................................................... 244 ENGINE BLOCK HEATER........................................................................... 245 DESCRIPTION............................................................................... 245 OPERATION................................................................................. 245 REMOVAL................................................................................... 245 REMOVAL - 2.4L........................................................................ 245 REMOVAL - 3.7L........................................................................ 245 INSTALLATION.............................................................................. 245 INSTALLATION - 2.4L................................................................... 245 INSTALLATION - 3.7L................................................................... 246 ENGINE COOLANT TEMPERATURE SENSOR............................................................. 246 DESCRIPTION............................................................................... 246 OPERATION................................................................................. 246 REMOVAL................................................................................... 247 2.4L ENGINE........................................................................... 247 3.7L ENGINE........................................................................... 247 2.8L DIESEL ENGINE.................................................................... 247 INSTALLATION.............................................................................. 247 2.4L ENGINE........................................................................... 247 3.7L ENGINE........................................................................... 248 2.8L DIESEL ENGINE.................................................................... 248 ENGINE COOLANT THERMOSTAT..................................................................... 248 DESCRIPTION............................................................................... 248 DESCRIPTION - 3.7L ENGINE............................................................. 248 OPERATION................................................................................. 249 DIAGNOSIS AND TESTING - THERMOSTAT........................................................ 249 ON-BOARD DIAGNOSTICS.................................................................. 249 REMOVAL................................................................................... 249 2.4L ENGINE........................................................................... 249 3.7L ENGINE........................................................................... 249 2.8L DIESEL ENGINE.................................................................... 250 INSTALLATION.............................................................................. 250 2.4L ENGINE........................................................................... 250 3.7L ENGINE........................................................................... 251 2.8L DIESEL ENGINE.................................................................... 251 HOSE CLAMPS................................................................................... 251 DESCRIPTION - HOSE CLAMPS................................................................. 251 OPERATION - HOSE CLAMPS................................................................... 252 RADIATOR...................................................................................... 252 DESCRIPTION............................................................................... 252 REMOVAL................................................................................... 252 3.7L/2.8L DIESEL ENGINES.............................................................. 252 2.4L ENGINE........................................................................... 254 CLEANING.................................................................................. 255 INSPECTION................................................................................ 255 INSTALLATION.............................................................................. 256 3.7L/2.8L DIESEL ENGINES.............................................................. 256 2.4L ENGINE........................................................................... 256 RADIATOR PRESSURE CAP......................................................................... 256 DESCRIPTION............................................................................... 256 OPERATION................................................................................. 257 DIAGNOSIS AND TESTING..................................................................... 257 RADIATOR PRESSURE CAP - GAS ENGINES................................................... 257 RADIATOR PRESSURE CAP - 3.7L/2.8L DIESEL.............................................. 257 PRESSURE RELIEF TEST - 3.7L/2.8L DIESEL............................................... 258 CLEANING.................................................................................. 258 INSPECTION................................................................................ 258 RADIATOR FAN - ELECTRIC....................................................................... 258 DESCRIPTION............................................................................... 258 OPERATION................................................................................. 258 REMOVAL................................................................................... 259 3.7L ENGINE........................................................................... 259 2.4L ENIGNE........................................................................... 260 INSTALLATION.............................................................................. 260 3.7L ENGINE........................................................................... 260 2.4L ENGINE........................................................................... 260 RADIATOR - FAN - VISCOUS...................................................................... 260 DESCRIPTION............................................................................... 260 OPERATION................................................................................. 261 DIAGNOSIS AND TESTING..................................................................... 261 VISCOUS FAN DRIVE..................................................................... 261 REMOVAL................................................................................... 261 3.7L ENGINE0 - 2 KJ (Continued)................................................... 261 2.8L DIESEL........................................................................... 261 CLEANING.................................................................................. 262 INSPECTION................................................................................ 263 INSTALLATION.............................................................................. 263 3.7L ENGINE........................................................................... 263 2.8L DIESEL........................................................................... 263 THERMOSTAT HOUSING............................................................................ 263 REMOVAL................................................................................... 263 INSTALLATION.............................................................................. 264 WATER PUMP.................................................................................... 264 DESCRIPTION............................................................................... 264 3.7L ENGINE........................................................................... 264 2.4L ENGINE........................................................................... 265 2.8L DIESEL ENGINE.................................................................... 265 DESCRIPTION - WATER PUMP BYPASS - 3.7L................................................ 265 OPERATION................................................................................. 265 2.8L DIESEL ENGINE.................................................................... 265 2.4L/3.7L ENGINES..................................................................... 265 REMOVAL................................................................................... 265 2.4L ENGINE........................................................................... 265 3.7L.................................................................................. 265 2.8L DIESEL ENGINE.................................................................... 267 CLEANING.................................................................................. 267 INSPECTION................................................................................ 267 INSTALLATION.............................................................................. 267 2.4L ENGINE........................................................................... 267 3.7L ENGINE........................................................................... 268 2.8L DIESEL ENGINE.................................................................... 269 8a-AUDIO/VIDEO........................................................................................ 272 AUDIO/VIDEO....................................................................................... 272 DESCRIPTION................................................................................... 272 OPERATION..................................................................................... 273 DIAGNOSIS AND TESTING - AUDIO................................................................. 273 AMPLIFIER CHOKE AND RELAY......................................................................... 275 DESCRIPTION................................................................................... 275 OPERATION..................................................................................... 275 DIAGNOSIS AND TESTING - AMPLIFIER CHOKE AND RELAY............................................. 275 REMOVAL....................................................................................... 275 INSTALLATION.................................................................................. 276 ANTENNA BODY & CABLE.............................................................................. 276 DESCRIPTION................................................................................... 276 DOMESTIC.................................................................................. 276 EXPORT.................................................................................... 276 OPERATION..................................................................................... 276 DIAGNOSIS AND TESTING - ANTENNA BODY AND CABLE................................................ 276 TEST 1.................................................................................... 277 TEST 2.................................................................................... 277 TEST 3.................................................................................... 277 TEST 4.................................................................................... 277 REMOVAL....................................................................................... 278 DOMESTIC ................................................................................. 278 EXPORT.................................................................................... 278 INSTALLATION.................................................................................. 278 DOMESTIC.................................................................................. 278 EXPORT.................................................................................... 279 ANTENNA CABLE - SATELLITE RADIO................................................................... 279 REMOVAL....................................................................................... 279 INSTALLATION.................................................................................. 280 ANTENNA MODULE.................................................................................... 280 DESCRIPTION................................................................................... 280 OPERATION..................................................................................... 280 DIAGNOSIS AND TESTING......................................................................... 280 ANTENNA MODULE............................................................................ 280 REMOVAL....................................................................................... 281 INSTALLATION.................................................................................. 281 ANTENNA-SATELLITE RADIO........................................................................... 281 DESCRIPTION................................................................................... 281 OPERATION..................................................................................... 281 REMOVAL....................................................................................... 281 INSTALLATION.................................................................................. 281 CD CHANGER........................................................................................ 282 DESCRIPTION................................................................................... 282 OPERATION..................................................................................... 282 REMOVAL....................................................................................... 282 INSTALLATION.................................................................................. 282 INSTRUMENT PANEL ANTENNA CABLE.................................................................... 282 REMOVAL....................................................................................... 282 DOMESTIC.................................................................................. 282 EXPORT.................................................................................... 283 INSTALLATION.................................................................................. 284 DOMESTIC.................................................................................. 284 EXPORT.................................................................................... 284 QUARTER GLASS INTEGRAL ANTENNA.................................................................... 284 DESCRIPTION................................................................................... 284 OPERATION..................................................................................... 284 DIAGNOSIS AND TESTING - QUARTER GLASS INTEGRAL ANTENNA........................................ 284 RADIO............................................................................................. 285 DESCRIPTION................................................................................... 285 RADIO..................................................................................... 285 COUNTRY CODE AND CABIN EQ SETTING - REK RADIO ONLY........................................ 285 OPERATION..................................................................................... 288 REMOVAL....................................................................................... 288 INSTALLATION.................................................................................. 288 RADIO NOISE SUPPRESSION COMPONENTS................................................................ 288 DESCRIPTION................................................................................... 288 OPERATION..................................................................................... 289 REMOVAL....................................................................................... 289 2.4L ENGINE .............................................................................. 289 2.5L ENGINE .............................................................................. 290 3.7L ENGINE .............................................................................. 290 INSTALLATION.................................................................................. 290 2.4L ENGINE............................................................................... 290 2.5L ENGINE............................................................................... 290 3.7L ENGINE............................................................................... 290 RECEIVER-SATELLITE................................................................................ 291 DESCRIPTION................................................................................... 291 OPERATION..................................................................................... 291 REMOVAL....................................................................................... 291 INSTALLATION.................................................................................. 291 REMOTE SWITCHES................................................................................... 291 DESCRIPTION................................................................................... 291 OPERATION..................................................................................... 292 DIAGNOSIS AND TESTING - REMOTE SWITCHES....................................................... 292 REMOVAL....................................................................................... 293 INSTALLATION.................................................................................. 293 SPEAKER........................................................................................... 293 DESCRIPTION................................................................................... 293 STANDARD.................................................................................. 293 PREMIUM................................................................................... 293 OPERATION..................................................................................... 293 DIAGNOSIS AND TESTING - SPEAKER............................................................... 294 REMOVAL....................................................................................... 294 FRONT DOOR ............................................................................... 294 INSTRUMENT PANEL ......................................................................... 294 REAR DOOR ................................................................................ 295 INSTALLATION.................................................................................. 295 FRONT DOOR................................................................................ 295 INSTRUMENT PANEL.......................................................................... 295 REAR DOOR................................................................................. 295 8b-CHIME/BUZZER....................................................................................... 296 CHIME WARNING SYSTEM.............................................................................. 296 DESCRIPTION................................................................................... 296 OPERATION..................................................................................... 296 DIAGNOSIS AND TESTING......................................................................... 300 CHIME WARNING SYSTEM...................................................................... 300 8e-ELECTRONIC CONTROL MODULES......................................................................... 302 ELECTRONIC CONTROL MODULES........................................................................ 302 STANDARD PROCEDURE - PCM/SKREEM PROGRAMMING................................................... 302 ANTILOCK BRAKE MODULE............................................................................. 303 DESCRIPTION................................................................................... 303 OPERATION..................................................................................... 304 REMOVAL....................................................................................... 304 INSTALLATION.................................................................................. 305 BODY CONTROL MODULE............................................................................... 306 DESCRIPTION................................................................................... 306 OPERATION..................................................................................... 308 DIAGNOSIS AND TESTING......................................................................... 310 BODY CONTROL MODULE....................................................................... 310 REMOVAL................................................................................... 310 INSTALLATION.............................................................................. 311 COMMUNICATION..................................................................................... 311 DESCRIPTION................................................................................... 311 OPERATION..................................................................................... 311 DATA LINK CONNECTOR............................................................................... 312 DESCRIPTION................................................................................... 312 OPERATION..................................................................................... 313 FRONT CONTROL MODULE.............................................................................. 313 DESCRIPTION................................................................................... 313 REMOVAL....................................................................................... 313 INSTALLATION.................................................................................. 313 ENGINE CONTROL MODULEDIESEL ENGINE................................................................ 314 DESCRIPTION................................................................................... 314 OPERATION..................................................................................... 314 STANDARD PROCEDURE - PCM/ECM/SKIM PROGRAMMING - DIESEL........................................ 315 REMOVAL....................................................................................... 317 INSTALLATION.................................................................................. 317 POWERTRAIN CONTROL MODULE......................................................................... 317 DESCRIPTION................................................................................... 317 DESCRIPTION - PCM......................................................................... 317 DESCRIPTION - MODES OF OPERATION.......................................................... 317 DESCRIPTION - 5 VOLT SUPPLIES............................................................. 320 DESCRIPTION - IGNITION CIRCUIT SENSE...................................................... 320 DESCRIPTION - POWER GROUNDS............................................................... 320 DESCRIPTION - SENSOR RETURN............................................................... 320 OPERATION..................................................................................... 320 OPERATION - PCM........................................................................... 320 OPERATION - 5 VOLT SUPPLIES............................................................... 321 OPERATION - IGNITION CIRCUIT SENSE........................................................ 321 REMOVAL................................................................................... 321 INSTALLATION.............................................................................. 322 TRANSMISSION CONTROL MODULE....................................................................... 322 DESCRIPTION................................................................................... 322 TRANSMISSION CONTROL MODULE GASOLINE ENGINES.............................................. 322 TRANSMISSION CONTROL MODULE - DIESEL ENGINE............................................... 322 OPERATION..................................................................................... 322 TRANSMISSION CONTROL MODULE - GASOLINE ENGINES............................................ 322 TRANSMISSION CONTROL MODULE - DIESEL ENGINE............................................... 325 STANDARD PROCEDURE............................................................................ 327 TCM QUICK LEARN........................................................................... 327 DRIVE LEARN............................................................................... 327 HEATED SEAT MODULE................................................................................ 329 DESCRIPTION................................................................................... 329 OPERATION..................................................................................... 330 DIAGNOSIS AND TESTING - HEATED SEAT MODULE.................................................... 330 REMOVAL....................................................................................... 332 INSTALLATION.................................................................................. 332 8f-ENGINE SYSTEMS..................................................................................... 334 BATTERY SYSTEM.................................................................................... 334 DESCRIPTION................................................................................... 334 OPERATION..................................................................................... 335 DIAGNOSIS AND TESTING - BATTERY SYSTEM........................................................ 335 MICRO 420 BATTERY TESTER.................................................................. 335 ABNORMAL BATTERY DISCHARGING.............................................................. 337 CLEANING...................................................................................... 337 INSPECTION.................................................................................... 339 SPECIFICATIONS................................................................................ 339 BATTERY....................................................................................... 339 DESCRIPTION............................................................................... 339 CONVENTIONAL BATTERY - GASOLINE ENGINES............................................... 339 SPIRAL PLATE BATTERY - DIESEL ENGINE.................................................. 340 OPERATION................................................................................. 340 DIAGNOSIS AND TESTING - BATTERY........................................................... 341 STANDARD PROCEDURE........................................................................ 342 STANDARD PROCEDURE - CONVENTIONAL BATTERY CHARGING.................................... 342 CHARGING A COMPLETELY DISCHARGED BATTERY.......................................... 342 CHARGING TIME REQUIRED............................................................ 343 STANDARD PROCEDURE - SPIRAL PLATE BATTERY CHARGING.................................... 343 CHARGING A COMPLETELY DISCHARGED BATTERY – SPIRAL PLATE BATTERY................... 344 CHARGING TIME REQUIRED............................................................ 344 STANDARD PROCEDURE - BUILT-IN INDICATOR TEST.......................................... 345 STANDARD PROCEDURE - HYDROMETER TEST.................................................. 345 STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST........................................ 346 STANDARD PROCEDURE - IGNITION-OFF DRAW TEST........................................... 347 STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER................................... 349 BATTERY TESTING................................................................... 349 REMOVAL................................................................................... 350 INSTALLATION.............................................................................. 350 BATTERY HOLDDOWN.............................................................................. 351 DESCRIPTION............................................................................... 351 OPERATION................................................................................. 351 REMOVAL................................................................................... 351 INSTALLATION.............................................................................. 351 BATTERY CABLES................................................................................ 351 DESCRIPTION............................................................................... 351 OPERATION................................................................................. 352 DIAGNOSIS AND TESTING - BATTERY CABLES.................................................... 352 VOLTAGE DROP TEST..................................................................... 352 BATTERY TRAY.................................................................................. 354 DESCRIPTION............................................................................... 354 OPERATION................................................................................. 354 REMOVAL................................................................................... 354 INSTALLATION.............................................................................. 354 CHARGING SYSTEM................................................................................... 355 DESCRIPTION................................................................................... 355 OPERATION..................................................................................... 355 DIAGNOSIS AND TESTING - CHARGING SYSTEM....................................................... 355 SPECIFICATIONS................................................................................ 356 TORQUE - EXCEPT DIESEL.................................................................... 356 GENERATOR RATINGS - GAS ENGINES........................................................... 356 SPECIAL TOOLS................................................................................. 357 BATTERY TEMPERATURE SENSOR.................................................................... 357 DESCRIPTION............................................................................... 357 OPERATION................................................................................. 357 REMOVAL................................................................................... 357 INSTALLATION.............................................................................. 357 GENERATOR..................................................................................... 358 DESCRIPTION............................................................................... 358 OPERATION................................................................................. 358 REMOVAL................................................................................... 358 INSTALLATION.............................................................................. 359 GENERATOR DECOUPLER PULLEY.................................................................... 359 DESCRIPTION............................................................................... 359 OPERATION................................................................................. 360 DIAGNOSIS AND TESTING - GENERATOR DECOUPLER............................................... 360 REMOVAL................................................................................... 360 INSTALLATION.............................................................................. 363 VOLTAGE REGULATOR............................................................................. 364 DESCRIPTION............................................................................... 364 OPERATION................................................................................. 364 STARTING SYSTEM................................................................................... 365 DESCRIPTION................................................................................... 365 OPERATION..................................................................................... 365 DIAGNOSIS AND TESTING - STARTING SYSTEM....................................................... 366 INSPECTION................................................................................ 367 TESTING................................................................................... 367 INSPECTION - STARTING SYSTEM.................................................................. 370 SPECIFICATIONS................................................................................ 371 TORQUE - GAS POWERED...................................................................... 371 STARTER MOTOR - GAS POWERED............................................................... 372 STARTER MOTOR................................................................................. 372 DIAGNOSIS AND TESTING - STARTER MOTOR..................................................... 372 REMOVAL................................................................................... 373 2.4L 4–Cylinder....................................................................... 373 3.7L V-6.............................................................................. 373 INSTALLATION.............................................................................. 373 2.4L 4–Cylinder....................................................................... 373 3.7L V-6.............................................................................. 374 STARTER MOTOR RELAY........................................................................... 374 DESCRIPTION............................................................................... 374 OPERATION................................................................................. 374 DIAGNOSIS AND TESTING - STARTER RELAY..................................................... 375 RELAY TEST............................................................................ 375 RELAY CIRCUIT TEST.................................................................... 375 REMOVAL................................................................................... 376 INSTALLATION.............................................................................. 376 8g-HEATED SYSTEMS..................................................................................... 378 HEATED GLASS...................................................................................... 378 DESCRIPTION................................................................................... 378 OPERATION..................................................................................... 379 DIAGNOSIS AND TESTING......................................................................... 379 ELECTRIC BACKLIGHT (EBL) SYSTEM........................................................... 379 REAR WINDOW DEFOGGER RELAY.................................................................... 380 DESCRIPTION............................................................................... 380 OPERATION................................................................................. 380 REMOVAL................................................................................... 381 INSTALLATION.............................................................................. 381 REAR WINDOW DEFOGGER SWITCH................................................................... 381 DESCRIPTION............................................................................... 381 OPERATION................................................................................. 382 DIAGNOSIS AND TESTING..................................................................... 382 REAR WINDOW DEFOGGER SWITCH........................................................... 382 STANDARD PROCEDURE............................................................................ 382 GRID LINE AND TERMINAL REPAIR............................................................. 382 HEATED MIRRORS.................................................................................... 384 DESCRIPTION................................................................................... 384 OPERATION..................................................................................... 384 HEATED SEAT SYSTEM................................................................................ 385 DESCRIPTION................................................................................... 385 OPERATION..................................................................................... 385 DIAGNOSIS AND TESTING - HEATED SEAT SYSTEM.................................................... 386 HEATED SEAT SYSTEM SELF-DIAGNOSIS......................................................... 386 HEATED SEAT SYSTEM TESTING................................................................ 386 DRIVER HEATED SEAT SWITCH..................................................................... 386 DESCRIPTION............................................................................... 386 OPERATION................................................................................. 386 DIAGNOSIS AND TESTING - DRIVER HEATED SEAT SWITCH......................................... 387 REMOVAL................................................................................... 387 INSTALLATION.............................................................................. 388 PASSENGER HEATED SEAT SWITCH.................................................................. 388 DESCRIPTION............................................................................... 388 OPERATION................................................................................. 388 DIAGNOSIS AND TESTING - PASSENGER HEATED SEAT SWITCH...................................... 388 REMOVAL................................................................................... 389 INSTALLATION.............................................................................. 389 HEATED SEAT ELEMENT........................................................................... 389 DESCRIPTION............................................................................... 389 OPERATION................................................................................. 389 DIAGNOSIS AND TESTING - HEATED SEAT ELEMENT............................................... 389 SEAT CUSHION ELEMENT.................................................................. 389 SEAT BACK ELEMENT..................................................................... 390 HEATED SEAT SENSOR............................................................................ 390 DESCRIPTION............................................................................... 390 OPERATION................................................................................. 390 DIAGNOSIS AND TESTING - HEATED SEAT SENSOR................................................ 390 REMOVAL................................................................................... 390 8h-HORN............................................................................................... 392 HORN SYSTEM....................................................................................... 392 DESCRIPTION................................................................................... 392 OPERATION..................................................................................... 392 DIAGNOSIS AND TESTING - HORN SYSTEM........................................................... 392 HORN.............................................................................................. 393 DIAGNOSIS AND TESTING - HORN.................................................................. 393 REMOVAL....................................................................................... 393 INSTALLATION.................................................................................. 393 HORN RELAY........................................................................................ 393 REMOVAL....................................................................................... 393 INSTALLATION.................................................................................. 394 HORN SWITCH....................................................................................... 394 DESCRIPTION................................................................................... 394 DIAGNOSIS AND TESTING - HORN SWITCH........................................................... 394 8i-IGNITION CONTROL................................................................................... 396 IGNITION CONTROL.................................................................................. 396 DESCRIPTION................................................................................... 396 OPERATION..................................................................................... 396 2.4L...................................................................................... 396 3.7L...................................................................................... 397 SPECIFICATIONS................................................................................ 397 SPECIFICATIONS - IGNITION TIMING.......................................................... 397 ENGINE FIRING ORDER - 2.4L 4-CYLINDER..................................................... 397 ENGINE FIRING ORDER - 3.7L V-6............................................................ 397 IGNITION COIL RESISTANCE - 2.4L........................................................... 397 IGNITION COIL RESISTANCE - 3.7L V-6....................................................... 397 SPARK PLUGS............................................................................... 398 SPARK PLUG CABLE RESISTANCE - 2.4L........................................................ 398 TORQUE - IGNITION SYSTEM.................................................................. 398 AUTO SHUT DOWN RELAY.............................................................................. 399 DESCRIPTION - PCM OUTPUT...................................................................... 399 OPERATION..................................................................................... 399 OPERATION - ASD SENSE - PCM INPUT......................................................... 399 OPERATION - PCM OUTPUT.................................................................... 399 DIAGNOSIS AND TESTING - ASD AND FUEL PUMP RELAYS.............................................. 399 REMOVAL....................................................................................... 400 INSTALLATION.................................................................................. 400 CAMSHAFT POSITION SENSOR.......................................................................... 400 DESCRIPTION................................................................................... 400 2.4L...................................................................................... 400 3.7L...................................................................................... 401 2.8L TURBODIESEL.......................................................................... 401 OPERATION..................................................................................... 402 2.4L...................................................................................... 402 3.7L...................................................................................... 402 2.8L TURBODIESEL.......................................................................... 402 REMOVAL....................................................................................... 403 GAS ENGINES............................................................................... 403 2.4L.................................................................................. 403 3.7L.................................................................................. 403 2.8L TURBODIESEL.......................................................................... 403 INSTALLATION.................................................................................. 404 GAS ENGINES............................................................................... 404 2.4L.................................................................................. 404 3.7L.................................................................................. 405 2.8L TURBODIESEL.......................................................................... 405 GLOW PLUG......................................................................................... 405 DESCRIPTION................................................................................... 405 OPERATION..................................................................................... 405 REMOVAL....................................................................................... 406 INSTALLATION.................................................................................. 406 GLOW PLUG MODULE.................................................................................. 407 DESCRIPTION................................................................................... 407 OPERATION..................................................................................... 407 REMOVAL....................................................................................... 408 INSTALLATION.................................................................................. 408 IGNITION COIL..................................................................................... 408 DESCRIPTION................................................................................... 