2003 Jeep Liberty KJ Service Manual – PDF DOWNLOAD
DESCRIPTION:
2003 Jeep Liberty KJ Service Manual – PDF DOWNLOAD
INTRODUCTION:
FASTENER IDENTIFICATION DESCRIPTION:
The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face.
DESCRIPTION – FASTENER USAGE:
WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL INJURY.
Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used.
DESCRIPTION – THREADED HOLE REPAIR: Most stripped threaded holes can be repaired using a Helicoilt. Follow the vehicle or Helicoilt recommendations for application and repair procedures.
INTERNATIONAL SYMBOLS DESCRIPTION : The graphic symbols illustrated in the following International Control and Display Symbols Chart (Fig. 3) are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.
TABLE OF CONTENTS:
2003 Jeep Liberty KJ Service Manual – PDF DOWNLOAD
KJ Service Manual.........................................................................................2144
FOREWORD.............................................................................................. 0
GROUP TAB LOCATOR..................................................................................... 1
in-INTRODUCTION....................................................................................... 2
FASTENER IDENTIFICATION........................................................................... 2
DESCRIPTION................................................................................... 2
FASTENER USAGE.................................................................................... 5
DESCRIPTION................................................................................... 5
DESCRIPTION - FASTENER USAGE.............................................................. 5
DESCRIPTION - THREADED HOLE REPAIR........................................................ 5
INTERNATIONAL SYMBOLS............................................................................. 5
DESCRIPTION................................................................................... 5
METRIC SYSTEM..................................................................................... 6
DESCRIPTION................................................................................... 6
TORQUE REFERENCES................................................................................. 8
DESCRIPTION................................................................................... 8
VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL................................................. 9
DESCRIPTION................................................................................... 9
VEHICLE IDENTIFICATION NUMBER..................................................................... 9
DESCRIPTION................................................................................... 9
VEHICLE SAFETY CERTIFICATION LABEL................................................................ 10
DESCRIPTION................................................................................... 10
0-LUBRICATION & MAINTENANCE........................................................................... 12
INTERNATIONAL SYMBOLS............................................................................. 12
DESCRIPTION................................................................................... 12
PARTS & LUBRICANT RECOMMENDATION.................................................................. 12
DESCRIPTION................................................................................... 12
DESCRIPTION - FLUID TYPES................................................................. 12
SAE VISCOSITY RATING.................................................................. 12
API QUALITY CLASSIFICATION............................................................ 13
GEAR LUBRICANTS....................................................................... 13
LUBRICANTS AND GREASES................................................................ 13
SPECIALIZED LUBRICANTS AND OILS....................................................... 13
DESCRIPTION - LUBRICANT RECOMMENDATIONS................................................... 13
Chassis............................................................................... 13
Body.................................................................................. 13
FLUID TYPES....................................................................................... 14
DESCRIPTION................................................................................... 14
DESCRIPTION - FLUID TYPES................................................................. 14
SAE VISCOSITY RATING.................................................................. 14
API QUALITY CLASSIFICATION............................................................ 14
GEAR LUBRICANTS....................................................................... 14
LUBRICANTS AND GREASES................................................................ 14
SPECIALIZED LUBRICANTS AND OILS....................................................... 14
DESCRIPTION - AXLE........................................................................ 14
DESCRIPTION - MANUAL TRANSMISSION......................................................... 15
DESCRIPTION - AUTOMATIC TRANSMISSION FLUID................................................ 15
FLUID ADDITIVES....................................................................... 15
DESCRIPTION - TRANSFER CASE - NV231....................................................... 15
DESCRIPTION - TRANSFER CASE - NV242....................................................... 15
DESCRIPTION - ENGINE COOLANT.............................................................. 15
COOLANT PERFORMANCE................................................................... 16
DESCRIPTION - ENGINE OIL - DIESEL ENGINES................................................. 16
SAE VISCOSITY GRADE................................................................... 16
DESCRIPTION - POWER STEERING FLUID........................................................ 16
OPERATION - AUTOMATIC TRANSMISSION FLUID...................................................... 16
FLUID CAPACITIES.................................................................................. 17
SPECIFICATIONS - FLUID CAPACITIES............................................................. 17
FLUID FILL/CHECK LOCATIONS........................................................................ 17
DESCRIPTION................................................................................... 17
MAINTENANCE SCHEDULES............................................................................. 17
DESCRIPTION................................................................................... 17
Schedule “B”.............................................................................. 18
Schedule “A”.............................................................................. 23
HOISTING.......................................................................................... 25
STANDARD PROCEDURE - HOISTING RECOMMENDATIONS................................................. 25
HOIST..................................................................................... 25
JUMP STARTING..................................................................................... 25
STANDARD PROCEDURE - JUMP STARTING PROCEDURE.................................................. 25
TO JUMP START A DISABLED VEHICLE:......................................................... 26
DISCONNECT CABLE CLAMPS AS FOLLOWS:....................................................... 26
TOWING............................................................................................ 26
STANDARD PROCEDURE - TOWING................................................................... 26
SAFETY PRECAUTIONS........................................................................ 27
TWO-WHEEL-DRIVE VEHICLE TOWING............................................................ 27
TWO WHEEL DRIVE TOWING-REAR END LIFTED.................................................... 27
TWO WHEEL DRIVE TOWING-FRONT END LIFTED................................................... 27
FOUR-WHEEL-DRIVE VEHICLE TOWING........................................................... 27
FOUR WHEEL DRIVE TOWING—REAR END LIFTED................................................... 27
FOUR WHEEL DRIVE TOWING—FRONT END LIFTED.................................................. 28
2-SUSPENSION.......................................................................................... 30
SUSPENSION........................................................................................ 30
DIAGNOSIS AND TESTING - SUSPENSION AND STEERING SYSTEM........................................ 30
WHEEL ALIGNMENT................................................................................... 32
WHEEL ALIGNMENT............................................................................... 32
DESCRIPTION............................................................................... 32
OPERATION................................................................................. 32
STANDARD PROCEDURE........................................................................ 33
STANDARD PROCEDURE - HEIGHT MEASUREMENT............................................... 33
RIDE HEIGHT....................................................................... 33
STANDARD PROCEDURE - CAMBER AND CASTER ADJUSTMENT..................................... 34
STANDARD PROCEDURE - TOE ADJUSTMENT................................................... 34
STANDARD PROCEDURE - CAMBER, CASTER AND TOE ADJUSTMENT................................ 34
CASTER............................................................................ 34
CAMBER............................................................................ 34
TOE ADJUSTMENT.................................................................... 34
SPECIFICATIONS............................................................................ 35
ALIGNMENT............................................................................. 35
FRONT............................................................................. 35
REAR.............................................................................. 35
FRONT............................................................................................. 36
FRONT......................................................................................... 36
DESCRIPTION............................................................................... 36
WARNING................................................................................... 37
SPECIFICATIONS............................................................................ 37
TORQUE CHART.......................................................................... 37
SPECIAL TOOLS............................................................................. 38
FRONT SUSPENSION...................................................................... 38
BUSHINGS...................................................................................... 39
REMOVAL................................................................................... 39
REMOVAL - STABILIZER BAR BUSHINGS..................................................... 39
REMOVAL - LOWER CONTROL ARM BUSHING................................................... 39
REMOVAL - CLEVIS BRACKET BUSHING...................................................... 39
REMOVAL - UPPER CONTROL ARM BUSHINGS.................................................. 39
INSTALLATION.............................................................................. 39
INSTALLATION - STABILIZER BAR BUSHINGS................................................ 39
INSTALLATION - LOWER CONTROL ARM BUSHING.............................................. 40
INSTALLATION - CLEVIS BRACKET BUSHING................................................. 40
INSTALLATION - UPPER CONTROL ARM BUSHINGS............................................. 41
HUB / BEARING................................................................................. 41
REMOVAL................................................................................... 41
INSTALLATION.............................................................................. 41
KNUCKLE....................................................................................... 42
REMOVAL................................................................................... 42
INSTALLATION.............................................................................. 42
LOWER BALL JOINT.............................................................................. 42
DIAGNOSIS AND TESTING - LOWER BALL JOINT.................................................. 42
REMOVAL................................................................................... 43
INSTALLATION.............................................................................. 43
LOWER CONTROL ARM............................................................................. 44
REMOVAL................................................................................... 44
INSTALLATION.............................................................................. 44
SHOCK......................................................................................... 44
REMOVAL................................................................................... 44
REMOVAL - LEFT SIDE................................................................... 44
REMOVAL - RIGHT SIDE.................................................................. 45
INSTALLATION.............................................................................. 45
INSTALLATION - LEFT SIDE.............................................................. 45
INSTALLATION - RIGHT SIDE............................................................. 46
SPRING........................................................................................ 46
REMOVAL................................................................................... 46
INSTALLATION.............................................................................. 46
CLEVIS BRACKET................................................................................ 47
REMOVAL................................................................................... 47
INSTALLATION.............................................................................. 47
STABILIZER BAR................................................................................ 47
REMOVAL................................................................................... 47
INSTALLATION.............................................................................. 47
STABILIZER LINK............................................................................... 48
REMOVAL................................................................................... 48
INSTALLATION.............................................................................. 48
UPPER CONTROL ARM............................................................................. 48
REMOVAL................................................................................... 48
REMOVAL - RIGHT SIDE.................................................................. 48
REMOVAL - LEFT SIDE................................................................... 48
INSTALLATION.............................................................................. 49
INSTALLATION - RIGHT SIDE............................................................. 49
INSTALLATION - LEFT SIDE.............................................................. 49
REAR.............................................................................................. 50
REAR.......................................................................................... 50
DESCRIPTION............................................................................... 50
WARNING................................................................................... 51
DIAGNOSIS AND TESTING - REAR SUSPENSION................................................... 51
SPECIFICATIONS............................................................................ 51
TORQUE CHART.......................................................................... 51
SPECIAL TOOLS............................................................................. 52
REAR SUSPENSION....................................................................... 52
SHOCK......................................................................................... 52
REMOVAL................................................................................... 52
INSTALLATION.............................................................................. 52
SPRING........................................................................................ 53
REMOVAL................................................................................... 53
INSTALLATION.............................................................................. 53
JOUNCE BUMPER................................................................................. 53
REMOVAL................................................................................... 53
INSTALLATION.............................................................................. 53
STABILIZER BAR................................................................................ 53
REMOVAL................................................................................... 53
INSTALLATION.............................................................................. 54
UPPER BALL JOINT.............................................................................. 54
REMOVAL................................................................................... 54
INSTALLATION.............................................................................. 54
UPPER CONTROL ARM............................................................................. 55
DESCRIPTION - UPPER SUSPENSION ARM, BUSHINGS, AND BALL JOINT.............................. 55
OPERATION - UPPER SUSPENSION ARM, BUSHINGS, AND BALL JOINT................................ 55
REMOVAL................................................................................... 55
INSTALLATION.............................................................................. 55
LOWER CONTROL ARM............................................................................. 56
DESCRIPTION............................................................................... 56
OPERATION................................................................................. 56
REMOVAL................................................................................... 56
INSTALLATION.............................................................................. 56
BUSHINGS...................................................................................... 56
REMOVAL................................................................................... 56
REMOVAL - LOWER SUSPENSION ARM BUSHING................................................ 56
REMOVAL - UPPER SUSPENSION ARM BUSHING................................................ 57
INSTALLATION.............................................................................. 57
INSTALLATION - LOWER SUSPENSION ARM BUSHING........................................... 57
INSTALLATION - UPPER SUSPENSION ARM BUSHING........................................... 58
3-DIFFERENTIAL & DRIVELINE............................................................................ 60
PROPELLER SHAFT................................................................................... 60
PROPELLER SHAFT............................................................................... 60
DIAGNOSIS AND TESTING..................................................................... 60
VIBRATION............................................................................. 60
BALANCE............................................................................... 61
RUNOUT................................................................................ 62
STANDARD PROCEDURE........................................................................ 62
STANDARD PROCEDURES................................................................... 62
PROPELLER SHAFT ANGLE............................................................. 62
SPECIFICATIONS............................................................................ 64
SPECIAL TOOLS............................................................................. 65
PROPELLER SHAFT - FRONT....................................................................... 65
REMOVAL................................................................................... 65
REMOVAL - 2.5L DIESEL................................................................. 65
REMOVAL............................................................................... 65
INSTALLATION.............................................................................. 66
INSTALLATION - 2.5L DIESEL............................................................ 66
INSTALLATION.......................................................................... 66
PROPELLER SHAFT - REAR........................................................................ 66
REMOVAL................................................................................... 66
INSTALLATION.............................................................................. 66
SINGLE CARDAN UNIVERSAL JOINTS................................................................ 67
DISASSEMBLY............................................................................... 67
ASSEMBLY.................................................................................. 68
HALF SHAFT........................................................................................ 69
HALF SHAFT.................................................................................... 69
CAUTION................................................................................... 69
DIAGNOSIS AND TESTING..................................................................... 69
NOISE/VIBRATION IN TURNS.............................................................. 69
CLUNKING NOISE DURING ACCELERATION.................................................... 69
SHUDDER/VIBRATION DURING ACCELERATION................................................. 69
VIBRATION AT HIGHWAY SPEEDS........................................................... 69
REMOVAL................................................................................... 69
INSTALLATION.............................................................................. 70
SPECIFICATIONS............................................................................ 70
SPECIAL TOOLS............................................................................. 71
CV JOINT/BOOT-OUTER........................................................................... 71
REMOVAL................................................................................... 71
INSTALLATION.............................................................................. 72
CV JOINT/BOOT-INNER........................................................................... 74
REMOVAL................................................................................... 74
INSTALLATION.............................................................................. 75
FRONT AXLE - 186FIA............................................................................... 77
FRONT AXLE - 186FIA........................................................................... 77
DESCRIPTION............................................................................... 77
OPERATION................................................................................. 77
DIAGNOSIS AND TESTING..................................................................... 78
GEAR NOISE............................................................................ 78
BEARING NOISE......................................................................... 78
LOW SPEED KNOCK....................................................................... 78
VIBRATION............................................................................. 78
DRIVELINE SNAP........................................................................ 78
REMOVAL................................................................................... 81
INSTALLATION.............................................................................. 83
ADJUSTMENTS............................................................................... 83
PINION DEPTH MEASUREMENT.............................................................. 84
DIFFERENTIAL.......................................................................... 85
SHIM SELECTION........................................................................ 85
GEAR CONTACT PATTERN.................................................................. 88
DIFFERENTIAL BEARING PRELOAD CHECK.................................................... 90
SPECIFICATIONS............................................................................ 90
SPECIAL TOOLS............................................................................. 90
AXLE SHAFTS................................................................................... 93
REMOVAL................................................................................... 93
INSTALLATION.............................................................................. 93
AXLE SHAFT SEALS.............................................................................. 94
REMOVAL................................................................................... 94
INSTALLATION.............................................................................. 94
AXLE BEARINGS................................................................................. 94
REMOVAL................................................................................... 94
INSTALLATION.............................................................................. 95
PINION SEAL................................................................................... 95
REMOVAL................................................................................... 95
INSTALLATION.............................................................................. 95
DIFFERENTIAL.................................................................................. 96
REMOVAL................................................................................... 96
DISASSEMBLY............................................................................... 97
ASSEMBLY.................................................................................. 98
INSTALLATION.............................................................................. 98
DIFFERENTIAL CASE BEARINGS.................................................................... 99
REMOVAL................................................................................... 99
INSTALLATION.............................................................................. 99
PINION GEAR/RING GEAR......................................................................... 100
REMOVAL................................................................................... 100
INSTALLATION.............................................................................. 102
REAR AXLE - 8 1/4................................................................................. 105
REAR AXLE - 8 1/4............................................................................. 105
DESCRIPTION............................................................................... 105
OPERATION................................................................................. 105
DIAGNOSIS AND TESTING..................................................................... 105
GEAR NOISE............................................................................ 105
BEARING NOISE......................................................................... 105
LOW SPEED KNOCK....................................................................... 106
VIBRATION............................................................................. 106
DRIVELINE SNAP........................................................................ 106
REMOVAL................................................................................... 108
INSTALLATION.............................................................................. 108
ADJUSTMENTS............................................................................... 109
PINION DEPTH MEASUREMENT.............................................................. 111
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH........................................ 112
GEAR CONTACT PATTERN.................................................................. 113
SIDE GEAR CLEARANCE................................................................... 114
SPECIFICATIONS............................................................................ 115
SPECIAL TOOLS............................................................................. 115
AXLE SHAFTS................................................................................... 118
REMOVAL................................................................................... 118
INSTALLATION.............................................................................. 119
AXLE SHAFT SEALS.............................................................................. 119
REMOVAL................................................................................... 119
INSTALLATION.............................................................................. 119
AXLE BEARINGS................................................................................. 119
REMOVAL................................................................................... 119
INSTALLATION.............................................................................. 119
PINION SEAL................................................................................... 119
REMOVAL................................................................................... 119
INSTALLATION.............................................................................. 120
DIFFERENTIAL.................................................................................. 121
DESCRIPTION............................................................................... 121
OPERATION................................................................................. 121
REMOVAL................................................................................... 121
DISASSEMBLY............................................................................... 122
ASSEMBLY.................................................................................. 122
INSTALLATION.............................................................................. 123
DIFFERENTIAL - TRAC-LOK....................................................................... 123
DESCRIPTION............................................................................... 123
OPERATION................................................................................. 124
DIAGNOSIS AND TESTING..................................................................... 124
DIFFERENTIAL TEST..................................................................... 124
DISASSEMBLY............................................................................... 124
ASSEMBLY.................................................................................. 126
DIFFERENTIAL CASE BEARINGS.................................................................... 127
REMOVAL................................................................................... 127
INSTALLATION.............................................................................. 128
PINION GEAR/RING GEAR/TONE RING............................................................... 128
REMOVAL................................................................................... 128
INSTALLATION.............................................................................. 130
5-BRAKES.............................................................................................. 134
BRAKES - BASE..................................................................................... 134
BRAKES - BASE................................................................................. 135
DESCRIPTION............................................................................... 135
WARNING................................................................................... 136
DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM................................................. 136
PRELIMINARY BRAKE CHECK............................................................... 136
ROAD TESTING.......................................................................... 136
BRAKE NOISES.......................................................................... 138
STANDARD PROCEDURE........................................................................ 138
STANDARD PROCEDURE - PRESSURE BLEEDING................................................ 138
STANDARD PROCEDURE - MANUAL BLEEDING.................................................. 139
SPECIFICATIONS............................................................................ 139
BRAKE COMPONENTS...................................................................... 139
TORQUE................................................................................ 140
SPECIAL TOOLS............................................................................. 140
BASE BRAKES........................................................................... 140
BRAKE LINES................................................................................... 141
DESCRIPTION............................................................................... 141
DIAGNOSIS AND TESTING - BRAKE LINE AND HOSES.............................................. 141
STANDARD PROCEDURE - DOUBLE INVERTED FLARING.............................................. 141
REMOVAL................................................................................... 142
REMOVAL - FRONT HOSE.................................................................. 142
REMOVAL - REAR BRAKE HOSE............................................................. 142
INSTALLATION.............................................................................. 143
INSTALLATION - FRONT OR REAR BRAKE CALIPER HOSE....................................... 143
INSTALLATION - REAR BRAKE HOSE........................................................ 143
BRAKE PADS / SHOES............................................................................ 143
REMOVAL................................................................................... 143
REMOVAL - FRONT BRAKE PADS............................................................ 143
REMOVAL - REAR DISC BRAKE PADS........................................................ 143
INSTALLATION.............................................................................. 143
INSTALLATION - FRONT BRAKE PADS....................................................... 143
INSTALLATION - REAR DISC BRAKE PADS................................................... 143
DISC BRAKE CALIPERS........................................................................... 144
DESCRIPTION............................................................................... 144
OPERATION................................................................................. 144
REMOVAL................................................................................... 145
REMOVAL - FRONT....................................................................... 145
REMOVAL - REAR........................................................................ 145
DISASSEMBLY............................................................................... 145
CLEANING.................................................................................. 146
INSPECTION................................................................................ 146
ASSEMBLY.................................................................................. 147
INSTALLATION.............................................................................. 148
INSTALLATION - FRONT.................................................................. 148
INSTALLATION - REAR................................................................... 148
DISC BRAKE CALIPER ADAPTER.................................................................... 149
REMOVAL................................................................................... 149
INSTALLATION.............................................................................. 149
ROTORS........................................................................................ 149
DIAGNOSIS AND TESTING..................................................................... 149
DIAGNOSIS AND TESTING - DISC BRAKE ROTOR.............................................. 149
ROTOR MINIMUM THICKNESS........................................................... 149
ROTOR RUNOUT...................................................................... 149
ROTOR THICKNESS VARIATION......................................................... 150
DIAGNOSIS AND TESTING - BRAKE DRUM IN HAT ROTOR....................................... 150
BRAKE DRUM RUNOUT................................................................. 150
STANDARD PROCEDURE........................................................................ 150
STANDARD PROCEDURE - DISC BRAKE ROTOR................................................. 150
STANDARD PROCEDURE - BRAKE DRUM IN HAT ROTOR MACHINING................................ 150
REMOVAL................................................................................... 151
REMOVAL - FRONT....................................................................... 151
REMOVAL - REAR........................................................................ 151
INSTALLATION.............................................................................. 151
INSTALLATION - FRONT.................................................................. 151
INSTALLATION - REAR................................................................... 151
BRAKE JUNCTION BLOCK.......................................................................... 152
DESCRIPTION............................................................................... 152
OPERATION................................................................................. 152
PROPORTIONING VALVE................................................................... 152
DIAGNOSIS AND TESTING - PROPORTIONING VALVE............................................... 152
REMOVAL................................................................................... 152
INSTALLATION.............................................................................. 152
PEDAL......................................................................................... 152
DESCRIPTION............................................................................... 152
OPERATION................................................................................. 152
REMOVAL................................................................................... 152
INSTALLATION.............................................................................. 152
POWER BRAKE BOOSTER........................................................................... 153
DESCRIPTION............................................................................... 153
OPERATION................................................................................. 153
DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER..................................... 154
POWER BOOSTER VACUUM TEST............................................................. 154
POWER BOOSTER CHECK VALVE TEST........................................................ 154
REMOVAL................................................................................... 155
REMOVAL - LHD......................................................................... 155
REMOVAL - RHD......................................................................... 155
INSTALLATION.............................................................................. 156
INSTALLATION - LHD.................................................................... 156
INSTALLATION - RHD.................................................................... 156
MASTER CYLINDER............................................................................... 157
DESCRIPTION............................................................................... 157
OPERATION................................................................................. 157
DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER..................................... 157
POWER BOOSTER VACUUM TEST............................................................. 157
POWER BOOSTER CHECK VALVE TEST........................................................ 158
STANDARD PROCEDURE - MASTER CYLINDER BLEEDING............................................. 158
REMOVAL................................................................................... 158
INSTALLATION.............................................................................. 158
FLUID RESERVOIR............................................................................... 159
REMOVAL................................................................................... 159
INSTALLATION.............................................................................. 159
FLUID......................................................................................... 159
DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION......................................... 159
STANDARD PROCEDURE - MASTER CYLINDER FLUID LEVEL.......................................... 159
SPECIFICATIONS............................................................................ 159
BRAKE FLUID........................................................................... 159
SUPPORT PLATE................................................................................. 160
REMOVAL................................................................................... 160
INSTALLATION.............................................................................. 160
PARKING BRAKE................................................................................. 160
DESCRIPTION............................................................................... 160
OPERATION................................................................................. 161
ADJUSTMENTS............................................................................... 161
ADJUSTMENT - LOCK OUT................................................................. 161
CABLES........................................................................................ 161
REMOVAL................................................................................... 161
INSTALLATION.............................................................................. 162
LEVER......................................................................................... 162
REMOVAL................................................................................... 162
INSTALLATION.............................................................................. 162
SHOES......................................................................................... 163
DESCRIPTION............................................................................... 163
OPERATION................................................................................. 163
REMOVAL................................................................................... 163
CLEANING - REAR DRUM IN HAT BRAKE......................................................... 163
INSPECTION - REAR DRUM IN HAT BRAKE....................................................... 164
INSTALLATION.............................................................................. 164
ADJUSTMENTS............................................................................... 165
ADJUSTMENT - REAR DRUM IN HAT PARK BRAKE (ROTOR REMOVED).............................. 165
ADJUSTMENT - WITH ADJUSTING TOOL...................................................... 166
ADJUSTMENT - REAR DRUM IN HAT PARK BRAKE (ROTOR REMOVED).............................. 166
BRAKES - ABS...................................................................................... 169
BRAKES - ABS.................................................................................. 169
DESCRIPTION............................................................................... 169
ANTILOCK BRAKING SYSTEM............................................................... 169
ELECTRONIC BRAKE DISTRIBUTION......................................................... 169
OPERATION................................................................................. 169
ANTILOCK BRAKING SYSTEM............................................................... 169
ELECTRONIC BRAKE DISTRIBUTION......................................................... 169
DIAGNOSIS AND TESTING - ANTILOCK BRAKING SYSTEM........................................... 170
STANDARD PROCEDURE - ABS BRAKE BLEEDING................................................... 170
SPECIFICATIONS............................................................................ 170
ELECTRICAL.................................................................................... 171
DESCRIPTION............................................................................... 171
OPERATION................................................................................. 171
FRONT WHEEL SPEED SENSOR...................................................................... 171
REMOVAL................................................................................... 171
INSTALLATION.............................................................................. 171
REAR WHEEL SPEED SENSOR....................................................................... 172
REMOVAL................................................................................... 172
INSTALLATION.............................................................................. 172
HCU (HYDRAULIC CONTROL UNIT).................................................................. 172
DESCRIPTION............................................................................... 172
OPERATION................................................................................. 172
PRESSURE DECREASE..................................................................... 172
PRESSURE HOLD......................................................................... 172
PRESSURE INCREASE..................................................................... 172
REMOVAL................................................................................... 172
INSTALLATION.............................................................................. 173
6-CLUTCH.............................................................................................. 174
CLUTCH............................................................................................ 174
DESCRIPTION................................................................................... 174
OPERATION..................................................................................... 174
WARNING....................................................................................... 175
DIAGNOSIS AND TESTING - CLUTCH................................................................ 175
CLUTCH CONTAMINATION...................................................................... 175
IMPROPER RELEASE OR CLUTCH ENGAGEMENT..................................................... 175
CLUTCH MISALIGNMENT....................................................................... 175
PRESSURE PLATE AND DISC RUNOUT............................................................ 175
FLYWHEEL RUNOUT........................................................................... 175
DIAGNOSIS CHART........................................................................... 176
SPECIFICATIONS................................................................................ 178
SPECIFICATIONS............................................................................ 178
SPECIFICATIONS - 2.5L DIESEL.............................................................. 179