408 2.4L...................................................................................... 408 3.7L...................................................................................... 408 OPERATION..................................................................................... 408 2.4L...................................................................................... 408 3.7L...................................................................................... 409 REMOVAL....................................................................................... 409 2.4L...................................................................................... 409 3.7L...................................................................................... 409 INSTALLATION.................................................................................. 410 2.4L...................................................................................... 410 3.7L...................................................................................... 410 KNOCK SENSOR...................................................................................... 410 DESCRIPTION................................................................................... 410 OPERATION..................................................................................... 410 REMOVAL....................................................................................... 411 INSTALLATION.................................................................................. 411 SPARK PLUG........................................................................................ 411 DESCRIPTION................................................................................... 411 OPERATION..................................................................................... 412 DIAGNOSIS AND TESTING - SPARK PLUG CONDITIONS................................................. 412 REMOVAL....................................................................................... 414 2.4L...................................................................................... 414 3.7L...................................................................................... 415 CLEANING SPARK PLUGS.......................................................................... 415 INSTALLATION.................................................................................. 415 2.4L...................................................................................... 415 3.7L...................................................................................... 415 IGNITION COIL CAPACITOR........................................................................... 415 DESCRIPTION................................................................................... 415 OPERATION..................................................................................... 415 REMOVAL....................................................................................... 415 INSTALLATION.................................................................................. 415 8j-INSTRUMENT CLUSTER................................................................................. 416 INSTRUMENT CLUSTER................................................................................ 417 DESCRIPTION................................................................................... 417 OPERATION..................................................................................... 420 INPUT AND OUTPUT CIRCUITS................................................................. 423 DIAGNOSIS AND TESTING......................................................................... 423 INSTRUMENT CLUSTER........................................................................ 423 ACTUATOR TEST......................................................................... 423 CLUSTER ILLUMINATION DIAGNOSIS........................................................ 424 REMOVAL....................................................................................... 424 DISASSEMBLY................................................................................... 425 CLUSTER BULB.............................................................................. 425 CLUSTER LENS, HOOD, AND MASK.............................................................. 425 ASSEMBLY...................................................................................... 426 CLUSTER BULB.............................................................................. 426 CLUSTER LENS, HOOD, AND MASK.............................................................. 426 INSTALLATION.................................................................................. 426 ABS INDICATOR..................................................................................... 427 DESCRIPTION................................................................................... 427 OPERATION..................................................................................... 427 AIRBAG INDICATOR.................................................................................. 428 DESCRIPTION................................................................................... 428 OPERATION..................................................................................... 428 BRAKE/PARK BRAKE INDICATOR........................................................................ 429 DESCRIPTION................................................................................... 429 OPERATION..................................................................................... 429 CHARGING INDICATOR................................................................................ 430 DESCRIPTION................................................................................... 430 OPERATION..................................................................................... 430 COOLANT LOW INDICATOR............................................................................. 431 DESCRIPTION................................................................................... 431 OPERATION..................................................................................... 431 CRUISE INDICATOR.................................................................................. 432 DESCRIPTION................................................................................... 432 OPERATION..................................................................................... 432 DOOR AJAR INDICATOR............................................................................... 432 DESCRIPTION................................................................................... 432 OPERATION..................................................................................... 433 ENGINE TEMPERATURE GAUGE.......................................................................... 433 DESCRIPTION................................................................................... 433 OPERATION..................................................................................... 433 ETC INDICATOR..................................................................................... 434 DESCRIPTION................................................................................... 434 OPERATION..................................................................................... 434 FRONT FOG LAMP INDICATOR.......................................................................... 435 DESCRIPTION................................................................................... 435 OPERATION..................................................................................... 435 FUEL GAUGE........................................................................................ 436 DESCRIPTION................................................................................... 436 OPERATION..................................................................................... 436 GATE AJAR INDICATOR............................................................................... 437 DESCRIPTION................................................................................... 437 OPERATION..................................................................................... 437 GLASS AJAR INDICATOR.............................................................................. 438 DESCRIPTION................................................................................... 438 OPERATION..................................................................................... 438 HIGH BEAM INDICATOR............................................................................... 439 DESCRIPTION................................................................................... 439 OPERATION..................................................................................... 439 LIGHT BAR LAMP INDICATOR.......................................................................... 439 DESCRIPTION................................................................................... 439 OPERATION..................................................................................... 440 LOW FUEL INDICATOR................................................................................ 440 DESCRIPTION................................................................................... 440 OPERATION..................................................................................... 440 LOW OIL PRESSURE INDICATOR........................................................................ 441 DESCRIPTION................................................................................... 441 OPERATION..................................................................................... 441 MALFUNCTION INDICATOR LAMP (MIL).................................................................. 442 DESCRIPTION................................................................................... 442 OPERATION..................................................................................... 442 ODOMETER.......................................................................................... 443 DESCRIPTION................................................................................... 443 OPERATION..................................................................................... 443 OVERDRIVE OFF INDICATOR........................................................................... 444 DESCRIPTION................................................................................... 444 OPERATION..................................................................................... 444 REAR FOG LAMP INDICATOR........................................................................... 445 DESCRIPTION................................................................................... 445 OPERATION..................................................................................... 445 SEATBELT INDICATOR................................................................................ 446 DESCRIPTION................................................................................... 446 OPERATION..................................................................................... 446 STANDARD PROCEDURE - ENHANCED SEATBELT REMINDER PROGRAMMING................................... 447 CUSTOMER PROGRAMMING SEQUENCE............................................................. 447 SECURITY INDICATOR................................................................................ 447 DESCRIPTION................................................................................... 447 OPERATION..................................................................................... 447 SHIFT INDICATOR (TRANSFER CASE)................................................................... 448 DESCRIPTION................................................................................... 448 PART TIME INDICATOR....................................................................... 448 FULL TIME INDICATOR....................................................................... 448 FOUR LOW MODE INDICATOR................................................................... 449 OPERATION..................................................................................... 449 PART TIME INDICATOR....................................................................... 449 FULL TIME INDICATOR....................................................................... 449 FOUR LOW MODE INDICATOR................................................................... 450 SPEEDOMETER....................................................................................... 451 DESCRIPTION................................................................................... 451 OPERATION..................................................................................... 451 TACHOMETER........................................................................................ 452 DESCRIPTION................................................................................... 452 OPERATION..................................................................................... 452 TIRE PRESSURE MONITOR INDICATOR................................................................... 453 DESCRIPTION................................................................................... 453 OPERATION..................................................................................... 453 TRANS TEMP INDICATOR.............................................................................. 453 DESCRIPTION................................................................................... 453 OPERATION..................................................................................... 454 TURN SIGNAL INDICATOR............................................................................. 454 DESCRIPTION................................................................................... 454 OPERATION..................................................................................... 454 WAIT-TO-START INDICATOR........................................................................... 455 DESCRIPTION................................................................................... 455 OPERATION..................................................................................... 455 WASHER FLUID INDICATOR............................................................................ 456 DESCRIPTION................................................................................... 456 OPERATION..................................................................................... 456 WATER-IN-FUEL INDICATOR........................................................................... 456 DESCRIPTION................................................................................... 456 OPERATION..................................................................................... 457 8l-LAMPS.............................................................................................. 458 LAMPS/LIGHTING - EXTERIOR......................................................................... 458 DESCRIPTION................................................................................... 460 OPERATION..................................................................................... 463 BACKUP LAMPS.............................................................................. 463 BRAKE LAMPS............................................................................... 463 DAYTIME RUNNING LAMPS..................................................................... 463 FRONT FOG LAMPS........................................................................... 463 HAZARD WARNING LAMPS...................................................................... 464 HEADLAMPS................................................................................. 464 HEADLAMP LEVELING......................................................................... 464 LIGHT BAR LAMPS........................................................................... 464 PARK LAMPS................................................................................ 465 REAR FOG LAMPS............................................................................ 465 TURN SIGNAL LAMPS......................................................................... 465 WARNINGS - LAMPS/LIGHTING - EXTERIOR.......................................................... 465 DIAGNOSIS AND TESTING......................................................................... 466 LAMPS/LIGHTING - EXTERIOR................................................................. 466 BACKUP LAMPS.......................................................................... 467 BRAKE LAMPS........................................................................... 467 DAYTIME RUNNING LAMPS................................................................. 468 FRONT FOG LAMPS....................................................................... 468 HAZARD WARNING LAMPS.................................................................. 469 HEADLAMPS............................................................................. 469 HEADLAMP LEVELING..................................................................... 471 LIGHT BAR LAMPS....................................................................... 471 PARK LAMPS............................................................................ 473 REAR FOG LAMPS........................................................................ 474 TURN SIGNAL LAMPS..................................................................... 475 SPECIFICATIONS................................................................................ 475 LAMPS/LIGHTING - EXTERIOR................................................................. 475 BACKUP LAMP SWITCH............................................................................ 476 DESCRIPTION............................................................................... 476 OPERATION................................................................................. 476 DIAGNOSIS AND TESTING..................................................................... 476 BACKUP LAMP SWITCH.................................................................... 476 BRAKE LAMP SWITCH............................................................................. 476 DESCRIPTION............................................................................... 476 OPERATION................................................................................. 477 DIAGNOSIS AND TESTING..................................................................... 477 BRAKE LAMP SWITCH..................................................................... 477 REMOVAL................................................................................... 478 INSTALLATION.............................................................................. 478 LAMP-HIGH MOUNTED STOP........................................................................ 479 REMOVAL................................................................................... 479 BULB.................................................................................. 479 LAMP.................................................................................. 479 INSTALLATION.............................................................................. 479 BULB.................................................................................. 479 LAMP.................................................................................. 480 COMBINATION FLASHER........................................................................... 480 DESCRIPTION............................................................................... 480 OPERATION................................................................................. 480 DAYTIME RUNNING LAMP RELAY.................................................................... 480 DESCRIPTION............................................................................... 480 OPERATION................................................................................. 481 REMOVAL................................................................................... 481 INSTALLATION.............................................................................. 482 FOG LAMP RELAY................................................................................ 482 DESCRIPTION............................................................................... 482 FRONT................................................................................. 482 REAR.................................................................................. 482 OPERATION................................................................................. 483 FRONT................................................................................. 483 REAR.................................................................................. 483 FRONT FOG LAMP................................................................................ 484 REMOVAL................................................................................... 484 BULB - GRILLE MOUNTED................................................................. 484 BULB - FASCIA MOUNTED................................................................. 484 LAMP - GRILLE MOUNTED................................................................. 485 LAMP - FASCIA MOUNTED................................................................. 485 INSTALLATION.............................................................................. 486 BULB - GRILLE MOUNTED................................................................. 486 BULB - FASCIA MOUNTED................................................................. 486 LAMP - GRILLE MOUNTED................................................................. 486 LAMP - FASCIA MOUNTED................................................................. 487 ADJUSTMENTS............................................................................... 487 FRONT FOG LAMP UNIT................................................................... 487 VEHICLE PREPARATION FOR FOG LAMP ALIGNMENT........................................ 487 FOG LAMP ALIGNMENT SCREEN PREPARATION............................................. 487 FOG LAMP ADJUSTMENT............................................................... 488 FRONT POSITION LAMP........................................................................... 488 REMOVAL - BULB............................................................................ 488 INSTALLATION - BULB....................................................................... 489 HAZARD SWITCH................................................................................. 489 DESCRIPTION............................................................................... 489 OPERATION................................................................................. 490 REMOVAL................................................................................... 490 INSTALLATION.............................................................................. 491 HEADLAMP HIGH BEAM RELAY...................................................................... 491 DESCRIPTION............................................................................... 491 OPERATION................................................................................. 491 REMOVAL................................................................................... 492 INSTALLATION.............................................................................. 493 HEADLAMP LEVELING MOTOR....................................................................... 493 DESCRIPTION............................................................................... 493 OPERATION................................................................................. 493 REMOVAL................................................................................... 494 INSTALLATION.............................................................................. 494 HEADLAMP LEVELING SWITCH...................................................................... 495 DESCRIPTION............................................................................... 495 OPERATION................................................................................. 495 DIAGNOSIS AND TESTING..................................................................... 495 HEADLAMP LEVELING SWITCH.............................................................. 495 REMOVAL................................................................................... 496 INSTALLATION.............................................................................. 496 HEADLAMP LOW BEAM RELAY....................................................................... 497 DESCRIPTION............................................................................... 497 OPERATION................................................................................. 497 HEADLAMP UNIT................................................................................. 497 REMOVAL................................................................................... 497 LAMP.................................................................................. 497 BULB - NORTH AMERICA.................................................................. 498 BULB - EXPORT......................................................................... 499 INSTALLATION.............................................................................. 500 LAMP.................................................................................. 500 BULB - NORTH AMERICA.................................................................. 500 BULB - EXPORT......................................................................... 500 ADJUSTMENTS............................................................................... 501 HEADLAMP UNIT......................................................................... 501 VEHICLE PREPARATION FOR HEADLAMP ALIGNMENT........................................ 501 HEADLAMP ALIGNMENT SCREEN PREPARATION............................................. 501 HEADLAMP ADJUSTMENT............................................................... 502 LICENSE PLATE LAMP............................................................................ 502 REMOVAL................................................................................... 502 BULB - NORTH AMERICA.................................................................. 502 BULB - EXPORT......................................................................... 502 LAMP - NORTH AMERICA.................................................................. 503 LAMP - EXPORT......................................................................... 503 INSTALLATION.............................................................................. 504 BULB - NORTH AMERICA.................................................................. 504 BULB - EXPORT......................................................................... 504 LAMP - NORTH AMERICA.................................................................. 504 LAMP - EXPORT......................................................................... 504 LAMP BAR...................................................................................... 504 REMOVAL................................................................................... 504 BULB.................................................................................. 504 LAMP.................................................................................. 505 COVER................................................................................. 505 REINFORCEMENT......................................................................... 505 INSTALLATION.............................................................................. 506 BULB.................................................................................. 506 LAMP.................................................................................. 507 COVER................................................................................. 507 REINFORCEMENT......................................................................... 507 ADJUSTMENTS............................................................................... 508 LIGHT BAR LAMP........................................................................ 508 VEHICLE PREPARATION FOR LIGHT BAR LAMP ALIGNMENT.................................. 508 LIGHT BAR LAMP ALIGNMENT SCREEN PREPARATION....................................... 508 LIGHT BAR LAMP ADJUSTMENT......................................................... 508 LAMP BAR SWITCH............................................................................... 508 DESCRIPTION............................................................................... 508 OPERATION................................................................................. 509 REMOVAL................................................................................... 509 INSTALLATION.............................................................................. 510 MARKER LAMP................................................................................... 510 REMOVAL................................................................................... 510 BULB.................................................................................. 510 LAMP.................................................................................. 510 INSTALLATION.............................................................................. 511 BULB.................................................................................. 511 LAMP.................................................................................. 511 MULTI-FUNCTION SWITCH......................................................................... 512 DESCRIPTION............................................................................... 512 LEFT CONTROL STALK.................................................................... 513 RIGHT CONTROL STALK................................................................... 513 OPERATION................................................................................. 513 LEFT CONTROL STALK.................................................................... 514 RIGHT CONTROL STALK................................................................... 515 DIAGNOSIS AND TESTING..................................................................... 516 MULTI-FUNCTION SWITCH................................................................. 516 REMOVAL0 - 4 KJ (Continued)........................................................... 518 INSTALLATION.............................................................................. 518 PARK BRAKE SWITCH............................................................................. 519 DESCRIPTION............................................................................... 519 OPERATION................................................................................. 519 DIAGNOSIS AND TESTING..................................................................... 519 PARK BRAKE SWITCH..................................................................... 519 REMOVAL................................................................................... 520 INSTALLATION.............................................................................. 520 PARK LAMP RELAY............................................................................... 521 DESCRIPTION............................................................................... 521 OPERATION................................................................................. 521 PARK/TURN SIGNAL LAMP......................................................................... 522 REMOVAL................................................................................... 522 BULB.................................................................................. 522 LAMP.................................................................................. 522 INSTALLATION.............................................................................. 523 BULB.................................................................................. 523 LAMP.................................................................................. 523 REAR LAMP UNIT................................................................................ 523 REMOVAL................................................................................... 523 BULB.................................................................................. 523 LAMP.................................................................................. 523 INSTALLATION.............................................................................. 524 BULB.................................................................................. 524 LAMP.................................................................................. 524 REPEATER LAMP................................................................................. 524 REMOVAL................................................................................... 524 BULB.................................................................................. 524 LAMP.................................................................................. 524 INSTALLATION.............................................................................. 525 BULB.................................................................................. 525 LAMP.................................................................................. 525 TRAILER TOW CONNECTOR......................................................................... 525 REMOVAL................................................................................... 525 INSTALLATION.............................................................................. 526 TRAILER TOW RELAY............................................................................. 526 DESCRIPTION............................................................................... 526 OPERATION................................................................................. 526 REMOVAL................................................................................... 527 INSTALLATION.............................................................................. 528 TRAILER TOW WIRING............................................................................ 528 DESCRIPTION............................................................................... 528 TURN SIGNAL CANCEL CAM........................................................................ 529 DESCRIPTION............................................................................... 529 OPERATION................................................................................. 529 LAMPS/LIGHTING - INTERIOR......................................................................... 530 DESCRIPTION................................................................................... 530 OPERATION..................................................................................... 532 COURTESY LAMP CIRCUIT..................................................................... 532 PANEL LAMPS DIMMER CIRCUIT................................................................ 533 WARNINGS - LAMPS/LIGHTING - INTERIOR.......................................................... 533 DIAGNOSIS AND TESTING......................................................................... 533 LAMPS/LIGHTING - INTERIOR................................................................. 533 COURTESY LAMP CIRCUIT................................................................. 534 PANEL LAMPS DIMMER CIRCUIT............................................................ 535 SPECIFICATIONS................................................................................ 536 LAMPS/LIGHTING - INTERIOR................................................................. 536 COURTESY LAMPS........................................................................ 536 PANEL LAMPS........................................................................... 536 AJAR SWITCH................................................................................... 536 DESCRIPTION............................................................................... 536 DOOR.................................................................................. 536 FLIP-UP GLASS......................................................................... 536 TAILGATE.............................................................................. 536 OPERATION................................................................................. 536 DOOR.................................................................................. 536 FLIP-UP GLASS......................................................................... 537 TAILGATE.............................................................................. 537 ASH RECEIVER LAMP............................................................................. 537 REMOVAL................................................................................... 537 BULB.................................................................................. 537 LAMP.................................................................................. 538 INSTALLATION.............................................................................. 538 BULB.................................................................................. 538 LAMP.................................................................................. 539 CARGO LAMP.................................................................................... 539 REMOVAL................................................................................... 539 BULB.................................................................................. 539 LAMP.................................................................................. 539 INSTALLATION.............................................................................. 540 BULB.................................................................................. 540 LAMP.................................................................................. 540 COURTESY LAMP................................................................................. 540 REMOVAL................................................................................... 540 BULB.................................................................................. 540 LAMP.................................................................................. 540 INSTALLATION.............................................................................. 541 BULB.................................................................................. 541 LAMP.................................................................................. 541 DOME LAMP..................................................................................... 541 REMOVAL................................................................................... 541 BULB - REAR........................................................................... 541 LAMP - REAR........................................................................... 542 INSTALLATION.............................................................................. 542 BULB - REAR........................................................................... 542 LAMP - REAR........................................................................... 542 ILLUMINATION LAMP............................................................................. 543 REMOVAL................................................................................... 543 BULB - CMTC CONTROL................................................................... 543 BULB - A/C-HEAT CONTROL............................................................... 543 BULB - TRANSMISSION RANGE INDICATOR................................................... 544 INSTALLATION.............................................................................. 544 BULB - CMTC CONTROL................................................................... 544 BULB - A/C-HEAT CONTROL............................................................... 545 BULB - TRANSMISSION RANGE INDICATOR................................................... 545 VANITY LAMP................................................................................... 545 REMOVAL - BULB............................................................................ 545 INSTALLATION - BULB....................................................................... 546 8m-MESSAGE SYSTEMS.................................................................................... 548 OVERHEAD CONSOLE.................................................................................. 548 DESCRIPTION................................................................................... 548 OPERATION..................................................................................... 548 DIAGNOSIS AND TESTING - OVERHEAD CONSOLE...................................................... 549 TESTING VOLTAGE AND GROUND SUPPLY TO OVERHEAD CONSOLE..................................... 549 STANDARD PROCEDURE............................................................................ 550 STANDARD PROCEDURE - MODULE LAMP REPLACEMENT.............................................. 550 STANDARD PROCEDURE - COURTESY LAMP REPLACEMENT............................................ 550 STANDARD PROCEDURE - COMPASS CALIBRATION.................................................. 550 STANDARD PROCEDURE - COMPASS DEMAGNETIZING................................................ 551 STANDARD PROCEDURE - COMPASS VARIATION ADJUSTMENT......................................... 551 STANDARD PROCEDURE - ELECTRONIC VEHICLE INFORMATION CENTER PROGRAMMING.................... 552 EVIC PROGRAMMING MODE................................................................. 552 PROGRAMMABLE FEATURES................................................................. 553 REMOVAL....................................................................................... 555 OVERHEAD CONSOLE - REMOVAL................................................................ 555 INSTALLATION.................................................................................. 555 SPECIAL TOOLS................................................................................. 555 ELECTRONIC VEHICLE INFO CENTER.................................................................... 555 DESCRIPTION................................................................................... 555 DESCRIPTION - COMPASS..................................................................... 556 DESCRIPTION - TEMPERATURE................................................................. 557 OPERATION..................................................................................... 557 DIAGNOSIS AND TESTING - ELECTRONIC VEHICLE INFORMATION CENTER................................. 557 SELF-DIAGNOSTIC TEST...................................................................... 558 REMOVAL....................................................................................... 558 INSTALLATION.................................................................................. 558 UNIVERSAL TRANSMITTER............................................................................. 559 DESCRIPTION................................................................................... 559 OPERATION..................................................................................... 559 DIAGNOSIS AND TESTING - UNIVERSAL TRANSMITTER................................................. 559 STANDARD PROCEDURE............................................................................ 560 STANDARD PROCEDURE - ERASING TRANSMITTER CODES............................................ 560 STANDARD PROCEDURE - PROGRAMMING TRANSMITTER CODES........................................ 560 AMBIENT TEMP SENSOR............................................................................... 561 DESCRIPTION................................................................................... 561 OPERATION..................................................................................... 561 DIAGNOSIS AND TESTING......................................................................... 561 DIAGNOSIS AND TESTING - AMBIENT TEMPERATURE SENSOR........................................ 561 DIAGNOSIS AND TESTING - AMBIENT TEMPERATURE SENSOR CIRCUIT................................ 561 REMOVAL....................................................................................... 562 INSTALLATION.................................................................................. 562 8n-POWER SYSTEMS...................................................................................... 564 POWER LOCKS....................................................................................... 564 DESCRIPTION................................................................................... 564 POWER LOCKS............................................................................... 564 REMOTE KEYLESS ENTRY...................................................................... 565 TAILGATE / FLIP-UP GLASS POWER RELEASE SYSTEM............................................. 565 COMBINATION FLASHER....................................................................... 566 HORN RELAY................................................................................ 566 LOW BEAM HEADLAMP RELAY................................................................... 566 OPERATION..................................................................................... 566 POWER LOCKS............................................................................... 566 AUTOMATIC DOOR LOCKS...................................................................... 566 DOOR LOCK INHIBIT......................................................................... 566 DOOR LOCK CIRCUIT PROTECTION.............................................................. 566 REMOTE KEYLESS ENTRY...................................................................... 566 DIAGNOSIS AND TESTING - POWER LOCKS........................................................... 566 PRELIMINARY DIAGNOSIS..................................................................... 567 DOOR LOCK / UNLOCK SWITCH..................................................................... 567 DIAGNOSIS AND TESTING - DOOR LOCK/UNLOCK SWITCH........................................... 567 REMOVAL................................................................................... 567 INSTALLATION.............................................................................. 568 DOOR LOCK MOTOR............................................................................... 568 DESCRIPTION............................................................................... 568 OPERATION................................................................................. 568 DIAGNOSIS AND TESTING - DOOR LOCK MOTOR................................................... 568 FLIP-UP GLASS RELEASE SWITCH.................................................................. 568 DIAGNOSIS AND TESTING - FLIP-UP GLASS RELEASE SWITCH...................................... 568 DOOR LOCK RELAY............................................................................... 569 REMOVAL................................................................................... 569 INSTALLATION.............................................................................. 569 REMOTE KEYLESS ENTRY MODULE................................................................... 569 DESCRIPTION............................................................................... 569 OPERATION................................................................................. 569 DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY MODULE....................................... 569 REMOVAL................................................................................... 569 INSTALLATION.............................................................................. 569 REMOTE KEYLESS ENTRY TRANSMITTER.............................................................. 570 DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY TRANSMITTER.................................. 570 STANDARD PROCEDURE........................................................................ 570 STANDARD PROCEDURE - RKE TRANSMITTER CUSTOMER PREFERENCES............................. 570 AUTOMATIC (ROLLING) LOCKS......................................................... 570 HORN CHIRP DISABLING / ENABLING................................................... 570 OPTICAL CHIRP (FLASH) DISABLING / ENABLING........................................ 570 TAIL GATE RELEASE DELAY........................................................... 570 UNLOCK SEQUENCE................................................................... 570 STANDARD PROCEDURE - RKE TRANSMITTER PROGRAMING....................................... 570 STANDARD PROCEDURE - RKE TRANSMITTER BATTERIES........................................ 571 SPECIFICATIONS - REMOTE KEYLESS ENTRY TRANSMITTER......................................... 571 RANGE................................................................................. 571 TAILGATE CYLINDER LOCK SWITCH................................................................. 571 DESCRIPTION............................................................................... 571 OPERATION................................................................................. 571 DIAGNOSIS AND TESTING - TAILGATE CYLINDER LOCK SWITCH..................................... 571 REMOVAL................................................................................... 571 INSTALLATION.............................................................................. 572 POWER MIRRORS..................................................................................... 573 DESCRIPTION................................................................................... 573 OPERATION..................................................................................... 573 DIAGNOSIS AND TESTING - POWER MIRRORS......................................................... 573 WIRING VOLTAGE TEST....................................................................... 573 POWER MIRROR MOTOR TEST................................................................... 573 AUTOMATIC DAY / NIGHT MIRROR.................................................................. 574 DESCRIPTION - REAR VIEW MIRROR............................................................ 574 OPERATION - REAR VIEW MIRROR.............................................................. 574 DIAGNOSIS AND TESTING - AUTOMATIC DAY / NIGHT MIRROR...................................... 574 POWER FOLDAWAY MIRROR SWITCH - EXPORT......................................................... 575 DESCRIPTION............................................................................... 575 OPERATION................................................................................. 575 DIAGNOSIS AND TESTING - POWER FOLDAWAY MIRROR SWITCH - EXPORT............................. 576 REMOVAL................................................................................... 576 POWER MIRROR SWITCH........................................................................... 576 DIAGNOSIS AND TESTING - POWER MIRROR SWITCH............................................... 576 REMOVAL................................................................................... 577 INSTALLATION.............................................................................. 577 SIDEVIEW MIRROR............................................................................... 577 REMOVAL................................................................................... 577 POWER SEATS....................................................................................... 578 DESCRIPTION................................................................................... 578 OPERATION..................................................................................... 579 DIAGNOSIS AND TESTING - POWER SEATS........................................................... 579 LEFT POWER SEAT SWITCH........................................................................ 579 DESCRIPTION............................................................................... 579 OPERATION................................................................................. 579 DIAGNOSIS AND TESTING - LEFT POWER SEAT SWITCH............................................ 580 REMOVAL................................................................................... 581 INSTALLATION.............................................................................. 581 RIGHT POWER SEAT SWITCH....................................................................... 581 DESCRIPTION............................................................................... 581 OPERATION................................................................................. 581 DIAGNOSIS AND TESTING - RIGHT POWER SEAT SWITCH........................................... 582 REMOVAL................................................................................... 583 INSTALLATION.............................................................................. 583 POWER SEAT TRACK.............................................................................. 583 DESCRIPTION............................................................................... 583 OPERATION................................................................................. 583 DIAGNOSIS AND TESTING - POWER SEAT TRACK.................................................. 584 REMOVAL................................................................................... 584 INSTALLATION.............................................................................. 584 POWER TOP - SUNROOF............................................................................... 585 DESCRIPTION................................................................................... 585 OPERATION..................................................................................... 585 DIAGNOSIS AND TESTING......................................................................... 585 SUNROOF................................................................................... 585 MOTOR/MODULE - SUNROOF........................................................................ 587 DIAGNOSIS AND TESTING -................................................................... 587 STANDARD PROCEDURE........................................................................ 588 STANDARD PROCEDURE - POWER SUNROOF TIMING............................................. 588 STANDARD PROCEDURE - RE-INITIALIZATION................................................ 588 STANDARD PROCEDURE - INITIALIZATION................................................... 588 REMOVAL................................................................................... 589 INSTALLATION.............................................................................. 589 SWITCH - SUNROOF.............................................................................. 590 DESCRIPTION............................................................................... 590 OPERATION................................................................................. 590 DIAGNOSIS AND TESTING..................................................................... 590 SUNROOF SWITCH........................................................................ 590 REMOVAL................................................................................... 591 INSTALLATION.............................................................................. 591 POWER WINDOWS..................................................................................... 592 DESCRIPTION................................................................................... 592 OPERATION..................................................................................... 592 WINDOW SWITCH............................................................................. 592 WINDOW MOTOR.............................................................................. 592 DIAGNOSIS AND TESTING - POWER WINDOWS......................................................... 592 WIRING VOLTAGE TEST....................................................................... 592 POWER WINDOW MOTOR TEST................................................................... 592 WINDOW MOTOR.................................................................................. 593 REMOVAL................................................................................... 593 WINDOW SWITCH................................................................................. 593 DIAGNOSIS AND TESTING - WINDOW SWITCH..................................................... 593 REMOVAL................................................................................... 594 FRONT................................................................................. 594 REAR.................................................................................. 594 INSTALLATION.............................................................................. 594 FRONT................................................................................. 594 REAR.................................................................................. 594 8o-RESTRAINTS......................................................................................... 596 RESTRAINTS........................................................................................ 597 DESCRIPTION................................................................................... 597 ACTIVE RESTRAINTS......................................................................... 597 PASSIVE RESTRAINTS........................................................................ 597 OPERATION..................................................................................... 600 ACTIVE RESTRAINTS......................................................................... 600 PASSIVE RESTRAINTS........................................................................ 600 WARNINGS - RESTRAINT SYSTEM................................................................... 601 DIAGNOSIS AND TESTING......................................................................... 602 SUPPLEMENTAL RESTRAINT SYSTEM............................................................. 602 STANDARD PROCEDURE............................................................................ 602 STANDARD PROCEDURE - HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS........................ 602 SUPPLEMENTAL RESTRAINT STORAGE........................................................ 603 STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT.................... 603 AIRBAG SQUIB STATUS................................................................... 603 CLEANUP PROCEDURE..................................................................... 604 STANDARD PROCEDURE - VERIFICATION TEST.................................................... 605 AIRBAG CONTROL MODULE............................................................................. 606 DESCRIPTION................................................................................... 606 OPERATION..................................................................................... 606 REMOVAL....................................................................................... 608 INSTALLATION.................................................................................. 609 BELT TENSION SENSOR............................................................................... 610 DESCRIPTION................................................................................... 610 OPERATION..................................................................................... 610 CHILD RESTRAINT ANCHOR............................................................................ 610 DESCRIPTION................................................................................... 610 OPERATION..................................................................................... 612 CLOCKSPRING....................................................................................... 612 DESCRIPTION................................................................................... 612 OPERATION..................................................................................... 613 STANDARD PROCEDURE - CLOCKSPRING CENTERING.................................................... 613 REMOVAL....................................................................................... 614 INSTALLATION.................................................................................. 615 CURTAIN AIRBAG.................................................................................... 616 DESCRIPTION................................................................................... 616 OPERATION..................................................................................... 616 REMOVAL....................................................................................... 616 INSTALLATION.................................................................................. 619 DRIVER AIRBAG..................................................................................... 620 DESCRIPTION................................................................................... 620 OPERATION..................................................................................... 621 REMOVAL....................................................................................... 621 INSTALLATION.................................................................................. 623 IMPACT SENSOR..................................................................................... 623 DESCRIPTION................................................................................... 623 FRONT..................................................................................... 623 SIDE...................................................................................... 624 OPERATION..................................................................................... 624 FRONT..................................................................................... 624 SIDE...................................................................................... 625 REMOVAL....................................................................................... 625 FRONT..................................................................................... 625 SIDE...................................................................................... 625 INSTALLATION.................................................................................. 626 FRONT..................................................................................... 626 SIDE...................................................................................... 627 OCCUPANT CLASSIFICATION MODULE.................................................................... 627 DESCRIPTION................................................................................... 627 OPERATION..................................................................................... 628 REMOVAL....................................................................................... 629 INSTALLATION.................................................................................. 630 PASSENGER AIRBAG.................................................................................. 631 DESCRIPTION................................................................................... 631 OPERATION..................................................................................... 632 REMOVAL....................................................................................... 632 AIRBAG.................................................................................... 632 DOOR...................................................................................... 633 BRACKETS.................................................................................. 634 INSTALLATION.................................................................................. 634 AIRBAG.................................................................................... 634 DOOR...................................................................................... 635 BRACKETS.................................................................................. 636 PASSENGER AIRBAG ON/OFF INDICATOR................................................................. 636 DESCRIPTION................................................................................... 636 OPERATION..................................................................................... 636 REMOVAL....................................................................................... 637 INSTALLATION.................................................................................. 638 SEAT BELT BUCKLE.................................................................................. 638 REMOVAL....................................................................................... 638 FRONT..................................................................................... 638 REAR...................................................................................... 640 INSTALLATION.................................................................................. 640 FRONT..................................................................................... 640 REAR...................................................................................... 641 SEAT BELT & RETRACTOR............................................................................. 641 REMOVAL....................................................................................... 641 FRONT..................................................................................... 641 REAR CENTER............................................................................... 643 REAR OUTBOARD............................................................................. 644 INSTALLATION.................................................................................. 644 FRONT..................................................................................... 644 REAR CENTER............................................................................... 646 REAR OUTBOARD............................................................................. 646 SEAT BELT SWITCH.................................................................................. 647 DESCRIPTION................................................................................... 647 OPERATION..................................................................................... 647 SEAT BELT TENSIONER............................................................................... 647 DESCRIPTION................................................................................... 647 OPERATION..................................................................................... 648 SEAT BELT TURNING LOOP ADJUSTER................................................................... 648 REMOVAL....................................................................................... 648 INSTALLATION.................................................................................. 649 SEAT WEIGHT SENSOR................................................................................ 649 DESCRIPTION................................................................................... 649 OPERATION..................................................................................... 650 REMOVAL....................................................................................... 650 INSTALLATION.................................................................................. 651 8p-SPEED CONTROL...................................................................................... 654 SPEED CONTROL..................................................................................... 654 DESCRIPTION................................................................................... 654 OPERATION..................................................................................... 654 DIAGNOSIS AND TESTING - ROAD TEST............................................................. 655 SPECIFICATIONS................................................................................ 655 TORQUE - SPEED CONTROL.................................................................... 655 CABLE............................................................................................. 656 DESCRIPTION................................................................................... 656 OPERATION..................................................................................... 656 REMOVAL - 3.7L................................................................................ 656 INSTALLATION - 3.7L........................................................................... 657 SERVO............................................................................................. 657 DESCRIPTION................................................................................... 657 OPERATION..................................................................................... 657 REMOVAL....................................................................................... 657 INSTALLATION.................................................................................. 658 SWITCH............................................................................................ 658 DESCRIPTION................................................................................... 658 OPERATION..................................................................................... 658 Multiplexing.............................................................................. 659 REMOVAL....................................................................................... 659 INSTALLATION.................................................................................. 659 VACUUM RESERVOIR.................................................................................. 659 DESCRIPTION................................................................................... 659 OPERATION..................................................................................... 659 DIAGNOSIS AND TESTING - VACUUM RESERVOIR...................................................... 660 REMOVAL....................................................................................... 660 INSTALLATION.................................................................................. 661 8q-VEHICLE THEFT SECURITY............................................................................. 662 VEHICLE THEFT SECURITY............................................................................ 662 DESCRIPTION................................................................................... 662 OPERATION..................................................................................... 664 VEHICLE THEFT ALARM....................................................................... 664 SENTRY KEY IMMOBILIZER SYSTEM............................................................. 666 DIAGNOSIS AND TESTING......................................................................... 667 VEHICLE THEFT SECURITY SYSTEM............................................................. 667 VEHICLE THEFT ALARM................................................................... 667 SENTRY KEY IMMOBILIZER SYSTEM......................................................... 667 STANDARD PROCEDURE............................................................................ 668 STANDARD PROCEDURE - SKIS INITIALIZATION.................................................. 668 STANDARD PROCEDURE - SENTRY KEY TRANSPONDER PROGRAMMING................................... 668 SECURED ACCESS METHOD................................................................. 669 CUSTOMER LEARN METHOD................................................................. 669 HOOD AJAR SWITCH.................................................................................. 669 DESCRIPTION................................................................................... 669 OPERATION..................................................................................... 670 REMOVAL....................................................................................... 670 SWITCH.................................................................................... 670 BRACKET................................................................................... 671 STRIKER................................................................................... 671 INSTALLATION.................................................................................. 671 SWITCH.................................................................................... 671 BRACKET................................................................................... 671 STRIKER................................................................................... 672 UK SECURITY SYSTEM MODULE......................................................................... 672 DESCRIPTION................................................................................... 672 OPERATION..................................................................................... 673 REMOVAL....................................................................................... 674 INSTALLATION.................................................................................. 674 SENTRY KEY REMOTE ENTRY MODULE.................................................................... 674 DESCRIPTION................................................................................... 674 OPERATION..................................................................................... 675 REMOVAL....................................................................................... 676 INSTALLATION.................................................................................. 677 SIREN............................................................................................. 677 DESCRIPTION................................................................................... 677 OPERATION..................................................................................... 678 REMOVAL....................................................................................... 678 INSTALLATION.................................................................................. 679 TRANSPONDER KEY................................................................................... 679 DESCRIPTION................................................................................... 679 OPERATION..................................................................................... 679 8r-WIPERS/WASHERS..................................................................................... 682 WIPERS/WASHERS.................................................................................... 683 DESCRIPTION................................................................................... 683 FRONT..................................................................................... 683 REAR...................................................................................... 684 OPERATION..................................................................................... 686 FRONT..................................................................................... 686 OPERATING MODES....................................................................... 686 REAR...................................................................................... 688 OPERATING MODES....................................................................... 688 DIAGNOSIS AND TESTING......................................................................... 689 FRONT..................................................................................... 689 REAR...................................................................................... 689 WIPER SYSTEM.......................................................................... 689 WASHER SYSTEM......................................................................... 690 CLEANING...................................................................................... 691 FRONT..................................................................................... 691 WIPER SYSTEM.......................................................................... 691 WASHER SYSTEM......................................................................... 691 REAR...................................................................................... 691 WIPER SYSTEM.......................................................................... 691 WASHER SYSTEM......................................................................... 692 INSPECTION.................................................................................... 692 FRONT..................................................................................... 692 WIPER SYSTEM ......................................................................... 692 WASHER SYSTEM......................................................................... 693 REAR...................................................................................... 693 WIPER SYSTEM ......................................................................... 693 WASHER SYSTEM......................................................................... 694 CHECK VALVE....................................................................................... 694 DESCRIPTION................................................................................... 694 OPERATION..................................................................................... 694 REMOVAL....................................................................................... 694 INSTALLATION.................................................................................. 695 REAR WIPER MOTOR.................................................................................. 695 DESCRIPTION................................................................................... 695 OPERATION..................................................................................... 696 REMOVAL....................................................................................... 696 INSTALLATION.................................................................................. 697 WASHER FLUID LEVEL SWITCH......................................................................... 697 DESCRIPTION................................................................................... 697 OPERATION..................................................................................... 698 REMOVAL....................................................................................... 698 INSTALLATION.................................................................................. 698 WASHER HOSES/TUBES................................................................................ 699 DESCRIPTION................................................................................... 699 FRONT..................................................................................... 699 REAR...................................................................................... 700 OPERATION..................................................................................... 700 FRONT..................................................................................... 700 REAR...................................................................................... 700 WASHER NOZZLE..................................................................................... 700 DESCRIPTION................................................................................... 700 FRONT..................................................................................... 700 REAR...................................................................................... 701 OPERATION..................................................................................... 701 FRONT..................................................................................... 701 REAR...................................................................................... 701 REMOVAL....................................................................................... 701 FRONT..................................................................................... 701 REAR...................................................................................... 702 INSTALLATION.................................................................................. 702 FRONT..................................................................................... 702 REAR...................................................................................... 703 WASHER PUMP/MOTOR................................................................................. 703 DESCRIPTION................................................................................... 703 OPERATION..................................................................................... 703 REMOVAL....................................................................................... 704 INSTALLATION.................................................................................. 704 WASHER RESERVOIR.................................................................................. 705 DESCRIPTION................................................................................... 705 OPERATION..................................................................................... 705 REMOVAL....................................................................................... 705 INSTALLATION.................................................................................. 706 WIPER ARM......................................................................................... 707 DESCRIPTION................................................................................... 707 FRONT..................................................................................... 707 REAR...................................................................................... 708 OPERATION..................................................................................... 708 FRONT..................................................................................... 708 REAR...................................................................................... 708 REMOVAL....................................................................................... 709 FRONT..................................................................................... 709 REAR...................................................................................... 709 INSTALLATION.................................................................................. 710 FRONT..................................................................................... 710 REAR...................................................................................... 710 WIPER ARM PARK RAMP............................................................................... 711 REMOVAL....................................................................................... 711 INSTALLATION.................................................................................. 711 WIPER BLADE....................................................................................... 711 DESCRIPTION................................................................................... 711 FRONT..................................................................................... 711 REAR...................................................................................... 712 OPERATION..................................................................................... 712 FRONT..................................................................................... 712 REAR...................................................................................... 712 REMOVAL....................................................................................... 713 FRONT..................................................................................... 713 REAR...................................................................................... 713 INSTALLATION.................................................................................. 714 FRONT..................................................................................... 714 REAR...................................................................................... 714 WIPER HIGH/LOW RELAY.............................................................................. 714 DESCRIPTION................................................................................... 714 OPERATION..................................................................................... 715 WIPER MODULE...................................................................................... 715 DESCRIPTION................................................................................... 715 OPERATION..................................................................................... 716 REMOVAL....................................................................................... 716 INSTALLATION.................................................................................. 717 WIPER ON/OFF RELAY................................................................................ 717 DESCRIPTION................................................................................... 717 OPERATION..................................................................................... 717 8t-NAVIGATION/TELECOMMUNICATION....................................................................... 720 NAVIGATION/TELECOMMUNICATION...................................................................... 720 DESCRIPTION................................................................................... 720 TELECOMMUNICATIONS........................................................................ 720 OPERATION..................................................................................... 720 TELECOMMUNICATION......................................................................... 720 HANDS FREE MODULE................................................................................. 720 REMOVAL....................................................................................... 720 INSTALLATION.................................................................................. 721 8w-WIRING............................................................................................. 722 8W-01 WIRING DIAGRAM INFORMATION.................................................................. 724 WIRING DIAGRAM INFORMATION.................................................................... 724 DESCRIPTION............................................................................... 724 DESCRIPTION - HOW TO USE WIRING DIAGRAMS.............................................. 724 DESCRIPTION - CIRCUIT INFORMATION..................................................... 728 DESCRIPTION - CIRCUIT FUNCTIONS....................................................... 729 DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION.................................. 729 DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION................................ 730 WARNINGS - GENERAL.................................................................... 730 DIAGNOSIS AND TESTING - WIRING HARNESS................................................ 730 STANDARD PROCEDURE........................................................................ 731 STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES.................. 731 STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL..................................... 732 STANDARD PROCEDURE - TESTING FOR CONTINUITY........................................... 732 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND.................................... 732 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS.... 732 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP....................................... 733 SPECIAL TOOLS................................................................................. 733 WIRING/TERMINAL........................................................................... 733 CONNECTOR..................................................................................... 734 REMOVAL................................................................................... 734 INSTALLATION.............................................................................. 734 DIODE......................................................................................... 737 REMOVAL................................................................................... 737 INSTALLATION.............................................................................. 737 TERMINAL...................................................................................... 737 REMOVAL................................................................................... 737 INSTALLATION.............................................................................. 737 WIRE.......................................................................................... 738 STANDARD PROCEDURE - WIRE SPLICING........................................................ 738 8W-02 COMPONENT INDEX............................................................................. 740 8W-10 POWER DISTRIBUTION.......................................................................... 742 8W-12 JUNCTION BLOCK.............................................................................. 768 8W-15 GROUND DISTRIBUTION......................................................................... 804 8W-18 BUS COMMUNICATIONS.......................................................................... 826 8W-20 CHARGING SYSTEM............................................................................. 832 8W-21 STARTING SYSTEM............................................................................. 836 8W-30 FUEL/IGNITION SYSTEM........................................................................ 840 8W-31 TRANSMISSION CONTROL SYSTEM................................................................. 878 8W-33 VEHICLE SPEED CONTROL....................................................................... 894 8W-35 ANTILOCK BRAKES............................................................................. 900 8W-39 VEHICLE THEFT SECURITY SYSTEM............................................................... 906 8W-40 INSTRUMENT CLUSTER.......................................................................... 918 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET............................................................. 926 8W-42 AIR CONDITIONING-HEATER..................................................................... 930 8W-43 AIRBAG SYSTEM............................................................................... 938 8W-44 INTERIOR LIGHTING........................................................................... 944 8W-45 BODY CONTROL MODULE......................................................................... 948 8W-47 AUDIO SYSTEM................................................................................ 958 8W-48 REAR WINDOW DEFOGGER........................................................................ 970 8W-49 OVERHEAD CONSOLE............................................................................ 972 8W-50 FRONT LIGHTING.............................................................................. 978 8W-51 REAR LIGHTING............................................................................... 