CLUTCH DISC....................................................................................... 179
REMOVAL....................................................................................... 179
INSTALLATION.................................................................................. 179
INSTALLATION.............................................................................. 179
INSTALLATION - 2.5L DIESEL................................................................ 180
CLUTCH RELEASE BEARING............................................................................ 180
REMOVAL....................................................................................... 180
INSTALLATION.................................................................................. 180
FLYWHEEL.......................................................................................... 181
DESCRIPTION................................................................................... 181
STANDARD FLYWHEEL......................................................................... 181
DUAL MASS FLYWHEEL........................................................................ 181
OPERATION..................................................................................... 181
DIAGNOSIS AND TESTING - FLYWHEEL.............................................................. 182
PILOT BEARING..................................................................................... 182
REMOVAL....................................................................................... 182
INSTALLATION.................................................................................. 182
LINKAGE........................................................................................... 182
REMOVAL....................................................................................... 182
INSTALLATION.................................................................................. 183
MASTER CYLINDER................................................................................... 183
INSPECTION.................................................................................... 183
CLUTCH PEDAL...................................................................................... 184
REMOVAL....................................................................................... 184
INSTALLATION.................................................................................. 184
CLUTCH SWITCH OVERRIDE RELAY...................................................................... 184
DESCRIPTION................................................................................... 184
OPERATION..................................................................................... 184
REMOVAL....................................................................................... 184
INSTALLATION.................................................................................. 184
CLUTCH PEDAL POSITION SWITCH...................................................................... 185
DESCRIPTION................................................................................... 185
OPERATION..................................................................................... 185
DIAGNOSIS AND TESTING - CLUTCH PEDAL POSITION SWITCH.......................................... 185
REMOVAL....................................................................................... 185
INSTALLATION.................................................................................. 185
7-COOLING............................................................................................. 186
COOLING........................................................................................... 186
DESCRIPTION................................................................................... 186
DESCRIPTION - COOLING SYSTEM 2.4L ENGINE.................................................. 186
DESCRIPTION - COOLING SYSTEM 3.7L ENGINE.................................................. 186
DESCRIPTION - COOLING SYSTEM ROUTING 3.7L ENGINE.......................................... 186
DESCRIPTION - HOSE CLAMPS................................................................. 187
OPERATION..................................................................................... 188
OPERATION - COOLING SYSTEM................................................................ 188
OPERATION - HOSE CLAMPS................................................................... 188
DIAGNOSIS AND TESTING......................................................................... 188
DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTICS (OBD)........................................ 188
COOLING SYSTEM RELATED DIAGNOSTICS.................................................... 188
ACCESSING DIAGNOSTIC TROUBLE CODES.................................................... 188
ERASING TROUBLE CODES................................................................. 188
DIAGNOSIS AND TESTING - PRELIMINARY CHECKS................................................ 188
ENGINE COOLING SYSTEM OVERHEATING..................................................... 188
DIAGNOSIS AND TESTING - COOLING SYSTEM LEAKS.............................................. 189
ULTRAVIOLET LIGHT METHOD.............................................................. 189
PRESSURE TESTER METHOD................................................................ 189
INTERNAL LEAKAGE INSPECTION........................................................... 190
COMBUSTION LEAKAGE TEST - WITHOUT PRESSURE TESTER..................................... 190
DIAGNOSIS AND TESTING - COOLING SYSTEM DIAGNOSIS CHART.................................... 191
STANDARD PROCEDURE............................................................................ 197
STANDARD PROCEDURE - DRAINING COOLING SYSTEM.............................................. 197
STANDARD PROCEDURE - REFILLING COOLING SYSTEM............................................. 197
STANDARD PROCEDURE - COOLING SYSTEM - REVERSE FLUSHING.................................... 197
CHEMICAL CLEANING..................................................................... 198
REVERSE FLUSHING RADIATOR............................................................. 198
REVERSE FLUSHING ENGINE............................................................... 198
SPECIFICATIONS................................................................................ 198
TORQUE.................................................................................... 198
SPECIAL TOOLS................................................................................. 199
COOLING................................................................................... 199
ACCESSORY DRIVE................................................................................... 200
ACCESSORY DRIVE............................................................................... 200
DIAGNOSIS AND TESTING - SERPENTINE DRIVE BELT DIAGNOSIS................................... 200
BELT TENSIONERS............................................................................... 202
REMOVAL................................................................................... 202
REMOVAL - 3.7L ENGINE................................................................. 202
REMOVAL - 2.4L ENGINE................................................................. 202
INSTALLATION.............................................................................. 203
INSTALLATION - 3.7L ENGINE............................................................ 203
INSTALLATION - 2.4L ENGINE............................................................ 203
DRIVE BELTS -2.4L............................................................................. 203
REMOVAL - 2.4L ENGINE..................................................................... 203
INSTALLATION - 2.4L ENGINE................................................................ 203
DRIVE BELTS - 3.7L............................................................................ 204
REMOVAL - 3.7L ENGINE..................................................................... 204
INSTALLATION - 3.7L ENGINE................................................................ 205
ENGINE............................................................................................ 206
COOLANT....................................................................................... 207
DESCRIPTION............................................................................... 207
DESCRIPTION - HOAT COOLANT............................................................ 207
COOLANT PERFORMANCE............................................................... 207
COOLANT SELECTION AND ADDITIVES................................................... 207
DESCRIPTION - ENGINE COOLANT.......................................................... 208
ETHYLENE-GLYCOL MIXTURES.......................................................... 208
PROPYLENE-GLYCOL MIXTURES......................................................... 208
OPERATION................................................................................. 208
COOLANT RECOVERY PRESS CONTAINER.............................................................. 208
DESCRIPTION............................................................................... 208
OPERATION................................................................................. 208
REMOVAL................................................................................... 209
INSTALLATION.............................................................................. 209
ENGINE BLOCK HEATER........................................................................... 209
DESCRIPTION............................................................................... 209
OPERATION................................................................................. 209
REMOVAL................................................................................... 209
REMOVAL - 2.4L........................................................................ 209
REMOVAL - 3.7L........................................................................ 209
INSTALLATION.............................................................................. 209
INSTALLATION - 2.4L................................................................... 209
INSTALLATION - 3.7L................................................................... 210
ENGINE COOLANT TEMPERATURE SENSOR............................................................. 210
DESCRIPTION............................................................................... 210
OPERATION................................................................................. 210
REMOVAL................................................................................... 211
2.4L.................................................................................. 211
3.7L.................................................................................. 211
INSTALLATION.............................................................................. 211
ENGINE COOLANT THERMOSTAT..................................................................... 211
DESCRIPTION - 3.7L ENGINE................................................................. 211
OPERATION................................................................................. 212
DIAGNOSIS AND TESTING - THERMOSTAT........................................................ 212
ON-BOARD DIAGNOSTICS.................................................................. 212
REMOVAL................................................................................... 212
REMOVAL - 3.7L ENGINE................................................................. 212
REMOVAL............................................................................... 212
INSTALLATION.............................................................................. 212
INSTALLATION - 3.7L ENGINE............................................................ 212
INSTALLATION.......................................................................... 213
FAN DRIVE VISCOUS CLUTCH...................................................................... 213
DESCRIPTION............................................................................... 213
OPERATION................................................................................. 213
DIAGNOSIS AND TESTING..................................................................... 214
VISCOUS FAN DRIVE..................................................................... 214
NOISE............................................................................. 214
LEAKS............................................................................. 215
TESTING........................................................................... 215
REMOVAL................................................................................... 215
INSTALLATION.............................................................................. 216
RADIATOR...................................................................................... 216
DESCRIPTION............................................................................... 216
REMOVAL................................................................................... 217
REMOVAL............................................................................... 217
REMOVAL............................................................................... 218
CLEANING.................................................................................. 220
INSPECTION................................................................................ 220
INSTALLATION.............................................................................. 220
INSTALLATION.......................................................................... 220
INSTALLATION.......................................................................... 220
RADIATOR PRESSURE CAP......................................................................... 221
DESCRIPTION............................................................................... 221
OPERATION................................................................................. 221
DIAGNOSIS AND TESTING - RADIATOR PRESSURE CAP............................................. 221
CLEANING.................................................................................. 221
INSPECTION................................................................................ 221
RADIATOR FAN - ELECTRIC....................................................................... 222
DESCRIPTION............................................................................... 222
OPERATION................................................................................. 222
REMOVAL................................................................................... 222
REMOVAL............................................................................... 222
REMOVAL............................................................................... 223
INSTALLATION.............................................................................. 223
INSTALLATION.......................................................................... 223
INSTALLATION.......................................................................... 223
RADIATOR - FAN - VISCOUS...................................................................... 223
DESCRIPTION............................................................................... 223
OPERATION................................................................................. 224
DIAGNOSIS AND TESTING - VISCOUS FAN DRIVE................................................. 224
REMOVAL................................................................................... 224
CLEANING0 - 2 KJ (Continued).......................................................... 225
INSPECTION................................................................................ 225
INSTALLATION.............................................................................. 225
THERMOSTAT HOUSING............................................................................ 225
REMOVAL................................................................................... 225
INSTALLATION.............................................................................. 226
WATER PUMP - 2.4L............................................................................. 226
DESCRIPTION............................................................................... 226
OPERATION................................................................................. 226
REMOVAL - 2.4L ENGINE..................................................................... 226
INSPECTION................................................................................ 227
INSTALLATION - 2.4L ENGINE................................................................ 227
WATER PUMP - 3.7L............................................................................. 228
DESCRIPTION............................................................................... 228
DESCRIPTION - WATER PUMP.............................................................. 228
DESCRIPTION - WATER PUMP BYPASS....................................................... 228
OPERATION - WATER PUMP.................................................................... 228
REMOVAL................................................................................... 228
REMOVAL............................................................................... 228
REMOVAL — 2.4L........................................................................ 229
CLEANING.................................................................................. 230
INSPECTION................................................................................ 230
INSTALLATION.............................................................................. 230
INSTALLATION.......................................................................... 230
INSTALLATION.......................................................................... 231
TRANSMISSION...................................................................................... 232
TRANS COOLER.................................................................................. 232
DESCRIPTION............................................................................... 232
8a-AUDIO.............................................................................................. 234
AUDIO............................................................................................. 234
DESCRIPTION................................................................................... 234
OPERATION..................................................................................... 235
DIAGNOSIS AND TESTING - AUDIO................................................................. 235
AMPLIFIER CHOKE AND RELAY......................................................................... 237
DESCRIPTION................................................................................... 237
OPERATION..................................................................................... 237
DIAGNOSIS AND TESTING - AMPLIFIER CHOKE AND RELAY............................................. 237
REMOVAL....................................................................................... 238
INSTALLATION.................................................................................. 238
ANTENNA BODY & CABLE.............................................................................. 238
DESCRIPTION................................................................................... 238
DOMESTIC.................................................................................. 238
EXPORT.................................................................................... 238
OPERATION..................................................................................... 238
DIAGNOSIS AND TESTING - ANTENNA BODY AND CABLE................................................ 239
TEST 1.................................................................................... 239
TEST 2.................................................................................... 239
TEST 3.................................................................................... 239
TEST 4.................................................................................... 240
REMOVAL....................................................................................... 240
DOMESTIC.................................................................................. 240
EXPORT.................................................................................... 240
INSTALLATION.................................................................................. 241
DOMESTIC.................................................................................. 241
EXPORT.................................................................................... 241
ANTENNA MODULE.................................................................................... 242
DESCRIPTION................................................................................... 242
OPERATION..................................................................................... 242
DIAGNOSIS AND TESTING - ANTENNA MODULE........................................................ 242
REMOVAL....................................................................................... 243
INSTALLATION.................................................................................. 243
CD CHANGER........................................................................................ 243
DESCRIPTION................................................................................... 243
OPERATION..................................................................................... 243
REMOVAL....................................................................................... 244
INSTALLATION.................................................................................. 244
INSTRUMENT PANEL ANTENNA CABLE.................................................................... 244
REMOVAL....................................................................................... 244
DOMESTIC.................................................................................. 244
EXPORT.................................................................................... 245
INSTALLATION.................................................................................. 245
DOMESTIC.................................................................................. 245
EXPORT.................................................................................... 246
QUARTER GLASS INTEGRAL ANTENNA.................................................................... 246
DESCRIPTION................................................................................... 246
OPERATION..................................................................................... 246
DIAGNOSIS AND TESTING - QUARTER GLASS INTEGRAL ANTENNA........................................ 246
RADIO............................................................................................. 246
DESCRIPTION................................................................................... 246
OPERATION..................................................................................... 247
REMOVAL....................................................................................... 247
INSTALLATION.................................................................................. 247
RADIO NOISE SUPPRESSION GROUND STRAP.............................................................. 247
DESCRIPTION................................................................................... 247
OPERATION..................................................................................... 248
REMOVAL....................................................................................... 248
2.4L ENGINE............................................................................... 248
2.5L ENGINE............................................................................... 249
3.7L ENGINE............................................................................... 249
INSTALLATION.................................................................................. 249
2.4L ENGINE............................................................................... 249
2.5L ENGINE............................................................................... 249
3.7L ENGINE............................................................................... 249
REMOTE SWITCHES................................................................................... 250
DESCRIPTION................................................................................... 250
OPERATION..................................................................................... 250
DIAGNOSIS AND TESTING - REMOTE SWITCHES....................................................... 250
REMOVAL....................................................................................... 251
INSTALLATION.................................................................................. 252
SPEAKER........................................................................................... 252
DESCRIPTION................................................................................... 252
STANDARD.................................................................................. 252
PREMIUM................................................................................... 252
OPERATION..................................................................................... 252
DIAGNOSIS AND TESTING - SPEAKER............................................................... 253
REMOVAL....................................................................................... 253
FRONT DOOR................................................................................ 253
INSTRUMENT PANEL.......................................................................... 254
REAR DOOR................................................................................. 254
INSTALLATION.................................................................................. 254
FRONT DOOR................................................................................ 254
INSTRUMENT PANEL.......................................................................... 254
REAR DOOR................................................................................. 254
8b-CHIME/BUZZER....................................................................................... 256
CHIME WARNING SYSTEM.............................................................................. 256
DESCRIPTION................................................................................... 256
OPERATION..................................................................................... 256
DIAGNOSIS AND TESTING - CHIME WARNING SYSTEM.................................................. 260
8e-ELECTRONIC CONTROL MODULES......................................................................... 262
ELECTRONIC CONTROL MODULES........................................................................ 262
STANDARD PROCEDURE - PCM/SKIM PROGRAMMING..................................................... 262
PROGRAMMING THE PCM (JTEC)................................................................ 262
PROGRAMMING THE SKIM...................................................................... 263
PROGRAMMING IGNITION KEYS TO THE SKIM..................................................... 263
BODY CONTROL MODULE............................................................................... 263
DESCRIPTION................................................................................... 263
OPERATION..................................................................................... 266
DIAGNOSIS AND TESTING - BODY CONTROL MODULE................................................... 268
REMOVAL....................................................................................... 268
INSTALLATION.................................................................................. 269
COMMUNICATION..................................................................................... 269
DESCRIPTION................................................................................... 269
OPERATION..................................................................................... 270
CONTROLLER ANTILOCK BRAKE......................................................................... 271
DESCRIPTION................................................................................... 271
OPERATION..................................................................................... 271
REMOVAL....................................................................................... 271
INSTALLATION.................................................................................. 271
DATA LINK CONNECTOR............................................................................... 272
DESCRIPTION - DATA LINK CONNECTOR............................................................. 272
OPERATION - DATA LINK CONNECTOR............................................................... 272
POWERTRAIN CONTROL MODULE......................................................................... 272
DESCRIPTION................................................................................... 272
DESCRIPTION - PCM......................................................................... 272
DESCRIPTION - MODES OF OPERATION.......................................................... 272
...................................................................................... 274
DESCRIPTION - 5 VOLT SUPPLIES............................................................. 275
DESCRIPTION - IGNITION CIRCUIT SENSE...................................................... 275
DESCRIPTION - POWER GROUNDS............................................................... 275
DESCRIPTION - SENSOR RETURN............................................................... 275
OPERATION..................................................................................... 275
OPERATION - PCM........................................................................... 275
OPERATION - 5 VOLT SUPPLIES............................................................... 276
OPERATION - IGNITION CIRCUIT SENSE........................................................ 276
REMOVAL....................................................................................... 276
INSTALLATION.................................................................................. 277
SENTRY KEY IMMOBILIZER MODULE..................................................................... 277
DESCRIPTION................................................................................... 277
OPERATION..................................................................................... 277
REMOVAL....................................................................................... 278
INSTALLATION.................................................................................. 279
TRANSMISSION CONTROL MODULE....................................................................... 279
DESCRIPTION................................................................................... 279
OPERATION..................................................................................... 280
BATTERY FEED.............................................................................. 280
CLUTCH VOLUME INDEXES (CVI)............................................................... 280
SHIFT SCHEDULES........................................................................... 281
STANDARD PROCEDURE............................................................................ 283
STANDARD PROCEDURE - TCM QUICK LEARN...................................................... 283
STANDARD PROCEDURE - DRIVE LEARN - RFE TRANSMISSIONS ONLY................................. 284
LEARN A SMOOTH 1ST NEUTRAL TO DRIVE SHIFT............................................. 284
LEARN A SMOOTH NEUTRAL TO DRIVE GARAGE SHIFT.......................................... 284
LEARN THE 1ST 2-3 SHIFT AFTER A RESTART OR SHIFT TO REVERSE........................... 284
LEARN A SMOOTH 2-3 AND 3-4 UPSHIFT.................................................... 284
LEARN A SMOOTH 4-3 COASTDOWN AND PART THROTTLE 4-3 KICKDOWN........................... 285
LEARN A SMOOTH 1-2 UPSHIFT AND 3-2 KICKDOWN........................................... 285
LEARN A SMOOTH MANUAL 2-1 PULLDOWN SHIFT AS WELL AS A NEUTRAL TO REVERSE SHIFT........ 285
LEARN A SMOOTH NEUTRAL TO REVERSE SHIFT............................................... 285
HEATED SEAT MODULE................................................................................ 285
DESCRIPTION................................................................................... 285
OPERATION..................................................................................... 286
DIAGNOSIS AND TESTING - HEATED SEAT MODULE.................................................... 286
RIGHT SEAT HEATER INOPERATIVE............................................................. 286
LEFT SEAT HEATER INOPERATIVE.............................................................. 287
BOTH SEATS INOPERATIVE.................................................................... 288
REMOVAL....................................................................................... 288
INSTALLATION.................................................................................. 288
8f-ENGINE SYSTEMS..................................................................................... 290
BATTERY SYSTEM.................................................................................... 290
BATTERY SYSTEM................................................................................ 290
DESCRIPTION............................................................................... 290
OPERATION................................................................................. 291
DIAGNOSIS AND TESTING - BATTERY SYSTEM.................................................... 291
MICRO 420 BATTERY TESTER.............................................................. 291
ABNORMAL BATTERY DISCHARGING.......................................................... 293
CLEANING.................................................................................. 294
INSPECTION................................................................................ 294
SPECIFICATIONS............................................................................ 295
BATTERY....................................................................................... 296
DESCRIPTION............................................................................... 296
OPERATION................................................................................. 296
DIAGNOSIS AND TESTING - BATTERY........................................................... 297
STANDARD PROCEDURE........................................................................ 298
STANDARD PROCEDURE - BATTERY CHARGING................................................. 298
CHARGING A COMPLETELY DISCHARGED BATTERY.......................................... 298
CHARGING TIME REQUIRED............................................................ 299
STANDARD PROCEDURE - BUILT-IN INDICATOR TEST.......................................... 299
STANDARD PROCEDURE - HYDROMETER TEST.................................................. 300
STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST........................................ 301
STANDARD PROCEDURE - IGNITION-OFF DRAW TEST........................................... 302
STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER................................... 303
BATTERY TESTING................................................................... 303
REMOVAL................................................................................... 304
INSTALLATION.............................................................................. 304
BATTERY HOLDDOWN.............................................................................. 305
DESCRIPTION............................................................................... 305
OPERATION................................................................................. 305
REMOVAL................................................................................... 305
INSTALLATION.............................................................................. 305
BATTERY CABLES................................................................................ 306
DESCRIPTION............................................................................... 306
OPERATION................................................................................. 306
DIAGNOSIS AND TESTING - BATTERY CABLES.................................................... 306
VOLTAGE DROP TEST..................................................................... 307
THERMAL GUARD................................................................................. 308
DESCRIPTION............................................................................... 308
OPERATION................................................................................. 308
REMOVAL................................................................................... 308
INSTALLATION.............................................................................. 309
BATTERY TRAY.................................................................................. 309
DESCRIPTION............................................................................... 309
OPERATION................................................................................. 309
REMOVAL................................................................................... 309
INSTALLATION.............................................................................. 309
CHARGING SYSTEM................................................................................... 310
CHARGING SYSTEM............................................................................... 310
DESCRIPTION............................................................................... 310
OPERATION................................................................................. 310
DIAGNOSIS AND TESTING - CHARGING SYSTEM................................................... 311
SPECIFICATIONS............................................................................ 311
TORQUE - EXCEPT DIESEL................................................................ 311
GENERATOR RATINGS - GAS ENGINES....................................................... 312
SPECIAL TOOLS............................................................................. 312
BATTERY TEMPERATURE SENSOR.................................................................... 312
DESCRIPTION............................................................................... 312
OPERATION................................................................................. 312
REMOVAL................................................................................... 312
INSTALLATION.............................................................................. 312
GENERATOR..................................................................................... 313
DESCRIPTION............................................................................... 313
OPERATION................................................................................. 313
REMOVAL................................................................................... 313
INSTALLATION.............................................................................. 313
GENERATOR DECOUPLER PULLEY.................................................................... 315
DESCRIPTION............................................................................... 315
OPERATION................................................................................. 315
DIAGNOSIS AND TESTING - GENERATOR DECOUPLER............................................... 315
REMOVAL................................................................................... 315
INSTALLATION.............................................................................. 317
VOLTAGE REGULATOR............................................................................. 319
DESCRIPTION............................................................................... 319
OPERATION................................................................................. 319
STARTING SYSTEM................................................................................... 320
STARTING SYSTEM............................................................................... 320
DESCRIPTION............................................................................... 320
OPERATION................................................................................. 320
DIAGNOSIS AND TESTING - STARTING SYSTEM................................................... 321
INSPECTION............................................................................ 322
TESTING............................................................................... 323
INSPECTION - STARTING SYSTEM.............................................................. 325
SPECIFICATIONS............................................................................ 326
TORQUE - GAS POWERED.................................................................. 326
STARTER MOTOR - GAS POWERED........................................................... 327
STARTER MOTOR................................................................................. 327
DIAGNOSIS AND TESTING - STARTER MOTOR..................................................... 327
REMOVAL................................................................................... 328
2.4L 4–Cylinder....................................................................... 328
3.7L V-6.............................................................................. 328
INSTALLATION.............................................................................. 329
2.4L 4–Cylinder....................................................................... 329
3.7L V-6.............................................................................. 329
STARTER MOTOR RELAY........................................................................... 329
DESCRIPTION............................................................................... 329
OPERATION................................................................................. 330
DIAGNOSIS AND TESTING - STARTER RELAY..................................................... 330
RELAY TEST............................................................................ 330
RELAY CIRCUIT TEST.................................................................... 330
REMOVAL................................................................................... 331
INSTALLATION.............................................................................. 331
8g-HEATED SYSTEMS..................................................................................... 332
HEATED MIRRORS.................................................................................... 332
HEATED MIRRORS................................................................................ 332
DESCRIPTION............................................................................... 332
OPERATION................................................................................. 332
DIAGNOSIS AND TESTING - HEATED MIRRORS.................................................... 332
WINDOW DEFOGGER................................................................................... 334
WINDOW DEFOGGER............................................................................... 334
DESCRIPTION - REAR WINDOW DEFOGGER........................................................ 334
OPERATION - REAR WINDOW DEFOGGER.......................................................... 334
DIAGNOSIS AND TESTING - REAR WINDOW DEFOGGER SYSTEM....................................... 334
STANDARD PROCEDURE - REAR GLASS HEATING GRID REPAIR....................................... 335
REAR WINDOW DEFOGGER GRID..................................................................... 336
DESCRIPTION............................................................................... 336
OPERATION................................................................................. 336
DIAGNOSIS AND TESTING - REAR WINDOW DEFOGGER GRID......................................... 336
REAR WINDOW DEFOGGER RELAY.................................................................... 337
DESCRIPTION............................................................................... 337
OPERATION................................................................................. 337
DIAGNOSIS AND TESTING - REAR WINDOW DEFOGGER RELAY........................................ 337
RELAY TEST............................................................................ 337
RELAY CIRCUIT TEST.................................................................... 338
REMOVAL................................................................................... 338
INSTALLATION.............................................................................. 338
REAR WINDOW DEFOGGER SWITCH................................................................... 339
DESCRIPTION............................................................................... 339
OPERATION................................................................................. 339
DIAGNOSIS AND TESTING..................................................................... 339
DIAGNOSIS AND TESTING - REAR WINDOW DEFOGGER SWITCH................................... 339
DIAGNOSIS AND TESTING - REAR HVAC CONTROL ASSEMBLY WINDOW DEFOGGER FUNCTION........... 340
REMOVAL................................................................................... 340
INSTALLATION.............................................................................. 340
HEATED SEAT SYSTEM................................................................................ 341
HEATED SEAT SYSTEM............................................................................ 341
DESCRIPTION............................................................................... 341
OPERATION................................................................................. 341
DIAGNOSIS AND TESTING - HEATED SEAT SYSTEM................................................ 342
HEATED SEAT SYSTEM SELF-DIAGNOSIS..................................................... 342
HEATED SEAT SYSTEM TESTING............................................................ 342
DRIVER HEATED SEAT SWITCH..................................................................... 343
DESCRIPTION............................................................................... 343
OPERATION................................................................................. 343
DIAGNOSIS AND TESTING - DRIVER HEATED SEAT SWITCH......................................... 343
REMOVAL................................................................................... 344
INSTALLATION.............................................................................. 344
PASSENGER HEATED SEAT SWITCH.................................................................. 344
DESCRIPTION............................................................................... 344
OPERATION................................................................................. 344
DIAGNOSIS AND TESTING - PASSENGER HEATED SEAT SWITCH...................................... 344
REMOVAL................................................................................... 345
INSTALLATION.............................................................................. 345
HEATED SEAT ELEMENT........................................................................... 345
DESCRIPTION............................................................................... 345
OPERATION................................................................................. 345
DIAGNOSIS AND TESTING - HEATED SEAT ELEMENT............................................... 346
SEAT CUSHION ELEMENT.................................................................. 346