996 8W-52 TURN SIGNALS................................................................................1002 8W-53 WIPERS......................................................................................1010 8W-54 TRAILER TOW.................................................................................1016 8W-55 NAVIGATION/TELECOMMUNICATIONS...............................................................1022 8W-60 POWER WINDOWS...............................................................................1026 8W-61 POWER DOOR LOCKS............................................................................1030 8W-62 POWER MIRRORS...............................................................................1038 8W-63 POWER SEAT..................................................................................1044 8W-64 POWER SUNROOF...............................................................................1050 8W-70 SPLICE INFORMATION..........................................................................1052 8W-80 CONNECTOR PIN-OUTS..........................................................................1062 8W-91 CONNECTOR/GROUND/SPLICE LOCATION............................................................1182 CONNECTOR/GROUND/SPLICE LOCATION..............................................................1182 DESCRIPTION...............................................................................1182 8W-97 POWER DISTRIBUTION..........................................................................1252 POWER DISTRIBUTION............................................................................1252 DESCRIPTION...............................................................................1252 OPERATION.................................................................................1252 SPECIAL TOOLS.................................................................................1253 POWER DISTRIBUTION SYSTEMS................................................................1253 CIGAR LIGHTER OUTLET..........................................................................1253 DESCRIPTION...............................................................................1253 OPERATION.................................................................................1253 DIAGNOSIS AND TESTING - CIGAR LIGHTER OUTLET..............................................1253 IOD FUSE......................................................................................1254 DESCRIPTION...............................................................................1254 OPERATION.................................................................................1254 REMOVAL...................................................................................1254 INSTALLATION..............................................................................1254 JUNCTION BLOCK................................................................................1255 DESCRIPTION...............................................................................1255 OPERATION.................................................................................1255 DIAGNOSIS AND TESTING - JUNCTION BLOCK....................................................1255 REMOVAL.......................................................................................1256 REMOVAL - LHD.............................................................................1256 REMOVAL - RHD.............................................................................1256 INSTALLATION..................................................................................1257 INSTALLATION - LHD........................................................................1257 INSTALLATION - RHD........................................................................1257 POWER DISTRIBUTION CENTER.....................................................................1257 DESCRIPTION...............................................................................1257 OPERATION.................................................................................1257 REMOVAL...................................................................................1258 DISASSEMBLY...................................................................................1258 POWER DISTRIBUTION CENTER DISASSEMBLY.....................................................1258 ASSEMBLY......................................................................................1260 POWER DISTRIBUTION CENTER ASSEMBLY........................................................1260 INSTALLATION..............................................................................1261 POWER OUTLET..................................................................................1262 DESCRIPTION...............................................................................1262 OPERATION.................................................................................1262 DIAGNOSIS AND TESTING - POWER OUTLET......................................................1262 REMOVAL...................................................................................1263 INSTALLATION..............................................................................1263 RELAY.........................................................................................1264 DESCRIPTION...............................................................................1264 OPERATION.................................................................................1264 DIAGNOSIS AND TESTING - RELAY.............................................................1264 REMOVAL...................................................................................1265 INSTALLATION..............................................................................1265 MICRO-RELAY...................................................................................1265 DESCRIPTION...............................................................................1265 OPERATION.................................................................................1265 DIAGNOSIS AND TESTING - MICRO-RELAY.......................................................1265 REMOVAL...................................................................................1265 INSTALLATION..............................................................................1265 9-ENGINE..............................................................................................1266 ENGINE - 2.4L.....................................................................................1266 DESCRIPTION...................................................................................1268 DIAGNOSIS AND TESTING.........................................................................1268 CYLINDER COMBUSTION PRESSURE LEAKAGE TEST.................................................1268 CYLINDER COMPRESSION PRESSURE TEST........................................................1268 ENGINE OIL LEAK INSPECTION................................................................1269 INSPECTION FOR REAR SEAL AREA LEAKS...................................................1269 ENGINE DIAGNOSIS..........................................................................1270 ENGINE DIAGNOSIS - PERFORMANCE............................................................1271 DIAGNOSIS AND TESTING - ENGINE MECHANICAL.................................................1273 STANDARD PROCEDURE............................................................................1275 ENGINE CORE AND OIL GALLERY PLUGS.........................................................1275 REPAIR OF DAMAGED OR WORN THREADS.........................................................1275 HYDROSTATIC LOCKED ENGINE.................................................................1275 FORM-IN-PLACE GASKETS AND SEALERS.........................................................1276 SEALER APPLICATION....................................................................1276 ENGINE GASKET SURFACE PREPARATION.........................................................1277 MEASURING BEARING CLEARANCE USING PLASTIGAGE..............................................1277 REMOVAL - ENGINE ASSEMBLY.....................................................................1278 INSTALLATION - ENGINE ASSEMBLY................................................................1278 SPECIFICATIONS................................................................................1279 SPECIFICATIONS - 2.4L ENGINE..............................................................1279 SPECIFICATIONS - TORQUE...................................................................1284 SPECIAL TOOLS.................................................................................1285 2.4L ENGINE...............................................................................1285 AIR CLEANER ELEMENT...........................................................................1287 REMOVAL - 2.4L............................................................................1287 INSTALLATION - 2.4L.......................................................................1287 AIR CLEANER HOUSING...........................................................................1287 REMOVAL...................................................................................1287 INSTALLATION..............................................................................1287 CYLINDER HEAD.................................................................................1287 DESCRIPTION...............................................................................1287 OPERATION.................................................................................1287 DIAGNOSIS AND TESTING.....................................................................1288 CYLINDER HEAD GASKET..................................................................1288 CYLINDER-TO-CYLINDER LEAKAGE TEST.................................................1288 CYLINDER-TO-WATER JACKET LEAKAGE TEST.............................................1288 REMOVAL - CYLINDER HEAD...................................................................1288 CLEANING..................................................................................1289 INSPECTION................................................................................1289 INSTALLATION - CYLINDER HEAD..............................................................1289 CAMSHAFT OIL SEAL(S)..........................................................................1291 REMOVAL...................................................................................1291 INSTALLATION..............................................................................1291 CAMSHAFT(S)...................................................................................1292 DESCRIPTION...............................................................................1292 OPERATION.................................................................................1292 STANDARD PROCEDURE - CAMSHAFT END-PLAY....................................................1292 REMOVAL...................................................................................1292 CLEANING..................................................................................1293 INSPECTION................................................................................1293 INSTALLATION..............................................................................1293 CYLINDER HEAD COVER...........................................................................1294 REMOVAL...................................................................................1294 CLEANING..................................................................................1294 INSPECTION................................................................................1294 INSTALLATION..............................................................................1294 INTAKE/EXHAUST VALVES & SEATS.................................................................1295 DESCRIPTION...............................................................................1295 CLEANING..................................................................................1295 VALVE SPRINGS.................................................................................1296 REMOVAL...................................................................................1296 REMOVAL - CYLINDER HEAD ON............................................................1296 REMOVAL - CYLINDER HEAD OFF...........................................................1296 INSPECTION................................................................................1296 INSTALLATION..............................................................................1296 INSTALLATION - CYLINDER HEAD ON.......................................................1296 INSTALLATION - CYLINDER HEAD OFF......................................................1297 HYDRAULIC LIFTERS.............................................................................1297 DIAGNOSIS AND TESTING.....................................................................1297 LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS................................................1297 REMOVAL...................................................................................1298 INSTALLATION..............................................................................1298 ROCKER ARMS...................................................................................1298 REMOVAL...................................................................................1298 INSPECTION................................................................................1299 INSTALLATION..............................................................................1299 ENGINE BLOCK..................................................................................1299 DESCRIPTION...............................................................................1299 STANDARD PROCEDURE........................................................................1299 STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING..................................1299 CYLINDER BORE HONING..................................................................1300 CLEANING0 - 6 KJ (Continued)..........................................................1300 INSPECTION................................................................................1300 ENGINE BLOCK..........................................................................1300 CYLINDER BORE.........................................................................1301 CONNECTING ROD BEARINGS.......................................................................1301 STANDARD PROCEDURE........................................................................1301 CONNECTING ROD - FITTING..............................................................1301 CRANKSHAFT....................................................................................1301 DESCRIPTION...............................................................................1301 OPERATION.................................................................................1301 STANDARD PROCEDURE - CRANKSHAFT END PLAY..................................................1301 REMOVAL...................................................................................1302 INSPECTION................................................................................1303 INSTALLATION..............................................................................1303 CRANKSHAFT MAIN BEARINGS......................................................................1304 STANDARD PROCEDURE - MAIN BEARING - FITTING...............................................1304 CRANKSHAFT MAIN BEARINGS..............................................................1304 MAIN BEARING INSTALLATION ............................................................1305 CRANKSHAFT OIL SEAL - FRONT...................................................................1306 REMOVAL...................................................................................1306 INSTALLATION..............................................................................1307 CRANKSHAFT OIL SEAL - REAR....................................................................1308 REMOVAL...................................................................................1308 INSTALLATION..............................................................................1308 PISTON & CONNECTING ROD.......................................................................1309 DESCRIPTION...............................................................................1309 OPERATION.................................................................................1309 REMOVAL...................................................................................1309 INSTALLATION..............................................................................1310 PISTON RINGS..................................................................................1311 STANDARD PROCEDURE........................................................................1311 PISTON RING - FITTING.................................................................1311 PISTON RINGS - INSTALLATION ......................................................1312 VIBRATION DAMPER..............................................................................1313 REMOVAL...................................................................................1313 INSTALLATION..............................................................................1313 STRUCTURAL COLLAR.............................................................................1313 REMOVAL...................................................................................1313 INSTALLATION..............................................................................1313 ENGINE MOUNTING...............................................................................1313 DESCRIPTION...............................................................................1313 FRONT MOUNT...................................................................................1313 REMOVAL...................................................................................1313 INSTALLATION..............................................................................1314 REAR MOUNT....................................................................................1314 REMOVAL...................................................................................1314 MANUAL TRANSMISSION...................................................................1314 AUTOMATIC TRANSMISSION................................................................1314 INSTALLATION..............................................................................1314 MANUAL TRANSMISSION:..................................................................1314 AUTOMATIC TRANSMISSION:...............................................................1314 LUBRICATION...................................................................................1316 DESCRIPTION...............................................................................1316 OPERATION.................................................................................1316 DIAGNOSIS AND TESTING.....................................................................1316 ENGINE OIL PRESSURE CHECKING..........................................................1316 OIL...........................................................................................1316 STANDARD PROCEDURE........................................................................1316 ENGINE OIL LEVEL CHECK................................................................1316 ENGINE OIL AND FILTER CHANGE..........................................................1316 OIL FILTER....................................................................................1317 DESCRIPTION...............................................................................1317 REMOVAL...................................................................................1317 INSTALLATION..............................................................................1317 OIL PAN.......................................................................................1317 REMOVAL...................................................................................1317 INSTALLATION..............................................................................1318 OIL PRESSURE SENSOR/SWITCH....................................................................1318 DESCRIPTION...............................................................................1318 OPERATION.................................................................................1318 OIL PUMP......................................................................................1318 REMOVAL...................................................................................1318 DISASSEMBLY...............................................................................1320 CLEANING..................................................................................1320 INSPECTION................................................................................1321 ASSEMBLY..................................................................................1321 INSTALLATION..............................................................................1322 INTAKE MANIFOLD...............................................................................1323 DESCRIPTION...............................................................................1323 OPERATION.................................................................................1323 DIAGNOSIS AND TESTING.....................................................................1323 INTAKE MANIFOLD LEAKS.................................................................1323 REMOVAL...................................................................................1323 REMOVAL — LOWER.......................................................................1323 INSPECTION................................................................................1324 INSTALLATION..............................................................................1324 INSTALLATION — UPPER..................................................................1324 INSTALLATION — LOWER..................................................................1324 EXHAUST MANIFOLD..............................................................................1325 DESCRIPTION...............................................................................1325 OPERATION.................................................................................1325 REMOVAL...................................................................................1325 CLEANING..................................................................................1325 INSPECTION................................................................................1325 INSTALLATION..............................................................................1325 TIMING BELT COVER(S)..........................................................................1325 REMOVAL...................................................................................1325 FRONT COVER...........................................................................1325 REAR COVER............................................................................1326 INSTALLATION..............................................................................1326 REAR COVER............................................................................1326 FRONT COVER...........................................................................1326 TIMING BELT AND SPROCKET(S)...................................................................1326 REMOVAL...................................................................................1326 TIMING BELT...........................................................................1326 CRANKSHAFT SPROCKET...................................................................1327 CLEANING..................................................................................1327 INSTALLATION..............................................................................1328 CRANKSHAFT SPROCKET...................................................................1328 TIMING BELT...........................................................................1328 TIMING BELT TENSIONER & PULLEY................................................................1330 REMOVAL...................................................................................1330 INSTALLATION..............................................................................1330 BALANCE SHAFTS AND CARRIER ASSEMBLY...........................................................1331 DESCRIPTION...............................................................................1331 OPERATION.................................................................................1331 REMOVAL...................................................................................1332 BALANCE SHAFTS........................................................................1332 BALANCE SHAFT CARRIER.................................................................1333 INSTALLATION..............................................................................1333 BALANCE SHAFT TIMING..................................................................1333 BALANCE SHAFT INSTALLATION........................................................1333 BALANCE SHAFT CARRIER.........................................................................1335 DESCRIPTION...............................................................................1335 OPERATION.................................................................................1335 REMOVAL...................................................................................1336 INSTALLATION..............................................................................1336 BALANCE SHAFT CHAIN...........................................................................1336 REMOVAL...................................................................................1336 INSTALLATION..............................................................................1336 ENGINE - 3.7L.....................................................................................1337 DESCRIPTION...................................................................................1339 DIAGNOSIS AND TESTING.........................................................................1340 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION...................................1340 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE....................................1340 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL.....................................1342 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION....................................1343 DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE.....................................1344 DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE..............................1344 STANDARD PROCEDURE............................................................................1345 ENGINE GASKET SURFACE PREPARATION.........................................................1345 STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS.......................................1346 ENGINE CORE AND OIL GALLERY PLUGS.........................................................1346 REMOVAL.......................................................................................1346 INSTALLATION..................................................................................1347 SPECIFICATIONS................................................................................1348 TORQUE....................................................................................1348 SPECIFICATIONS - 3.7L ENGINE..............................................................1348 SPECIAL TOOLS.................................................................................1352 3.7L ENGINE...............................................................................1352 AIR CLEANER ELEMENT...........................................................................1356 REMOVAL - 3.7L............................................................................1356 INSTALLATION - 3.7L.......................................................................1356 CYLINDER HEAD - LEFT..........................................................................1356 DESCRIPTION - VALVE GUIDES................................................................1356 DIAGNOSIS AND TESTING.....................................................................1356 DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER.......................................1356 CYLINDER HEAD GASKET..................................................................1356 CYLINDER-TO-CYLINDER LEAKAGE TEST.................................................1357 CYLINDER-TO-WATER JACKET LEAKAGE TEST.............................................1357 REMOVAL...................................................................................1357 CLEANING..................................................................................1359 INSTALLATION..............................................................................1359 CAMSHAFT......................................................................................1360 DESCRIPTION...............................................................................1360 REMOVAL...................................................................................1360 INSTALLATION..............................................................................1361 COVER - CYLINDER HEAD.........................................................................1362 DESCRIPTION...............................................................................1362 REMOVAL...................................................................................1362 INSTALLATION..............................................................................1363 INTAKE/EXHAUST VALVES & SEATS.................................................................1363 DESCRIPTION...............................................................................1363 STANDARD PROCEDURE - REFACING.............................................................1363 REMOVAL...................................................................................1364 TESTING VALVE SPRINGS.................................................................1365 INSTALLATION..............................................................................1365 ROCKER ARM....................................................................................1366 DESCRIPTION...............................................................................1366 REMOVAL...................................................................................1366 SEALS - VALVE GUIDE...........................................................................1366 DESCRIPTION...............................................................................1366 SPRINGS VALVE.................................................................................1366 DESCRIPTION...............................................................................1366 REMOVAL...................................................................................1366 INSTALLATION..............................................................................1367 CYLINDER HEAD - RIGHT.........................................................................1367 DESCRIPTION...............................................................................1367 DESCRIPTION - CYLINDER HEAD...........................................................1367 DESCRIPTION - VALVE GUIDES............................................................1367 DIAGNOSIS AND TESTING.....................................................................1367 DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER.......................................1367 DIAGNOSIS AND TESTING - CYLINDER HEAD GASKET..........................................1367 CYLINDER-TO-CYLINDER LEAKAGE TEST.................................................1368 CYLINDER-TO-WATER JACKET LEAKAGE TEST.............................................1368 REMOVAL...................................................................................1368 CLEANING..................................................................................1370 INSPECTION................................................................................1370 INSTALLATION..............................................................................1370 CAMSHAFT......................................................................................1372 DESCRIPTION...............................................................................1372 REMOVAL...................................................................................1372 INSTALLATION..............................................................................1374 COVER - CYLINDER HEAD.........................................................................1374 REMOVAL...................................................................................1374 INSTALLATION..............................................................................1374 INTAKE/EXHAUST VALVES & SEATS.................................................................1375 STANDARD PROCEDURE - REFACING.............................................................1375 REMOVAL...................................................................................1376 TESTING VALVE SPRINGS.................................................................1376 INSTALLATION..............................................................................1376 ROCKER ARM....................................................................................1377 DESCRIPTION...............................................................................1377 REMOVAL...................................................................................1377 INSTALLATION..............................................................................1378 SEALS - VALVE GUIDE...........................................................................1378 DESCRIPTION...............................................................................1378 SPRINGS - VALVE...............................................................................1378 DESCRIPTION...............................................................................1378 REMOVAL...................................................................................1378 INSTALLATION..............................................................................1379 ENGINE BLOCK..................................................................................1379 DESCRIPTION...............................................................................1379 STANDARD PROCEDURE - CYLINDER BORE HONING.................................................1379 CLEANING..................................................................................1380 INSPECTION................................................................................1380 CRANKSHAFT....................................................................................1381 DESCRIPTION...............................................................................1381 REMOVAL...................................................................................1381 INSPECTION................................................................................1381 INSTALLATION..............................................................................1382 CRANKSHAFT MAIN BEARINGS......................................................................1384 STANDARD PROCEDURE........................................................................1384 MAIN BEARING - FITTING................................................................1384 SELECT FIT IDENTIFICATION.........................................................1384 INSPECTION........................................................................1384 MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)................................1384 CRANKSHAFT MAIN BEARING SELECTION.................................................1384 CRANKSHAFT OIL SEAL - FRONT...................................................................1385 REMOVAL...................................................................................1385 INSTALLATION..............................................................................1386 CRANKSHAFT OIL SEAL - REAR....................................................................1386 DIAGNOSIS AND TESTING - REAR SEAL AREA LEAKS..............................................1386 REMOVAL...................................................................................1387 INSTALLATION..............................................................................1387 FLEX PLATE....................................................................................1388 REMOVAL...................................................................................1388 INSTALLATION..............................................................................1388 PISTON & CONNECTING ROD.......................................................................1388 DESCRIPTION...............................................................................1388 STANDARD PROCEDURE........................................................................1389 CONNECTING ROD BEARING FITTING........................................................1389 STANDARD PROCEDURE - PISTON FITTING...................................................1391 REMOVAL...................................................................................1391 CLEANING..................................................................................1392 INSPECTION................................................................................1392 INSTALLATION..............................................................................1392 PISTON RINGS..................................................................................1393 STANDARD PROCEDURE - PISTON RING FITTING..................................................1393 VIBRATION DAMPER..............................................................................1395 REMOVAL...................................................................................1395 INSTALLATION..............................................................................1396 STRUCTURAL COVER..............................................................................1396 DESCRIPTION...............................................................................1396 OPERATION.................................................................................1396 REMOVAL...................................................................................1396 INSTALLATION..............................................................................1396 FRONT MOUNT...................................................................................1397 REMOVAL...................................................................................1397 INSTALLATION..............................................................................1397 REAR MOUNT....................................................................................1398 REMOVAL...................................................................................1398 MANUAL TRANSMISSION...................................................................1398 AUTOMATIC TRANSMISSION................................................................1398 INSTALLATION..............................................................................1398 MANUAL TRANSMISSION:..................................................................1398 AUTOMATIC TRANSMISSION:...............................................................1399 LUBRICATION...................................................................................1399 DESCRIPTION...............................................................................1399 OPERATION.................................................................................1400 DIAGNOSIS AND TESTING.....................................................................1402 DIAGNOSIS AND TESTING - ENGINE OIL LEAK...............................................1402 Air Leak Detection Test Method....................................................1402 INSPECTION FOR REAR SEAL AREA LEAKS...............................................1402 DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE..................................1403 DIAGNOSIS AND TESTING - REAR SEAL AREA LEAKS..........................................1403 OIL...........................................................................................1404 STANDARD PROCEDURE - ENGINE OIL SERVICE...................................................1404 CRANKCASE OIL LEVEL INSPECTION........................................................1404 ENGINE OIL CHANGE.....................................................................1404 OIL FILTER....................................................................................1405 REMOVAL...................................................................................1405 INSTALLATION..............................................................................1405 OIL PAN.......................................................................................1405 DESCRIPTION...............................................................................1405 REMOVAL...................................................................................1406 REMOVAL - 4x4.........................................................................1406 CLEANING..................................................................................1407 INSPECTION................................................................................1407 INSTALLATION..............................................................................1407 INSTALLATION - 4x4....................................................................1407 SWITCH - OIL PRESSURE.........................................................................1408 DESCRIPTION...............................................................................1408 OPERATION.................................................................................1408 REMOVAL...................................................................................1408 INSTALLATION..............................................................................1408 PUMP - ENGINE OIL.............................................................................1409 REMOVAL...................................................................................1409 DISASSEMBLY...............................................................................1409 INSPECTION................................................................................1409 ASSEMBLY..................................................................................1410 INSTALLATION..............................................................................1410 MANIFOLD - INTAKE.............................................................................1411 DESCRIPTION...............................................................................1411 DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS.............................................1411 REMOVAL...................................................................................1411 INSTALLATION..............................................................................1412 MANIFOLD - EXHAUST............................................................................1413 DESCRIPTION...............................................................................1413 REMOVAL...................................................................................1413 RIGHT EXHAUST MANIFOLD ...............................................................1413 LEFT EXHAUST MANIFOLD ................................................................1413 INSTALLATION..............................................................................1413 RIGHT EXHAUST MANIFOLD................................................................1413 LEFT EXHAUST MANIFOLD.................................................................1414 VALVE TIMING..................................................................................1414 DESCRIPTION...............................................................................1414 OPERATION.................................................................................1414 STANDARD PROCEDURE........................................................................1416 MEASURING TIMING CHAIN WEAR...........................................................1416 SERVICE PROCEDURE - TIMING VERIFICATION...............................................1416 COUNTER BALANCE SHAFT TIMING .....................................................1417 TIMING - SINGLE CAMSHAFT .........................................................1418 BALANCE SHAFT.................................................................................1418 REMOVAL...................................................................................1418 INSTALLATION..............................................................................1420 TIMING BELT / CHAIN COVER(S)..................................................................1420 REMOVAL...................................................................................1420 INSTALLATION..............................................................................1421 IDLER SHAFT...................................................................................1422 REMOVAL...................................................................................1422 INSTALLATION..............................................................................1422 TIMING BELT/CHAIN AND SPROCKET(S).............................................................1422 REMOVAL...................................................................................1422 INSPECTION................................................................................1424 INSTALLATION..............................................................................1424 2.8L COMMON RAIL DIESEL ENGINE....................................................................1428 DESCRIPTION...................................................................................1430 2.8L COMMON RAIL DIESEL ENGINE............................................................1430 ENGINE COVER..............................................................................1431 DIAGNOSIS AND TESTING.........................................................................1431 ENGINE DIAGNOSIS - MECHANICAL.............................................................1431 SMOKE DIAGNOSIS CHARTS....................................................................1434 STANDARD PROCEDURE............................................................................1436 FORM-IN-PLACE GASKETS AND SEALERS.........................................................1436 FORM-IN-PLACE GASKET AND SEALER APPLICATION...........................................1437 REPAIR DAMAGED OR WORN THREADS............................................................1437 HYDROSTATIC LOCK..........................................................................1437 REMOVAL.......................................................................................1437 2.8L COMMON RAIL DIESEL ENGINE............................................................1437 ENGINE COVER..............................................................................1442 INSTALLATION..................................................................................1442 2.8L COMMON RAIL DIESEL ENGINE............................................................1442 ENGINE COVER..............................................................................1446 SPECIFICATIONS................................................................................1447 ENGINE SPECIFICATIONS.....................................................................1447 TORQUE....................................................................................1450 SPECIAL TOOLS.................................................................................1452 AIR CLEANER ELEMENT...........................................................................1456 REMOVAL...................................................................................1456 INSTALLATION..............................................................................1456 AIR CLEANER HOUSING...........................................................................1456 REMOVAL...................................................................................1456 INSTALLATION..............................................................................1456 CYLINDER HEAD.................................................................................1457 DESCRIPTION...............................................................................1457 STANDARD PROCEDURE........................................................................1457 VALVE SEALS - IN VEHICLE..............................................................1457 VALVE SERVICE.........................................................................1458 DISASSEMBLY.......................................................................1458 VALVE CLEANING....................................................................1458 INSPECTION........................................................................1458 VALVE SEAT REFACING...............................................................1458 VALVE GUIDES......................................................................1458 VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT.........................................1458 STANDARD PROCEDURE - MEASURING PISTON PROTRUSION......................................1459 REMOVAL - CYLINDER HEAD...................................................................1460 CLEANING..................................................................................1461 INSPECTION................................................................................1462 INSTALLATION - CYLINDER HEAD..............................................................1462 CAMSHAFT OIL SEAL(S)..........................................................................1464 REMOVAL...................................................................................1464 INSTALLATION..............................................................................1465 CAMSHAFT(S)...................................................................................1465 DESCRIPTION...............................................................................1465 OPERATION.................................................................................1465 REMOVAL - CAMSHAFTS.......................................................................1465 INSTALLATION - CAMSHAFTS..................................................................1466 CHECKING CAMSHAFT ENDPLAY.............................................................1466 CYLINDER HEAD COVER...........................................................................1467 DESCRIPTION...............................................................................1467 REMOVAL - CYLINDER HEAD COVER.............................................................1467 INSTALLATION..............................................................................1469 CYLINDER HEAD COVER/INTAKE MANIFOLD TIGHTENING PROCEDURE..............................1469 ROCKER ARMS...................................................................................1471 DESCRIPTION...............................................................................1471 OPERATION.................................................................................1471 REMOVAL...................................................................................1471 INSTALLATION..............................................................................1471 HYDRAULIC LIFTERS.............................................................................1472 DESCRIPTION...............................................................................1472 REMOVAL...................................................................................1472 INSPECTION................................................................................1473 INSTALLATION..............................................................................1473 ENGINE BLOCK..................................................................................1473 DESCRIPTION...............................................................................1473 CRANKSHAFT....................................................................................1473 DESCRIPTION...............................................................................1473 OPERATION.................................................................................1473 STANDARD PROCEDURE - CHECKING CRANKSHAFT END PLAY.........................................1473 REMOVAL - CRANKSHAFT......................................................................1473 INSTALLATION - CRANKSHAFT.................................................................1476 CRANKSHAFT MAIN BEARINGS......................................................................1478 REMOVAL...................................................................................1478 CRANKSHAFT MAIN BEARINGS..............................................................1478 CRANKSHAFT FRONT MAIN BEARING ........................................................1478 INSTALLATION..............................................................................1479 CRANKSHAFT MAIN BEARINGS..............................................................1479 FRONT CRANKSHAFT MAIN BEARING.........................................................1481 CRANKSHAFT OIL SEAL - FRONT...................................................................1481 REMOVAL...................................................................................1481 INSTALLATION..............................................................................1481 CRANKSHAFT OIL SEAL - REAR....................................................................1483 DESCRIPTION...............................................................................1483 REMOVAL...................................................................................1483 INSTALLATION..............................................................................1484 FLEX PLATE....................................................................................1484 REMOVAL...................................................................................1484 INSTALLATION..............................................................................1484 CYLINDER LINERS...............................................................................1485 DESCRIPTION...............................................................................1485 REMOVAL...................................................................................1485 INSPECTION................................................................................1485 INSTALLATION..............................................................................1486 PISTON & CONNECTING ROD.......................................................................1487 DESCRIPTION...............................................................................1487 STANDARD PROCEDURE - PISTON RING FITTING..................................................1488 REMOVAL...................................................................................1488 PISTON PIN - REMOVAL..................................................................1489 PISTON RING - REMOVAL.................................................................1489 INSPECTION................................................................................1489 PISTONS...............................................................................1489 CONNECTING RODS.......................................................................1490 PISTON PINS...........................................................................1490 INSTALLATION..............................................................................1490 PISTON PIN INSTALLATION...............................................................1490 PISTON RINGS - INSTALLATION...........................................................1491 INSTALLATION .........................................................................1491 VIBRATION DAMPER..............................................................................1493 REMOVAL...................................................................................1493 INSTALLATION..............................................................................1493 INTERNAL VACUUM PUMP..........................................................................1493 DESCRIPTION...............................................................................1493 REMOVAL...................................................................................1493 INSTALLATION..............................................................................1494 ENGINE COVER - FRONT..........................................................................1495 DESCRIPTION...............................................................................1495 REMOVAL...................................................................................1495 INSTALLATION..............................................................................1495 LEFT MOUNT....................................................................................1496 REMOVAL...................................................................................1496 INSTALLATION..............................................................................1496 RIGHT MOUNT...................................................................................1497 REMOVAL...................................................................................1497 INSTALLATION..............................................................................1497 OIL...........................................................................................1498 DESCRIPTION...............................................................................1498 OIL PAN.......................................................................................1498 REMOVAL...................................................................................1498 INSTALLATION..............................................................................1498 OIL PRESSURE RELIEF VALVE.....................................................................1499 DESCRIPTION...............................................................................1499 REMOVAL...................................................................................1499 INSTALLATION..............................................................................1499 OIL PRESSURE SENDING UNIT.....................................................................1500 DESCRIPTION...............................................................................1500 OPERATION.................................................................................1500 REMOVAL...................................................................................1500 INSTALLATION..............................................................................1501 OIL PUMP......................................................................................1502 REMOVAL...................................................................................1502 REMOVAL - OIL PUMP PICKUP TUBE........................................................1502 REMOVAL - OIL PUMP....................................................................1502 INSTALLATION..............................................................................1503 INSTALLATION - OIL PUMP PICKUP TUBE...................................................1503 INSTALLATION - OIL PUMP...............................................................1503 OIL JET.......................................................................................1504 DESCRIPTION...............................................................................1504 REMOVAL...................................................................................1504 INSTALLATION..............................................................................1505 OIL SEPARATOR.................................................................................1505 REMOVAL...................................................................................1505 INSTALLATION..............................................................................1506 OIL COOLER....................................................................................1506 DESCRIPTION...............................................................................1506 REMOVAL...................................................................................1506 INSTALLATION..............................................................................1507 INTAKE MANIFOLD...............................................................................1507 DESCRIPTION...............................................................................1507 REMOVAL...................................................................................1507 INSTALLATION..............................................................................1507 EXHAUST MANIFOLD..............................................................................1507 REMOVAL...................................................................................1507 INSTALLATION..............................................................................1507 VALVE TIMING..................................................................................1507 STANDARD PROCEDURE - LOCKING ENGINE 90 DEGREES AFTER TDC..................................1507 BALANCE SHAFT.................................................................................1510 DESCRIPTION...............................................................................1510 OPERATION.................................................................................1510 REMOVAL...................................................................................1510 INSTALLATION..............................................................................1510 TIMING BELT / CHAIN COVER(S)..................................................................1512 REMOVAL...................................................................................1512 REMOVAL - TIMING BELT INNER COVER.....................................................1512 REMOVAL - TIMING BELT OUTER COVER.....................................................1513 INSTALLATION..............................................................................1513 INSTALLATION - TIMING BELT INNER COVER................................................1513 INSTALLATION - TIMING BELT OUTER COVER................................................1514 TIMING BELT IDLER PULLEY......................................................................1514 REMOVAL...................................................................................1514 INSTALLATION..............................................................................1515 TIMING BELT/CHAIN AND SPROCKET(S).............................................................1516 REMOVAL...................................................................................1516 INSTALLATION..............................................................................1517 TIMING BELT/CHAIN TENSIONER & PULLEY..........................................................1518 REMOVAL...................................................................................1518 INSTALLATION..............................................................................1519 ADJUSTMENTS...............................................................................1520 ADJUSTMENT - TIMING BELT TENSIONER....................................................1520 11-EXHAUST SYSTEM.....................................................................................1522 EXHAUST SYSTEM AND TURBOCHARGER...................................................................1522 DESCRIPTION...................................................................................1522 GAS ENGINES...............................................................................1522 2.8L DIESEL...............................................................................1523 DIAGNOSIS AND TESTING.........................................................................1524 DIAGNOSIS AND TESTING - EXHAUST SYSTEM....................................................1524 DIESEL ENGINE.............................................................................1525 SPECIFICATIONS................................................................................1525 TORQUE....................................................................................1525 CATALYTIC CONVERTER...............................................................................1526 DESCRIPTION - CATALYTIC CONVERTER.............................................................1526 REMOVAL.......................................................................................1526 2.4L ENGINE...............................................................................1526 3.7L ENGINE...............................................................................1526 2.8L DIESEL ENGINE........................................................................1527 INSPECTION....................................................................................1527 INSTALLATION..................................................................................1527 2.4L ENGINE...............................................................................1527 3.7L ENGINE...............................................................................1528 2.8L DIESEL...............................................................................1528 MUFFLER...........................................................................................1529 REMOVAL.......................................................................................1529 INSTALLATION..................................................................................1529 HEAT SHIELDS......................................................................................1530 DESCRIPTION...................................................................................1530 TURBOCHARGER SYSTEM...............................................................................1530 DESCRIPTION...................................................................................1530 OPERATION.....................................................................................1530 DIAGNOSIS AND TESTING.........................................................................1532 TURBOCHARGER BOOST PRESSURE...............................................................1532 CHARGE AIR COOLER AND PLUMBING....................................................................1532 DIAGNOSIS AND TESTING.........................................................................1532 CHARGE AIR COOLER SYSTEM - LEAKS..........................................................1532 REMOVAL.......................................................................................1533 REMOVAL - CAC INLET HOSE..................................................................1533 REMOVAL - CAC OUTLET HOSE.................................................................1533 INSTALLATION..................................................................................1533 INSTALLATION - CAC INLET HOSE.............................................................1533 INSTALLATION - CAC OUTLET HOSE............................................................1533 TURBOCHARGER......................................................................................1534 DESCRIPTION...................................................................................1534 OPERATION.....................................................................................1534 REMOVAL.......................................................................................1535 CLEANING......................................................................................1538 INSTALLATION..................................................................................1538 13-FRAME & BUMPERS....................................................................................1540 FRONT FASCIA......................................................................................1540 REMOVAL.......................................................................................1540 INSTALLATION..................................................................................1540 REAR FASCIA.......................................................................................1541 REMOVAL.......................................................................................1541 INSTALLATION..................................................................................1541 REAR FASCIA SUPPORT...............................................................................1541 REMOVAL.......................................................................................1541 INSTALLATION..................................................................................1542 REAR FASCIA - STEP PAD............................................................................1542 REMOVAL.......................................................................................1542 INSTALLATION..................................................................................1542 REAR FASCIA - RAIN DIVERTER.......................................................................1542 REMOVAL.......................................................................................1542 INSTALLATION..................................................................................1542 FRAME.............................................................................................1542 SPECIFICATIONS................................................................................1542 SPECIFICATIONS - FRAME DIMENSIONS.........................................................1542 VEHICLE PREPARATION...................................................................1542 DIMENSION ILLUSTRATIONS...............................................................1542 SPECIFICATIONS - TORQUE...................................................................1544 FRONT SKID PLATE..................................................................................1545 REMOVAL.......................................................................................1545 INSTALLATION..................................................................................1545 ENGINE CRADLE CROSSMEMBER.........................................................................1545 REMOVAL.......................................................................................1545 INSTALLATION..................................................................................1545 TRANSFER CASE SKID PLATE..........................................................................1546 REMOVAL.......................................................................................1546 INSTALLATION..................................................................................1546 REAR CROSSMEMBER..................................................................................1546 REMOVAL.......................................................................................1546 INSTALLATION..................................................................................1546 FRONT TOW HOOK....................................................................................1547 REMOVAL.......................................................................................1547 INSTALLATION..................................................................................1547 REAR TOW HOOK.....................................................................................1547 REMOVAL.......................................................................................1547 INSTALLATION..................................................................................1547 TRAILER HITCH.....................................................................................1547 REMOVAL.......................................................................................1547 INSTALLATION..................................................................................1547 FUEL TANK SKID PLATE..............................................................................1547 REMOVAL.......................................................................................1547 INSTALLATION..................................................................................1548 14-FUEL SYSTEM........................................................................................1550 FUEL DELIVERY - 2.4L/3.7L GAS.....................................................................1550 DESCRIPTION...................................................................................1551 OPERATION.....................................................................................1551 STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE.............................................1551 SPECIFICATIONS................................................................................1553 FUEL SYSTEM PRESSURE......................................................................1553 TORQUE....................................................................................1553 SPECIAL TOOLS.................................................................................1554 FUEL SYSTEM...............................................................................1554 FLOW MANAGEMENT VALVE.........................................................................1555 DESCRIPTION...............................................................................1555 OPERATION.................................................................................1555 FUEL FILTER...................................................................................1555 DESCRIPTION...............................................................................1555 FUEL LEVEL SENDING UNIT / SENSOR..............................................................1555 DESCRIPTION...............................................................................1555 OPERATION.................................................................................1555 FUEL LINES....................................................................................1555 DESCRIPTION...............................................................................1555 QUICK CONNECT FITTING.........................................................................1556 DESCRIPTION...............................................................................1556 STANDARD PROCEDURE - QUICK-CONNECT FITTINGS...............................................1556 DISCONNECTING.........................................................................1556 CONNECTING............................................................................1559 FUEL PRESSURE REGULATOR.......................................................................1560 DESCRIPTION...............................................................................1560 OPERATION.................................................................................1560 FUEL PUMP.....................................................................................1561 DESCRIPTION...............................................................................1561 OPERATION.................................................................................1561 FUEL PUMP MODULE..............................................................................1561 DESCRIPTION...............................................................................1561 OPERATION.................................................................................1561 REMOVAL...................................................................................1562 INSTALLATION..............................................................................1562 FUEL RAIL.....................................................................................1563 DESCRIPTION...............................................................................1563 OPERATION.................................................................................1563 REMOVAL...................................................................................1564 INSTALLATION..............................................................................1566 FUEL TANK.....................................................................................1567 DESCRIPTION...............................................................................1567 OPERATION.................................................................................1567 REMOVAL...................................................................................1567 Fuel Tank Draining....................................................................1567 Tank Removal .........................................................................1569 INSTALLATION0 - 8 KJ (Continued)......................................................1569 FUEL INJECTION - 2.4L/3.7L GAS....................................................................1573 DESCRIPTION...................................................................................1573 ACCELERATOR PEDAL.............................................................................1574 REMOVAL...................................................................................1574 INSTALLATION..............................................................................1574 CRANKSHAFT POSITION SENSOR....................................................................1574 DESCRIPTION...............................................................................1574 2.4L..................................................................................1574 3.7L..................................................................................1575 OPERATION.................................................................................1575 2.4L..................................................................................1575 3.7L..................................................................................1575 REMOVAL...................................................................................1576 2.4L..................................................................................1576 3.7L..................................................................................1576 INSTALLATION..............................................................................1576 2.4L..................................................................................1576 3.7L..................................................................................1577 FUEL INJECTOR.................................................................................1577 DESCRIPTION...............................................................................1577 OPERATION.................................................................................1577 OPERATION - FUEL INJECTOR.............................................................1577 OPERATION - PCM OUTPUT................................................................1577 REMOVAL...................................................................................1578 INSTALLATION..............................................................................1578 FUEL PUMP RELAY...............................................................................1578 DESCRIPTION...............................................................................1578 OPERATION.................................................................................1578 REMOVAL...................................................................................1578 INSTALLATION..............................................................................1578 IDLE AIR CONTROL MOTOR........................................................................1579 DESCRIPTION...............................................................................1579 OPERATION.................................................................................1579 REMOVAL...................................................................................1580 2.4L..................................................................................1580 3.7L..................................................................................1580 INSTALLATION..............................................................................1580 2.4L..................................................................................1580 3.7L..................................................................................1580 INTAKE AIR TEMPERATURE SENSOR.................................................................1580 DESCRIPTION...............................................................................1580 OPERATION.................................................................................1580 REMOVAL...................................................................................1581 2.4L..................................................................................1581 3.7L..................................................................................1581 INSTALLATION..............................................................................1582 2.4L..................................................................................1582 3.7L..................................................................................1582 MAP SENSOR....................................................................................1582 DESCRIPTION...............................................................................1582 2.4L..................................................................................1582 3.7L..................................................................................1582 OPERATION.................................................................................1582 REMOVAL...................................................................................1583 2.4L..................................................................................1583 3.7L..................................................................................1583 INSTALLATION..............................................................................1584 2.4L..................................................................................1584 3.7L..................................................................................1584 OXYGEN SENSOR.................................................................................1584 DESCRIPTION...............................................................................1584 OPERATION.................................................................................1584 REMOVAL...................................................................................1585 INSTALLATION..............................................................................1587 THROTTLE BODY.................................................................................1587 DESCRIPTION...............................................................................1587 OPERATION.................................................................................1587 REMOVAL...................................................................................1587 2.4L..................................................................................1587 3.7L..................................................................................1587 INSTALLATION..............................................................................1588 2.4L..................................................................................1588 3.7L..................................................................................1588 THROTTLE CONTROL CABLE........................................................................1588 REMOVAL...................................................................................1588 2.4L..................................................................................1588 3.7L..................................................................................1589 INSTALLATION..............................................................................1590 THROTTLE POSITION SENSOR......................................................................1590 DESCRIPTION...............................................................................1590 OPERATION.................................................................................1590 REMOVAL...................................................................................1591 2.4L..................................................................................1591 3.7L..................................................................................1591 INSTALLATION..............................................................................1592 2.4L..................................................................................1592 3.7L..................................................................................1592 FUEL DELIVERY - 2.8L DIESEL.......................................................................1593 DESCRIPTION - DIESEL FUEL DELIVERY SYSTEM.....................................................1593 WARNING - HIGH FUEL SYSTEM PRESSURE...........................................................1594 DIAGNOSIS AND TESTING.........................................................................1594 FUEL SYSTEM SUPPLY........................................................................1594 HIGH PRESSURE FUEL LEAKS..................................................................1595 AIR IN FUEL SYSTEM........................................................................1595 FUEL SUPPLY RESTRICTIONS..................................................................1596 LOW-PRESSURE LINES....................................................................1596 HIGH-PRESSURE LINES...................................................................1596 FUEL FILTER...............................................................................1596 Testing The Filter For Restrictions ..................................................1596 INJECTOR LEAK QUANTITY....................................................................1596 Cranking Test.........................................................................1597 Engine Running........................................................................1597 STANDARD PROCEDURE............................................................................1598 PRIMING FUEL SYSTEM.......................................................................1598 CLEANING FUEL SYSTEM COMPONENTS...........................................................1598 DRAINING WATER IN FUEL....................................................................1598 SPECIFICATIONS - TORQUE.......................................................................1600 SPECIAL TOOLS - DIESEL........................................................................1600 FUEL FILTER / WATER SEPARATOR.................................................................1601 DESCRIPTION...............................................................................1601 OPERATION.................................................................................1601 REMOVAL...................................................................................1602 REMOVAL - FUEL FILTER/WATER SEPARATOR ASSEMBLY........................................1602 REMOVAL - FUEL FILTER.................................................................1602 INSTALLATION..............................................................................1603 INSTALLATION - FUEL FILTER / WATER SEPARATOR ASSEMBLY.................................1603 INSTALLATION - FUEL FILTER............................................................1604 WATER IN FUEL SENSOR..........................................................................1605 DESCRIPTION...............................................................................1605 OPERATION.................................................................................1606 REMOVAL...................................................................................1606 INSTALLATION..............................................................................1607 FUEL RAIL.....................................................................................1608 DESCRIPTION...............................................................................1608 OPERATION.................................................................................1608 REMOVAL...................................................................................1609 INSTALLATION..............................................................................1609 FUEL LINES....................................................................................1610 DESCRIPTION...............................................................................1610 DESCRIPTION - HIGH PRESSURE FUEL LINES................................................1610 OPERATION - HIGH PRESSURE FUEL LINES......................................................1610 FUEL INJECTION PUMP...........................................................................1610 DESCRIPTION...............................................................................1610 OPERATION.................................................................................1611 REMOVAL...................................................................................1611 INSTALLATION..............................................................................1614 FUEL LEVEL SENDING UNIT / SENSOR..............................................................1614 DESCRIPTION...............................................................................1614 OPERATION.................................................................................1614 DIAGNOSIS AND TESTING - FUEL LEVEL SENDING UNIT...........................................1614 REMOVAL...................................................................................1615 INSTALLATION..............................................................................1615 FUEL HEATER...................................................................................1616 DESCRIPTION...............................................................................1616 OPERATION.................................................................................1616 REMOVAL...................................................................................1616 INSTALLATION..............................................................................1617 FUEL QUANTITY SOLENOID........................................................................1618 DESCRIPTION...............................................................................1618 OPERATION.................................................................................1618 REMOVAL...................................................................................1618 INSTALLATION..............................................................................1619 FUEL TANK.....................................................................................1619 REMOVAL - DIESEL..........................................................................1619 Fuel Tank Draining ...................................................................1619 Tank Removal..........................................................................1619 INSTALLATION - DIESEL.....................................................................1621 FUEL TANK MODULE..............................................................................1623 