SEAT BACK ELEMENT..................................................................... 346
HEATED SEAT SENSOR............................................................................ 346
DESCRIPTION............................................................................... 346
OPERATION................................................................................. 346
DIAGNOSIS AND TESTING - HEATED SEAT SENSOR................................................ 346
REMOVAL................................................................................... 347
8h-HORN............................................................................................... 348
HORN SYSTEM....................................................................................... 348
DESCRIPTION................................................................................... 348
OPERATION..................................................................................... 348
DIAGNOSIS AND TESTING - HORN SYSTEM........................................................... 348
HORN.............................................................................................. 349
DIAGNOSIS AND TESTING - HORN.................................................................. 349
REMOVAL....................................................................................... 350
INSTALLATION.................................................................................. 350
HORN RELAY........................................................................................ 350
DIAGNOSIS AND TESTING - HORN RELAY............................................................ 350
REMOVAL....................................................................................... 350
INSTALLATION.................................................................................. 351
HORN SWITCH....................................................................................... 351
DESCRIPTION................................................................................... 351
DIAGNOSIS AND TESTING - HORN SWITCH........................................................... 351
8i-IGNITION CONTROL................................................................................... 352
IGNITION CONTROL.................................................................................. 352
DESCRIPTION................................................................................... 352
OPERATION..................................................................................... 352
2.4L...................................................................................... 352
3.7L...................................................................................... 353
SPECIFICATIONS................................................................................ 353
SPECIFICATIONS - IGNITION TIMING.......................................................... 353
ENGINE FIRING ORDER - 2.4L 4-CYLINDER..................................................... 353
ENGINE FIRING ORDER - 3.7L V-6............................................................ 353
IGNITION COIL RESISTANCE - 2.4L........................................................... 353
IGNITION COIL RESISTANCE - 3.7L V-6....................................................... 353
SPARK PLUGS............................................................................... 354
SPARK PLUG CABLE RESISTANCE - 2.4L........................................................ 354
TORQUE - IGNITION SYSTEM.................................................................. 354
AUTO SHUT DOWN RELAY.............................................................................. 355
DESCRIPTION - PCM OUTPUT...................................................................... 355
OPERATION..................................................................................... 355
OPERATION - ASD SENSE - PCM INPUT......................................................... 355
OPERATION - PCM OUTPUT.................................................................... 355
DIAGNOSIS AND TESTING - ASD AND FUEL PUMP RELAYS.............................................. 355
REMOVAL....................................................................................... 356
INSTALLATION.................................................................................. 356
CAMSHAFT POSITION SENSOR.......................................................................... 356
DESCRIPTION................................................................................... 356
DESCRIPTION - 2.4L........................................................................ 356
DESCRIPTION-3.7L.......................................................................... 356
OPERATION..................................................................................... 356
OPERATION - 2.4L.......................................................................... 356
OPERATION - 3.7L.......................................................................... 357
REMOVAL....................................................................................... 357
2.4L...................................................................................... 357
3.7L...................................................................................... 358
INSTALLATION.................................................................................. 358
2.4L...................................................................................... 358
3.7L...................................................................................... 359
IGNITION COIL..................................................................................... 360
DESCRIPTION................................................................................... 360
2.4L...................................................................................... 360
3.7L...................................................................................... 360
OPERATION..................................................................................... 360
2.4L...................................................................................... 360
3.7L...................................................................................... 361
REMOVAL....................................................................................... 361
2.4L...................................................................................... 361
3.7L...................................................................................... 361
INSTALLATION.................................................................................. 362
2.4L...................................................................................... 362
3.7L...................................................................................... 362
KNOCK SENSOR...................................................................................... 362
DESCRIPTION................................................................................... 362
OPERATION..................................................................................... 362
REMOVAL....................................................................................... 362
INSTALLATION.................................................................................. 363
SPARK PLUG........................................................................................ 363
DESCRIPTION................................................................................... 363
OPERATION..................................................................................... 363
DIAGNOSIS AND TESTING - SPARK PLUG CONDITIONS................................................. 364
REMOVAL....................................................................................... 366
2.4L...................................................................................... 366
3.7L...................................................................................... 366
CLEANING...................................................................................... 366
CLEANING SPARK PLUGS...................................................................... 366
INSTALLATION.................................................................................. 366
2.4L...................................................................................... 366
3.7L...................................................................................... 366
IGNITION COIL CAPACITOR........................................................................... 367
DESCRIPTION................................................................................... 367
OPERATION..................................................................................... 367
REMOVAL....................................................................................... 367
INSTALLATION.................................................................................. 367
8j-INSTRUMENT CLUSTER................................................................................. 368
INSTRUMENT CLUSTER................................................................................ 369
DESCRIPTION................................................................................... 369
OPERATION..................................................................................... 372
INPUT AND OUTPUT CIRCUITS................................................................. 375
DIAGNOSIS AND TESTING - INSTRUMENT CLUSTER.................................................... 375
REMOVAL....................................................................................... 377
DISASSEMBLY................................................................................... 377
ASSEMBLY...................................................................................... 379
INSTALLATION.................................................................................. 379
ABS INDICATOR..................................................................................... 380
DESCRIPTION................................................................................... 380
OPERATION..................................................................................... 380
AIRBAG INDICATOR.................................................................................. 380
DESCRIPTION................................................................................... 380
OPERATION..................................................................................... 381
BRAKE/PARK BRAKE INDICATOR........................................................................ 381
DESCRIPTION................................................................................... 381
OPERATION..................................................................................... 381
DIAGNOSIS AND TESTING - BRAKE INDICATOR....................................................... 382
CHARGING INDICATOR................................................................................ 383
DESCRIPTION................................................................................... 383
OPERATION..................................................................................... 383
COOLANT LOW INDICATOR............................................................................. 384
DESCRIPTION................................................................................... 384
OPERATION..................................................................................... 384
CRUISE INDICATOR.................................................................................. 385
DESCRIPTION................................................................................... 385
OPERATION..................................................................................... 385
DOOR AJAR INDICATOR............................................................................... 385
DESCRIPTION................................................................................... 385
OPERATION..................................................................................... 386
ENGINE TEMPERATURE GAUGE.......................................................................... 386
DESCRIPTION................................................................................... 386
OPERATION..................................................................................... 386
FRONT FOG LAMP INDICATOR.......................................................................... 387
DESCRIPTION................................................................................... 387
OPERATION..................................................................................... 387
FUEL GAUGE........................................................................................ 388
DESCRIPTION................................................................................... 388
OPERATION..................................................................................... 388
GATE AJAR INDICATOR............................................................................... 389
DESCRIPTION................................................................................... 389
OPERATION..................................................................................... 389
GLASS AJAR INDICATOR.............................................................................. 389
DESCRIPTION................................................................................... 389
OPERATION..................................................................................... 390
HIGH BEAM INDICATOR............................................................................... 390
DESCRIPTION................................................................................... 390
OPERATION..................................................................................... 390
LIGHT BAR LAMP INDICATOR.......................................................................... 391
DESCRIPTION................................................................................... 391
OPERATION..................................................................................... 391
LOW FUEL INDICATOR................................................................................ 392
DESCRIPTION................................................................................... 392
OPERATION..................................................................................... 392
LOW OIL PRESSURE INDICATOR........................................................................ 393
DESCRIPTION................................................................................... 393
OPERATION..................................................................................... 393
MALFUNCTION INDICATOR LAMP (MIL).................................................................. 393
DESCRIPTION................................................................................... 393
OPERATION..................................................................................... 394
ODOMETER.......................................................................................... 394
DESCRIPTION................................................................................... 394
OPERATION..................................................................................... 395
OVERDRIVE OFF INDICATOR........................................................................... 395
DESCRIPTION................................................................................... 395
OPERATION..................................................................................... 396
REAR FOG LAMP INDICATOR........................................................................... 396
DESCRIPTION................................................................................... 396
OPERATION..................................................................................... 396
SEATBELT INDICATOR................................................................................ 397
DESCRIPTION................................................................................... 397
OPERATION..................................................................................... 397
SECURITY INDICATOR................................................................................ 398
DESCRIPTION................................................................................... 398
OPERATION..................................................................................... 398
SHIFT INDICATOR (TRANSFER CASE)................................................................... 398
DESCRIPTION................................................................................... 398
DESCRIPTION - PART TIME INDICATOR......................................................... 398
DESCRIPTION - FULL TIME INDICATOR......................................................... 398
DESCRIPTION - FOUR LOW MODE INDICATOR..................................................... 399
OPERATION..................................................................................... 399
OPERATION - PART TIME INDICATOR........................................................... 399
OPERATION - FULL TIME INDICATOR........................................................... 399
OPERATION - FOUR LOW MODE INDICATOR....................................................... 400
SKIS INDICATOR.................................................................................... 400
DESCRIPTION................................................................................... 400
OPERATION..................................................................................... 401
SPEEDOMETER....................................................................................... 401
DESCRIPTION................................................................................... 401
OPERATION..................................................................................... 402
TACHOMETER........................................................................................ 402
DESCRIPTION................................................................................... 402
OPERATION..................................................................................... 402
TRANS TEMP INDICATOR.............................................................................. 403
DESCRIPTION................................................................................... 403
OPERATION..................................................................................... 403
TURN SIGNAL INDICATOR............................................................................. 404
DESCRIPTION................................................................................... 404
OPERATION..................................................................................... 404
WAIT-TO-START INDICATOR........................................................................... 404
DESCRIPTION................................................................................... 404
OPERATION..................................................................................... 404
WASHER FLUID INDICATOR............................................................................ 405
DESCRIPTION................................................................................... 405
OPERATION..................................................................................... 405
DIAGNOSIS AND TESTING - WASHER FLUID INDICATOR................................................ 406
WATER-IN-FUEL INDICATOR........................................................................... 406
DESCRIPTION................................................................................... 406
OPERATION..................................................................................... 407
8l-LAMPS.............................................................................................. 408
LAMPS/LIGHTING - EXTERIOR......................................................................... 408
LAMPS/LIGHTING - EXTERIOR..................................................................... 409
DESCRIPTION............................................................................... 409
OPERATION................................................................................. 412
DIAGNOSIS AND TESTING - LAMPS/LIGHTING - EXTERIOR......................................... 414
SPECIFICATIONS - LAMPS/LIGHTING - EXTERIOR................................................ 421
BACKUP LAMP SWITCH............................................................................ 421
DESCRIPTION............................................................................... 421
OPERATION................................................................................. 422
DIAGNOSIS AND TESTING - BACKUP LAMP SWITCH................................................ 422
BRAKE LAMP SWITCH............................................................................. 422
DESCRIPTION............................................................................... 422
OPERATION................................................................................. 422
DIAGNOSIS AND TESTING - BRAKE LAMP SWITCH................................................. 423
REMOVAL................................................................................... 423
INSTALLATION.............................................................................. 424
CENTER HIGH MOUNTED STOP LAMP BULB............................................................ 424
REMOVAL................................................................................... 424
INSTALLATION.............................................................................. 425
CENTER HIGH MOUNTED STOP LAMP UNIT............................................................ 425
REMOVAL................................................................................... 425
INSTALLATION.............................................................................. 425
COMBINATION FLASHER........................................................................... 425
DESCRIPTION............................................................................... 425
OPERATION................................................................................. 425
DAYTIME RUNNING LAMP RELAY.................................................................... 426
DESCRIPTION............................................................................... 426
OPERATION................................................................................. 426
REMOVAL................................................................................... 426
INSTALLATION.............................................................................. 427
FRONT FOG LAMP BULB........................................................................... 427
REMOVAL................................................................................... 427
INSTALLATION.............................................................................. 427
FRONT FOG LAMP RELAY.......................................................................... 428
DESCRIPTION............................................................................... 428
OPERATION................................................................................. 428
DIAGNOSIS AND TESTING - FRONT FOG LAMP RELAY.............................................. 428
REMOVAL................................................................................... 429
INSTALLATION.............................................................................. 429
FRONT FOG LAMP UNIT........................................................................... 430
REMOVAL................................................................................... 430
INSTALLATION.............................................................................. 430
ADJUSTMENTS............................................................................... 431
ADJUSTMENT - FRONT FOG LAMP UNIT...................................................... 431
FRONT LAMP BULB............................................................................... 431
REMOVAL................................................................................... 431
INSTALLATION.............................................................................. 431
FRONT LAMP UNIT............................................................................... 431
REMOVAL................................................................................... 431
INSTALLATION.............................................................................. 433
FRONT POSITION LAMP BULB...................................................................... 433
REMOVAL................................................................................... 433
INSTALLATION.............................................................................. 433
HAZARD SWITCH................................................................................. 434
DESCRIPTION............................................................................... 434
OPERATION................................................................................. 434
REMOVAL................................................................................... 434
INSTALLATION.............................................................................. 435
HEADLAMP BULB................................................................................. 435
REMOVAL................................................................................... 435
INSTALLATION.............................................................................. 437
HEADLAMP HIGH BEAM RELAY...................................................................... 437
DESCRIPTION............................................................................... 437
OPERATION................................................................................. 438
DIAGNOSIS AND TESTING - HEADLAMP HIGH BEAM RELAY.......................................... 438
REMOVAL................................................................................... 439
INSTALLATION.............................................................................. 439
HEADLAMP LEVELING MOTOR....................................................................... 439
DESCRIPTION............................................................................... 439
OPERATION................................................................................. 440
REMOVAL................................................................................... 440
INSTALLATION.............................................................................. 440
HEADLAMP LEVELING SWITCH...................................................................... 441
DESCRIPTION............................................................................... 441
OPERATION................................................................................. 441
DIAGNOSIS AND TESTING - HEADLAMP LEVELING SWITCH.......................................... 442
REMOVAL................................................................................... 442
INSTALLATION.............................................................................. 443
HEADLAMP LOW BEAM RELAY....................................................................... 443
DESCRIPTION............................................................................... 443
OPERATION................................................................................. 443
DIAGNOSIS AND TESTING - HEADLAMP LOW BEAM RELAY........................................... 444
REMOVAL................................................................................... 444
INSTALLATION.............................................................................. 445
HEADLAMP UNIT................................................................................. 445
REMOVAL................................................................................... 445
INSTALLATION.............................................................................. 446
ADJUSTMENTS............................................................................... 446
ADJUSTMENT - HEADLAMP UNIT............................................................ 446
LAMP BAR...................................................................................... 448
DESCRIPTION............................................................................... 448
OPERATION................................................................................. 448
DIAGNOSIS AND TESTING - LAMP BAR.......................................................... 448
STANDARD PROCEDURE - LAMP BAR AIMING...................................................... 449
REMOVAL................................................................................... 449
REMOVAL - LAMP BAR.................................................................... 449
REMOVAL - LAMP........................................................................ 449
INSTALLATION.............................................................................. 449
INSTALLATION - LAMP BAR............................................................... 449
INSTALLATION - LAMP................................................................... 449
LAMP BAR SWITCH............................................................................... 450
DESCRIPTION............................................................................... 450
REMOVAL................................................................................... 450
INSTALLATION.............................................................................. 450
LICENSE PLATE LAMP BULB....................................................................... 450
REMOVAL................................................................................... 450
INSTALLATION.............................................................................. 451
LICENSE PLATE LAMP UNIT....................................................................... 452
REMOVAL................................................................................... 452
INSTALLATION.............................................................................. 452
MULTI-FUNCTION SWITCH......................................................................... 453
DESCRIPTION............................................................................... 453
OPERATION................................................................................. 454
DIAGNOSIS AND TESTING - MULTI-FUNCTION SWITCH............................................. 456
REMOVAL................................................................................... 458
INSTALLATION.............................................................................. 459
PARK LAMP RELAY............................................................................... 459
DESCRIPTION............................................................................... 459
OPERATION................................................................................. 460
DIAGNOSIS AND TESTING - PARK LAMP RELAY................................................... 460
REMOVAL................................................................................... 461
INSTALLATION.............................................................................. 461
REAR FOG LAMP RELAY........................................................................... 461
DESCRIPTION............................................................................... 461
OPERATION................................................................................. 462
DIAGNOSIS AND TESTING - REAR FOG LAMP RELAY............................................... 462
REMOVAL................................................................................... 463
INSTALLATION.............................................................................. 463
REAR LAMP BULB................................................................................ 464
REMOVAL0 - 4 KJ (Continued)........................................................... 464
INSTALLATION.............................................................................. 464
REAR LAMP UNIT................................................................................ 464
REMOVAL................................................................................... 464
INSTALLATION.............................................................................. 465
REPEATER LAMP BULB............................................................................ 465
REMOVAL................................................................................... 465
INSTALLATION.............................................................................. 465
REPEATER LAMP UNIT............................................................................ 465
REMOVAL................................................................................... 465
INSTALLATION.............................................................................. 465
TRAILER TOW CONNECTOR......................................................................... 466
REMOVAL................................................................................... 466
INSTALLATION.............................................................................. 466
TRAILER TOW RELAY............................................................................. 466
DESCRIPTION............................................................................... 466
OPERATION................................................................................. 467
DIAGNOSIS AND TESTING - TRAILER TOW RELAY................................................. 467
REMOVAL................................................................................... 467
INSTALLATION.............................................................................. 468
TRAILER TOW WIRING............................................................................ 469
DESCRIPTION............................................................................... 469
LAMPS/LIGHTING - INTERIOR......................................................................... 470
LAMPS/LIGHTING - INTERIOR..................................................................... 470
DESCRIPTION............................................................................... 470
OPERATION................................................................................. 472
DIAGNOSIS AND TESTING - LAMPS/LIGHTING - INTERIOR......................................... 473
SPECIFICATIONS - LAMPS/LIGHTING - INTERIOR................................................ 475
ASH RECEIVER LAMP BULB........................................................................ 475
REMOVAL................................................................................... 475
INSTALLATION.............................................................................. 476
ASH RECEIVER LAMP UNIT........................................................................ 476
REMOVAL................................................................................... 476
INSTALLATION.............................................................................. 477
CARGO LAMP BULB............................................................................... 477
REMOVAL................................................................................... 477
INSTALLATION.............................................................................. 477
CARGO LAMP SWITCH............................................................................. 478
REMOVAL................................................................................... 478
INSTALLATION.............................................................................. 478
CARGO LAMP UNIT............................................................................... 478
REMOVAL................................................................................... 478
INSTALLATION.............................................................................. 478
COMPASS MINI-TRIP ILLUMINATION BULB........................................................... 479
REMOVAL................................................................................... 479
INSTALLATION.............................................................................. 479
COURTESY LAMP BULB............................................................................ 480
REMOVAL................................................................................... 480
INSTALLATION.............................................................................. 480
COURTESY LAMP UNIT............................................................................ 481
REMOVAL................................................................................... 481
INSTALLATION.............................................................................. 481
DOOR AJAR SWITCH.............................................................................. 482
DESCRIPTION............................................................................... 482
OPERATION................................................................................. 482
FLIP-UP GLASS AJAR SWITCH..................................................................... 482
DESCRIPTION............................................................................... 482
OPERATION................................................................................. 482
HEATER-A/C CONTROL ILLUMINATION BULB.......................................................... 482
REMOVAL................................................................................... 482
INSTALLATION.............................................................................. 483
READING LAMP BULB............................................................................. 483
REMOVAL................................................................................... 483
INSTALLATION.............................................................................. 484
READING LAMP SWITCH........................................................................... 484
REMOVAL................................................................................... 484
INSTALLATION.............................................................................. 485
READING LAMP UNIT............................................................................. 485
REMOVAL................................................................................... 485
INSTALLATION.............................................................................. 486
TAILGATE AJAR SWITCH.......................................................................... 486
DESCRIPTION............................................................................... 486
OPERATION................................................................................. 486
TRANSMISSION RANGE INDICATOR ILLUMINATION BULB................................................ 487
REMOVAL................................................................................... 487
INSTALLATION.............................................................................. 487
VANITY LAMP BULB.............................................................................. 488
REMOVAL................................................................................... 488
INSTALLATION.............................................................................. 488
8m-MESSAGE SYSTEMS.................................................................................... 490
OVERHEAD CONSOLE.................................................................................. 490
DESCRIPTION................................................................................... 490
OPERATION..................................................................................... 490
STANDARD PROCEDURE............................................................................ 490
STANDARD PROCEDURE - MODULE LENS REPLACEMENT.............................................. 490
STANDARD PROCEDURE - MODULE LAMP REPLACEMENT.............................................. 491
STANDARD PROCEDURE - COURTESY LAMP REPLACEMENT............................................ 491
STANDARD PROCEDURE - COMPASS CALIBRATION.................................................. 491
STANDARD PROCEDURE - COMPASS DEMAGNETIZING................................................ 492
STANDARD PROCEDURE - COMPASS VARIATION ADJUSTMENT......................................... 493
STANDARD PROCEDURE - ELECTRONIC VEHICLE INFORMATION CENTER PROGRAMMING.................... 493
EVIC PROGRAMMING MODE................................................................. 493
PROGRAMMABLE FEATURES................................................................. 493
REMOVAL....................................................................................... 495
OVERHEAD CONSOLE - REMOVAL................................................................ 495
INSTALLATION.................................................................................. 495
COMPASS MINI/TRIP COMPUTER........................................................................ 495
DESCRIPTION................................................................................... 495
DESCRIPTION - COMPASS..................................................................... 496
DESCRIPTION - THERMOMETER................................................................. 496
OPERATION..................................................................................... 496
DIAGNOSIS AND TESTING - COMPASS MINI-TRIP COMPUTER............................................ 497
TEMPERATURE............................................................................... 497
TRIP ODOMETER............................................................................. 497
COMPASS DISPLAY........................................................................... 497
COMPASS MINI-TRIP COMPUTER - SELF DIAGNOSTIC TEST......................................... 497
REMOVAL....................................................................................... 498
INSTALLATION.................................................................................. 498
ELECTRONIC VEHICLE INFO CENTER.................................................................... 498
DESCRIPTION - ELECTRONIC VEHICLE INFORMATION CENTER (EVIC).................................... 498
DESCRIPTION - COMPASS..................................................................... 499
DESCRIPTION - TEMPERATURE................................................................. 499
OPERATION..................................................................................... 499
DIAGNOSIS AND TESTING - ELECTRONIC VEHICLE INFORMATION CENTER................................. 500
SELF-DIAGNOSTIC TEST...................................................................... 500
REMOVAL....................................................................................... 501
INSTALLATION.................................................................................. 501
UNIVERSAL TRANSMITTER............................................................................. 501
DESCRIPTION................................................................................... 501
OPERATION..................................................................................... 502
DIAGNOSIS AND TESTING - UNIVERSAL TRANSMITTER................................................. 502
STANDARD PROCEDURE............................................................................ 502
STANDARD PROCEDURE - ERASING TRANSMITTER CODES............................................ 502
STANDARD PROCEDURE - SETTING TRANSMITTER CODES............................................ 502
AMBIENT TEMP SENSOR............................................................................... 503
DESCRIPTION................................................................................... 503
OPERATION..................................................................................... 503
DIAGNOSIS AND TESTING......................................................................... 503
DIAGNOSIS AND TESTING - AMBIENT TEMPERATURE SENSOR........................................ 503
DIAGNOSIS AND TESTING - AMBIENT TEMPERATURE SENSOR CIRCUIT................................ 503
REMOVAL....................................................................................... 504
INSTALLATION.................................................................................. 504
8n-POWER SYSTEMS...................................................................................... 506
POWER LOCKS....................................................................................... 506
POWER LOCKS................................................................................... 506
DESCRIPTION............................................................................... 506
POWER LOCKS........................................................................... 506
REMOTE KEYLESS ENTRY.................................................................. 507
TAILGATE / FLIP-UP GLASS POWER RELEASE SYSTEM......................................... 507
COMBINATION FLASHER................................................................... 508
HORN RELAY............................................................................ 508
LOW BEAM HEADLAMP RELAY............................................................... 508
OPERATION................................................................................. 508
POWER LOCKS........................................................................... 508
AUTOMATIC DOOR LOCKS.................................................................. 508
DOOR LOCK INHIBIT..................................................................... 508
DOOR LOCK CIRCUIT PROTECTION.......................................................... 508
REMOTE KEYLESS ENTRY.................................................................. 508
DIAGNOSIS AND TESTING - POWER LOCKS....................................................... 509
PRELIMINARY DIAGNOSIS................................................................. 509
DOOR LOCK / UNLOCK SWITCH..................................................................... 509
DIAGNOSIS AND TESTING - DOOR LOCK/UNLOCK SWITCH........................................... 509
REMOVAL................................................................................... 510
INSTALLATION.............................................................................. 510
DOOR LOCK MOTOR............................................................................... 510
DESCRIPTION............................................................................... 510
OPERATION................................................................................. 510
DIAGNOSIS AND TESTING - DOOR LOCK MOTOR................................................... 510
FLIP-UP GLASS RELEASE SWITCH.................................................................. 511
DIAGNOSIS AND TESTING - FLIP-UP GLASS RELEASE SWITCH...................................... 511
DOOR LOCK RELAY............................................................................... 511
DESCRIPTION............................................................................... 511
OPERATION................................................................................. 511
DIAGNOSIS AND TESTING - DOOR LOCK RELAY................................................... 511
REMOVAL................................................................................... 512
INSTALLATION.............................................................................. 512
REMOTE KEYLESS ENTRY MODULE................................................................... 512
DESCRIPTION............................................................................... 512
OPERATION................................................................................. 512
DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY MODULE....................................... 512
REMOVAL................................................................................... 512
INSTALLATION.............................................................................. 512
REMOTE KEYLESS ENTRY TRANSMITTER.............................................................. 513
DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY TRANSMITTER.................................. 513
STANDARD PROCEDURE........................................................................ 513
STANDARD PROCEDURE - RKE TRANSMITTER CUSTOMER PREFERENCES............................. 513
AUTOMATIC (ROLLING) LOCKS......................................................... 513
HORN CHIRP DISABLING / ENABLING................................................... 513
OPTICAL CHIRP (FLASH) DISABLING / ENABLING........................................ 513
TAIL GATE RELEASE DELAY........................................................... 513
UNLOCK SEQUENCE................................................................... 514
STANDARD PROCEDURE - RKE TRANSMITTER PROGRAMING....................................... 514
STANDARD PROCEDURE - RKE TRANSMITTER BATTERIES........................................ 514
SPECIFICATIONS - REMOTE KEYLESS ENTRY TRANSMITTER......................................... 514
RANGE................................................................................. 514
TAILGATE CYLINDER LOCK SWITCH................................................................. 514
DESCRIPTION............................................................................... 514
OPERATION................................................................................. 514
DIAGNOSIS AND TESTING - TAILGATE CYLINDER LOCK SWITCH..................................... 515
REMOVAL................................................................................... 515
INSTALLATION.............................................................................. 515
POWER MIRRORS..................................................................................... 516
POWER MIRRORS................................................................................. 516
DESCRIPTION............................................................................... 516
OPERATION................................................................................. 516
DIAGNOSIS AND TESTING - POWER MIRRORS..................................................... 516
WIRING VOLTAGE TEST................................................................... 516
POWER MIRROR MOTOR TEST............................................................... 517
AUTOMATIC DAY / NIGHT MIRROR.................................................................. 517
DESCRIPTION............................................................................... 517
DESCRIPTION - REAR VIEW MIRROR........................................................ 517
DESCRIPTION - OUTSIDE REAR VIEW MIRROR................................................ 517
OPERATION................................................................................. 518
OPERATION - REAR VIEW MIRROR.......................................................... 518
OPERATION - OUTSIDE REAR VIEW MIRROR.................................................. 518
DIAGNOSIS AND TESTING - AUTOMATIC DAY / NIGHT MIRROR...................................... 518
POWER FOLDAWAY MIRROR SWITCH - EXPORT......................................................... 519
DESCRIPTION............................................................................... 519
OPERATION................................................................................. 519
DIAGNOSIS AND TESTING - POWER FOLDAWAY MIRROR SWITCH - EXPORT............................. 519
REMOVAL................................................................................... 520
POWER MIRROR SWITCH........................................................................... 520
DIAGNOSIS AND TESTING - POWER MIRROR SWITCH............................................... 520
REMOVAL................................................................................... 521
INSTALLATION.............................................................................. 521
SIDEVIEW MIRROR............................................................................... 521
REMOVAL................................................................................... 521
POWER SEATS....................................................................................... 522
POWER SEATS................................................................................... 522
DESCRIPTION............................................................................... 522
OPERATION................................................................................. 523
DIAGNOSIS AND TESTING - POWER SEATS....................................................... 523
LEFT POWER SEAT SWITCH........................................................................ 523
DESCRIPTION............................................................................... 523
OPERATION................................................................................. 524
DIAGNOSIS AND TESTING - LEFT POWER SEAT SWITCH............................................ 524
REMOVAL................................................................................... 525
INSTALLATION.............................................................................. 525
RIGHT POWER SEAT SWITCH....................................................................... 525
DESCRIPTION............................................................................... 525
OPERATION................................................................................. 525
DIAGNOSIS AND TESTING - RIGHT POWER SEAT SWITCH........................................... 526
REMOVAL................................................................................... 527
INSTALLATION.............................................................................. 527
POWER SEAT TRACK.............................................................................. 527
DESCRIPTION............................................................................... 527
OPERATION................................................................................. 528
DIAGNOSIS AND TESTING - POWER SEAT TRACK.................................................. 528
REMOVAL................................................................................... 528
INSTALLATION.............................................................................. 528
POWER WINDOWS..................................................................................... 529
POWER WINDOWS................................................................................. 529
DESCRIPTION............................................................................... 529
OPERATION................................................................................. 529
WINDOW SWITCH......................................................................... 529
WINDOW MOTOR.......................................................................... 529
DIAGNOSIS AND TESTING - POWER WINDOWS..................................................... 529
WIRING VOLTAGE TEST................................................................... 529
POWER WINDOW MOTOR TEST............................................................... 529
WINDOW MOTOR.................................................................................. 530
REMOVAL................................................................................... 530
WINDOW SWITCH................................................................................. 530
DIAGNOSIS AND TESTING - WINDOW SWITCH..................................................... 530
REMOVAL................................................................................... 531
FRONT................................................................................. 531
REAR.................................................................................. 531
INSTALLATION.............................................................................. 531
FRONT................................................................................. 531
REAR.................................................................................. 531
8o-RESTRAINTS......................................................................................... 556
RESTRAINTS........................................................................................ 557
DESCRIPTION................................................................................... 557
ACTIVE RESTRAINTS......................................................................... 558
PASSIVE RESTRAINTS........................................................................ 558
OPERATION..................................................................................... 559
ACTIVE RESTRAINTS......................................................................... 559
PASSIVE RESTRAINTS........................................................................ 559
WARNING....................................................................................... 560
WARNINGS - RESTRAINT SYSTEM............................................................... 560
DIAGNOSIS AND TESTING - SUPPLEMENTAL RESTRAINT SYSTEM......................................... 561
STANDARD PROCEDURE............................................................................ 561
STANDARD PROCEDURE - HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS........................ 561
SUPPLEMENTAL RESTRAINT STORAGE........................................................ 561
STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT.................... 562
AIRBAG SQUIB STATUS................................................................... 562
CLEANUP PROCEDURE..................................................................... 563
STANDARD PROCEDURE - VERIFICATION TEST.................................................... 564
AIRBAG CONTROL MODULE............................................................................. 565
DESCRIPTION................................................................................... 565
OPERATION..................................................................................... 565
REMOVAL....................................................................................... 567
INSTALLATION.................................................................................. 568
CHILD RESTRAINT ANCHOR............................................................................ 568
DESCRIPTION................................................................................... 568
OPERATION..................................................................................... 570
CLOCKSPRING....................................................................................... 570
DESCRIPTION................................................................................... 570
OPERATION..................................................................................... 571
STANDARD PROCEDURE - CLOCKSPRING CENTERING.................................................... 572
REMOVAL....................................................................................... 572
INSTALLATION.................................................................................. 573
DRIVER AIRBAG..................................................................................... 574
DESCRIPTION................................................................................... 574
OPERATION..................................................................................... 575
REMOVAL....................................................................................... 576
INSTALLATION.................................................................................. 576
FRONT IMPACT SENSOR............................................................................... 578
DESCRIPTION................................................................................... 578
OPERATION..................................................................................... 578
REMOVAL....................................................................................... 579
INSTALLATION.................................................................................. 579
FRONT SEAT BELT & RETRACTOR....................................................................... 580
REMOVAL....................................................................................... 580
INSTALLATION.................................................................................. 581
FRONT SEAT BELT BUCKLE............................................................................ 582
REMOVAL....................................................................................... 582
INSTALLATION.................................................................................. 584
PASSENGER AIRBAG.................................................................................. 584
DESCRIPTION................................................................................... 584
OPERATION..................................................................................... 585
REMOVAL....................................................................................... 586
INSTALLATION.................................................................................. 586
PASSENGER AIRBAG DOOR............................................................................. 587
REMOVAL....................................................................................... 587
INSTALLATION.................................................................................. 588
PASSENGER AIRBAG MOUNTING BRACKET................................................................. 589
REMOVAL....................................................................................... 589
INSTALLATION.................................................................................. 589
REAR CENTER SEAT BELT & RETRACTOR................................................................. 590
REMOVAL....................................................................................... 590
INSTALLATION.................................................................................. 591
REAR OUTBOARD SEAT BELT & RETRACTOR............................................................... 591
REMOVAL....................................................................................... 591
INSTALLATION.................................................................................. 592
REAR SEAT BELT BUCKLE............................................................................. 593
REMOVAL....................................................................................... 593
INSTALLATION.................................................................................. 593
SEAT BELT SWITCH.................................................................................. 593
DESCRIPTION................................................................................... 593
OPERATION..................................................................................... 594
SEAT BELT TENSIONER............................................................................... 594
DESCRIPTION................................................................................... 594
OPERATION..................................................................................... 595
SEAT BELT TURNING LOOP ADJUSTER................................................................... 595
REMOVAL....................................................................................... 595
INSTALLATION.................................................................................. 596
SIDE CURTAIN AIRBAG............................................................................... 597
DESCRIPTION................................................................................... 597
OPERATION..................................................................................... 597
REMOVAL....................................................................................... 597
INSTALLATION.................................................................................. 600
SIDE IMPACT AIRBAG CONTROL MODULE................................................................. 601
DESCRIPTION................................................................................... 601
OPERATION..................................................................................... 601
REMOVAL....................................................................................... 602
INSTALLATION.................................................................................. 603
8p-SPEED CONTROL...................................................................................... 604
SPEED CONTROL..................................................................................... 604
DESCRIPTION................................................................................... 604
OPERATION..................................................................................... 604
DIAGNOSIS AND TESTING - ROAD TEST............................................................. 605
SPECIFICATIONS................................................................................ 605
TORQUE - SPEED CONTROL.................................................................... 605
CABLE............................................................................................. 606
DESCRIPTION................................................................................... 606
OPERATION..................................................................................... 606
REMOVAL - 3.7L................................................................................ 606
INSTALLATION - 3.7L........................................................................... 607
SERVO............................................................................................. 607
DESCRIPTION................................................................................... 607
OPERATION..................................................................................... 607
REMOVAL....................................................................................... 608
INSTALLATION.................................................................................. 608
SWITCH............................................................................................ 608
DESCRIPTION................................................................................... 608
OPERATION..................................................................................... 608
Multiplexing.............................................................................. 609
REMOVAL....................................................................................... 609
INSTALLATION.................................................................................. 609
VACUUM RESERVOIR.................................................................................. 610
DESCRIPTION................................................................................... 610
OPERATION..................................................................................... 610
DIAGNOSIS AND TESTING - VACUUM RESERVOIR...................................................... 610
REMOVAL....................................................................................... 610
INSTALLATION.................................................................................. 611
8q-VEHICLE THEFT SECURITY............................................................................. 612
VEHICLE THEFT SECURITY............................................................................ 612
DESCRIPTION................................................................................... 612
OPERATION..................................................................................... 614
DIAGNOSIS AND TESTING - VEHICLE THEFT SECURITY SYSTEM......................................... 616
VEHICLE THEFT ALARM....................................................................... 617
SENTRY KEY IMMOBILIZER SYSTEM............................................................. 617
STANDARD PROCEDURE............................................................................ 618
STANDARD PROCEDURE - SKIS INITIALIZATION.................................................. 618
STANDARD PROCEDURE - SENTRY KEY TRANSPONDER PROGRAMMING................................... 619
DOOR CYLINDER LOCK SWITCH......................................................................... 620
DESCRIPTION................................................................................... 620
OPERATION..................................................................................... 620
DIAGNOSIS AND TESTING - DOOR CYLINDER LOCK SWITCH............................................. 620
REMOVAL....................................................................................... 620
INSTALLATION.................................................................................. 621
HOOD AJAR SWITCH.................................................................................. 621
DESCRIPTION................................................................................... 621
OPERATION..................................................................................... 621
DIAGNOSIS AND TESTING - HOOD AJAR SWITCH...................................................... 622
REMOVAL....................................................................................... 622
INSTALLATION.................................................................................. 622
HOOD AJAR SWITCH BRACKET.......................................................................... 622
REMOVAL....................................................................................... 622
INSTALLATION.................................................................................. 623
HOOD AJAR SWITCH STRIKER.......................................................................... 623
REMOVAL....................................................................................... 623
INSTALLATION.................................................................................. 623
INTRUSION TRANSCEIVER MODULE...................................................................... 624
DESCRIPTION................................................................................... 624
OPERATION..................................................................................... 624
REMOVAL....................................................................................... 625
INSTALLATION.................................................................................. 626
SIREN............................................................................................. 626
DESCRIPTION................................................................................... 626
OPERATION..................................................................................... 626
REMOVAL....................................................................................... 627
INSTALLATION.................................................................................. 627
TRANSPONDER KEY................................................................................... 628
DESCRIPTION................................................................................... 628
OPERATION..................................................................................... 628
8r-WIPERS/WASHERS..................................................................................... 630
FRONT WIPERS/WASHERS.............................................................................. 630
FRONT WIPERS/WASHERS.......................................................................... 631
DESCRIPTION............................................................................... 631
OPERATING MODES....................................................................... 632
OPERATION................................................................................. 633
OPERATING MODES....................................................................... 633
DIAGNOSIS AND TESTING - FRONT WIPER & WASHER SYSTEM....................................... 635
WIPER SYSTEM.......................................................................... 635
WASHER SYSTEM......................................................................... 635
CLEANING - FRONT WIPER & WASHER SYSTEM.................................................... 636
WIPER SYSTEM.......................................................................... 636
WASHER SYSTEM......................................................................... 636
INSPECTION - FRONT WIPER & WASHER SYSTEM.................................................. 636
WIPER SYSTEM.......................................................................... 636
WASHER SYSTEM......................................................................... 637
FRONT CHECK VALVE............................................................................. 637
DESCRIPTION............................................................................... 637
OPERATION................................................................................. 638
REMOVAL................................................................................... 638
INSTALLATION.............................................................................. 639
FRONT WASHER HOSES/TUBES...................................................................... 639
DESCRIPTION............................................................................... 639
OPERATION................................................................................. 640
FRONT WASHER NOZZLE........................................................................... 640
DESCRIPTION............................................................................... 640
OPERATION................................................................................. 640
REMOVAL................................................................................... 640
INSTALLATION.............................................................................. 640
FRONT WIPER ARM............................................................................... 641
DESCRIPTION............................................................................... 641
OPERATION................................................................................. 641
REMOVAL................................................................................... 641
INSTALLATION.............................................................................. 642
FRONT WIPER BLADE............................................................................. 642
DESCRIPTION............................................................................... 642
OPERATION................................................................................. 643
REMOVAL................................................................................... 643
INSTALLATION.............................................................................. 643
FRONT WIPER MODULE............................................................................ 644
DESCRIPTION............................................................................... 644
OPERATION................................................................................. 644
REMOVAL................................................................................... 645
INSTALLATION.............................................................................. 645
FRONT WIPER/WASHER SWITCH..................................................................... 645
DESCRIPTION............................................................................... 645
OPERATION................................................................................. 645
WASHER FLUID LEVEL SWITCH..................................................................... 646
DESCRIPTION............................................................................... 646
OPERATION................................................................................. 646
REMOVAL................................................................................... 646
INSTALLATION.............................................................................. 647
WASHER PUMP/MOTOR............................................................................. 647
DESCRIPTION............................................................................... 647
OPERATION................................................................................. 648
REMOVAL................................................................................... 648
INSTALLATION.............................................................................. 649
WASHER RESERVOIR.............................................................................. 650
DESCRIPTION............................................................................... 650
OPERATION................................................................................. 650
REMOVAL................................................................................... 650
INSTALLATION.............................................................................. 651
WIPER HIGH/LOW RELAY.......................................................................... 652
DESCRIPTION............................................................................... 652
OPERATION................................................................................. 652
DIAGNOSIS AND TESTING - WIPER HIGH/LOW RELAY.............................................. 653
REMOVAL................................................................................... 653
INSTALLATION.............................................................................. 654
WIPER ON/OFF RELAY............................................................................ 654
DESCRIPTION............................................................................... 654
OPERATION................................................................................. 654
DIAGNOSIS AND TESTING - WIPER ON/OFF RELAY................................................ 655
REMOVAL................................................................................... 655
INSTALLATION.............................................................................. 655
REAR WIPERS/WASHERS............................................................................... 656
REAR WIPERS/WASHERS........................................................................... 656
DESCRIPTION............................................................................... 656
OPERATING MODES....................................................................... 658
OPERATION................................................................................. 658
OPERATING MODES....................................................................... 659
DIAGNOSIS AND TESTING - REAR WIPER & WASHER SYSTEM........................................ 659
WIPER SYSTEM.......................................................................... 659
WASHER SYSTEM......................................................................... 661
CLEANING - REAR WIPER & WASHER SYSTEM..................................................... 661
WIPER SYSTEM.......................................................................... 661
WASHER SYSTEM......................................................................... 661
INSPECTION - REAR WIPER & WASHER SYSTEM................................................... 662
WIPER SYSTEM.......................................................................... 662
WASHER SYSTEM......................................................................... 662
REAR WASHER HOSES/TUBES....................................................................... 663
DESCRIPTION............................................................................... 663
OPERATION................................................................................. 663
REAR WASHER NOZZLE............................................................................ 664
DESCRIPTION............................................................................... 664
OPERATION................................................................................. 664
REMOVAL................................................................................... 664
INSTALLATION.............................................................................. 664
REAR WIPER ARM................................................................................ 665
DESCRIPTION............................................................................... 665
OPERATION................................................................................. 665
REMOVAL................................................................................... 665
INSTALLATION.............................................................................. 666
REAR WIPER BLADE.............................................................................. 667
DESCRIPTION............................................................................... 667
OPERATION................................................................................. 667
REMOVAL................................................................................... 667
INSTALLATION.............................................................................. 668
REAR WIPER MOTOR.............................................................................. 668
DESCRIPTION............................................................................... 668
OPERATION................................................................................. 669
REMOVAL................................................................................... 669
INSTALLATION.............................................................................. 670
REAR WIPER/WASHER SWITCH...................................................................... 670
DESCRIPTION............................................................................... 670
OPERATION................................................................................. 670
WIPER ARM PARK RAMP........................................................................... 671
REMOVAL................................................................................... 671
INSTALLATION.............................................................................. 671
8w-WIRING............................................................................................. 672
8W-01 WIRING DIAGRAM INFORMATION.................................................................. 674
WIRING DIAGRAM INFORMATION.................................................................... 674
DESCRIPTION............................................................................... 674
DESCRIPTION - HOW TO USE WIRING DIAGRAMS.............................................. 674
SYMBOLS........................................................................... 674
TERMINOLOGY....................................................................... 678
DESCRIPTION - CIRCUIT INFORMATION..................................................... 678
DESCRIPTION - CIRCUIT FUNCTIONS....................................................... 679
DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION.................................. 679
DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION................................ 680
IDENTIFICATION.................................................................... 680
LOCATIONS......................................................................... 680
WARNING................................................................................... 680
WARNINGS - GENERAL.................................................................... 680
DIAGNOSIS AND TESTING - WIRING HARNESS.................................................... 680
TROUBLESHOOTING TOOLS................................................................. 680
INTERMITTENT AND POOR CONNECTIONS..................................................... 681
TROUBLESHOOTING WIRING PROBLEMS....................................................... 681
STANDARD PROCEDURE........................................................................ 681
STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES.................. 681
STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL..................................... 682
STANDARD PROCEDURE - TESTING FOR CONTINUITY........................................... 682
STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND.................................... 682
STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS.... 683
STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP....................................... 683
SPECIAL TOOLS............................................................................. 683
WIRING/TERMINAL....................................................................... 683
CONNECTOR..................................................................................... 684
REMOVAL................................................................................... 684
INSTALLATION.............................................................................. 684
DIODE......................................................................................... 687
REMOVAL................................................................................... 687
INSTALLATION.............................................................................. 687
TERMINAL...................................................................................... 687
REMOVAL................................................................................... 687
INSTALLATION.............................................................................. 687
WIRE.......................................................................................... 688
STANDARD PROCEDURE - WIRE SPLICING........................................................ 688
8W-02 COMPONENT INDEX............................................................................. 690
8W-10 POWER DISTRIBUTION.......................................................................... 692
8W-12 JUNCTION BLOCK.............................................................................. 722
8W-15 GROUND DISTRIBUTION......................................................................... 756
8W-18 BUS COMMUNICATIONS.......................................................................... 776
8W-20 CHARGING SYSTEM............................................................................. 782
8W-21 STARTING SYSTEM............................................................................. 786
8W-30 FUEL/IGNITION SYSTEM........................................................................ 794
8W-31 TRANSMISSION CONTROL SYSTEM................................................................. 832
8W-33 VEHICLE SPEED CONTROL....................................................................... 848
8W-35 ANTILOCK BRAKES............................................................................. 854
8W-39 VEHICLE THEFT SECURITY SYSTEM............................................................... 858
8W-40 INSTRUMENT CLUSTER.......................................................................... 870
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET............................................................. 878
8W-42 AIR CONDITIONING-HEATER..................................................................... 882
8W-43 AIRBAG SYSTEM............................................................................... 890
8W-44 INTERIOR LIGHTING........................................................................... 894
8W-45 BODY CONTROL MODULE......................................................................... 898
8W-47 AUDIO SYSTEM................................................................................ 910
8W-48 REAR WINDOW DEFOGGER........................................................................ 920
8W-49 OVERHEAD CONSOLE............................................................................ 922
8W-50 FRONT LIGHTING.............................................................................. 928
8W-51 REAR LIGHTING............................................................................... 946
8W-52 TURN SIGNALS................................................................................ 952
8W-53 WIPERS...................................................................................... 960
8W-54 TRAILER TOW................................................................................. 966
8W-60 POWER WINDOWS............................................................................... 972
8W-61 POWER DOOR LOCKS............................................................................ 976
8W-62 POWER MIRRORS............................................................................... 984
8W-63 POWER SEAT.................................................................................. 990
8W-64 POWER SUNROOF............................................................................... 996
8W-70 SPLICE INFORMATION.......................................................................... 998
8W-80 CONNECTOR PIN-OUTS..........................................................................1006
8W-91 CONNECTOR/GROUND/SPLICE LOCATION............................................................1112
CONNECTOR/GROUND/SPLICE LOCATION..............................................................1112
DESCRIPTION...............................................................................1112
8W-97 POWER DISTRIBUTION..........................................................................1174
POWER DISTRIBUTION............................................................................1174
DESCRIPTION...............................................................................1174
OPERATION.................................................................................1174
SPECIAL TOOLS.............................................................................1175
POWER DISTRIBUTION SYSTEMS............................................................1175
CIGAR LIGHTER OUTLET..........................................................................1175
DESCRIPTION...............................................................................1175
OPERATION.................................................................................1175
DIAGNOSIS AND TESTING - CIGAR LIGHTER OUTLET..............................................1175
IOD FUSE......................................................................................1176
DESCRIPTION...............................................................................1176
CIRCUITS INCLUDED WITH IOD FUSE.......................................................1176
OPERATION.................................................................................1176
REMOVAL...................................................................................1176
INSTALLATION..............................................................................1176
JUNCTION BLOCK................................................................................1177
DESCRIPTION...............................................................................1177
OPERATION.................................................................................1177
DIAGNOSIS AND TESTING - JUNCTION BLOCK....................................................1177
REMOVAL...................................................................................1178
REMOVAL - LHD.........................................................................1178
REMOVAL - RHD.........................................................................1178
INSTALLATION..............................................................................1179
INSTALLATION - LHD....................................................................1179
INSTALLATION - RHD....................................................................1179
POWER DISTRIBUTION CENTER.....................................................................1179
DESCRIPTION...............................................................................1179
OPERATION.................................................................................1179
REMOVAL...................................................................................1180
DISASSEMBLY...............................................................................1180
POWER DISTRIBUTION CENTER DISASSEMBLY.................................................1180
PDC HOUSING LOWER COVER...........................................................1180
PDC B+ TERMINAL MODULE............................................................1181
PDC RELAY WEDGE...................................................................1181
PDC RELAY CASSETTE................................................................1181
ASSEMBLY..................................................................................1182
POWER DISTRIBUTION CENTER ASSEMBLY....................................................1182
PDC B(+) TERMINAL MODULE..........................................................1182
RELAY WEDGE.......................................................................1182
RELAY CASSETTE....................................................................1183
PDC LOWER COVER...................................................................1183
INSTALLATION..............................................................................1183
POWER OUTLET..................................................................................1184
DESCRIPTION...............................................................................1184
OPERATION.................................................................................1184
DIAGNOSIS AND TESTING - POWER OUTLET......................................................1184
REMOVAL...................................................................................1184
INSTALLATION..............................................................................1185
RELAY.........................................................................................1185
DESCRIPTION...............................................................................1185
OPERATION.................................................................................1186
DIAGNOSIS AND TESTING - RELAY.............................................................1186
DIAGNOSIS & TESTING - RELAY CIRCUIT TEST..............................................1186
REMOVAL...................................................................................1186
INSTALLATION..............................................................................1186
MICRO-RELAY...................................................................................1186
DESCRIPTION...............................................................................1186
OPERATION.................................................................................1187
DIAGNOSIS AND TESTING - MICRO-RELAY.......................................................1187
REMOVAL...................................................................................1187
INSTALLATION..............................................................................1187
9-ENGINE..............................................................................................1188
ENGINE - 2.4L.....................................................................................1188
ENGINE - 2.4L.................................................................................1190
DESCRIPTION...............................................................................1190
DIAGNOSIS AND TESTING.....................................................................1190
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST.....................1190
DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST............................1191
DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION0 - 6 KJ (Continued)............1191
INSPECTION FOR REAR SEAL AREA LEAKS...............................................1192
DIAGNOSIS AND TESTING - ENGINE........................................................1192
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE................................1193
DIAGNOSIS AND TESTING - ENGINE MECHANICAL.............................................1195