DESCRIPTION...............................................................................1623 REMOVAL...................................................................................1624 INSTALLATION..............................................................................1625 FUEL INJECTION - 2.8L DIESEL......................................................................1626 ACCELERATOR PEDAL POSITION SENSOR.............................................................1627 DESCRIPTION...............................................................................1627 REMOVAL...................................................................................1627 INSTALLATION..............................................................................1627 BOOST PRESSURE SENSOR.........................................................................1627 DESCRIPTION...............................................................................1627 OPERATION.................................................................................1628 DIAGNOSIS AND TESTING - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR......................1628 REMOVAL...................................................................................1628 INSTALLATION..............................................................................1628 CAMSHAFT POSITION SENSOR......................................................................1628 DESCRIPTION...............................................................................1628 OPERATION.................................................................................1629 REMOVAL...................................................................................1629 INSTALLATION..............................................................................1629 CRANKSHAFT POSITION SENSOR....................................................................1629 DESCRIPTION...............................................................................1629 OPERATION.................................................................................1629 REMOVAL...................................................................................1630 INSTALLATION..............................................................................1630 FUEL INJECTOR.................................................................................1631 DESCRIPTION...............................................................................1631 FUEL INJECTOR.........................................................................1631 OPERATION.................................................................................1631 Injector closed (with high pressure applied)..........................................1631 Injector opens (start of injection)...................................................1632 Injector opens fully..................................................................1632 Injector closes (end of injection)....................................................1632 STANDARD PROCEDURE........................................................................1632 STANDARD PROCEDURE - CLEANING FUEL INJECTORS..........................................1632 STANDARD PROCEDURE - INJECTOR CLASSIFICATION..........................................1632 INJECTOR CLASSIFICATION PROCEDURE.................................................1633 REMOVAL...................................................................................1633 INSTALLATION..............................................................................1634 FUEL PRESSURE SENSOR..........................................................................1635 DESCRIPTION...............................................................................1635 OPERATION.................................................................................1635 REMOVAL...................................................................................1635 INSTALLATION..............................................................................1635 FUEL PRESSURE SOLENOID........................................................................1635 DESCRIPTION...............................................................................1635 OPERATION.................................................................................1635 REMOVAL...................................................................................1636 INSTALLATION..............................................................................1637 FUEL TEMPERATURE SENSOR.......................................................................1638 DESCRIPTION...............................................................................1638 OPERATION.................................................................................1638 REMOVAL...................................................................................1638 INSTALLATION..............................................................................1638 INTAKE AIR TEMPERATURE SENSOR.................................................................1639 DESCRIPTION...............................................................................1639 OPERATION.................................................................................1639 REMOVAL...................................................................................1639 INSTALLATION..............................................................................1639 MASS AIR FLOW SENSOR..........................................................................1639 DESCRIPTION...............................................................................1639 OPERATION.................................................................................1640 REMOVAL...................................................................................1640 INSTALLATION..............................................................................1640 19-STEERING...........................................................................................1642 STEERING..........................................................................................1642 DESCRIPTION...................................................................................1642 OPERATION.....................................................................................1642 DIAGNOSIS AND TESTING.........................................................................1643 DIAGNOSIS AND TESTING - POWER STEERING SYSTEM.............................................1643 DIAGNOSIS AND TESTING - POWER STEERING FLOW AND PRESSURE..................................1645 FLOW AND PRESSURE TEST................................................................1645 COLUMN............................................................................................1646 DESCRIPTION...................................................................................1646 OPERATION - SERVICE PRECAUTIONS...............................................................1646 REMOVAL.......................................................................................1647 INSTALLATION..................................................................................1648 SPECIFICATIONS................................................................................1650 TORQUE CHART..............................................................................1650 SPECIAL TOOLS.................................................................................1650 STEERING COLUMN...........................................................................1650 IGNITION SWITCH...............................................................................1650 DESCRIPTION...............................................................................1650 DIAGNOSIS AND TESTING - IGNITION SWITCH...................................................1650 ELECTRICAL DIAGNOSIS..................................................................1650 MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE)........................................1650 REMOVAL - IGNITION SWITCH.................................................................1651 INSTALLATION..............................................................................1651 IGNITION SWITCH INSTALLATION..........................................................1651 KEY-IN IGNITION SWITCH........................................................................1652 DESCRIPTION...............................................................................1652 DIAGNOSIS AND TESTING - KEY-IN IGNITION SWITCH............................................1652 KEY CYLINDER..................................................................................1652 REMOVAL...................................................................................1652 INSTALLATION..............................................................................1653 INTERMEDIATE SHAFT............................................................................1653 REMOVAL...................................................................................1653 INSTALLATION..............................................................................1654 STEERING WHEEL................................................................................1655 REMOVAL...................................................................................1655 INSTALLATION..............................................................................1655 GEAR..............................................................................................1656 DESCRIPTION...................................................................................1656 OPERATION.....................................................................................1656 REMOVAL.......................................................................................1656 4WD.......................................................................................1656 2WD.......................................................................................1657 DIESEL....................................................................................1658 REMOVAL - RHD - 4X2 & 4X4.................................................................1659 INSTALLATION..................................................................................1659 4WD.......................................................................................1659 2WD.......................................................................................1660 DIESEL....................................................................................1661 INSTALLATION - RHD - 4X2 & 4X4............................................................1662 SPECIFICATIONS................................................................................1663 TORQUE CHART..............................................................................1663 SPECIAL TOOLS.................................................................................1663 OUTER TIE ROD END REMOVAL TOOL............................................................1663 LINKAGE...........................................................................................1664 STANDARD PROCEDURE - STEERING LINKAGE.........................................................1664 TIE ROD END...................................................................................1664 REMOVAL...................................................................................1664 INSTALLATION..............................................................................1664 21-TRANSMISSION AND TRANSFER CASE.....................................................................1684 MANUAL TRANSMISSION - NSG370......................................................................1684 DIAGNOSIS AND TESTING.........................................................................1684 MANUAL TRANSMISSION - NSG370..............................................................1684 LOW LUBRICANT LEVEL...................................................................1684 HARD SHIFTING.........................................................................1684 TRANSMISSION NOISE....................................................................1684 STANDARD PROCEDURE - DRAIN AND FILL...........................................................1685 REMOVAL.......................................................................................1685 DISASSEMBLY...................................................................................1687 MAINSHAFT ................................................................................1690 COUNTERSHAFT .............................................................................1694 FRONT HOUSING ............................................................................1694 INPUT SHAFT ..............................................................................1695 REAR HOUSING .............................................................................1696 CLEANING......................................................................................1698 INSPECTION....................................................................................1698 ASSEMBLY......................................................................................1700 MAINSHAFT ................................................................................1700 REAR HOUSING .............................................................................1706 INPUT SHAFT ..............................................................................1708 FRONT HOUSING ............................................................................1709 FINAL ASSEMBLY ...........................................................................1710 INSTALLATION..................................................................................1715 SPECIFICATIONS - NSG370.......................................................................1718 SPECIAL TOOLS.................................................................................1718 AUTOMATIC TRANSMISSION - 42RLE....................................................................1721 DESCRIPTION...................................................................................1722 TRANSMISSION IDENTIFICATION ..............................................................1724 OPERATION.....................................................................................1724 FIRST GEAR POWERFLOW .....................................................................1725 SECOND GEAR POWERFLOW ....................................................................1726 THIRD GEAR POWERFLOW .....................................................................1727 FOURTH GEAR POWERFLOW ....................................................................1728 REVERSE GEAR POWERFLOW ...................................................................1729 DIAGNOSIS AND TESTING.........................................................................1730 AUTOMATIC TRANSMISSION....................................................................1730 ROAD TEST.................................................................................1730 HYDRAULIC PRESSURE TESTS..................................................................1731 TEST ONE - SELECTOR IN MANUAL 1 (1st Gear)............................................1732 TEST TWO - SELECTOR IN MANUAL 2 (Second Gear).........................................1732 TEST TWO A - SELECTOR IN DRIVE (OD ON - Fourth Gear)..................................1732 TEST THREE - SELECTOR IN DRIVE (OD OFF - Third and Second Gear).......................1732 TEST FOUR - SELECTOR IN DRIVE (OD ON - Fourth Gear)...................................1732 TEST FIVE-SELECTOR IN DRIVE (OD ON - Fourth Gear, CC on)..............................1732 TEST SIX-SELECTOR IN REVERSE..........................................................1732 TEST RESULT INDICATIONS...............................................................1733 CLUTCH AIR PRESSURE TESTS.................................................................1734 2/4 CLUTCH............................................................................1734 OVERDRIVE CLUTCH......................................................................1734 REVERSE CLUTCH........................................................................1734 LOW/REVERSE CLUTCH....................................................................1734 UNDERDRIVE CLUTCH ....................................................................1734 FLUID LEAKAGE.............................................................................1734 FLUID LEAKAGE - TORQUE CONVERTER HOUSING AREA ........................................1734 TORQUE CONVERTER LEAKAGE .............................................................1735 STANDARD PROCEDURE - ALUMINUM THREAD REPAIR...................................................1735 REMOVAL.......................................................................................1735 DISASSEMBLY...................................................................................1737 ASSEMBLY......................................................................................1753 INSTALLATION..................................................................................1769 SCHEMATICS AND DIAGRAMS - 42RLE TRANSMISSION..................................................1772 SPECIFICATIONS................................................................................1785 42RLE AUTOMATIC TRANSMISSION..............................................................1785 SPECIAL TOOLS.................................................................................1786 42RLE AUTOMATIC TRANSMISSION..............................................................1786 ACCUMULATOR...................................................................................1790 DESCRIPTION...............................................................................1790 OPERATION.................................................................................1790 ADAPTER HOUSING SEAL..........................................................................1790 REMOVAL...................................................................................1790 INSTALLATION..............................................................................1790 BEARINGS......................................................................................1791 ADJUSTMENTS...............................................................................1791 BEARING ADJUSTMENT PROCEDURES.........................................................1791 BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM..................................................1791 DESCRIPTION...............................................................................1791 OPERATION.................................................................................1791 DIAGNOSIS AND TESTING - BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM.........................1791 DRIVING CLUTCHES..............................................................................1791 DESCRIPTION...............................................................................1791 OPERATION.................................................................................1791 UNDERDRIVE CLUTCH.....................................................................1792 OVERDRIVE CLUTCH......................................................................1792 REVERSE CLUTCH........................................................................1792 EXTENSION HOUSING SEAL........................................................................1792 REMOVAL...................................................................................1792 INSTALLATION..............................................................................1792 FLUID AND FILTER..............................................................................1793 DIAGNOSIS AND TESTING.....................................................................1793 DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID.........................................1793 EFFECTS OF INCORRECT FLUID LEVEL......................................................1793 FLUID CONTAMINATION...................................................................1793 STANDARD PROCEDURE........................................................................1793 FLUID LEVEL CHECK.....................................................................1793 FLUID LEVEL CHECK USING SCAN TOOL ................................................1793 FLUID/FILTER SERVICE..................................................................1794 STANDARD PROCEDURE - TRANSMISSION FILL................................................1795 GEARSHIFT CABLE...............................................................................1795 DIAGNOSIS AND TESTING.....................................................................1795 GEARSHIFT CABLE.......................................................................1795 REMOVAL...................................................................................1796 INSTALLATION..............................................................................1797 ADJUSTMENTS - GEARSHIFT CABLE.............................................................1797 Gearshift Adjustment Procedure........................................................1797 HOLDING CLUTCHES..............................................................................1798 DESCRIPTION...............................................................................1798 OPERATION.................................................................................1798 2/4 CLUTCH............................................................................1799 LOW/REVERSE CLUTCH....................................................................1799 INPUT CLUTCH ASSEMBLY.........................................................................1799 DISASSEMBLY...............................................................................1799 ASSEMBLY..................................................................................1806 INPUT SPEED SENSOR............................................................................1815 DESCRIPTION...............................................................................1815 OPERATION.................................................................................1815 REMOVAL...................................................................................1816 INSTALLATION..............................................................................1816 OIL PUMP......................................................................................1816 DESCRIPTION...............................................................................1816 OPERATION.................................................................................1817 DISASSEMBLY...............................................................................1817 ASSEMBLY..................................................................................1818 OUTPUT SPEED SENSOR...........................................................................1818 DESCRIPTION...............................................................................1818 OPERATION.................................................................................1818 REMOVAL...................................................................................1818 INSTALLATION..............................................................................1819 OVERDRIVE SWITCH..............................................................................1819 DESCRIPTION...............................................................................1819 OPERATION.................................................................................1819 PARK INTERLOCK CABLE..........................................................................1819 REMOVAL...................................................................................1819 INSTALLATION..............................................................................1820 ADJUSTMENTS - PARK-INTERLOCK CABLE........................................................1820 PLANETARY GEARTRAIN...........................................................................1821 DESCRIPTION...............................................................................1821 OPERATION.................................................................................1821 OIL PUMP SEAL.................................................................................1821 REMOVAL...................................................................................1821 INSTALLATION..............................................................................1821 SHIFT MECHANISM...............................................................................1822 DESCRIPTION...............................................................................1822 OPERATION.................................................................................1822 REMOVAL...................................................................................1822 INSTALLATION..............................................................................1823 SOLENOID......................................................................................1823 DESCRIPTION...............................................................................1823 OPERATION.................................................................................1824 SOLENOID/PRESSURE SWITCH ASSY.................................................................1824 DESCRIPTION...............................................................................1824 OPERATION.................................................................................1824 SOLENOIDS.............................................................................1824 PRESSURE SWITCHES.....................................................................1825 REMOVAL...................................................................................1825 INSTALLATION..............................................................................1826 TORQUE CONVERTER..............................................................................1826 DESCRIPTION...............................................................................1826 IMPELLER .............................................................................1827 TURBINE ..............................................................................1828 STATOR ...............................................................................1829 TORQUE CONVERTER CLUTCH (TCC) ........................................................1829 OPERATION.................................................................................1830 TURBINE...............................................................................1830 STATOR................................................................................1830 TORQUE CONVERTER CLUTCH (TCC).........................................................1830 REMOVAL...................................................................................1831 INSTALLATION..............................................................................1831 TRANSMISSION CONTROL RELAY....................................................................1831 DESCRIPTION...............................................................................1831 OPERATION.................................................................................1832 TRANSMISSION RANGE SENSOR.....................................................................1832 DESCRIPTION...............................................................................1832 OPERATION.................................................................................1832 REMOVAL...................................................................................1833 INSTALLATION..............................................................................1833 TRANSMISSION TEMPERATURE SENSOR...............................................................1834 DESCRIPTION...............................................................................1834 OPERATION.................................................................................1834 CALCULATED TEMPERATURE................................................................1834 VALVE BODY....................................................................................1834 DESCRIPTION...............................................................................1834 OPERATION.................................................................................1835 THERMAL VALVE ........................................................................1835 REGULATOR VALVE ......................................................................1836 SOLENOID SWITCH VALVE ................................................................1836 MANUAL VALVE .........................................................................1837 CONVERTER CLUTCH SWITCH VALVE ........................................................1837 CONVERTER CLUTCH CONTROL VALVE .......................................................1838 T/C REGULATOR VALVE...................................................................1838 LOW/REVERSE SWITCH VALVE..............................................................1838 REMOVAL...................................................................................1838 DISASSEMBLY...............................................................................1840 ASSEMBLY..................................................................................1845 INSTALLATION..............................................................................1849 AUTOMATIC TRANSMISSION - 545RFE...................................................................1851 DESCRIPTION...................................................................................1852 TRANSMISSION IDENTIFICATION ..............................................................1853 GEAR RATIOS...............................................................................1853 OPERATION.....................................................................................1853 DIAGNOSIS AND TESTING.........................................................................1854 AUTOMATIC TRANSMISSION....................................................................1854 PRELIMINARY...............................................................................1854 VEHICLE IS DRIVABLE...................................................................1854 VEHICLE IS DISABLED...................................................................1854 ROAD TESTING..............................................................................1854 HYDRAULIC PRESSURE TEST...................................................................1855 Pressure Test Port Locations..........................................................1855 TEST PROCEDURE........................................................................1855 AIR CHECKING TRANSMISSION CLUTCH OPERATION................................................1856 CONVERTER HOUSING FLUID LEAK..............................................................1857 TORQUE CONVERTER LEAK POINTS .........................................................1857 STANDARD PROCEDURE - ALUMINUM THREAD REPAIR...................................................1857 REMOVAL.......................................................................................1857 DISASSEMBLY...................................................................................1860 CLEANING......................................................................................1866 INSPECTION....................................................................................1866 ASSEMBLY......................................................................................1867 INSTALLATION..................................................................................1874 SCHEMATICS AND DIAGRAMS.......................................................................1877 HYDRAULIC SCHEMATICS......................................................................1877 SPECIFICATIONS................................................................................1898 TRANSMISSION..............................................................................1898 SPECIAL TOOLS.................................................................................1899 AUTOMATIC TRANSMISSION - RFE..............................................................1899 4C RETAINER/BULKHEAD..........................................................................1902 DISASSEMBLY...............................................................................1902 ASSEMBLY..................................................................................1903 ADAPTER HOUSING SEAL..........................................................................1905 REMOVAL...................................................................................1905 INSTALLATION..............................................................................1905 BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM.....................................................1905 DESCRIPTION...............................................................................1905 OPERATION.................................................................................1905 DIAGNOSIS AND TESTING - BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM.........................1906 FLUID AND FILTER..............................................................................1906 DIAGNOSIS AND TESTING.....................................................................1906 EFFECTS OF INCORRECT FLUID LEVEL......................................................1906 CAUSES OF BURNT FLUID.................................................................1906 FLUID CONTAMINATION...................................................................1906 STANDARD PROCEDURE........................................................................1907 FLUID LEVEL CHECK.....................................................................1907 FLUID AND FILTER REPLACEMENT..........................................................1907 REMOVAL...........................................................................1907 INSPECTION........................................................................1907 CLEANING..........................................................................1907 INSTALLATION......................................................................1908 TRANSMISSION FILL.....................................................................1908 GEARSHIFT CABLE...............................................................................1909 DIAGNOSIS AND TESTING.....................................................................1909 GEARSHIFT CABLE.......................................................................1909 REMOVAL...................................................................................1909 INSTALLATION..............................................................................1909 ADJUSTMENTS - GEARSHIFT CABLE.............................................................1911 Gearshift Adjustment Procedure........................................................1911 HOLDING CLUTCHES..............................................................................1911 DESCRIPTION...............................................................................1911 OPERATION.................................................................................1911 2C CLUTCH.............................................................................1911 4C CLUTCH.............................................................................1911 LOW/REVERSE CLUTCH....................................................................1912 INPUT CLUTCH ASSEMBLY.........................................................................1913 DESCRIPTION...............................................................................1913 OPERATION.................................................................................1913 UNDERDRIVE CLUTCH.....................................................................1913 OVERDRIVE CLUTCH......................................................................1914 REVERSE CLUTCH........................................................................1914 DISASSEMBLY...............................................................................1915 ASSEMBLY..................................................................................1918 INPUT SPEED SENSOR............................................................................1923 DESCRIPTION...............................................................................1923 OPERATION.................................................................................1923 REMOVAL...................................................................................1924 INSTALLATION..............................................................................1924 LINE PRESSURE (LP) SENSOR.....................................................................1924 DESCRIPTION...............................................................................1924 OPERATION.................................................................................1925 REMOVAL...................................................................................1925 INSTALLATION..............................................................................1925 LOW/REVERSE CLUTCH............................................................................1926 DISASSEMBLY...............................................................................1926 CLEANING..................................................................................1927 INSPECTION................................................................................1927 ASSEMBLY..................................................................................1927 OIL PUMP......................................................................................1930 DESCRIPTION...............................................................................1930 OPERATION.................................................................................1930 CONVERTER CLUTCH SWITCH VALVE.........................................................1930 CONVERTER CLUTCH REGULATOR VALVE......................................................1931 TORQUE CONVERTER LIMIT VALVE..........................................................1931 STANDARD PROCEDURE - OIL PUMP VOLUME CHECK................................................1931 DISASSEMBLY...............................................................................1932 CLEANING..................................................................................1934 INSPECTION................................................................................1934 ASSEMBLY..................................................................................1934 OIL PUMP FRONT SEAL...........................................................................1938 REMOVAL...................................................................................1938 INSTALLATION..............................................................................1938 OUTPUT SPEED SENSOR...........................................................................1938 DESCRIPTION...............................................................................1938 OPERATION0 - 10 KJ (Continued)........................................................1938 REMOVAL...................................................................................1938 INSTALLATION..............................................................................1939 OVERDRIVE SWITCH..............................................................................1939 DESCRIPTION...............................................................................1939 OPERATION.................................................................................1939 PARK INTERLOCK CABLE..........................................................................1939 REMOVAL...................................................................................1939 INSTALLATION..............................................................................1939 ADJUSTMENTS - PARK-INTERLOCK CABLE........................................................1940 PLANETARY GEARTRAIN...........................................................................1941 DESCRIPTION...............................................................................1941 OPERATION.................................................................................1941 REACTION PLANETARY GEARTRAIN..........................................................1941 REVERSE PLANETARY GEARTRAIN...........................................................1941 INPUT PLANETARY GEARTRAIN.............................................................1944 DISASSEMBLY...............................................................................1944 CLEANING..................................................................................1944 INSPECTION................................................................................1944 ASSEMBLY..................................................................................1944 SHIFT MECHANISM...............................................................................1945 DESCRIPTION...............................................................................1945 OPERATION.................................................................................1945 REMOVAL...................................................................................1946 INSTALLATION..............................................................................1946 SOLENOID SWITCH VALVE.........................................................................1947 DESCRIPTION...............................................................................1947 OPERATION.................................................................................1947 TORQUE CONVERTER..............................................................................1947 DESCRIPTION...............................................................................1947 IMPELLER .............................................................................1948 TURBINE ..............................................................................1949 STATOR ...............................................................................1950 TORQUE CONVERTER CLUTCH (TCC) ........................................................1950 OPERATION.................................................................................1951 TURBINE...............................................................................1951 STATOR................................................................................1951 TORQUE CONVERTER CLUTCH (TCC).........................................................1951 REMOVAL...................................................................................1952 INSTALLATION..............................................................................1952 TRANSMISSION CONTROL RELAY....................................................................1953 DESCRIPTION...............................................................................1953 OPERATION.................................................................................1953 TRANSMISSION RANGE SENSOR.....................................................................1953 DESCRIPTION...............................................................................1953 OPERATION.................................................................................1953 TRANSMISSION SOLENOID/TRS ASSEMBLY............................................................1954 DESCRIPTION...............................................................................1954 OPERATION.................................................................................1954 SOLENOIDS.............................................................................1954 PRESSURE SWITCHES.....................................................................1954 REMOVAL...................................................................................1954 INSTALLATION..............................................................................1955 TRANSMISSION TEMPERATURE SENSOR...............................................................1955 DESCRIPTION...............................................................................1955 OPERATION.................................................................................1955 Calculated Temperature................................................................1955 VALVE BODY....................................................................................1956 DESCRIPTION...............................................................................1956 OPERATION.................................................................................1957 SOLENOID SWITCH VALVE.................................................................1957 MANUAL VALVE .........................................................................1957 LOW/REVERSE SWITCH VALVE..............................................................1957 REMOVAL...................................................................................1957 DISASSEMBLY...............................................................................1958 CLEANING..................................................................................1960 INSPECTION................................................................................1960 ASSEMBLY..................................................................................1962 INSTALLATION..............................................................................1964 TRANSFER CASE - NV231.............................................................................1965 DESCRIPTION...................................................................................1965 OPERATING RANGES..........................................................................1965 SHIFT MECHANISM...........................................................................1965 IDENTIFICATION............................................................................1966 OPERATION.....................................................................................1966 DIAGNOSIS AND TESTING - TRANSFER CASE - NV231.................................................1966 REMOVAL.......................................................................................1967 DISASSEMBLY...................................................................................1968 REAR RETAINER AND OIL PUMP................................................................1968 COMPANION FLANGE AND RANGE LEVER..........................................................1970 FRONT OUTPUT SHAFT AND DRIVE CHAIN........................................................1971 SHIFT FORKS AND MAINSHAFT.................................................................1972 MAINSHAFT.................................................................................1973 INPUT GEAR AND LOW RANGE GEAR.............................................................1974 INPUT AND LOW RANGE GEAR..................................................................1975 CLEANING......................................................................................1976 INSPECTION....................................................................................1976 MAINSHAFT/SPROCKET/HUB....................................................................1976 INPUT GEAR AND PLANETARY CARRIER..........................................................1976 SHIFT FORKS/HUBS/SLEEVES..................................................................1978 REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT..................................................1978 REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN........................................................1978 LOW RANGE ANNULUS GEAR....................................................................1978 FRONT/REAR CASES AND FRONT RETAINER.......................................................1978 OIL PUMP/OIL PICKUP.......................................................................1979 ASSEMBLY......................................................................................1980 BEARINGS AND SEALS........................................................................1980 INPUT AND LOW RANGE GEAR..................................................................1984 MAINSHAFT.................................................................................1985 SHIFT FORKS, SECTOR, AND MAINSHAFT........................................................1985 FRONT OUTPUT SHAFT AND DRIVE CHAIN........................................................1987 OIL PUMP AND REAR CASE....................................................................1988 COMPANION FLANGE AND RANGE LEVER..........................................................1989 REAR RETAINER.............................................................................1989 INSTALLATION..................................................................................1990 SPECIFICATIONS................................................................................1990 TRANSFER CASE - NV231.....................................................................1990 SPECIAL TOOLS.................................................................................1991 TRANSFER CASE - NV231.....................................................................1991 FLUID.........................................................................................1993 STANDARD PROCEDURE - FLUID DRAIN AND FILL.................................................1993 FRONT OUTPUT SHAFT SEAL.......................................................................1993 REMOVAL...................................................................................1993 INSTALLATION..............................................................................1993 POSITION SENSOR...............................................................................1993 DESCRIPTION...............................................................................1993 OPERATION.................................................................................1994 REMOVAL...................................................................................1994 INSTALLATION..............................................................................1995 REAR OUTPUT SHAFT SEAL........................................................................1995 REMOVAL...................................................................................1995 INSTALLATION..............................................................................1996 SHIFT LEVER...................................................................................1997 REMOVAL...................................................................................1997 INSTALLATION..............................................................................1997 TRANSFER CASE - NV241 GENII.......................................................................1998 DESCRIPTION...................................................................................1998 IDENTIFICATION ...........................................................................1998 OPERATION.....................................................................................1998 OPERATING RANGE...........................................................................1998 SHIFT MECHANISM...........................................................................1999 SHIFTING..................................................................................1999 DIAGNOSIS AND TESTING - TRANSFER CASE - NV241 GENII...........................................1999 REMOVAL.......................................................................................2001 DISASSEMBLY...................................................................................2002 COMPANION FLANGE AND RANGE LEVER .........................................................2002 REAR EXTENSION ...........................................................................2003 OIL PUMP AND REAR CASE ...................................................................2003 FRONT OUTPUT SHAFT AND DRIVE CHAIN .......................................................2004 SHIFT FORKS AND MAINSHAFT ................................................................2005 MAINSHAFT ................................................................................2007 INPUT AND PLANETARY GEAR .................................................................2008 INPUT AND PLANETARY GEAR .................................................................2009 CLEANING......................................................................................2010 INSPECTION....................................................................................2010 MAINSHAFT/SPROCKET/HUB....................................................................2010 INPUT GEAR AND PLANETARY CARRIER .........................................................2010 SHIFT FORKS/HUBS/SLEEVES .................................................................2010 REAR RETAINER COMPONENTS..................................................................2010 DRIVE CHAIN...............................................................................2010 LOW RANGE ANNULUS GEAR ...................................................................2012 FRONT CASE AND REAR CASE..................................................................2012 OIL PUMP/OIL PICKUP.......................................................................2012 ASSEMBLY......................................................................................2012 BEARINGS AND SEALS .......................................................................2012 INPUT AND PLANETARY GEAR .................................................................2014 SHIFT FORKS AND MAINSHAFT ................................................................2015 FRONT OUTPUT SHAFT AND DRIVE CHAIN .......................................................2018 OIL PUMP AND REAR CASE ...................................................................2020 REAR EXTENSION ...........................................................................2021 COMPANION FLANGE AND RANGE LEVER .........................................................2021 INSTALLATION..................................................................................2022 SPECIFICATIONS................................................................................2023 TRANSFER CASE - NV241 GENII...............................................................2023 SPECIAL TOOLS.................................................................................2024 TRANSFER CASE - NV241 GENII...............................................................2024 EXTENSION HOUSING SEAL........................................................................2026 REMOVAL...................................................................................2026 INSTALLATION..............................................................................2026 FLUID.........................................................................................2026 STANDARD PROCEDURE - FLUID DRAIN AND FILL.................................................2026 FRONT OUTPUT SHAFT SEAL.......................................................................2026 REMOVAL...................................................................................2026 INSTALLATION..............................................................................2027 POSITION SENSOR...............................................................................2027 DESCRIPTION...............................................................................2027 OPERATION.................................................................................2027 REMOVAL...................................................................................2028 INSTALLATION..............................................................................2028 SHIFT LEVER...................................................................................2028 REMOVAL...................................................................................2028 INSTALLATION..............................................................................2029 TRANSFER CASE - NV242.............................................................................2030 DESCRIPTION...................................................................................2030 TRANSFER CASE IDENTIFICATION..............................................................2030 OPERATING RANGES..........................................................................2030 SHIFT MECHANISM...........................................................................2030 OPERATION.....................................................................................2031 DIAGNOSIS AND TESTING - TRANSFER CASE - NV242.................................................2031 REMOVAL.......................................................................................2032 DISASSEMBLY...................................................................................2033 REAR RETAINER.............................................................................2033 COMPANION FLANGE AND RANGE LEVER..........................................................2035 FRONT OUTPUT SHAFT AND DRIVE CHAIN........................................................2036 SHIFT FORKS AND MAINSHAFT.................................................................2037 INPUT GEAR/LOW RANGE ASSEMBLY.............................................................2040 DIFFERENTIAL..............................................................................2041 CLEANING......................................................................................2042 INSPECTION....................................................................................2042 MAINSHAFT/SPROCKET/HUB....................................................................2042 INPUT GEAR AND PLANETARY CARRIER..........................................................2043 SHIFT FORKS/HUBS/SLEEVES..................................................................2043 REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT..................................................2043 REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN........................................................2044 LOW RANGE ANNULUS GEAR....................................................................2045 FRONT-REAR CASES AND FRONT RETAINER.......................................................2045 OIL PUMP/OIL PICKUP.......................................................................2045 ASSEMBLY......................................................................................2045 BEARINGS AND SEALS........................................................................2045 DIFFERENTIAL..............................................................................2048 INPUT GEAR/LOW RANGE ASSEMBLY.............................................................2049 SHIFT FORKS, SECTOR, AND MAINSHAFT........................................................2051 FRONT OUTPUT SHAFT AND DRIVE CHAIN........................................................2055 OIL PUMP AND REAR CASE....................................................................2055 REAR RETAINER.............................................................................2056 COMPANION FLANGE AND RANGE LEVER..........................................................2058 INSTALLATION..................................................................................2058 SPECIFICATIONS................................................................................2059 NV242 TRANSFER CASE.......................................................................2059 SPECIAL TOOLS.................................................................................2059 TRANSFER CASE - NV242.....................................................................2059 FLUID.........................................................................................2062 STANDARD PROCEDURE - FLUID DRAIN AND FILL.................................................2062 FRONT OUTPUT SHAFT SEAL.......................................................................2062 REMOVAL...................................................................................2062 INSTALLATION..............................................................................2062 POSITION SENSOR...............................................................................2062 DESCRIPTION...............................................................................2062 OPERATION.................................................................................2063 REMOVAL...................................................................................2064 INSTALLATION..............................................................................2064 REAR OUTPUT SHAFT SEAL........................................................................2064 REMOVAL...................................................................................2064 INSTALLATION..............................................................................2065 SHIFT LEVER...................................................................................2065 REMOVAL...................................................................................2065 INSTALLATION..............................................................................2066 22-TIRES/WHEELS.......................................................................................2068 TIRES/WHEELS......................................................................................2068 DIAGNOSIS AND TESTING.........................................................................2068 TIRE AND WHEEL RUNOUT.....................................................................2068 METHOD 1 (RELOCATE WHEEL ON HUB)......................................................2069 METHOD 2 (RELOCATE TIRE ON WHEEL).....................................................2069 STANDARD PROCEDURE............................................................................2069 TIRE ROTATION.............................................................................2069 MATCH MOUNTING............................................................................2070 WHEEL BALANCING...........................................................................2071 TIRES.............................................................................................2073 DESCRIPTION...................................................................................2073 TIRES.....................................................................................2073 TIRE IDENTIFICATION...................................................................2073 TIRE CHAINS...........................................................................2073 RADIAL-PLY TIRES..........................................................................2073 TIRE PRESSURE FOR HIGH SPEED..............................................................2073 SPARE / TEMPORARY TIRE....................................................................2074 FULL SIZE, SPARE WHEEL WITH MATCHING TIRE.................................................2074 REPLACEMENT TIRES.........................................................................2074 DIAGNOSIS AND TESTING.........................................................................2074 PRESSURE GAUGES...........................................................................2074 TIRE INFLATION............................................................................2074 TREAD WEAR INDICATORS.....................................................................2075 TIRE WEAR PATTERNS........................................................................2075 TIRE NOISE OR VIBRATION...................................................................2075 TIRE/VEHICLE LEAD.........................................................................2075 STANDARD PROCEDURE............................................................................2077 TIRE REPAIR AREA..........................................................................2077 CLEANING......................................................................................2077 TIRES.....................................................................................2077 SPECIFICATIONS................................................................................2077 TIRE SIZE CHART...........................................................................2077 SPARE TIRE CARRIER................................................................................2077 REMOVAL.......................................................................................2077 INSTALLATION..................................................................................2077 WHEELS............................................................................................2077 DESCRIPTION...................................................................................2077 WHEEL DESIGN..............................................................................2077 DIAGNOSIS AND TESTING.........................................................................2078 WHEEL INSPECTION..........................................................................2078 STANDARD PROCEDURE............................................................................2078 WHEEL INSTALLATION........................................................................2078 WHEEL REPLACEMENT.........................................................................2078 SPECIFICATIONS................................................................................2079 STUDS.............................................................................................2079 REMOVAL.......................................................................................2079 INSTALLATION..................................................................................2079 TIRE PRESSURE MONITORING SYSTEM...................................................................2080 DESCRIPTION...................................................................................2080 BASE TIRE PRESSURE MONITORING.............................................................2080 PREMIUM TIRE PRESSURE MONITORING..........................................................2080 WIRELESS CONTROL MODULE (WCM).............................................................2080 OPERATION.....................................................................................2080 BASE TIRE PRESSURE MONITORING.............................................................2080 PREMIUM TIRE PRESSURE MONITORING..........................................................2081 DIAGNOSIS AND TESTING - TIRE PRESSURE MONITORING SYSTEM.......................................2081 SPECIFICATIONS................................................................................2081 TORQUE CHART..............................................................................2081 SENSOR............................................................................................2082 DESCRIPTION...................................................................................2082 OPERATION.....................................................................................2083 CAUTION.......................................................................................2083 DIAGNOSIS AND TESTING.........................................................................2083 TIRE PRESSURE SENSOR......................................................................2083 REMOVAL.......................................................................................2084 INSTALLATION..................................................................................2085 TRANSPONDER.......................................................................................2087 DESCRIPTION...................................................................................2087 OPERATION.....................................................................................2087 REMOVAL.......................................................................................2087 FRONT TRANSPONDER.........................................................................2087 REAR TRANSPONDER..........................................................................2087 INSTALLATION..................................................................................2088 FRONT TRANSPONDER.........................................................................2088 REAR TRANSPONDER..........................................................................2088 23-BODY...............................................................................................2090 BODY..............................................................................................2090 WARNING.......................................................................................2090 SAFETY PRECAUTIONS AND WARNINGS...........................................................2090 DIAGNOSIS AND TESTING.........................................................................2090 WATER LEAKS...............................................................................2090 VISUAL INSPECTION BEFORE WATER LEAK TESTS.............................................2091 WATER LEAK TESTS......................................................................2091 WATER LEAK DETECTION..................................................................2091 WIND NOISE................................................................................2091 VISUAL INSPECTION BEFORE TESTS........................................................2091 STANDARD PROCEDURE............................................................................2092 STANDARD PROCEDURE - BODY LUBRICATION.....................................................2092 HEAT STAKING..............................................................................2092 STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR............................................2092 Rigid Plastics:.......................................................................2093 Semi-Rigid Plastics:..................................................................2093 Flexible Plastics:....................................................................2093 Repair Procedure:.....................................................................2093 Adhesion Promoter/Surface Modifier:...................................................2093 SAFETY PRECAUTION AND WARNINGS........................................................2093 RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES...................................2093 PANEL SECTIONING......................................................................2095 PANEL REINFORCEMENT...................................................................2096 VISUAL INSPECTION.....................................................................2096 PANEL SURFACE PREPARATION.............................................................2097 PATCHING PANELS0 - 12 KJ (Continued)..............................................2097 PANEL PATCH FABRICATIONS..............................................................2097 PANEL PATCH INSTALLATION..............................................................2098 PATCHED PANEL SURFACING...............................................................2100 BUZZ, SQUEAK & RATTLE.....................................................................2100 SPECIFICATIONS................................................................................2102 SPECIAL TOOLS.................................................................................2103 BODY......................................................................................2103 HOOD..............................................................................................2104 HINGE.........................................................................................2104 REMOVAL...................................................................................2104 INSTALLATION..............................................................................2104 REMOVAL.......................................................................................2104 INSTALLATION..................................................................................2104 ADJUSTMENTS...................................................................................2104 ADJUSTMENT................................................................................2104 LATCH.........................................................................................2104 REMOVAL...................................................................................2104 INSTALLATION..............................................................................2105 LATCH RELEASE CABLE...........................................................................2105 REMOVAL...................................................................................2105 INSTALLATION..............................................................................2105 SUPPORT CYLINDER..............................................................................2105 REMOVAL...................................................................................2105 INSTALLATION..............................................................................2106 LATCH RELEASE HANDLE..........................................................................2106 REMOVAL...................................................................................2106 INSTALLATION..............................................................................2106 DOOR - FRONT......................................................................................2107 CHECK STRAP...................................................................................2107 REMOVAL...................................................................................2107 INSTALLATION..............................................................................2107 DOOR..........................................................................................2108 REMOVAL...................................................................................2108 INSTALLATION..............................................................................2108 ADJUSTMENTS...............................................................................2108 ADJUSTMENT............................................................................2108 FORE/AFT..........................................................................2108 UP/DOWN...........................................................................2108 IN/OUT............................................................................2109 DOOR GLASS....................................................................................2109 REMOVAL...................................................................................2109 INSTALLATION..............................................................................2109 EXTERIOR HANDLE...............................................................................2109 REMOVAL...................................................................................2109 INSTALLATION..............................................................................2110 GLASS RUN CHANNEL.............................................................................2110 REMOVAL...................................................................................2110 INSTALLATION..............................................................................2110 HINGE.........................................................................................2110 REMOVAL...................................................................................2110 INSTALLATION..............................................................................2110 LATCH.........................................................................................2110 REMOVAL...................................................................................2110 INSTALLATION..............................................................................2111 LATCH STRIKER.................................................................................2111 REMOVAL...................................................................................2111 INSTALLATION..............................................................................2111 LOCK CYLINDER.................................................................................2111 REMOVAL...................................................................................2111 INSTALLATION..............................................................................2111 TRIM PANEL....................................................................................2112 REMOVAL...................................................................................2112 INSTALLATION..............................................................................2112 WATERDAM......................................................................................2112 REMOVAL...................................................................................2112 INSTALLATION..............................................................................2113 WINDOW REGULATOR - MANUAL.....................................................................2113 REMOVAL...................................................................................2113 INSTALLATION..............................................................................2114 WINDOW REGULATOR - POWER......................................................................2114 REMOVAL...................................................................................2114 INSTALLATION..............................................................................2115 DOORS - REAR......................................................................................2116 CHECK STRAP...................................................................................2116 REMOVAL...................................................................................2116 INSTALLATION..............................................................................2116 DOOR..........................................................................................2117 REMOVAL...................................................................................2117 INSTALLATION..............................................................................2117 ADJUSTMENTS...............................................................................2117 ADJUSTMENT............................................................................2117 FORE/AFT..........................................................................2117 UP/DOWN...........................................................................2117 IN/OUT............................................................................2118 DOOR GLASS....................................................................................2118 REMOVAL...................................................................................2118 INSTALLATION..............................................................................2118 EXTERIOR HANDLE...............................................................................2119 REMOVAL...................................................................................2119 INSTALLATION..............................................................................2119 GLASS RUN CHANNEL.............................................................................2119 REMOVAL...................................................................................2119 INSTALLATION..............................................................................2120 HINGE.........................................................................................2120 REMOVAL...................................................................................2120 INSTALLATION..............................................................................2120 LATCH.........................................................................................2120 REMOVAL...................................................................................2120 INSTALLATION..............................................................................2120 ADJUSTMENTS...............................................................................2121 ADJUSTMENT............................................................................2121 LATCH STRIKER.................................................................................2121 REMOVAL...................................................................................2121 INSTALLATION..............................................................................2121 TRIM PANEL....................................................................................2121 REMOVAL...................................................................................2121 INSTALLATION..............................................................................2122 WATERDAM......................................................................................2122 REMOVAL...................................................................................2122 INSTALLATION..............................................................................2122 WINDOW REGULATOR - MANUAL.....................................................................2122 REMOVAL...................................................................................2122 INSTALLATION..............................................................................2123 WINDOW REGULATOR - POWER......................................................................2123 REMOVAL...................................................................................2123 INSTALLATION..............................................................................2124 SWING GATE........................................................................................2125 FLIP-UP GLASS.................................................................................2125 REMOVAL...................................................................................2125 INSTALLATION..............................................................................2125 ADJUSTMENTS...............................................................................2125 ADJUSTMENT............................................................................2125 FLIP-UP GLASS LATCH...........................................................................2126 REMOVAL...................................................................................2126 INSTALLATION..............................................................................2126 FLIP-UP GLASS - HINGE.........................................................................2126 REMOVAL...................................................................................2126 INSTALLATION..............................................................................2127 FLIP-UP GLASS - HINGE COVER...................................................................2127 REMOVAL...................................................................................2127 INSTALLATION..............................................................................2127 FLIP-UP GLASS SUPPORT CYLINDER................................................................2128 REMOVAL...................................................................................2128 INSTALLATION..............................................................................2128 TRIM PANEL....................................................................................2129 REMOVAL...................................................................................2129 INSTALLATION..............................................................................2129 LATCH.........................................................................................2129 REMOVAL...................................................................................2129 INSTALLATION..............................................................................2129 LATCH STRIKER.................................................................................2130 REMOVAL...................................................................................2130 INSTALLATION..............................................................................2130 ADJUSTMENTS...............................................................................2130 ADJUSTMENT............................................................................2130 LATCH - ACCESS PANEL..........................................................................2130 DESCRIPTION...............................................................................2130 REMOVAL...................................................................................2130 INSTALLATION..............................................................................2130 EXTERIOR HANDLE...............................................................................2130 REMOVAL...................................................................................2130 INSTALLATION..............................................................................2130 LOCK CYLINDER.................................................................................2131 REMOVAL...................................................................................2131 INSTALLATION..............................................................................2131 CHECK STRAP...................................................................................2131 REMOVAL...................................................................................2131 INSTALLATION..............................................................................2131 STABILIZER WEDGE/INSERT.......................................................................2132 REMOVAL...................................................................................2132 INSTALLATION..............................................................................2132 ADJUSTMENTS...............................................................................2133 ADJUSTMENT............................................................................2133 HINGE.........................................................................................2133 REMOVAL...................................................................................2133 INSTALLATION..............................................................................2133 REMOVAL.......................................................................................2134 INSTALLATION..................................................................................2134 ADJUSTMENTS...................................................................................2134 ADJUSTMENT................................................................................2134 IN/OUT................................................................................2134 UP/DOWN...............................................................................2135 LEFT/RIGHT............................................................................2135 EXTERIOR..........................................................................................2136 BODY SIDE MOLDINGS............................................................................2136 REMOVAL...................................................................................2136 INSTALLATION..............................................................................2136 COWL GRILLE...................................................................................2136 REMOVAL...................................................................................2136 INSTALLATION..............................................................................2136 EXTERIOR NAME PLATES..........................................................................2137 REMOVAL...................................................................................2137 INSTALLATION..............................................................................2137 FRONT FENDER..................................................................................2137 REMOVAL...................................................................................2137 INSTALLATION..............................................................................2137 FUEL FILL DOOR/HOUSING........................................................................2138 REMOVAL...................................................................................2138 INSTALLATION..............................................................................2138 GRILLE........................................................................................2138 REMOVAL...................................................................................2138 INSTALLATION..............................................................................2139 GRILLE OPENING REINFORCEMENT..................................................................2139 REMOVAL...................................................................................2139 INSTALLATION..............................................................................2139 FRONT WHEELHOUSE SPLASH SHIELD................................................................2140 REMOVAL...................................................................................2140 INSTALLATION..............................................................................2140 LUGGAGE RACK..................................................................................2141 REMOVAL...................................................................................2141 INSTALLATION..............................................................................2141 REAR WHEELHOUSE SPLASH SHIELD.................................................................2141 REMOVAL...................................................................................2141 INSTALLATION..............................................................................2141 FRONT WHEEL OPENING FLARE MOLDINGS............................................................2142 REMOVAL...................................................................................2142 INSTALLATION..............................................................................2142 REAR WHEEL OPENING FLARE MOLDINGS.............................................................2142 REMOVAL...................................................................................2142 INSTALLATION..............................................................................2142 RADIATOR CROSSMEMBER..........................................................................2143 REMOVAL...................................................................................2143 INSTALLATION..............................................................................2143 SIDE VIEW MIRROR..............................................................................2143 REMOVAL...................................................................................2143 INSTALLATION..............................................................................2143 GLASS-OUTSIDE REARVIEW MIRROR.................................................................2143 REMOVAL...................................................................................2143 INSTALLATION..............................................................................2144 SIDE STEP.....................................................................................2144 REMOVAL...................................................................................2144 