STANDARD PROCEDURE........................................................................1197
STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS................................1197
STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS................................1197
STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE........................................1197
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS................................1198
SEALER APPLICATION................................................................1198
STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION................................1199
STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE.....................1199
REMOVAL - ENGINE ASSEMBLY.................................................................1200
INSTALLATION - ENGINE ASSEMBLY............................................................1200
SPECIFICATIONS............................................................................1201
SPECIFICATIONS - 2.4L ENGINE..........................................................1201
SPECIFICATIONS - TORQUE...............................................................1204
SPECIAL TOOLS.............................................................................1205
2.4L ENGINE...........................................................................1205
AIR CLEANER ELEMENT...........................................................................1207
REMOVAL - 2.4L............................................................................1207
INSTALLATION - 2.4L.......................................................................1207
CYLINDER HEAD.................................................................................1207
DESCRIPTION...............................................................................1207
OPERATION.................................................................................1207
DIAGNOSIS AND TESTING - CYLINDER HEAD GASKET..............................................1207
CYLINDER-TO-CYLINDER LEAKAGE TEST.....................................................1208
CYLINDER-TO-WATER JACKET LEAKAGE TEST.................................................1208
REMOVAL - CYLINDER HEAD...................................................................1208
CLEANING..................................................................................1208
INSPECTION................................................................................1209
INSTALLATION - CYLINDER HEAD..............................................................1209
CAMSHAFT OIL SEAL(S)..........................................................................1210
REMOVAL...................................................................................1210
INSTALLATION..............................................................................1210
CAMSHAFT(S)...................................................................................1211
DESCRIPTION...............................................................................1211
OPERATION.................................................................................1211
STANDARD PROCEDURE - CAMSHAFT END-PLAY....................................................1211
REMOVAL...................................................................................1211
CLEANING..................................................................................1212
INSPECTION................................................................................1212
INSTALLATION..............................................................................1213
CYLINDER HEAD COVER...........................................................................1213
REMOVAL...................................................................................1213
CLEANING..................................................................................1214
INSPECTION................................................................................1214
INSTALLATION..............................................................................1214
INTAKE/EXHAUST VALVES & SEATS.................................................................1215
DESCRIPTION...............................................................................1215
CLEANING..................................................................................1215
VALVE SPRINGS.................................................................................1215
REMOVAL...................................................................................1215
REMOVAL - CYLINDER HEAD ON............................................................1215
REMOVAL - CYLINDER HEAD OFF...........................................................1215
INSPECTION................................................................................1215
INSTALLATION..............................................................................1215
INSTALLATION - CYLINDER HEAD ON.......................................................1215
INSTALLATION - CYLINDER HEAD OFF......................................................1216
HYDRAULIC LIFTERS.............................................................................1216
DIAGNOSIS AND TESTING - LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS............................1216
REMOVAL...................................................................................1217
INSTALLATION..............................................................................1217
ROCKER ARMS...................................................................................1217
REMOVAL...................................................................................1217
INSPECTION................................................................................1217
INSTALLATION..............................................................................1218
ENGINE BLOCK..................................................................................1218
DESCRIPTION...............................................................................1218
STANDARD PROCEDURE........................................................................1218
STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING..................................1218
STANDARD PROCEDURE - CYLINDER BORE HONING.............................................1218
CLEANING..................................................................................1219
INSPECTION................................................................................1219
ENGINE BLOCK..........................................................................1219
CYLINDER BORE.........................................................................1220
CONNECTING ROD BEARINGS.......................................................................1220
STANDARD PROCEDURE........................................................................1220
CONNECTING ROD - FITTING..............................................................1220
CRANKSHAFT....................................................................................1220
DESCRIPTION...............................................................................1220
OPERATION.................................................................................1220
STANDARD PROCEDURE - CRANKSHAFT END PLAY..................................................1220
REMOVAL...................................................................................1221
INSPECTION................................................................................1221
INSTALLATION..............................................................................1222
CRANKSHAFT MAIN BEARINGS......................................................................1223
STANDARD PROCEDURE - MAIN BEARING - FITTING...............................................1223
CRANKSHAFT MAIN BEARINGS..............................................................1223
MAIN BEARING INSTALLATION.............................................................1223
CRANKSHAFT OIL SEAL - FRONT...................................................................1224
REMOVAL...................................................................................1224
INSTALLATION..............................................................................1225
CRANKSHAFT OIL SEAL - REAR....................................................................1226
REMOVAL...................................................................................1226
INSTALLATION..............................................................................1226
PISTON & CONNECTING ROD.......................................................................1227
DESCRIPTION...............................................................................1227
OPERATION.................................................................................1227
REMOVAL...................................................................................1228
INSTALLATION..............................................................................1228
PISTON RINGS..................................................................................1229
STANDARD PROCEDURE........................................................................1229
PISTON RING - FITTING.................................................................1229
PISTON RINGS - INSTALLATION.......................................................1229
VIBRATION DAMPER..............................................................................1230
REMOVAL...................................................................................1230
INSTALLATION..............................................................................1230
STRUCTURAL COLLAR.............................................................................1231
REMOVAL...................................................................................1231
INSTALLATION..............................................................................1231
ENGINE MOUNTING...............................................................................1231
DESCRIPTION...............................................................................1231
FRONT MOUNT...................................................................................1231
REMOVAL...................................................................................1231
INSTALLATION..............................................................................1231
REAR MOUNT....................................................................................1232
REMOVAL...................................................................................1232
MANUAL TRANSMISSION...................................................................1232
AUTOMATIC TRANSMISSION................................................................1232
INSTALLATION..............................................................................1232
MANUAL TRANSMISSION:..................................................................1232
AUTOMATIC TRANSMISSION:...............................................................1232
LUBRICATION...................................................................................1233
DESCRIPTION...............................................................................1233
OPERATION.................................................................................1233
DIAGNOSIS AND TESTING - ENGINE OIL PRESSURE CHECKING......................................1234
OIL...........................................................................................1234
STANDARD PROCEDURE........................................................................1234
ENGINE OIL LEVEL CHECK................................................................1234
STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE.....................................1234
OIL FILTER....................................................................................1235
DESCRIPTION...............................................................................1235
REMOVAL...................................................................................1235
INSTALLATION..............................................................................1235
OIL PAN.......................................................................................1235
REMOVAL...................................................................................1235
INSTALLATION..............................................................................1235
OIL PRESSURE SENSOR/SWITCH....................................................................1236
DESCRIPTION...............................................................................1236
OPERATION.................................................................................1236
OIL PUMP......................................................................................1236
REMOVAL...................................................................................1236
DISASSEMBLY...............................................................................1237
CLEANING..................................................................................1237
INSPECTION................................................................................1237
ASSEMBLY..................................................................................1237
INSTALLATION..............................................................................1238
INTAKE MANIFOLD...............................................................................1239
DESCRIPTION...............................................................................1239
OPERATION.................................................................................1240
DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS.............................................1240
REMOVAL...................................................................................1240
REMOVAL — UPPER.......................................................................1240
REMOVAL — LOWER.......................................................................1240
INSPECTION................................................................................1240
INSTALLATION..............................................................................1240
INSTALLATION — UPPER..................................................................1240
INSTALLATION — LOWER..................................................................1241
EXHAUST MANIFOLD..............................................................................1241
DESCRIPTION...............................................................................1241
OPERATION.................................................................................1241
REMOVAL...................................................................................1241
CLEANING..................................................................................1242
INSPECTION................................................................................1242
INSTALLATION..............................................................................1242
TIMING BELT COVER(S)..........................................................................1242
REMOVAL...................................................................................1242
FRONT COVER...........................................................................1242
REAR COVER............................................................................1242
INSTALLATION..............................................................................1242
REAR COVER............................................................................1242
FRONT COVER...........................................................................1242
TIMING BELT AND SPROCKET(S)...................................................................1243
REMOVAL...................................................................................1243
REMOVAL - TIMING BELT.................................................................1243
REMOVAL - CRANKSHAFT SPROCKET.........................................................1243
CLEANING..................................................................................1243
INSTALLATION..............................................................................1244
INSTALLATION - CRANKSHAFT SPROCKET....................................................1244
INSTALLATION - TIMING BELT............................................................1245
TIMING BELT TENSIONER & PULLEY................................................................1247
REMOVAL...................................................................................1247
INSTALLATION..............................................................................1247
BALANCE SHAFT.................................................................................1247
DESCRIPTION...............................................................................1247
OPERATION.................................................................................1247
REMOVAL...................................................................................1248
BALANCE SHAFTS........................................................................1248
BALANCE SHAFT CARRIER.................................................................1248
INSTALLATION..............................................................................1250
BALANCE SHAFT TIMING..................................................................1250
BALANCE SHAFT INSTALLATION........................................................1250
BALANCE SHAFT CARRIER.........................................................................1251
REMOVAL...................................................................................1251
INSTALLATION..............................................................................1251
BALANCE SHAFT CHAIN...........................................................................1251
REMOVAL...................................................................................1251
INSTALLATION..............................................................................1251
ENGINE - 3.7L.....................................................................................1252
ENGINE - 3.7L.................................................................................1254
DESCRIPTION...............................................................................1254
DIAGNOSIS AND TESTING.....................................................................1255
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION...............................1255
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE................................1255
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL.................................1257
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION................................1258
DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE.................................1259
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE..........................1259
STANDARD PROCEDURE........................................................................1260
STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION................................1260
STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS...................................1260
STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS................................1261
REMOVAL...................................................................................1261
INSTALLATION..............................................................................1262
SPECIFICATIONS............................................................................1263
TORQUE................................................................................1263
SPECIFICATIONS – 3.7L ENGINE..........................................................1263
SPECIAL TOOLS.............................................................................1266
3.7L ENGINE...........................................................................1266
AIR CLEANER ELEMENT...........................................................................1270
REMOVAL - 3.7L............................................................................1270
INSTALLATION - 3.7L.......................................................................1270
CYLINDER HEAD - LEFT..........................................................................1270
DESCRIPTION - VALVE GUIDES................................................................1270
DIAGNOSIS AND TESTING.....................................................................1270
DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER.......................................1270
DIAGNOSIS AND TESTING - CYLINDER HEAD GASKET..........................................1270
CYLINDER-TO-CYLINDER LEAKAGE TEST.................................................1271
CYLINDER-TO-WATER JACKET LEAKAGE TEST.............................................1271
REMOVAL...................................................................................1271
CLEANING..................................................................................1273
INSTALLATION..............................................................................1273
CAMSHAFT(S)...................................................................................1274
DESCRIPTION...............................................................................1274
REMOVAL...................................................................................1274
INSTALLATION..............................................................................1275
CYLINDER HEAD COVER(S)........................................................................1276
DESCRIPTION...............................................................................1276
REMOVAL...................................................................................1276
INSTALLATION..............................................................................1277
INTAKE/EXHAUST VALVES & SEATS.................................................................1277
DESCRIPTION...............................................................................1277
STANDARD PROCEDURE - REFACING.............................................................1277
REMOVAL...................................................................................1277
TESTING VALVE SPRINGS.................................................................1278
INSTALLATION..............................................................................1278
ROCKER ARM....................................................................................1279
DESCRIPTION...............................................................................1279
REMOVAL...................................................................................1279
VALVE GUIDE SEALS.............................................................................1280
DESCRIPTION...............................................................................1280
VALVE SPRINGS.................................................................................1280
DESCRIPTION...............................................................................1280
REMOVAL...................................................................................1280
INSTALLATION..............................................................................1280
CYLINDER HEAD - RIGHT.........................................................................1281
DESCRIPTION...............................................................................1281
DESCRIPTION - CYLINDER HEAD...........................................................1281
DESCRIPTION - VALVE GUIDES............................................................1281
DESCRIPTION...........................................................................1281
DIAGNOSIS AND TESTING.....................................................................1281
DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER.......................................1281
DIAGNOSIS AND TESTING - CYLINDER HEAD GASKET..........................................1281
CYLINDER-TO-CYLINDER LEAKAGE TEST.................................................1281
CYLINDER-TO-WATER JACKET LEAKAGE TEST.............................................1282
REMOVAL...................................................................................1282
CLEANING..................................................................................1283
INSPECTION................................................................................1283
INSTALLATION..............................................................................1283
CAMSHAFT(S)...................................................................................1284
DESCRIPTION...............................................................................1284
REMOVAL...................................................................................1284
INSTALLATION..............................................................................1285
CYLINDER HEAD COVER(S)........................................................................1286
REMOVAL...................................................................................1286
INSTALLATION..............................................................................1286
INTAKE/EXHAUST VALVES & SEATS.................................................................1286
STANDARD PROCEDURE - REFACING.............................................................1286
REMOVAL...................................................................................1286
TESTING VALVE SPRINGS.................................................................1287
INSTALLATION..............................................................................1287
ROCKER ARM....................................................................................1288
DESCRIPTION...............................................................................1288
REMOVAL...................................................................................1288
INSTALLATION..............................................................................1289
VALVE GUIDE SEALS.............................................................................1289
DESCRIPTION...............................................................................1289
VALVE SPRINGS.................................................................................1289
DESCRIPTION...............................................................................1289
REMOVAL...................................................................................1289
INSTALLATION..............................................................................1290
ENGINE BLOCK..................................................................................1290
DESCRIPTION...............................................................................1290
STANDARD PROCEDURE - CYLINDER BORE HONING.................................................1290
CLEANING..................................................................................1291
INSPECTION................................................................................1291
CRANKSHAFT....................................................................................1292
DESCRIPTION...............................................................................1292
REMOVAL...................................................................................1292
INSPECTION................................................................................1293
INSTALLATION..............................................................................1293
CRANKSHAFT MAIN BEARINGS......................................................................1294
STANDARD PROCEDURE........................................................................1294
MAIN BEARING - FITTING................................................................1294
SELECT FIT IDENTIFICATION.........................................................1294
INSPECTION........................................................................1294
MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)................................1294
CRANKSHAFT MAIN BEARING SELECTION.................................................1296
CRANKSHAFT OIL SEAL - FRONT...................................................................1296
REMOVAL...................................................................................1296
INSTALLATION..............................................................................1297
CRANKSHAFT OIL SEAL - REAR....................................................................1298
REMOVAL...................................................................................1298
INSTALLATION..............................................................................1298
FLEX PLATE....................................................................................1299
REMOVAL...................................................................................1299
INSTALLATION..............................................................................1299
PISTON & CONNECTING ROD.......................................................................1299
DESCRIPTION...............................................................................1299
STANDARD PROCEDURE........................................................................1299
CONNECTING ROD BEARING FITTING........................................................1299
STANDARD PROCEDURE - PISTON FITTING...................................................1302
REMOVAL...................................................................................1302
CLEANING..................................................................................1303
INSPECTION................................................................................1303
INSTALLATION..............................................................................1303
PISTON RINGS..................................................................................1304
STANDARD PROCEDURE - PISTON RING FITTING..................................................1304
VIBRATION DAMPER..............................................................................1306
REMOVAL...................................................................................1306
INSTALLATION..............................................................................1306
STRUCTURAL COVER..............................................................................1307
DESCRIPTION...............................................................................1307
OPERATION.................................................................................1307
REMOVAL...................................................................................1307
INSTALLATION..............................................................................1307
FRONT MOUNT...................................................................................1308
REMOVAL...................................................................................1308
INSTALLATION..............................................................................1308
REAR MOUNT....................................................................................1309
REMOVAL...................................................................................1309
MANUAL TRANSMISSION...................................................................1309
AUTOMATIC TRANSMISSION................................................................1309
INSTALLATION..............................................................................1309
MANUAL TRANSMISSION:..................................................................1309
AUTOMATIC TRANSMISSION:...............................................................1309
LUBRICATION...................................................................................1310
DESCRIPTION...............................................................................1310
OPERATION.................................................................................1310
DIAGNOSIS AND TESTING.....................................................................1311
DIAGNOSIS AND TESTING - ENGINE OIL LEAK...............................................1311
Air Leak Detection Test Method....................................................1311
INSPECTION FOR REAR SEAL AREA LEAKS...............................................1313
DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE..................................1313
DIAGNOSIS AND TESTING - REAR SEAL AREA LEAKS..........................................1313
OIL...........................................................................................1314
STANDARD PROCEDURE - ENGINE OIL...........................................................1314
ENGINE OIL SPECIFICATION..............................................................1314
API SERVICE GRADE CERTIFIED...........................................................1314
SAE VISCOSITY.........................................................................1314
ENERGY CONSERVING OIL.................................................................1314
CONTAINER IDENTIFICATION..............................................................1314
OIL LEVEL INDICATOR (DIPSTICK)........................................................1314
CRANKCASE OIL LEVEL INSPECTION........................................................1315
ENGINE OIL CHANGE.....................................................................1315
USED ENGINE OIL DISPOSAL..............................................................1315
OIL FILTER....................................................................................1315
REMOVAL...................................................................................1315
INSTALLATION..............................................................................1316
OIL PAN.......................................................................................1316
DESCRIPTION...............................................................................1316
REMOVAL...................................................................................1316
REMOVAL...............................................................................1316
REMOVAL - 4x4.........................................................................1317
CLEANING..................................................................................1317
INSPECTION................................................................................1317
INSTALLATION..............................................................................1318
INSTALLATION..........................................................................1318
INSTALLATION - 4x4....................................................................1318
OIL PRESSURE SENSOR/SWITCH....................................................................1318
DESCRIPTION...............................................................................1318
OPERATION.................................................................................1319
REMOVAL...................................................................................1319
INSTALLATION..............................................................................1319
OIL PUMP......................................................................................1319
REMOVAL...................................................................................1319
DISASSEMBLY...............................................................................1319
INSPECTION................................................................................1319
ASSEMBLY..................................................................................1320
INSTALLATION..............................................................................1320
INTAKE MANIFOLD...............................................................................1322
DESCRIPTION...............................................................................1322
DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS.............................................1322
REMOVAL...................................................................................1322
INSTALLATION..............................................................................1322
EXHAUST MANIFOLD..............................................................................1323
DESCRIPTION...............................................................................1323
REMOVAL...................................................................................1323
RIGHT EXHAUST MANIFOLD................................................................1323
LEFT EXHAUST MANIFOLD.................................................................1324
INSTALLATION..............................................................................1325
RIGHT EXHAUST MANIFOLD................................................................1325
LEFT EXHAUST MANIFOLD.................................................................1325
VALVE TIMING..................................................................................1325
DESCRIPTION...............................................................................1325
OPERATION.................................................................................1325
STANDARD PROCEDURE........................................................................1327
MEASURING TIMING CHAIN WEAR...........................................................1327
SERVICE PROCEDURE - TIMING VERIFICATION...............................................1327
COUNTER BALANCE SHAFT TIMING......................................................1327
TIMING - SINGLE CAMSHAFT..........................................................1327
BALANCE SHAFT.................................................................................1329
REMOVAL...................................................................................1329
INSTALLATION..............................................................................1329
TIMING BELT / CHAIN COVER(S)..................................................................1330
REMOVAL...................................................................................1330
INSTALLATION..............................................................................1330
IDLER SHAFT...................................................................................1331
REMOVAL...................................................................................1331
INSTALLATION..............................................................................1332
TIMING BELT/CHAIN AND SPROCKET(S).............................................................1332
REMOVAL...................................................................................1332
INSPECTION................................................................................1334
INSTALLATION..............................................................................1334
11-EXHAUST SYSTEM.....................................................................................1338
EXHAUST SYSTEM....................................................................................1338
DESCRIPTION...................................................................................1338
DIAGNOSIS AND TESTING - EXHAUST SYSTEM........................................................1339
CATALYTIC CONVERTER...............................................................................1339
DESCRIPTION - CATALYTIC CONVERTER.............................................................1339
REMOVAL.......................................................................................1339
2.4L ENGINES..............................................................................1339
3.7L ENGINES..............................................................................1340
INSPECTION....................................................................................1340
INSTALLATION..................................................................................1340
CROSS-OVER PIPE...................................................................................1341
REMOVAL.......................................................................................1341
INSTALLATION..................................................................................1341
EXHAUST PIPE-2.4L.................................................................................1341
REMOVAL.......................................................................................1341
INSTALLATION..................................................................................1342
HEAT SHIELDS......................................................................................1342
DESCRIPTION...................................................................................1342
MUFFLER...........................................................................................1342
DESCRIPTION...................................................................................1342
REMOVAL.......................................................................................1342
INSTALLATION..................................................................................1343
13-FRAMES & BUMPERS...................................................................................1346
FRONT FASCIA......................................................................................1346
REMOVAL.......................................................................................1346
INSTALLATION..................................................................................1347
REAR FASCIA.......................................................................................1347
REMOVAL.......................................................................................1347
INSTALLATION..................................................................................1347
REAR FASCIA SUPPORT...............................................................................1347
REMOVAL.......................................................................................1347
INSTALLATION..................................................................................1348
REAR FASCIA - STEP PAD............................................................................1348
REMOVAL.......................................................................................1348
INSTALLATION..................................................................................1348
REAR FASCIA - RAIN DIVERTER.......................................................................1348
REMOVAL.......................................................................................1348
INSTALLATION..................................................................................1348
FRAME.............................................................................................1348
SPECIFICATIONS................................................................................1348
SPECIFICATIONS - FRAME DIMENSIONS.........................................................1348
VEHICLE PREPARATION...................................................................1348
DIMENSION ILLUSTRATIONS...............................................................1348
SPECIFICATIONS - TORQUE...................................................................1350
FRONT SKID PLATE..................................................................................1351
REMOVAL.......................................................................................1351
INSTALLATION..................................................................................1351
ENGINE CRADLE CROSSMEMBER.........................................................................1351
REMOVAL.......................................................................................1351
INSTALLATION..................................................................................1351
TRANSFER CASE SKID PLATE..........................................................................1351
REMOVAL.......................................................................................1351
INSTALLATION..................................................................................1351
REAR CROSSMEMBER..................................................................................1352
REMOVAL.......................................................................................1352
INSTALLATION..................................................................................1352
FRONT TOW HOOK....................................................................................1352
REMOVAL.......................................................................................1352
INSTALLATION..................................................................................1352
REAR TOW HOOK.....................................................................................1353
REMOVAL.......................................................................................1353
INSTALLATION..................................................................................1353
TRAILER HITCH.....................................................................................1353
REMOVAL.......................................................................................1353
INSTALLATION..................................................................................1353
FUEL TANK SKID PLATE..............................................................................1353
REMOVAL.......................................................................................1353
INSTALLATION..................................................................................1353
14-FUEL SYSTEM........................................................................................1354
FUEL DELIVERY.....................................................................................1354
FUEL DELIVERY.................................................................................1355
DESCRIPTION...............................................................................1355
OPERATION.................................................................................1355
STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE.........................................1355
SPECIFICATIONS............................................................................1355
FUEL SYSTEM PRESSURE..................................................................1355
TORQUE................................................................................1357
SPECIAL TOOLS.............................................................................1358
FUEL SYSTEM...........................................................................1358
FLOW MANAGEMENT VALVE.........................................................................1358
DESCRIPTION...............................................................................1358
OPERATION.................................................................................1358
REMOVAL...................................................................................1359
INSTALLATION..............................................................................1359
FUEL FILTER...................................................................................1359
DESCRIPTION...............................................................................1359
REMOVAL...................................................................................1359
INSTALLATION..............................................................................1360
FUEL LEVEL SENDING UNIT / SENSOR..............................................................1361
DESCRIPTION...............................................................................1361
OPERATION.................................................................................1361
REMOVAL...................................................................................1361
INSTALLATION..............................................................................1362
FUEL LINES....................................................................................1362
DESCRIPTION...............................................................................1362
QUICK CONNECT FITTING.........................................................................1362
DESCRIPTION...............................................................................1362
STANDARD PROCEDURE - QUICK-CONNECT FITTINGS...............................................1363
DISCONNECTING.........................................................................1363
CONNECTING............................................................................1366
FUEL PRESSURE REGULATOR.......................................................................1366
DESCRIPTION...............................................................................1366
OPERATION.................................................................................1366
REMOVAL...................................................................................1366
INSTALLATION..............................................................................1367
FUEL PUMP.....................................................................................1367
DESCRIPTION...............................................................................1367
OPERATION.................................................................................1367
FUEL PUMP MODULE..............................................................................1367
DESCRIPTION...............................................................................1367
OPERATION.................................................................................1367
REMOVAL...................................................................................1367
INSTALLATION..............................................................................1368
FUEL RAIL.....................................................................................1370
DESCRIPTION...............................................................................1370
OPERATION.................................................................................1371
REMOVAL...................................................................................1371
INSTALLATION..............................................................................1373
FUEL TANK.....................................................................................1374
DESCRIPTION...............................................................................1374
OPERATION.................................................................................1374
REMOVAL...................................................................................1374
Fuel Tank Draining....................................................................1374
Tank Removal..........................................................................1375
INSTALLATION..............................................................................1376
FUEL TANK CHECK VALVE.........................................................................1377
DESCRIPTION...............................................................................1377
OPERATION.................................................................................1377
REMOVAL...................................................................................1377
INSTALLATION..............................................................................1377
INLET FILTER..................................................................................1378
REMOVAL...................................................................................1378
INSTALLATION..............................................................................1378
FUEL INJECTION....................................................................................1379
FUEL INJECTION................................................................................1379
DESCRIPTION...............................................................................1379
ACCELERATOR PEDAL.............................................................................1379
REMOVAL...................................................................................1379
INSTALLATION..............................................................................1379
CRANKSHAFT POSITION SENSOR....................................................................1380
DESCRIPTION...............................................................................1380
2.4L..................................................................................1380
3.7L..................................................................................1380
OPERATION.................................................................................1380
2.4L..................................................................................1380
3.7L..................................................................................1381
REMOVAL...................................................................................1381
2.4L..................................................................................1381
3.7L..................................................................................1382
INSTALLATION..............................................................................1382
2.4L..................................................................................1382
3.7L..................................................................................1382
FUEL INJECTOR.................................................................................1382
DESCRIPTION...............................................................................1382
OPERATION.................................................................................1382
OPERATION - FUEL INJECTOR.............................................................1382
OPERATION - PCM OUTPUT................................................................1383
REMOVAL...................................................................................1383
INSTALLATION..............................................................................1383
FUEL PUMP RELAY...............................................................................1384
DESCRIPTION...............................................................................1384
OPERATION.................................................................................1384
REMOVAL...................................................................................1384
INSTALLATION..............................................................................1384
IDLE AIR CONTROL MOTOR........................................................................1384
DESCRIPTION...............................................................................1384
OPERATION.................................................................................1384
REMOVAL...................................................................................1385
2.4L..................................................................................1385
3.7L..................................................................................1385
INSTALLATION..............................................................................1386
2.4L..................................................................................1386
3.7L..................................................................................1386
INTAKE AIR TEMPERATURE SENSOR.................................................................1386
DESCRIPTION...............................................................................1386
OPERATION.................................................................................1386
REMOVAL...................................................................................1386
2.4L..................................................................................1386
3.7L..................................................................................1387
INSTALLATION..............................................................................1387
2.4L..................................................................................1387
3.7L..................................................................................1387
MAP SENSOR....................................................................................1387
DESCRIPTION...............................................................................1387
2.4L..................................................................................1387
3.7L..................................................................................1387
OPERATION.................................................................................1387
REMOVAL...................................................................................1388
2.4L..................................................................................1388
3.7L..................................................................................1388
INSTALLATION..............................................................................1389
2.4L..................................................................................1389
3.7L..................................................................................1389
OXYGEN SENSOR.................................................................................1389
DESCRIPTION...............................................................................1389
OPERATION.................................................................................1390
REMOVAL...................................................................................1391
INSTALLATION..............................................................................1392
THROTTLE BODY.................................................................................1392
DESCRIPTION...............................................................................1392
OPERATION.................................................................................1392
REMOVAL...................................................................................1393
2.4L..................................................................................1393
3.7L..................................................................................1393
INSTALLATION..............................................................................1393
2.4L..................................................................................1393
3.7L..................................................................................1393
THROTTLE CONTROL CABLE........................................................................1394
REMOVAL...................................................................................1394
2.4L..................................................................................1394
3.7L..................................................................................1395
INSTALLATION..............................................................................1396
THROTTLE POSITION SENSOR......................................................................1396
DESCRIPTION...............................................................................1396
OPERATION.................................................................................1396
REMOVAL...................................................................................1396
2.4L..................................................................................1396
3.7L..................................................................................1397
INSTALLATION..............................................................................1397
2.4L..................................................................................1397
3.7L..................................................................................1397
19-STEERING...........................................................................................1398
STEERING..........................................................................................1398
DESCRIPTION...................................................................................1398
OPERATION.....................................................................................1398
DIAGNOSIS AND TESTING.........................................................................1398
DIAGNOSIS AND TESTING - POWER STEERING SYSTEM.............................................1398
DIAGNOSIS AND TESTING - POWER STEERING FLOW AND PRESSURE..................................1401
FLOW AND PRESSURE TEST................................................................1401
COLUMN............................................................................................1402
COLUMN........................................................................................1402
DESCRIPTION...............................................................................1402
OPERATION - SERVICE PRECAUTIONS...........................................................1402
REMOVAL...................................................................................1402
INSTALLATION..............................................................................1404
SPECIFICATIONS............................................................................1405
TORQUE CHART..........................................................................1405
SPECIAL TOOLS.............................................................................1405
STEERING COLUMN.......................................................................1405
IGNITION SWITCH...............................................................................1405
DESCRIPTION...............................................................................1405
DIAGNOSIS AND TESTING - IGNITION SWITCH...................................................1405
ELECTRICAL DIAGNOSIS..................................................................1405
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE)........................................1405
REMOVAL...................................................................................1406
IGNITION SWITCH REMOVAL...............................................................1406
INSTALLATION..............................................................................1406
IGNITION SWITCH INSTALLATION..........................................................1406
KEY-IN IGNITION SWITCH........................................................................1407
DESCRIPTION...............................................................................1407
DIAGNOSIS AND TESTING - KEY-IN IGNITION SWITCH............................................1407
KEY CYLINDER0 - 8 KJ (Continued)..........................................................1407
REMOVAL...................................................................................1407
INSTALLATION..............................................................................1408
INTERMEDIATE SHAFT............................................................................1408
REMOVAL...................................................................................1408
INSTALLATION..............................................................................1408
STEERING WHEEL................................................................................1409
REMOVAL...................................................................................1409
INSTALLATION..............................................................................1409
GEAR..............................................................................................1410
GEAR..........................................................................................1410
DESCRIPTION...............................................................................1410
OPERATION.................................................................................1410
REMOVAL...................................................................................1410
REMOVAL - 4WD.........................................................................1410
REMOVAL - 2WD.........................................................................1411
REMOVAL - 2.5L DIESEL.................................................................1411
REMOVAL - RHD - 4X2 & 4X4.............................................................1412
INSTALLATION..............................................................................1412
INSTALLATION - 4WD....................................................................1412
INSTALLATION - 2WD....................................................................1413
INSTALLATION - 2.5L DIESEL............................................................1413
INSTALLATION - RHD - 4X2 & 4X4........................................................1413
SPECIFICATIONS............................................................................1414
TORQUE CHART..........................................................................1414
SPECIAL TOOLS.............................................................................1414
OUTER TIE ROD END REMOVAL TOOL........................................................1414
LINKAGE...........................................................................................1415
LINKAGE.......................................................................................1415
STANDARD PROCEDURE - STEERING LINKAGE.....................................................1415
TIE ROD END...................................................................................1415
REMOVAL...................................................................................1415
INSTALLATION..............................................................................1415
PUMP..............................................................................................1416
PUMP..........................................................................................1416
DESCRIPTION...............................................................................1416
DESCRIPTION...........................................................................1416
DESCRIPTION...........................................................................1416
OPERATION.................................................................................1416
STANDARD PROCEDURE - POWER STEERING PUMP - INITIAL OPERATION..............................1417
REMOVAL...................................................................................1417
REMOVAL...............................................................................1417
REMOVAL - 3.7L........................................................................1418
REMOVAL - 2.4L........................................................................1418
INSTALLATION..............................................................................1418
INSTALLATION..........................................................................1418
INSTALLATION - 3.7L...................................................................1419
INSTALLATION - 2.4L...................................................................1419
SPECIFICATIONS............................................................................1419
TORQUE CHART..........................................................................1419
SPECIAL TOOLS.............................................................................1420
POWER STEERING PUMP...................................................................1420
FLUID COOLER..................................................................................1420
DESCRIPTION...............................................................................1420
OPERATION.................................................................................1420
REMOVAL...................................................................................1420
INSTALLATION..............................................................................1420
HOSES.........................................................................................1421
REMOVAL...................................................................................1421
REMOVAL...............................................................................1421
REMOVAL - PRESSURE HOSE...............................................................1421
REMOVAL - RETURN HOSE (GEAR TO THE COOLER)............................................1421
REMOVAL - RETURN HOSE (RESERVOIR TO THE COOLER).......................................1421
INSTALLATION..............................................................................1421
INSTALLATION..........................................................................1421
INSTALLATION - PRESSURE HOSE..........................................................1422
INSTALLATION - RETURN HOSE (GEAR TO THE COOLER).......................................1422
INSTALLATION - RETURN HOSE (RESERVOIR TO THE COOLER)..................................1423
POWER STEERING PRESSURE SWITCH................................................................1423
DESCRIPTION...............................................................................1423
OPERATION.................................................................................1423
REMOVAL...................................................................................1423
INSTALLATION..............................................................................1423
PULLEY........................................................................................1423
REMOVAL...................................................................................1423
REMOVAL - DIESEL......................................................................1423
REMOVAL...............................................................................1423
INSTALLATION..............................................................................1424
INSTALLATION - DIESEL.................................................................1424
INSTALLATION..........................................................................1424
RESERVOIR.....................................................................................1424
REMOVAL...................................................................................1424
REMOVAL - DIESEL......................................................................1424
REMOVAL - 3.7L........................................................................1425
REMOVAL - 2.4L........................................................................1425
INSTALLATION..............................................................................1425
INSTALLATION - DIESEL.................................................................1425
INSTALLATION - 3.7L...................................................................1425
INSTALLATION - 2.4L...................................................................1425
21-TRANSMISSION AND TRANSFER CASE.....................................................................1426
MANUAL - NV1500...................................................................................1426
MANUAL - NV1500...............................................................................1426
DESCRIPTION...............................................................................1426
OPERATION.................................................................................1426
DIAGNOSIS AND TESTING.....................................................................1427
LOW LUBRICANT LEVEL...................................................................1427
HARD SHIFTING.........................................................................1427
TRANSMISSION NOISE....................................................................1428
REMOVAL...................................................................................1428
DISASSEMBLY...............................................................................1429
CLEANING..................................................................................1436
INSPECTION................................................................................1436
SHIFT LEVER ASSEMBLY..................................................................1436
SHIFT SHAFT AND FORKS.................................................................1436
FRONT/REAR HOUSINGS AND BEARING RETAINERS.............................................1436
COUNTERSHAFT BEARINGS AND RACES.......................................................1437
REVERSE IDLER COMPONENTS..............................................................1437
Shift Socket..........................................................................1438
Output Shaft And Geartrain............................................................1438
ASSEMBLY..................................................................................1438
INSTALLATION..............................................................................1455
SPECIFICATIONS............................................................................1456
SPECIAL TOOLS.............................................................................1456
EXTENSION HOUSING SEAL........................................................................1458
REMOVAL...................................................................................1458
INSTALLATION..............................................................................1458
MANUAL - NV3550...................................................................................1459
MANUAL - NV3550...............................................................................1459
DESCRIPTION...............................................................................1459
OPERATION.................................................................................1459
DIAGNOSIS AND TESTING.....................................................................1459
LOW LUBRICANT LEVEL...................................................................1459
HARD SHIFTING.........................................................................1460
TRANSMISSION NOISE....................................................................1460
REMOVAL...................................................................................1460
DISASSEMBLY...............................................................................1461
FRONT HOUSING.........................................................................1461
SHIFT/FORK SHAFTS AND REVERSE IDLER SEGMENT...........................................1464
REAR HOUSING - 2WD....................................................................1467
REAR ADAPTER HOUSING - 4WD............................................................1469
GEARTRAIN FROM FIXTURE................................................................1470
OUTPUT SHAFT..........................................................................1470
REVERSE IDLER.........................................................................1473
CLEANING..................................................................................1473
INSPECTION................................................................................1474
SHIFT LEVER ASSEMBLY..................................................................1474
SHIFT SHAFT AND FORKS.................................................................1474
FRONT/REAR HOUSINGS AND BEARING RETAINERS.............................................1474
COUNTERSHAFT BEARINGS AND RACES.......................................................1475
REVERSE IDLER COMPONENTS..............................................................1475
Shift Socket..........................................................................1475
Output Shaft And Geartrain............................................................1475
ASSEMBLY..................................................................................1475
SYNCHRONIZER..........................................................................1475
OUTPUT SHAFT..........................................................................1476
REVERSE IDLER ASSEMBLY................................................................1483
SHIFT SHAFT AND BUSHINGS/BEARINGS.....................................................1484
DETENT PLUNGER BUSHING................................................................1484
GEARTRAIN ASSEMBLY....................................................................1485
REAR HOUSING - 2WD....................................................................1487
ADAPTER HOUSING - 4WD.................................................................1489
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET.................................1490
FRONT HOUSING AND INPUT SHAFT BEARING RETAINER........................................1493
SHIFT TOWER AND LEVER.................................................................1496
INSTALLATION..............................................................................1496
SPECIFICATIONS............................................................................1497
SPECIAL TOOLS.............................................................................1498
EXTENSION HOUSING BUSHING.....................................................................1500
REMOVAL...................................................................................1500
INSTALLATION..............................................................................1500
EXTENSION HOUSING SEAL........................................................................1500
REMOVAL...................................................................................1500
INSTALLATION..............................................................................1500
AUTOMATIC TRANSMISSION - 42RLE....................................................................1501
AUTOMATIC TRANSMISSION - 42RLE................................................................1502
DESCRIPTION...............................................................................1502
TRANSMISSION IDENTIFICATION...........................................................1504
OPERATION.................................................................................1504
FIRST GEAR POWERFLOW..................................................................1505
SECOND GEAR POWERFLOW.................................................................1506
THIRD GEAR POWERFLOW..................................................................1507
FOURTH GEAR POWERFLOW.................................................................1508
REVERSE GEAR POWERFLOW................................................................1509
DIAGNOSIS AND TESTING.....................................................................1509
DIAGNOSIS AND TESTING - AUTOMATIC TRANSMISSION........................................1509
DIAGNOSIS AND TESTING - ROAD TEST.....................................................1510
DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TESTS......................................1511
TEST ONE-SELECTOR IN L (1st Gear).................................................1511
TEST TWO-SELECTOR IN DRIVE (Second Gear)..........................................1511
TEST TWO A–SELECTOR IN OD (Fourth Gear)...........................................1511
TEST THREE-SELECTOR IN OVERDRIVE (Third and Second Gear)..........................1511
TEST FOUR-SELECTOR IN OD (Fourth Gear)............................................1511
TEST FIVE-SELECTOR IN OVERDRIVE (Fourth Gear, CC on)..............................1512
TEST SIX-SELECTOR IN REVERSE......................................................1512
TEST RESULT INDICATIONS...........................................................1512
DIAGNOSIS AND TESTING - CLUTCH AIR PRESSURE TESTS.....................................1513
OVERDRIVE CLUTCH..................................................................1513
UNDERDRIVE CLUTCH.................................................................1513
REVERSE CLUTCH....................................................................1513
2/4 CLUTCH........................................................................1513
LOW/REVERSE CLUTCH................................................................1513
DIAGNOSIS AND TESTING - FLUID LEAKAGE.................................................1513
FLUID LEAKAGE - TORQUE CONVERTER HOUSING AREA.....................................1513
TORQUE CONVERTER LEAKAGE..........................................................1514
STANDARD PROCEDURE - ALUMINUM THREAD REPAIR...............................................1514
REMOVAL...................................................................................1514
DISASSEMBLY...............................................................................1516
ASSEMBLY..................................................................................1533
INSTALLATION..............................................................................1550
SCHEMATICS AND DIAGRAMS - 42RLE TRANSMISSION..............................................1552
SPECIFICATIONS............................................................................1565
42RLE AUTOMATIC TRANSMISSION..........................................................1565
SPECIAL TOOLS.............................................................................1567
42RLE AUTOMATIC TRANSMISSION..........................................................1567
ACCUMULATOR...................................................................................1570
DESCRIPTION...............................................................................1570
OPERATION.................................................................................1570
ADAPTER HOUSING SEAL..........................................................................1570
REMOVAL...................................................................................1570
INSTALLATION..............................................................................1570
BEARINGS......................................................................................1571
ADJUSTMENTS...............................................................................1571
BEARING ADJUSTMENT PROCEDURES.........................................................1571
BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM..................................................1571
DESCRIPTION...............................................................................1571
OPERATION.................................................................................1571
DIAGNOSIS AND TESTING - BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM.........................1571
DRIVING CLUTCHES..............................................................................1571
DESCRIPTION...............................................................................1571
OPERATION.................................................................................1571
UNDERDRIVE CLUTCH.....................................................................1572
OVERDRIVE CLUTCH......................................................................1572
REVERSE CLUTCH........................................................................1572
EXTENSION HOUSING SEAL........................................................................1572
REMOVAL...................................................................................1572
INSTALLATION..............................................................................1572
FLUID AND FILTER..............................................................................1573
DIAGNOSIS AND TESTING.....................................................................1573
DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID.........................................1573
DIAGNOSIS AND TESTING - EFFECTS OF INCORRECT FLUID LEVEL..............................1573
DIAGNOSIS AND TESTING - FLUID CONTAMINATION...........................................1573
STANDARD PROCEDURE........................................................................1573
STANDARD PROCEDURE - FLUID LEVEL CHECK................................................1573
FLUID LEVEL CHECK.................................................................1573
FLUID LEVEL CHECK USING DRB.......................................................1573
STANDARD PROCEDURE - FLUID/FILTER SERVICE.............................................1574
STANDARD PROCEDURE - TRANSMISSION FILL................................................1574
GEARSHIFT CABLE...............................................................................1575
DIAGNOSIS AND TESTING - GEARSHIFT CABLE...................................................1575
REMOVAL...................................................................................1575
INSTALLATION..............................................................................1576
ADJUSTMENTS - GEARSHIFT CABLE.............................................................1577
Gearshift Adjustment Procedure........................................................1577
HOLDING CLUTCHES..............................................................................1577
DESCRIPTION...............................................................................1577
OPERATION.................................................................................1577
2/4 CLUTCH............................................................................1577
LOW/REVERSE CLUTCH....................................................................1578
INPUT CLUTCH ASSEMBLY.........................................................................1578
DISASSEMBLY...............................................................................1578
ASSEMBLY..................................................................................1585
INPUT SPEED SENSOR............................................................................1595
DESCRIPTION...............................................................................1595
OPERATION.................................................................................1595
REMOVAL...................................................................................1596
INSTALLATION..............................................................................1596
OIL PUMP......................................................................................1596
DESCRIPTION...............................................................................1596
OPERATION.................................................................................1596
DISASSEMBLY...............................................................................1596
ASSEMBLY..................................................................................1597
OUTPUT SPEED SENSOR...........................................................................1598
DESCRIPTION...............................................................................1598
OPERATION.................................................................................1598
REMOVAL...................................................................................1598
INSTALLATION..............................................................................1598
OVERDRIVE SWITCH..............................................................................1598
DESCRIPTION...............................................................................1598
OPERATION.................................................................................1598
PARK - INTERLOCK CABLE........................................................................1599
REMOVAL...................................................................................1599
INSTALLATION..............................................................................1599
ADJUSTMENTS - PARK-INTERLOCK CABLE........................................................1600
PLANETARY GEARTRAIN...........................................................................1601
DESCRIPTION...............................................................................1601
OPERATION.................................................................................1601
SEAL - OIL PUMP...............................................................................1601
REMOVAL...................................................................................1601
INSTALLATION..............................................................................1601
SHIFT MECHANISM...............................................................................1601
DESCRIPTION...............................................................................1601
OPERATION.................................................................................1601
REMOVAL...................................................................................1602
INSTALLATION..............................................................................1602
SOLENOID......................................................................................1602
DESCRIPTION...............................................................................1602
OPERATION.................................................................................1603
SOLENOID/PRESSURE SWITCH ASSY.................................................................1604
DESCRIPTION...............................................................................1604
OPERATION.................................................................................1604
SOLENOIDS.............................................................................1604
PRESSURE SWITCHES.....................................................................1604
REMOVAL...................................................................................1605
INSTALLATION..............................................................................1605
TORQUE CONVERTER..............................................................................1606
DESCRIPTION...............................................................................1606
IMPELLER..............................................................................1607
TURBINE...............................................................................1608
STATOR................................................................................1609
TORQUE CONVERTER CLUTCH (TCC).........................................................1609
OPERATION.................................................................................1610
TURBINE...............................................................................1610
STATOR................................................................................1611
TORQUE CONVERTER CLUTCH (TCC).........................................................1611
REMOVAL...................................................................................1611
INSTALLATION..............................................................................1611
TRANSMISSION CONTROL RELAY....................................................................1612
DESCRIPTION...............................................................................1612
OPERATION.................................................................................1612
TRANSMISSION RANGE SENSOR.....................................................................1612
DESCRIPTION...............................................................................1612
OPERATION.................................................................................1612
REMOVAL...................................................................................1613
INSTALLATION..............................................................................1613
TRANSMISSION TEMPERATURE SENSOR...............................................................1613
DESCRIPTION...............................................................................1613
OPERATION.................................................................................1614
CALCULATED TEMPERATURE................................................................1614
VALVE BODY....................................................................................1614
DESCRIPTION...............................................................................1614
OPERATION.................................................................................1614
THERMAL VALVE.........................................................................1614
REGULATOR VALVE.......................................................................1614
SOLENOID SWITCH VALVE.................................................................1616
MANUAL VALVE..........................................................................1616
CONVERTER CLUTCH SWITCH VALVE.........................................................1616
CONVERTER CLUTCH CONTROL VALVE........................................................1616
T/C REGULATOR VALVE...................................................................1616
LOW/REVERSE SWITCH VALVE..............................................................1616
REMOVAL...................................................................................1617
DISASSEMBLY...............................................................................1619
ASSEMBLY..................................................................................1625
INSTALLATION..............................................................................1630
AUTOMATIC TRANSMISSION - 45RFE....................................................................1631
AUTOMATIC TRANSMISSION - 45RFE................................................................1632
DESCRIPTION...............................................................................1632
TRANSMISSION IDENTIFICATION...........................................................1633
GEAR RATIOS...........................................................................1633
OPERATION.................................................................................1633
DIAGNOSIS AND TESTING.....................................................................1633
DIAGNOSIS AND TESTING - AUTOMATIC TRANSMISSION........................................1633
DIAGNOSIS AND TESTING - PRELIMINARY...................................................1634
VEHICLE IS DRIVABLE...............................................................1634
VEHICLE IS DISABLED...............................................................1634
DIAGNOSIS AND TESTING - ROAD TESTING..................................................1634
DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TEST.......................................1635
Pressure Test Port Locations......................................................1635
TEST PROCEDURE....................................................................1635
DIAGNOSIS AND TESTING - AIR CHECKING TRANSMISSION CLUTCH OPERATION....................1636
DIAGNOSIS AND TESTING - CONVERTER HOUSING FLUID LEAK..................................1636
TORQUE CONVERTER LEAK POINTS......................................................1636
STANDARD PROCEDURE - ALUMINUM THREAD REPAIR...............................................1637
REMOVAL...................................................................................1637
DISASSEMBLY...............................................................................1639
CLEANING..................................................................................1645
INSPECTION................................................................................1645
ASSEMBLY..................................................................................1646
INSTALLATION..............................................................................1652
SCHEMATICS AND DIAGRAMS...................................................................1656
HYDRAULIC SCHEMATICS..................................................................1656
SPECIFICATIONS............................................................................1675
TRANSMISSION..........................................................................1675
SPECIAL TOOLS.............................................................................1676
RFE TRANSMISSION......................................................................1676
4C RETAINER/BULKHEAD..........................................................................1679
DISASSEMBLY...............................................................................1679
ASSEMBLY..................................................................................1679