INSTALLATION..............................................................................2144 ROCK RAIL.....................................................................................2144 REMOVAL...................................................................................2144 INSTALLATION..............................................................................2145 MOLDING - SILL................................................................................2145 REMOVAL...................................................................................2145 Front Sill Molding ...................................................................2145 Rear Sill Molding ....................................................................2146 INSTALLATION..............................................................................2146 Rear Sill Molding.....................................................................2146 Front Sill Molding....................................................................2146 INSTRUMENT PANEL..................................................................................2148 CLUSTER BEZEL.................................................................................2148 REMOVAL...................................................................................2148 INSTALLATION..............................................................................2148 GLOVE BOX.....................................................................................2149 REMOVAL...................................................................................2149 INSTALLATION..............................................................................2149 GLOVE BOX LATCH...............................................................................2149 REMOVAL...................................................................................2149 INSTALLATION..............................................................................2149 GLOVE BOX LATCH STRIKER.......................................................................2149 REMOVAL...................................................................................2149 INSTALLATION..............................................................................2150 INSTRUMENT PANEL ASSEMBLY.....................................................................2150 REMOVAL...................................................................................2150 INSTALLATION..............................................................................2153 INSTRUMENT PANEL TOP COVER....................................................................2154 REMOVAL...................................................................................2154 INSTALLATION..............................................................................2155 INSTRUMENT PANEL END CAP......................................................................2155 REMOVAL...................................................................................2155 INSTALLATION..............................................................................2155 INSTRUMENT PANEL DRIVER SIDE BEZELS...........................................................2155 REMOVAL...................................................................................2155 INSTALLATION..............................................................................2156 INSTRUMENT PANEL CENTER BEZEL.................................................................2156 REMOVAL...................................................................................2156 INSTALLATION..............................................................................2156 INSTRUMENT PANEL PASSENGER SIDE BEZEL.........................................................2156 REMOVAL...................................................................................2156 On vehicles equipped with a grab handle: .............................................2157 On vehicles without a grab handle: ...................................................2157 INSTALLATION..............................................................................2157 On vehicles without a grab handle:....................................................2157 On vehicles equipped with a grab handle:..............................................2157 KNEE BLOCKER..................................................................................2157 REMOVAL...................................................................................2157 INSTALLATION..............................................................................2158 INTERIOR..........................................................................................2159 4WD FLOOR SHIFT BOOT..........................................................................2159 REMOVAL...................................................................................2159 INSTALLATION..............................................................................2159 A-PILLAR TRIM AND GRAB HANDLE.................................................................2159 REMOVAL...................................................................................2159 INSTALLATION..............................................................................2159 COWL TRIM COVER...............................................................................2160 REMOVAL...................................................................................2160 INSTALLATION..............................................................................2160 DOOR SILL SCUFF PLATE.........................................................................2160 REMOVAL...................................................................................2160 INSTALLATION..............................................................................2160 ASSIST HANDLE.................................................................................2160 REMOVAL...................................................................................2160 INSTALLATION..............................................................................2160 B-PILLAR LOWER TRIM...........................................................................2160 REMOVAL...................................................................................2160 INSTALLATION..............................................................................2160 B-PILLAR UPPER TRIM...........................................................................2160 REMOVAL...................................................................................2160 INSTALLATION..............................................................................2161 CARPETS AND FLOOR MATS........................................................................2161 REMOVAL...................................................................................2161 Front Carpet..........................................................................2161 Rear Cargo Carpet.....................................................................2161 INSTALLATION..............................................................................2161 Front Carpet..........................................................................2161 Rear Cargo Carpet.....................................................................2161 SHIFT BEZEL...................................................................................2161 REMOVAL...................................................................................2161 INSTALLATION..............................................................................2161 FLOOR CONSOLE.................................................................................2161 REMOVAL...................................................................................2161 INSTALLATION..............................................................................2161 FLOOR CONSOLE LID LATCH.......................................................................2162 REMOVAL...................................................................................2162 INSTALLATION..............................................................................2162 HEADLINER.....................................................................................2162 REMOVAL...................................................................................2162 INSTALLATION..............................................................................2162 QUARTER TRIM PANEL............................................................................2162 REMOVAL...................................................................................2162 INSTALLATION..............................................................................2163 REAR DOOR SCUFF PLATE.........................................................................2163 REMOVAL...................................................................................2163 INSTALLATION..............................................................................2163 SUN VISOR.....................................................................................2163 REMOVAL...................................................................................2163 INSTALLATION..............................................................................2163 SUN VISOR SUPPORT.............................................................................2163 REMOVAL...................................................................................2163 INSTALLATION..............................................................................2163 REAR VIEW MIRROR..............................................................................2164 REMOVAL...................................................................................2164 INSTALLATION..............................................................................2164 INSTALLATION - REAR VIEW MIRROR SUPPORT BRACKET.......................................2164 PAINT.............................................................................................2165 SPECIFICATIONS - PAINT CODES..................................................................2165 PAINT CODE....................................................................................2165 DESCRIPTION...............................................................................2165 BASE COAT/CLEAR COAT FINISH...................................................................2166 DESCRIPTION...............................................................................2166 PAINT TOUCH-UP................................................................................2166 DESCRIPTION...............................................................................2166 OPERATION.............................................................................2166 FINESSE SANDING/BUFFING & POLISHING...........................................................2166 DESCRIPTION...............................................................................2166 SEATS0 - 14 KJ (Continued)....................................................................2167 HEADREST......................................................................................2167 REMOVAL...................................................................................2167 INSTALLATION..............................................................................2167 HEADREST SLEEVE...............................................................................2167 REMOVAL...................................................................................2167 INSTALLATION..............................................................................2167 SEAT - FRONT..................................................................................2168 REMOVAL...................................................................................2168 INSTALLATION..............................................................................2168 SEAT BACK - FRONT.............................................................................2170 REMOVAL...................................................................................2170 INSTALLATION..............................................................................2171 SEAT BACK RECLINER - FRONT....................................................................2171 REMOVAL...................................................................................2171 INSTALLATION..............................................................................2172 SEAT BACK COVER - FRONT.......................................................................2172 REMOVAL...................................................................................2172 INSTALLATION..............................................................................2173 SEAT BACK CUSHION - FRONT.....................................................................2174 REMOVAL...................................................................................2174 INSTALLATION..............................................................................2174 SEAT CUSHION - FRONT..........................................................................2175 REMOVAL...................................................................................2175 INSTALLATION..............................................................................2176 SEAT CUSHION COVER - FRONT....................................................................2177 REMOVAL...................................................................................2177 INSTALLATION..............................................................................2178 MANUAL SEAT RISER.............................................................................2179 REMOVAL...................................................................................2179 INSTALLATION..............................................................................2180 SEAT TRACK....................................................................................2180 REMOVAL...................................................................................2180 INSTALLATION..............................................................................2181 SEAT - REAR...................................................................................2181 REMOVAL...................................................................................2181 INSTALLATION..............................................................................2182 SEAT BACK - REAR..............................................................................2182 REMOVAL...................................................................................2182 60/40 Split Seat - Left...............................................................2182 60/40 Split Seat - Right..............................................................2182 INSTALLATION..............................................................................2183 60/40 Split Seat - Left...............................................................2183 60/40 Split Seat - Right..............................................................2183 SEAT BACK COVER - REAR........................................................................2184 REMOVAL...................................................................................2184 INSTALLATION..............................................................................2184 SEAT BACK CUSHION - REAR......................................................................2184 REMOVAL...................................................................................2184 INSTALLATION..............................................................................2184 FOLDING REAR SEAT BACK LATCH / LOCK...........................................................2184 REMOVAL...................................................................................2184 INSTALLATION..............................................................................2184 REAR SEAT BACK LATCH STRIKER..................................................................2185 REMOVAL...................................................................................2185 INSTALLATION..............................................................................2185 SEAT BACK FRAME - REAR........................................................................2185 REMOVAL...................................................................................2185 INSTALLATION..............................................................................2185 SEAT CUSHION - REAR...........................................................................2185 REMOVAL...................................................................................2185 INSTALLATION..............................................................................2185 STATIONARY GLASS..................................................................................2186 DOOR GLASS....................................................................................2186 REMOVAL...................................................................................2186 INSTALLATION..............................................................................2186 QUARTER WINDOW................................................................................2186 REMOVAL...................................................................................2186 INSTALLATION..............................................................................2186 WINDSHIELD....................................................................................2187 WARNING...................................................................................2187 WINDSHIELD SAFETY PRECAUTIONS.........................................................2187 REMOVAL...................................................................................2187 INSTALLATION..............................................................................2187 SUNROOF...........................................................................................2189 DESCRIPTION...................................................................................2189 SUNROOF OPERATION INSTRUCTIONS............................................................2190 DIAGNOSIS AND TESTING.........................................................................2190 WATER DRAINAGE AND WIND NOISE DIAGNOSIS...................................................2190 DIAGNOSTIC PROCEDURES.....................................................................2190 GLASS PANEL...................................................................................2192 REMOVAL...................................................................................2192 INSTALLATION..............................................................................2192 ADJUSTMENTS...............................................................................2192 SUNROOF GLASS PANEL ADJUSTMENT........................................................2192 GLASS PANEL SEAL..............................................................................2192 REMOVAL...................................................................................2192 INSTALLATION..............................................................................2193 SUNSHADE......................................................................................2193 REMOVAL...................................................................................2193 INSTALLATION..............................................................................2193 TROUGH........................................................................................2193 REMOVAL...................................................................................2193 INSTALLATION..............................................................................2193 TROUGH GUIDE ASSEMBLY.........................................................................2193 REMOVAL...................................................................................2193 INSTALLATION..............................................................................2194 WIND DEFLECTOR................................................................................2194 REMOVAL...................................................................................2194 INSTALLATION..............................................................................2194 OPENING TRIM LACE.............................................................................2194 REMOVAL...................................................................................2194 INSTALLATION..............................................................................2194 DRAIN TUBE....................................................................................2194 REMOVAL...................................................................................2194 FRONT DRAIN TUBES.....................................................................2194 REAR DRAIN TUBES......................................................................2195 INSTALLATION..............................................................................2195 FRONT DRAIN TUBES.....................................................................2195 REAR DRAIN TUBES......................................................................2195 MODULE/FRAME ASSEMBLY.........................................................................2195 REMOVAL...................................................................................2195 INSTALLATION..............................................................................2196 WIRE HARNESS..................................................................................2197 REMOVAL...................................................................................2197 INSTALLATION..............................................................................2197 DRIVE MOTOR...................................................................................2197 STANDARD PROCEDURE........................................................................2197 DRIVE MOTOR TEACH PROCEDURE...........................................................2197 REPLACEMENT DRIVE MOTOR...........................................................2197 ORIGINAL DRIVE MOTOR..............................................................2197 REMOVAL...................................................................................2198 INSTALLATION..............................................................................2198 CONTROL SWITCH................................................................................2198 DESCRIPTION...............................................................................2198 OPERATION.................................................................................2198 DIAGNOSIS AND TESTING - CONTROL SWITCH....................................................2199 REMOVAL...................................................................................2199 INSTALLATION..............................................................................2199 WEATHERSTRIP/SEALS................................................................................2200 A-PILLAR SEAL.................................................................................2200 REMOVAL...................................................................................2200 INSTALLATION..............................................................................2200 COWL WEATHERSTRIP.............................................................................2200 REMOVAL...................................................................................2200 INSTALLATION..............................................................................2200 DOOR PRIMARY WEATHERSTRIP.....................................................................2200 REMOVAL...................................................................................2200 INSTALLATION..............................................................................2200 DOOR LOWER WEATHERSTRIP.......................................................................2201 REMOVAL...................................................................................2201 INSTALLATION..............................................................................2201 FRONT DOOR OUTER BELT MOLDING.................................................................2201 REMOVAL...................................................................................2201 INSTALLATION..............................................................................2201 SWING GATE BELTLINE WEATHERSTRIP..............................................................2201 REMOVAL...................................................................................2201 INSTALLATION..............................................................................2201 SWING GATE OPENING WEATHERSTRIP...............................................................2201 REMOVAL...................................................................................2201 INSTALLATION..............................................................................2202 REAR DOOR OUTER BELT MOLDING..................................................................2202 REMOVAL...................................................................................2202 INSTALLATION..............................................................................2202 SIDE RAIL WEATHERSTRIP/RETAINER...............................................................2202 REMOVAL...................................................................................2202 INSTALLATION..............................................................................2203 WINDSHIELD A-PILLAR WEATHERSTRIP/RETAINER.....................................................2203 REMOVAL...................................................................................2203 INSTALLATION..............................................................................2203 COWL/PLENUM SEAL..............................................................................2203 REMOVAL...................................................................................2203 INSTALLATION..............................................................................2203 COWL/PLENUM WINDOW BAFFLE SEAL................................................................2203 REMOVAL...................................................................................2203 INSTALLATION..............................................................................2203 AIR INLET SEAL................................................................................2203 REMOVAL...................................................................................2203 INSTALLATION..............................................................................2203 FRONT DOOR INNER BELT WEATHERSTRIP............................................................2203 REMOVAL...................................................................................2203 INSTALLATION..............................................................................2203 REAR DOOR INNER BELT WEATHERSTRIP.............................................................2203 REMOVAL...................................................................................2203 INSTALLATION..............................................................................2203 24-HEATING & AIR CONDITIONING.........................................................................2318 HEATING & AIR CONDITIONING........................................................................2318 DESCRIPTION...................................................................................2318 OPERATION.....................................................................................2319 DIAGNOSIS AND TESTING.........................................................................2320 A/C PERFORMANCE...........................................................................2320 PERFORMANCE TEST PROCEDURE............................................................2320 HEATER PERFORMANCE........................................................................2324 SPECIFICATIONS................................................................................2325 HEATING-A/C SYSTEM........................................................................2325 CONTROLS..........................................................................................2327 A/C COMPRESSOR CLUTCH.........................................................................2328 DESCRIPTION...............................................................................2328 OPERATION.................................................................................2328 DIAGNOSIS AND TESTING.....................................................................2328 A/C COMPRESSOR CLUTCH COIL............................................................2328 STANDARD PROCEDURE........................................................................2329 DIODE REPLACEMENT.....................................................................2329 A/C CLUTCH INSPECTION.................................................................2329 A/C CLUTCH BREAK-IN...................................................................2330 REMOVAL...................................................................................2330 INSTALLATION..............................................................................2331 A/C CLUTCH RELAY..............................................................................2333 DESCRIPTION...............................................................................2333 OPERATION.................................................................................2333 REMOVAL...................................................................................2334 INSTALLATION..............................................................................2334 A/C HEATER CONTROL............................................................................2334 DESCRIPTION...............................................................................2334 DIAGNOSIS AND TESTING.....................................................................2335 VACUUM CONTROL SYSTEM.................................................................2335 VACUUM CHECK VALVE................................................................2335 A/C HEATER CONTROLS...............................................................2335 LOCATING VACUUM LEAKS.............................................................2336 STANDARD PROCEDURE........................................................................2338 A/C-HEATER CONTROL CALIBRATION........................................................2338 REMOVAL...................................................................................2338 INSTALLATION..............................................................................2339 A/C HIGH PRESSURE SWITCH......................................................................2339 DESCRIPTION...............................................................................2339 OPERATION.................................................................................2339 DIAGNOSIS AND TESTING.....................................................................2339 A/C HIGH PRESSURE SWITCH..............................................................2339 REMOVAL...................................................................................2340 INSTALLATION..............................................................................2340 A/C LOW PRESSURE SWITCH.......................................................................2340 DESCRIPTION...............................................................................2340 OPERATION.................................................................................2340 DIAGNOSIS AND TESTING.....................................................................2341 A/C LOW PRESSURE SWITCH...............................................................2341 REMOVAL...................................................................................2341 INSTALLATION..............................................................................2341 A/C PRESSURE TRANSDUCER.......................................................................2342 DESCRIPTION...............................................................................2342 OPERATION.................................................................................2342 DIAGNOSIS AND TESTING.....................................................................2342 A/C PRESSURE TRANSDUCER...............................................................2342 REMOVAL...................................................................................2343 INSTALLATION..............................................................................2343 BLEND DOOR ACTUATOR...........................................................................2343 DESCRIPTION...............................................................................2343 OPERATION.................................................................................2343 REMOVAL...................................................................................2344 INSTALLATION..............................................................................2344 BLOWER MOTOR RELAY............................................................................2345 DESCRIPTION...............................................................................2345 OPERATION.................................................................................2345 REMOVAL...................................................................................2346 INSTALLATION..............................................................................2346 BLOWER MOTOR RESISTOR.........................................................................2346 DESCRIPTION...............................................................................2346 OPERATION.................................................................................2346 DIAGNOSIS AND TESTING.....................................................................2347 BLOWER MOTOR RESISTOR.................................................................2347 REMOVAL...................................................................................2347 INSTALLATION..............................................................................2347 MODE DOOR ACTUATOR............................................................................2348 DESCRIPTION...............................................................................2348 REMOVAL...................................................................................2348 INSTALLATION..............................................................................2349 RECIRCULATION DOOR ACTUATOR...................................................................2349 DESCRIPTION...............................................................................2349 REMOVAL...................................................................................2350 INSTALLATION..............................................................................2351 VACUUM CHECK VALVE............................................................................2351 DESCRIPTION...............................................................................2351 OPERATION.................................................................................2351 REMOVAL...................................................................................2351 INSTALLATION..............................................................................2351 DISTRIBUTION......................................................................................2352 AIR OUTLETS...................................................................................2352 DESCRIPTION...............................................................................2352 REMOVAL...................................................................................2352 INSTALLATION..............................................................................2352 BLEND DOOR....................................................................................2353 REMOVAL...................................................................................2353 INSTALLATION..............................................................................2353 BLOWER MOTOR..................................................................................2354 DESCRIPTION...............................................................................2354 OPERATION.................................................................................2354 DIAGNOSIS AND TESTING.....................................................................2354 BLOWER MOTOR..........................................................................2354 REMOVAL...................................................................................2355 INSTALLATION..............................................................................2355 DEFROSTER DUCT................................................................................2356 REMOVAL...................................................................................2356 INSTALLATION..............................................................................2356 FLOOR DISTRIBUTION DUCT.......................................................................2356 REMOVAL...................................................................................2356 INSTALLATION..............................................................................2356 HVAC HOUSING..................................................................................2356 REMOVAL...................................................................................2356 DISASSEMBLY...............................................................................2357 ASSEMBLY..................................................................................2358 INSTALLATION..............................................................................2359 MODE DOOR.....................................................................................2359 REMOVAL...................................................................................2359 PANEL-AIR DOOR........................................................................2359 FLOOR/DEFROST-AIR DOOR................................................................2360 INSTALLATION..............................................................................2361 PANEL-AIR DOOR........................................................................2361 FLOOR/DEFROST-AIR DOOR................................................................2361 REAR FLOOR HEAT DUCT..........................................................................2361 REMOVAL...................................................................................2361 INSTALLATION..............................................................................2361 RECIRCULATION DOOR............................................................................2362 REMOVAL...................................................................................2362 INSTALLATION..............................................................................2362 25-EMISSIONS CONTROL..................................................................................2388 EMISSIONS CONTROL.................................................................................2388 DESCRIPTION...................................................................................2388 GAS ENGINES...............................................................................2388 2.8L TURBODIESEL..........................................................................2389 ECM MONITORED SYSTEMS.................................................................2389 ECM NON-MONITORED SYSTEMS.............................................................2389 HIGH AND LOW LIMITS...................................................................2389 DESCRIPTION - STATE DISPLAY TEST MODE.....................................................2389 DESCRIPTION - CIRCUIT ACTUATION TEST MODE.................................................2389 DESCRIPTION - DIAGNOSTIC TROUBLE CODES....................................................2390 DESCRIPTION - TASK MANAGER................................................................2390 DESCRIPTION - MONITORED SYSTEMS...........................................................2390 OXYGEN SENSOR (O2S) MONITOR...........................................................2390 OXYGEN SENSOR HEATER MONITOR..........................................................2391 LEAK DETECTION PUMP MONITOR (IF EQUIPPED).............................................2391 MISFIRE MONITOR.......................................................................2391 FUEL SYSTEM MONITOR...................................................................2392 CATALYST MONITOR......................................................................2392 DESCRIPTION - TRIP DEFINITION.............................................................2392 DESCRIPTION - COMPONENT MONITORS..........................................................2393 DESCRIPTION - NON-MONITORED CIRCUITS......................................................2393 DESCRIPTION - HIGH AND LOW LIMITS.........................................................2394 DESCRIPTION - LOAD VALUE..................................................................2394 OPERATION - TASK MANAGER......................................................................2394 Test Sequence.............................................................................2394 MIL Illumination..........................................................................2394 Diagnostic Trouble Codes (DTCs)...........................................................2395 DTC Self Erasure..........................................................................2395 Trip Indicator............................................................................2395 Freeze Frame Data Storage.................................................................2396 Similar Conditions Window.................................................................2396 EVAPORATIVE EMISSIONS.............................................................................2398 DESCRIPTION - EVAPORATION CONTROL SYSTEM......................................................2398 SPECIFICATIONS................................................................................2400 TORQUE....................................................................................2400 EVAP/PURGE SOLENOID0 - 16 KJ (Continued)..................................................2401 DESCRIPTION...............................................................................2401 OPERATION.................................................................................2401 REMOVAL...................................................................................2401 INSTALLATION..............................................................................2401 FUEL FILLER CAP...............................................................................2401 DESCRIPTION...............................................................................2401 OPERATION.................................................................................2401 ORVR..........................................................................................2401 DESCRIPTION...............................................................................2401 OPERATION.................................................................................2401 PUMP-NATURAL VAC LEAK DETECTION...............................................................2402 DESCRIPTION...............................................................................2402 OPERATION.................................................................................2402 REMOVAL...................................................................................2403 INSTALLATION..............................................................................2403 PCV VALVE.....................................................................................2404 DESCRIPTION...............................................................................2404 2.4L..................................................................................2404 3.7L..................................................................................2404 OPERATION.................................................................................2405 DIAGNOSIS AND TESTING - PCV VALVE.........................................................2405 REMOVAL...................................................................................2406 INSTALLATION..............................................................................2406 VACUUM LINES..................................................................................2407 DESCRIPTION...............................................................................2407 VAPOR CANISTER................................................................................2407 DESCRIPTION...............................................................................2407 OPERATION.................................................................................2407 REMOVAL...................................................................................2408 INSTALLATION..............................................................................2408 INDEX.................................................................................................2418 COMMENTS..............................................................................................2422
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
1 review for 2002 2003 2004 2005 2006 2007 Jeep Liberty KJ JEEP CHEROKEE COMPLETE Service Repair Workshop Manual – PDF DOWNLOAD
Add a review
Arthur Ford –