ADAPTER HOUSING SEAL..........................................................................1680
REMOVAL...................................................................................1680
INSTALLATION..............................................................................1680
BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM.....................................................1681
DESCRIPTION...............................................................................1681
OPERATION.................................................................................1681
DIAGNOSIS AND TESTING - BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM.........................1681
FLUID AND FILTER..............................................................................1681
DIAGNOSIS AND TESTING.....................................................................1681
DIAGNOSIS AND TESTING - EFFECTS OF INCORRECT FLUID LEVEL..............................1681
DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID.........................................1681
DIAGNOSIS AND TESTING - FLUID CONTAMINATION...........................................1681
STANDARD PROCEDURE........................................................................1682
STANDARD PROCEDURE - FLUID LEVEL CHECK................................................1682
STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT.....................................1682
REMOVAL...........................................................................1682
INSPECTION........................................................................1683
CLEANING..........................................................................1683
INSTALLATION......................................................................1684
STANDARD PROCEDURE - TRANSMISSION FILL................................................1684
GEARSHIFT CABLE...............................................................................1684
DIAGNOSIS AND TESTING - GEARSHIFT CABLE...................................................1684
REMOVAL...................................................................................1684
INSTALLATION..............................................................................1685
ADJUSTMENTS - GEARSHIFT CABLE.............................................................1686
Gearshift Adjustment Procedure........................................................1686
HOLDING CLUTCHES..............................................................................1687
DESCRIPTION...............................................................................1687
OPERATION.................................................................................1688
2C CLUTCH.............................................................................1688
4C CLUTCH.............................................................................1688
LOW/REVERSE CLUTCH....................................................................1688
INPUT CLUTCH ASSEMBLY.........................................................................1689
DESCRIPTION...............................................................................1689
OPERATION.................................................................................1689
UNDERDRIVE CLUTCH.....................................................................1689
OVERDRIVE CLUTCH......................................................................1691
REVERSE CLUTCH........................................................................1691
DISASSEMBLY...............................................................................1691
ASSEMBLY..................................................................................1693
INPUT SPEED SENSOR............................................................................1698
DESCRIPTION...............................................................................1698
OPERATION.................................................................................1698
REMOVAL...................................................................................1698
INSTALLATION..............................................................................1699
LINE PRESSURE (LP) SENSOR.....................................................................1699
DESCRIPTION...............................................................................1699
OPERATION.................................................................................1699
REMOVAL...................................................................................1699
INSTALLATION..............................................................................1699
LOW/REVERSE CLUTCH............................................................................1700
DISASSEMBLY...............................................................................1700
CLEANING..................................................................................1701
INSPECTION................................................................................1701
ASSEMBLY..................................................................................1701
OIL PUMP......................................................................................1702
DESCRIPTION...............................................................................1702
OPERATION.................................................................................1702
CONVERTER CLUTCH SWITCH VALVE.........................................................1702
CONVERTER CLUTCH REGULATOR VALVE......................................................1703
TORQUE CONVERTER LIMIT VALVE..........................................................1703
STANDARD PROCEDURE - OIL PUMP VOLUME CHECK................................................1703
DISASSEMBLY...............................................................................1704
CLEANING..................................................................................1705
INSPECTION................................................................................1705
ASSEMBLY..................................................................................1706
OIL PUMP FRONT SEAL...........................................................................1707
REMOVAL...................................................................................1707
INSTALLATION..............................................................................1707
OUTPUT SPEED SENSOR...........................................................................1707
DESCRIPTION...............................................................................1707
OPERATION.................................................................................1707
REMOVAL...................................................................................1707
INSTALLATION..............................................................................1707
OVERDRIVE SWITCH..............................................................................1708
DESCRIPTION...............................................................................1708
OPERATION.................................................................................1708
PARK - INTERLOCK CABLE........................................................................1708
REMOVAL...................................................................................1708
INSTALLATION..............................................................................1708
ADJUSTMENTS - PARK-INTERLOCK CABLE........................................................1709
PISTONS.......................................................................................1710
DESCRIPTION...............................................................................1710
OPERATION.................................................................................1710
PRESSURE..............................................................................1710
PRESSURE ON A CONFINED FLUID..........................................................1710
FORCE MULTIPLICATION..................................................................1711
PISTON TRAVEL.........................................................................1711
PLANETARY GEARTRAIN...........................................................................1712
DESCRIPTION...............................................................................1712
OPERATION.................................................................................1712
REACTION PLANETARY GEARTRAIN..........................................................1712
REVERSE PLANETARY GEARTRAIN...........................................................1712
INPUT PLANETARY GEARTRAIN.............................................................1713
DISASSEMBLY...............................................................................1713
CLEANING..................................................................................1713
INSPECTION................................................................................1713
ASSEMBLY..................................................................................1714
SHIFT MECHANISM...............................................................................1715
DESCRIPTION...............................................................................1715
OPERATION.................................................................................1715
REMOVAL...................................................................................1715
INSTALLATION..............................................................................1716
SOLENOID SWITCH VALVE.........................................................................1716
DESCRIPTION...............................................................................1716
OPERATION.................................................................................1716
SOLENOIDS.....................................................................................1716
DESCRIPTION...............................................................................1716
OPERATION.................................................................................1717
TORQUE CONVERTER..............................................................................1717
DESCRIPTION...............................................................................1717
IMPELLER..............................................................................1718
TURBINE...............................................................................1719
STATOR................................................................................1720
TORQUE CONVERTER CLUTCH (TCC).........................................................1720
OPERATION.................................................................................1721
TURBINE...............................................................................1721
STATOR................................................................................1721
TORQUE CONVERTER CLUTCH (TCC).........................................................1721
REMOVAL...................................................................................1722
INSTALLATION..............................................................................1722
TRANSMISSION CONTROL RELAY....................................................................1723
DESCRIPTION...............................................................................1723
OPERATION.................................................................................1723
TRANSMISSION RANGE SENSOR.....................................................................1723
DESCRIPTION...............................................................................1723
OPERATION.................................................................................1723
TRANSMISSION SOLENOID/TRS ASSEMBLY............................................................1724
DESCRIPTION...............................................................................1724
OPERATION.................................................................................1724
SOLENOIDS.............................................................................1724
PRESSURE SWITCHES.....................................................................1724
REMOVAL...................................................................................1725
INSTALLATION..............................................................................1725
TRANSMISSION TEMPERATURE SENSOR...............................................................1725
DESCRIPTION...............................................................................1725
OPERATION.................................................................................1725
Calculated Temperature................................................................1725
VALVE BODY....................................................................................1726
DESCRIPTION...............................................................................1726
OPERATION.................................................................................1726
SOLENOID SWITCH VALVE.................................................................1726
MANUAL VALVE..........................................................................1727
LOW/REVERSE SWITCH VALVE..............................................................1727
REMOVAL...................................................................................1727
DISASSEMBLY...............................................................................1728
CLEANING..................................................................................1730
INSPECTION................................................................................1731
ASSEMBLY..................................................................................1732
INSTALLATION..............................................................................1732
TRANSFER CASE - NV231.............................................................................1733
TRANSFER CASE - NV231.........................................................................1733
DESCRIPTION...............................................................................1733
OPERATING RANGES......................................................................1733
SHIFT MECHANISM.......................................................................1734
IDENTIFICATION........................................................................1734
OPERATION.................................................................................1734
DIAGNOSIS AND TESTING - TRANSFER CASE - NV231.............................................1735
REMOVAL...................................................................................1736
DISASSEMBLY...............................................................................1737
REAR RETAINER AND OIL PUMP............................................................1737
COMPANION FLANGE AND RANGE LEVER......................................................1738
FRONT OUTPUT SHAFT AND DRIVE CHAIN....................................................1739
SHIFT FORKS AND MAINSHAFT.............................................................1740
MAINSHAFT.............................................................................1742
INPUT GEAR AND LOW RANGE GEAR.........................................................1742
INPUT AND LOW RANGE GEAR..............................................................1743
CLEANING..................................................................................1745
INSPECTION................................................................................1745
MAINSHAFT/SPROCKET/HUB................................................................1745
INPUT GEAR AND PLANETARY CARRIER......................................................1746
SHIFT FORKS/HUBS/SLEEVES..............................................................1746
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT..............................................1747
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN....................................................1748
LOW RANGE ANNULUS GEAR................................................................1748
FRONT/REAR CASES AND FRONT RETAINER...................................................1748
OIL PUMP/OIL PICKUP...................................................................1748
ASSEMBLY..................................................................................1748
BEARINGS AND SEALS....................................................................1748
INPUT AND LOW RANGE GEAR..............................................................1752
MAINSHAFT.............................................................................1753
SHIFT FORKS, SECTOR, AND MAINSHAFT....................................................1753
FRONT OUTPUT SHAFT AND DRIVE CHAIN....................................................1755
OIL PUMP AND REAR CASE................................................................1756
COMPANION FLANGE AND RANGE LEVER......................................................1757
REAR RETAINER.........................................................................1757
INSTALLATION..............................................................................1758
SPECIFICATIONS............................................................................1758
TRANSFER CASE - NV231.................................................................1758
SPECIAL TOOLS.............................................................................1759
TRANSFER CASE - NV231.................................................................1759
FLUID.........................................................................................1761
STANDARD PROCEDURE - FLUID DRAIN AND FILL.................................................1761
FRONT OUTPUT SHAFT SEAL.......................................................................1761
REMOVAL...................................................................................1761
INSTALLATION..............................................................................1761
POSITION SENSOR...............................................................................1761
DESCRIPTION...............................................................................1761
OPERATION.................................................................................1762
REMOVAL...................................................................................1763
INSTALLATION..............................................................................1763
REAR OUTPUT SHAFT SEAL........................................................................1763
REMOVAL...................................................................................1763
INSTALLATION..............................................................................1764
SHIFT LEVER...................................................................................1765
REMOVAL...................................................................................1765
INSTALLATION..............................................................................1765
TRANSFER CASE - NV242.............................................................................1766
TRANSFER CASE - NV242.........................................................................1766
DESCRIPTION...............................................................................1766
TRANSFER CASE IDENTIFICATION..........................................................1766
OPERATING RANGES......................................................................1766
SHIFT MECHANISM.......................................................................1766
OPERATION.................................................................................1767
DIAGNOSIS AND TESTING - TRANSFER CASE - NV242.............................................1767
REMOVAL...................................................................................1768
DISASSEMBLY...............................................................................1769
REAR RETAINER.........................................................................1769
COMPANION FLANGE AND RANGE LEVER......................................................1771
FRONT OUTPUT SHAFT AND DRIVE CHAIN....................................................1772
SHIFT FORKS AND MAINSHAFT.............................................................1773
INPUT GEAR/LOW RANGE ASSEMBLY.........................................................1776
DIFFERENTIAL..........................................................................1778
CLEANING..................................................................................1779
INSPECTION................................................................................1779
MAINSHAFT/SPROCKET/HUB................................................................1779
INPUT GEAR AND PLANETARY CARRIER......................................................1779
SHIFT FORKS/HUBS/SLEEVES..............................................................1780
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT..............................................1780
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN....................................................1780
LOW RANGE ANNULUS GEAR................................................................1780
FRONT-REAR CASES AND FRONT RETAINER...................................................1780
OIL PUMP/OIL PICKUP...................................................................1780
ASSEMBLY..................................................................................1782
BEARINGS AND SEALS....................................................................1782
DIFFERENTIAL..........................................................................1785
INPUT GEAR/LOW RANGE ASSEMBLY.........................................................1786
SHIFT FORKS, SECTOR, AND MAINSHAFT....................................................1787
FRONT OUTPUT SHAFT AND DRIVE CHAIN....................................................1792
OIL PUMP AND REAR CASE................................................................1792
REAR RETAINER.........................................................................1793
COMPANION FLANGE AND RANGE LEVER......................................................1794
INSTALLATION..............................................................................1795
SPECIFICATIONS............................................................................1795
NV242 TRANSFER CASE...................................................................1795
SPECIAL TOOLS.............................................................................1796
TRANSFER CASE - NV242.................................................................1796
FLUID.........................................................................................1798
STANDARD PROCEDURE - FLUID DRAIN AND FILL.................................................1798
FRONT OUTPUT SHAFT SEAL.......................................................................1798
REMOVAL...................................................................................1798
INSTALLATION..............................................................................1798
POSITION SENSOR...............................................................................1798
DESCRIPTION...............................................................................1798
OPERATION.................................................................................1799
REMOVAL...................................................................................1800
INSTALLATION..............................................................................1800
REAR OUTPUT SHAFT SEAL........................................................................1800
REMOVAL...................................................................................1800
INSTALLATION..............................................................................1801
SHIFT LEVER...................................................................................1801
REMOVAL...................................................................................1801
INSTALLATION..............................................................................1802
22-TIRES/WHEELS.......................................................................................1804
TIRES/WHEELS......................................................................................1804
DIAGNOSIS AND TESTING - TIRE AND WHEEL RUNOUT.................................................1804
METHOD 1 (RELOCATE WHEEL ON HUB)..........................................................1804
METHOD 2 (RELOCATE TIRE ON WHEEL).........................................................1804
STANDARD PROCEDURE............................................................................1805
STANDARD PROCEDURE - TIRE ROTATION........................................................1805
STANDARD PROCEDURE - MATCH MOUNTING.......................................................1806
STANDARD PROCEDURE - WHEEL BALANCING......................................................1807
SPARE TIRE........................................................................................1808
DESCRIPTION...................................................................................1808
DESCRIPTION - SPARE / TEMPORARY TIRE......................................................1808
DESCRIPTION - FULL SIZE, SPARE WHEEL WITH MATCHING TIRE...................................1808
REMOVAL.......................................................................................1808
INSTALLATION..................................................................................1808
TIRES.............................................................................................1808
DESCRIPTION...................................................................................1808
DESCRIPTION - TIRES.......................................................................1808
TIRE IDENTIFICATION...................................................................1809
TIRE CHAINS...........................................................................1809
DESCRIPTION - RADIAL-PLY TIRES............................................................1809
DESCRIPTION - SPARE TIRE &TEMPORARY.......................................................1809
DESCRIPTION - TIRE PRESSURE FOR HIGH SPEED................................................1809
DESCRIPTION - REPLACEMENT TIRES...........................................................1810
DIAGNOSIS AND TESTING.........................................................................1810
DIAGNOSIS AND TESTING - TIRE INFLATION....................................................1810
DIAGNOSIS AND TESTING - TREAD WEAR INDICATORS.............................................1811
DIAGNOSIS AND TESTING - PRESSURE GAUGES...................................................1811
DIAGNOSIS AND TESTING - TIRE/VEHICLE LEAD.................................................1811
DIAGNOSIS AND TESTING - TIRE WEAR PATTERNS................................................1811
DIAGNOSIS AND TESTING - TIRE NOISE OR VIBRATION...........................................1811
STANDARD PROCEDURE - REPAIRING LEAKS..........................................................1811
CLEANING......................................................................................1811
SPECIFICATIONS................................................................................1813
WHEELS............................................................................................1813
DESCRIPTION...................................................................................1813
DIAGNOSIS AND TESTING - WHEELS................................................................1814
STANDARD PROCEDURE............................................................................1814
STANDARD PROCEDURE - WHEEL REPLACEMENT....................................................1814
STANDARD PROCEDURE - WHEEL MOUNTING.......................................................1814
SPECIFICATIONS................................................................................1815
SPECIFICATION.............................................................................1815
STUDS.............................................................................................1815
REMOVAL.......................................................................................1815
INSTALLATION..................................................................................1815
23-BODY...............................................................................................1824
BODY..............................................................................................1824
WARNING.......................................................................................1824
SAFETY PRECAUTIONS AND WARNINGS0 - 10 KJ (Continued)..................................1824
DIAGNOSIS AND TESTING.........................................................................1824
DIAGNOSIS AND TESTING - WATER LEAKS.......................................................1824
VISUAL INSPECTION BEFORE WATER LEAK TESTS.............................................1825
WATER LEAK TESTS......................................................................1825
WATER LEAK DETECTION..................................................................1825
DIAGNOSIS AND TESTING - WIND NOISE........................................................1825
VISUAL INSPECTION BEFORE TESTS........................................................1825
STANDARD PROCEDURE............................................................................1826
STANDARD PROCEDURE - BODY LUBRICATION.....................................................1826
STANDARD PROCEDURE - HEAT STAKING.........................................................1826
STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR............................................1826
Rigid Plastics:.......................................................................1826
Semi-Rigid Plastics:..................................................................1827
Flexible Plastics:....................................................................1827
Repair Procedure:.....................................................................1827
Adhesion Promoter/Surface Modifier:...................................................1827
SAFETY PRECAUTION AND WARNINGS........................................................1827
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES...................................1827
PANEL SECTIONING......................................................................1829
PANEL REINFORCEMENT...................................................................1829
VISUAL INSPECTION.....................................................................1830
PANEL SURFACE PREPARATION.............................................................1830
PATCHING PANELS.......................................................................1831
PANEL PATCH FABRICATIONS..............................................................1831
PANEL PATCH INSTALLATION..............................................................1831
PATCHED PANEL SURFACING...............................................................1833
STANDARD PROCEDURE - BUZZ, SQUEAK & RATTLE................................................1833
SPECIFICATIONS................................................................................1835
SPECIAL TOOLS.................................................................................1836
BODY......................................................................................1836
HOOD..............................................................................................1837
HINGE.........................................................................................1837
REMOVAL...................................................................................1837
INSTALLATION..............................................................................1837
HOOD..........................................................................................1837
REMOVAL...................................................................................1837
INSTALLATION..............................................................................1837
ADJUSTMENTS...............................................................................1837
ADJUSTMENT............................................................................1837
LATCH.........................................................................................1837
REMOVAL...................................................................................1837
INSTALLATION..............................................................................1838
LATCH RELEASE CABLE...........................................................................1838
REMOVAL...................................................................................1838
INSTALLATION..............................................................................1838
SUPPORT CYLINDER..............................................................................1839
REMOVAL...................................................................................1839
INSTALLATION..............................................................................1839
LATCH RELEASE HANDLE..........................................................................1839
REMOVAL...................................................................................1839
INSTALLATION..............................................................................1839
DOOR - FRONT......................................................................................1840
CHECK STRAP...................................................................................1840
REMOVAL...................................................................................1840
INSTALLATION..............................................................................1840
DOOR..........................................................................................1841
REMOVAL...................................................................................1841
INSTALLATION..............................................................................1841
ADJUSTMENTS...............................................................................1841
ADJUSTMENT............................................................................1841
FORE/AFT..........................................................................1841
UP/DOWN...........................................................................1841
IN/OUT............................................................................1842
DOOR GLASS....................................................................................1842
REMOVAL...................................................................................1842
INSTALLATION..............................................................................1842
EXTERIOR HANDLE...............................................................................1843
REMOVAL...................................................................................1843
INSTALLATION..............................................................................1843
GLASS RUN CHANNEL.............................................................................1843
REMOVAL...................................................................................1843
INSTALLATION..............................................................................1843
HINGE.........................................................................................1843
REMOVAL...................................................................................1843
INSTALLATION..............................................................................1843
LATCH.........................................................................................1844
REMOVAL...................................................................................1844
INSTALLATION..............................................................................1844
LATCH STRIKER.................................................................................1844
REMOVAL...................................................................................1844
INSTALLATION..............................................................................1844
LOCK CYLINDER.................................................................................1845
REMOVAL...................................................................................1845
INSTALLATION..............................................................................1845
TRIM PANEL....................................................................................1845
REMOVAL...................................................................................1845
INSTALLATION..............................................................................1845
WATERDAM......................................................................................1846
REMOVAL...................................................................................1846
INSTALLATION..............................................................................1846
WINDOW REGULATOR - MANUAL.....................................................................1846
REMOVAL...................................................................................1846
INSTALLATION..............................................................................1847
WINDOW REGULATOR - POWER......................................................................1847
REMOVAL...................................................................................1847
INSTALLATION..............................................................................1848
DOORS - REAR......................................................................................1849
CHECK STRAP...................................................................................1849
REMOVAL...................................................................................1849
INSTALLATION..............................................................................1849
DOOR..........................................................................................1850
REMOVAL...................................................................................1850
INSTALLATION..............................................................................1850
ADJUSTMENTS...............................................................................1850
ADJUSTMENT............................................................................1850
FORE/AFT..........................................................................1850
UP/DOWN...........................................................................1850
IN/OUT............................................................................1851
DOOR GLASS....................................................................................1851
REMOVAL...................................................................................1851
INSTALLATION..............................................................................1852
EXTERIOR HANDLE...............................................................................1852
REMOVAL...................................................................................1852
INSTALLATION..............................................................................1852
GLASS RUN CHANNEL.............................................................................1853
REMOVAL...................................................................................1853
INSTALLATION..............................................................................1853
HINGE.........................................................................................1853
REMOVAL...................................................................................1853
INSTALLATION..............................................................................1853
LATCH.........................................................................................1853
REMOVAL...................................................................................1853
INSTALLATION..............................................................................1854
ADJUSTMENTS...............................................................................1854
ADJUSTMENT............................................................................1854
LATCH STRIKER.................................................................................1854
REMOVAL...................................................................................1854
INSTALLATION..............................................................................1854
TRIM PANEL....................................................................................1854
REMOVAL...................................................................................1854
INSTALLATION..............................................................................1855
WATERDAM......................................................................................1855
REMOVAL...................................................................................1855
INSTALLATION..............................................................................1855
WINDOW REGULATOR - MANUAL.....................................................................1856
REMOVAL...................................................................................1856
INSTALLATION..............................................................................1856
WINDOW REGULATOR - POWER......................................................................1856
REMOVAL...................................................................................1856
INSTALLATION..............................................................................1857
SWING GATE........................................................................................1858
FLIP-UP GLASS.................................................................................1858
REMOVAL...................................................................................1858
INSTALLATION..............................................................................1858
ADJUSTMENTS...............................................................................1858
ADJUSTMENT............................................................................1858
FLIP-UP GLASS LATCH...........................................................................1859
REMOVAL...................................................................................1859
INSTALLATION..............................................................................1859
FLIP-UP GLASS - HINGE.........................................................................1859
REMOVAL...................................................................................1859
INSTALLATION..............................................................................1860
FLIP-UP GLASS - HINGE COVER...................................................................1860
REMOVAL...................................................................................1860
INSTALLATION..............................................................................1860
FLIP-UP GLASS SUPPORT CYLINDER................................................................1861
REMOVAL...................................................................................1861
INSTALLATION..............................................................................1861
TRIM PANEL....................................................................................1862
REMOVAL...................................................................................1862
INSTALLATION..............................................................................1862
LATCH.........................................................................................1862
REMOVAL...................................................................................1862
INSTALLATION..............................................................................1862
LATCH STRIKER.................................................................................1862
REMOVAL...................................................................................1862
INSTALLATION..............................................................................1862
ADJUSTMENTS...............................................................................1862
ADJUSTMENT............................................................................1862
LATCH - ACCESS PANEL..........................................................................1863
DESCRIPTION...............................................................................1863
REMOVAL...................................................................................1863
INSTALLATION..............................................................................1863
EXTERIOR HANDLE...............................................................................1863
REMOVAL...................................................................................1863
INSTALLATION..............................................................................1863
LOCK CYLINDER.................................................................................1863
REMOVAL...................................................................................1863
INSTALLATION..............................................................................1863
CHECK STRAP...................................................................................1864
REMOVAL...................................................................................1864
INSTALLATION..............................................................................1864
STABILIZER WEDGE/INSERT.......................................................................1864
REMOVAL...................................................................................1864
INSTALLATION..............................................................................1864
ADJUSTMENTS...............................................................................1864
ADJUSTMENT............................................................................1864
HINGE.........................................................................................1865
REMOVAL...................................................................................1865
INSTALLATION..............................................................................1865
SWING GATE....................................................................................1866
REMOVAL...................................................................................1866
INSTALLATION..............................................................................1866
ADJUSTMENTS...............................................................................1867
ADJUSTMENT............................................................................1867
IN/OUT............................................................................1867
UP/DOWN...........................................................................1867
LEFT/RIGHT........................................................................1867
EXTERIOR..........................................................................................1868
BODY SIDE MOLDINGS............................................................................1868
REMOVAL...................................................................................1868
INSTALLATION..............................................................................1868
COWL GRILLE...................................................................................1868
REMOVAL...................................................................................1868
INSTALLATION..............................................................................1868
EXTERIOR NAME PLATES..........................................................................1869
REMOVAL...................................................................................1869
INSTALLATION..............................................................................1869
FRONT FENDER..................................................................................1869
REMOVAL...................................................................................1869
INSTALLATION..............................................................................1869
FUEL FILL DOOR/HOUSING........................................................................1870
REMOVAL...................................................................................1870
INSTALLATION..............................................................................1870
GRILLE........................................................................................1871
REMOVAL...................................................................................1871
INSTALLATION..............................................................................1871
GRILLE OPENING REINFORCEMENT..................................................................1871
REMOVAL...................................................................................1871
INSTALLATION..............................................................................1871
FRONT WHEELHOUSE SPLASH SHIELD................................................................1872
REMOVAL...................................................................................1872
INSTALLATION..............................................................................1872
LUGGAGE RACK..................................................................................1873
REMOVAL...................................................................................1873
INSTALLATION..............................................................................1873
REAR WHEELHOUSE SPLASH SHIELD.................................................................1873
REMOVAL...................................................................................1873
INSTALLATION..............................................................................1873
SIDE VIEW MIRROR..............................................................................1874
REMOVAL...................................................................................1874
INSTALLATION..............................................................................1874
FRONT WHEEL OPENING FLARE MOLDINGS............................................................1874
REMOVAL...................................................................................1874
INSTALLATION..............................................................................1874
REAR WHEEL OPENING FLARE MOLDINGS.............................................................1875
REMOVAL...................................................................................1875
INSTALLATION..............................................................................1875
RADIATOR CROSSMEMBER..........................................................................1875
REMOVAL...................................................................................1875
INSTALLATION..............................................................................1876
SIDE VIEW MIRROR GLASS........................................................................1876
REMOVAL...................................................................................1876
INSTALLATION..............................................................................1876
INSTRUMENT PANEL..................................................................................1877
CLUSTER BEZEL.................................................................................1877
REMOVAL...................................................................................1877
INSTALLATION..............................................................................1877
GLOVE BOX.....................................................................................1878
REMOVAL...................................................................................1878
INSTALLATION..............................................................................1878
GLOVE BOX LATCH...............................................................................1878
REMOVAL...................................................................................1878
INSTALLATION..............................................................................1878
GLOVE BOX LATCH STRIKER.......................................................................1878
REMOVAL...................................................................................1878
INSTALLATION..............................................................................1879
INSTRUMENT PANEL ASSEMBLY.....................................................................1879
REMOVAL...................................................................................1879
INSTALLATION..............................................................................1882
INSTRUMENT PANEL TOP COVER....................................................................1883
REMOVAL...................................................................................1883
INSTALLATION..............................................................................1884
INSTRUMENT PANEL END CAP......................................................................1884
REMOVAL...................................................................................1884
INSTALLATION..............................................................................1884
INSTRUMENT PANEL DRIVER SIDE BEZELS...........................................................1884
REMOVAL...................................................................................1884
INSTALLATION..............................................................................1885
INSTRUMENT PANEL CENTER BEZEL.................................................................1885
REMOVAL...................................................................................1885
INSTALLATION..............................................................................1885
INSTRUMENT PANEL PASSENGER SIDE BEZEL.........................................................1885
REMOVAL...................................................................................1885
INSTALLATION..............................................................................1886
KNEE BLOCKER..................................................................................1886
REMOVAL...................................................................................1886
INSTALLATION..............................................................................1886
INTERIOR..........................................................................................1887
4WD FLOOR SHIFT BOOT..........................................................................1887
REMOVAL...................................................................................1887
INSTALLATION..............................................................................1887
A-PILLAR TRIM AND GRAB HANDLE.................................................................1887
REMOVAL...................................................................................1887
INSTALLATION..............................................................................1887
COWL TRIM COVER...............................................................................1888
REMOVAL...................................................................................1888
INSTALLATION..............................................................................1888
DOOR SILL SCUFF PLATE.........................................................................1888
REMOVAL...................................................................................1888
INSTALLATION..............................................................................1888
ASSIST HANDLE.................................................................................1888
REMOVAL...................................................................................1888
INSTALLATION..............................................................................1888
B-PILLAR LOWER TRIM...........................................................................1888
REMOVAL...................................................................................1888
INSTALLATION..............................................................................1888
B-PILLAR UPPER TRIM...........................................................................1889
REMOVAL...................................................................................1889
INSTALLATION..............................................................................1889
CARPETS AND FLOOR MATS........................................................................1889
REMOVAL...................................................................................1889
Front Carpet..........................................................................1889
Rear Cargo Carpet.....................................................................1889
INSTALLATION..............................................................................1889
Front Carpet..........................................................................1889
Rear Cargo Carpet.....................................................................1889
SHIFT BEZEL...................................................................................1889
REMOVAL...................................................................................1889
INSTALLATION..............................................................................1889
FLOOR CONSOLE.................................................................................1889
REMOVAL...................................................................................1889
INSTALLATION..............................................................................1890
FLOOR CONSOLE LID LATCH.......................................................................1890
REMOVAL...................................................................................1890
INSTALLATION..............................................................................1890
HEADLINER.....................................................................................1890
REMOVAL...................................................................................1890
INSTALLATION..............................................................................1890
QUARTER TRIM PANEL............................................................................1891
REMOVAL...................................................................................1891
INSTALLATION..............................................................................1891
REAR DOOR SCUFF PLATE.........................................................................1891
REMOVAL...................................................................................1891
INSTALLATION..............................................................................1891
SUN VISOR.....................................................................................1891
REMOVAL...................................................................................1891
INSTALLATION..............................................................................1891
SUN VISOR SUPPORT.............................................................................1891
REMOVAL...................................................................................1891
INSTALLATION..............................................................................1891
REAR VIEW MIRROR..............................................................................1892
REMOVAL...................................................................................1892
INSTALLATION..............................................................................1892
INSTALLATION..........................................................................1892
INSTALLATION - REARVIEW MIRROR SUPPORT BRACKET........................................1892
PAINT.............................................................................................1893
PAINT.........................................................................................1893
SPECIFICATIONS - PAINT CODES..............................................................1893
PAINT CODE....................................................................................1893
DESCRIPTION...............................................................................1893
BASE COAT/CLEAR COAT FINISH...................................................................1894
DESCRIPTION...............................................................................1894
PAINT TOUCH-UP................................................................................1894
DESCRIPTION...............................................................................1894
OPERATION.............................................................................1894
FINESSE SANDING/BUFFING & POLISHING...........................................................1894
DESCRIPTION...............................................................................1894
SEATS.............................................................................................1895
HEADREST......................................................................................1895
REMOVAL0 - 12 KJ (Continued)..........................................................1895
INSTALLATION..............................................................................1895
HEADREST SLEEVE...............................................................................1895
REMOVAL...................................................................................1895
INSTALLATION..............................................................................1895
SEAT - FRONT..................................................................................1896
REMOVAL...................................................................................1896
INSTALLATION..............................................................................1896
SEAT BACK - FRONT.............................................................................1897
REMOVAL...................................................................................1897
INSTALLATION..............................................................................1897
SEAT BACK RECLINER - FRONT....................................................................1897
REMOVAL...................................................................................1897
INSTALLATION..............................................................................1897
SEAT BACK COVER - FRONT.......................................................................1897
REMOVAL...................................................................................1897
INSTALLATION..............................................................................1898
SEAT BACK CUSHION - FRONT.....................................................................1898
REMOVAL...................................................................................1898
INSTALLATION..............................................................................1898
SEAT CUSHION - FRONT..........................................................................1898
REMOVAL...................................................................................1898
INSTALLATION..............................................................................1898
SEAT CUSHION COVER - FRONT....................................................................1898
REMOVAL...................................................................................1898
INSTALLATION..............................................................................1898
SEAT CUSHION SIDE SHIELDS.....................................................................1898
REMOVAL...................................................................................1898
INSTALLATION..............................................................................1898
MANUAL SEAT RISER.............................................................................1898
REMOVAL...................................................................................1898
INSTALLATION..............................................................................1898
SEAT TRACK....................................................................................1899
REMOVAL...................................................................................1899
INSTALLATION..............................................................................1899
SEAT - REAR...................................................................................1899
REMOVAL...................................................................................1899
INSTALLATION..............................................................................1899
SEAT BACK - REAR..............................................................................1900
REMOVAL...................................................................................1900
60/40 Split Seat - Left...............................................................1900
60/40 Split Seat - Right..............................................................1900
INSTALLATION..............................................................................1900
60/40 Split Seat - Left...............................................................1900
60/40 Split Seat - Right..............................................................1900
SEAT BACK COVER - REAR........................................................................1901
REMOVAL...................................................................................1901
INSTALLATION..............................................................................1901
SEAT BACK CUSHION - REAR......................................................................1901
REMOVAL...................................................................................1901
INSTALLATION..............................................................................1901
FOLDING REAR SEAT BACK LATCH / LOCK...........................................................1901
REMOVAL...................................................................................1901
INSTALLATION..............................................................................1901
REAR SEAT BACK LATCH STRIKER..................................................................1902
REMOVAL...................................................................................1902
INSTALLATION..............................................................................1902
SEAT BACK FRAME - REAR........................................................................1903
REMOVAL...................................................................................1903
INSTALLATION..............................................................................1903
SEAT CUSHION - REAR...........................................................................1903
REMOVAL...................................................................................1903
INSTALLATION..............................................................................1903
STATIONARY GLASS..................................................................................1904
DOOR GLASS....................................................................................1904
REMOVAL...................................................................................1904
INSTALLATION..............................................................................1904
QUARTER WINDOW................................................................................1904
REMOVAL...................................................................................1904
INSTALLATION..............................................................................1904
WINDSHIELD....................................................................................1905
WARNING...................................................................................1905
WINDSHIELD SAFETY PRECAUTIONS.........................................................1905
REMOVAL...................................................................................1905
INSTALLATION..............................................................................1905
SUNROOF...........................................................................................1907
SUNROOF.......................................................................................1907
DESCRIPTION...............................................................................1907
SUNROOF OPERATION INSTRUCTIONS........................................................1908
DIAGNOSIS AND TESTING.....................................................................1908
WATER DRAINAGE AND WIND NOISE DIAGNOSIS...............................................1908
DIAGNOSTIC PROCEDURES.................................................................1908
GLASS PANEL...................................................................................1910
REMOVAL...................................................................................1910
INSTALLATION..............................................................................1910
ADJUSTMENTS...............................................................................1910
SUNROOF GLASS PANEL ADJUSTMENT........................................................1910
GLASS PANEL SEAL..............................................................................1910
REMOVAL...................................................................................1910
INSTALLATION..............................................................................1910
SUNSHADE......................................................................................1911
REMOVAL...................................................................................1911
INSTALLATION..............................................................................1911
GUIDE ASSEMBLY................................................................................1911
REMOVAL...................................................................................1911
INSTALLATION..............................................................................1911
WIND DEFLECTOR................................................................................1912
REMOVAL...................................................................................1912
INSTALLATION..............................................................................1912
OPENING TRIM LACE.............................................................................1912
REMOVAL...................................................................................1912
INSTALLATION..............................................................................1912
DRAIN TUBE....................................................................................1912
REMOVAL...................................................................................1912
FRONT DRAIN TUBES.....................................................................1912
REAR DRAIN TUBES......................................................................1913
INSTALLATION..............................................................................1913
FRONT DRAIN TUBES.....................................................................1913
REAR DRAIN TUBES......................................................................1913
MODULE ASSEMBLY...............................................................................1913
REMOVAL...................................................................................1913
INSTALLATION..............................................................................1913
DRIVE MOTOR...................................................................................1914
REMOVAL...................................................................................1914
INSTALLATION..............................................................................1914
CONTROL MODULE................................................................................1914
REMOVAL...................................................................................1914
INSTALLATION..............................................................................1914
CONTROL SWITCH................................................................................1915
DESCRIPTION...............................................................................1915
OPERATION.................................................................................1915
DIAGNOSIS AND TESTING - CONTROL SWITCH....................................................1916
REMOVAL...................................................................................1916
INSTALLATION..............................................................................1916
WEATHERSTRIP/SEALS................................................................................1917
A-PILLAR SEAL.................................................................................1917
REMOVAL...................................................................................1917
INSTALLATION..............................................................................1917
COWL WEATHERSTRIP.............................................................................1917
REMOVAL...................................................................................1917
INSTALLATION..............................................................................1917
DOOR PRIMARY WEATHERSTRIP.....................................................................1917
REMOVAL...................................................................................1917
INSTALLATION..............................................................................1917
DOOR LOWER WEATHERSTRIP.......................................................................1918
REMOVAL...................................................................................1918
INSTALLATION..............................................................................1918
FRONT DOOR OUTER BELT MOLDING.................................................................1918
REMOVAL...................................................................................1918
INSTALLATION..............................................................................1918
SWING GATE BELTLINE WEATHERSTRIP..............................................................1918
REMOVAL...................................................................................1918
INSTALLATION..............................................................................1918
SWING GATE OPENING WEATHERSTRIP...............................................................1918
REMOVAL...................................................................................1918
INSTALLATION..............................................................................1918
REAR DOOR OUTER BELT MOLDING..................................................................1919
REMOVAL...................................................................................1919
INSTALLATION..............................................................................1919
SIDE RAIL WEATHERSTRIP/RETAINER...............................................................1919
REMOVAL...................................................................................1919
INSTALLATION..............................................................................1919
WINDSHIELD A-PILLAR WEATHERSTRIP/RETAINER.....................................................1919
REMOVAL...................................................................................1919
INSTALLATION..............................................................................1919
COWL/PLENUM SEAL..............................................................................1919
REMOVAL...................................................................................1919
INSTALLATION..............................................................................1919
COWL/PLENUM WINDOW BAFFLE SEAL................................................................1920
REMOVAL...................................................................................1920
INSTALLATION..............................................................................1920
AIR INLET SEAL................................................................................1920
REMOVAL...................................................................................1920
INSTALLATION..............................................................................1920
FRONT DOOR INNER BELT WEATHERSTRIP............................................................1920
REMOVAL...................................................................................1920
INSTALLATION..............................................................................1920
REAR DOOR INNER BELT WEATHERSTRIP.............................................................1920
REMOVAL...................................................................................1920
INSTALLATION..............................................................................1920
BODY STRUCTURE....................................................................................1921
ASSEMBLY......................................................................................1921
SPECIFICATIONS............................................................................1921
SPECIFICATION.........................................................................1921
WELD AND STRUCTURAL ADHESIVE LOCATIONS........................................................1924
SPECIFICATIONS............................................................................1924
FRONT END ASSEMBLY....................................................................1928
FRONT END ASSEMBLY/UNDERBODY..........................................................1945
REAR FRAME RAILS......................................................................1950
REAR FLOOR PAN ASSEMBLY...............................................................1956
FULL FLOOR PAN ASSEMBLY...............................................................1963
BODY SIDE PANELS AND SUB ASSEMBLIES...................................................1969
BODY SIDE PANELS......................................................................1976
FENDER ASSEMBLIES.....................................................................1988
ROOF PANEL ASSEMBLIES.................................................................1992
BODY SIDE PANELS & FLOOR PAN ASSEMBLIES...............................................1996
SEALER LOCATIONS..............................................................................2002
SPECIFICATIONS............................................................................2002
OPENING DIMENSIONS............................................................................2026
SPECIFICATIONS............................................................................2026
GAP AND FLUSH.................................................................................2031
SPECIFICATIONS............................................................................2031
24-HEATING & AIR CONDITIONING.........................................................................2034
HEATING & AIR CONDITIONING........................................................................2034
DESCRIPTION...................................................................................2034
DESCRIPTION - HEATER AND AIR CONDITIONER..................................................2034
DESCRIPTION - COOLING SYSTEM REQUIREMENTS.................................................2034
DESCRIPTION - REFRIGERANT SYSTEM SERVICE PORT.............................................2035
OPERATION.....................................................................................2035
OPERATION - HEATER AND AIR CONDITIONER....................................................2035
OPERATION - REFRIGERANT SYSTEM SERVICE PORT...............................................2035
DIAGNOSIS AND TESTING.........................................................................2035
DIAGNOSIS AND TESTING - A/C PERFORMANCE...................................................2035
DIAGNOSIS AND TESTING - HEATER PERFORMANCE................................................2039
MAXIMUM HEATER OUTPUT.................................................................2039
TEMPERATURE CONTROL...................................................................2039
DIAGNOSIS AND TESTING - VACUUM SYSTEM.....................................................2039
VACUUM CHECK VALVE....................................................................2040
A/C HEATER CONTROLS...................................................................2040
LOCATING VACUUM LEAKS.................................................................2040
STANDARD PROCEDURE - DIODE REPLACEMENT........................................................2042
SPECIFICATIONS................................................................................2042
A/C APPLICATION TABLE.....................................................................2042
SPECIFICATIONS............................................................................2043
CONTROLS..........................................................................................2044
A/C COMPRESSOR CLUTCH.........................................................................2045
DESCRIPTION - 3.7L and 2.4L...............................................................2045
OPERATION - 3.7L and 2.4L.................................................................2045
DIAGNOSIS AND TESTING - A/C COMPRESSOR CLUTCH.............................................2045
STANDARD PROCEDURE - A/C COMPRESSOR CLUTCH BREAK-IN.......................................2046
REMOVAL...................................................................................2046
INSPECTION................................................................................2047
INSTALLATION..............................................................................2047
A/C COMPRESSOR CLUTCH RELAY...................................................................2048
DESCRIPTION...............................................................................2048
OPERATION.................................................................................2048
DIAGNOSIS AND TESTING - COMPRESSOR CLUTCH RELAY...........................................2048
RELAY TEST............................................................................2048
RELAY CIRCUIT TEST....................................................................2049
REMOVAL...................................................................................2049
INSTALLATION..............................................................................2049
A/C HEATER CONTROL............................................................................2049
DESCRIPTION...............................................................................2049
REMOVAL...................................................................................2050
INSTALLATION..............................................................................2050
A/C HIGH PRESSURE SWITCH......................................................................2050
DESCRIPTION...............................................................................2050
OPERATION.................................................................................2051
DIAGNOSIS AND TESTING - A/C HIGH PRESSURE SWITCH..........................................2051
REMOVAL...................................................................................2051
INSTALLATION..............................................................................2051
A/C LOW PRESSURE SWITCH.......................................................................2051
DESCRIPTION...............................................................................2051
OPERATION.................................................................................2051
DIAGNOSIS AND TESTING - A/C LOW PRESSURE SWITCH...........................................2052
REMOVAL...................................................................................2052
INSTALLATION..............................................................................2052
BLEND DOOR ACTUATOR...........................................................................2053
REMOVAL...................................................................................2053
INSTALLATION..............................................................................2053
BLOWER MOTOR RELAY............................................................................2053
DESCRIPTION...............................................................................2053
OPERATION.................................................................................2053
DIAGNOSIS AND TESTING - BLOWER MOTOR RELAY................................................2054
RELAY TEST............................................................................2054
RELAY CIRCUIT TEST....................................................................2054
REMOVAL...................................................................................2054
INSTALLATION..............................................................................2055
BLOWER MOTOR RESISTOR BLOCK...................................................................2055
DESCRIPTION...............................................................................2055
OPERATION.................................................................................2055
DIAGNOSIS AND TESTING - BLOWER MOTOR RESISTOR.............................................2055
REMOVAL...................................................................................2055
INSTALLATION..............................................................................2055
BLOWER MOTOR SWITCH...........................................................................2056
DESCRIPTION...............................................................................2056
OPERATION.................................................................................2056
DIAGNOSIS AND TESTING - BLOWER MOTOR SWITCH...............................................2056
REMOVAL...................................................................................2056
INSTALLATION..............................................................................2056
MODE DOOR ACTUATOR............................................................................2057
REMOVAL...................................................................................2057
REMOVAL - PANEL DOOR ACTUATOR.........................................................2057
REMOVAL - FLOOR - DEFROST DOOR ACTUATOR...............................................2057
INSTALLATION..............................................................................2058
INSTALLATION - PANEL DOOR ACTUATOR....................................................2058
INSTALLATION - FLOOR - DEFROST DOOR ACTUATOR..........................................2058
RECIRCULATION DOOR ACTUATOR...................................................................2059
REMOVAL...................................................................................2059
INSTALLATION..............................................................................2059
VACUUM CHECK VALVE............................................................................2060
DESCRIPTION...............................................................................2060
OPERATION.................................................................................2060
REMOVAL...................................................................................2061
INSTALLATION..............................................................................2061
DISTRIBUTION......................................................................................2062
AIR OUTLETS...................................................................................2062
DESCRIPTION - DEMISTER OUTLETS............................................................2062
REMOVAL - PANEL OUTLET BARRELS............................................................2062
INSTALLATION - PANEL OUTLET BARRELS.......................................................2062
BLEND DOOR....................................................................................2063
REMOVAL...................................................................................2063
INSTALLATION..............................................................................2063
BLOWER MOTOR..................................................................................2063
DESCRIPTION...............................................................................2063
OPERATION.................................................................................2063
DIAGNOSIS AND TESTING - BLOWER MOTOR......................................................2064
VIBRATION.............................................................................2064
NOISE.................................................................................2064
REMOVAL...................................................................................2064
INSTALLATION..............................................................................2064
DEFROST - DEMISTER DUCT.......................................................................2065
REMOVAL - DEFROST DUCT/DEMISTER ADAPTOR...................................................2065
INSTALLATION - DEFROST/DEMISTER DUCT......................................................2065
FLOOR CONSOLE DUCT............................................................................2066
REMOVAL...................................................................................2066
INSTALLATION..............................................................................2066
FLOOR DUCT....................................................................................2066
REMOVAL...................................................................................2066
INSTALLATION..............................................................................2066
HVAC HOUSING..................................................................................2066
REMOVAL...................................................................................2066
DISASSEMBLY...............................................................................2067
ASSEMBLY..................................................................................2068
INSTALLATION..............................................................................2068
MODE DOOR.....................................................................................2069
REMOVAL...................................................................................2069
REMOVAL - DEFROST DOOR................................................................2069
REMOVAL - FLOOR - DEFROST DOOR........................................................2069
INSTALLATION..............................................................................2070
INSTALLATION - PANEL DOOR.............................................................2070
INSTALLATION - FLOOR - DEFROST DOOR...................................................2070
RECIRCULATION DOOR............................................................................2070
REMOVAL...................................................................................2070
INSTALLATION..............................................................................2071
PLUMBING..........................................................................................2072
PLUMBING......................................................................................2072
DESCRIPTION - REFRIGERANT LINE............................................................2072
WARNING...................................................................................2073
SERVICE WARNINGS......................................................................2073
CAUTION...................................................................................2073
SERVICE CAUTIONS......................................................................2073
CAUTION - REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS...................................2074
STANDARD PROCEDURE........................................................................2074
STANDARD PROCEDURE - REFRIGERANT SYSTEM SERVICE EQUIPMENT.............................2074
MANIFOLD GAUGE SET CONNECTIONS....................................................2074
STANDARD PROCEDURE - REFRIGERANT RECOVERY.............................................2075
STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE......................................2075
STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE........................................2075
SPECIFICATIONS - CHARGE CAPACITY0 - 14 KJ (Continued).................................2076
A/C COMPRESSOR................................................................................2076
DESCRIPTION...............................................................................2076
DESCRIPTION...........................................................................2076
DESCRIPTION - HIGH PRESSURE RELIEF VALVE..............................................2076
OPERATION.................................................................................2076
OPERATION.............................................................................2076
OPERATION - HIGH PRESSURE RELIEF VALVE................................................2076
DIAGNOSIS AND TESTING - A/C COMPRESSOR NOISE..............................................2076
REMOVAL...................................................................................2077
INSTALLATION..............................................................................2078
A/C CONDENSER.................................................................................2079
DESCRIPTION...............................................................................2079
OPERATION.................................................................................2079
REMOVAL...................................................................................2079
INSTALLATION..............................................................................2080
A/C DISCHARGE LINE............................................................................2080
REMOVAL...................................................................................2080
INSTALLATION..............................................................................2081
A/C LIQUID LINE...............................................................................2081
REMOVAL...................................................................................2081
INSTALLATION..............................................................................2081
A/C SUCTION LINE..............................................................................2082
REMOVAL...................................................................................2082
INSTALLATION..............................................................................2083
A/C EVAPORATOR................................................................................2083
DESCRIPTION...............................................................................2083
OPERATION.................................................................................2083
REMOVAL...................................................................................2083
INSTALLATION..............................................................................2083
A/C ORIFICE TUBE..............................................................................2084
DESCRIPTION...............................................................................2084
OPERATION.................................................................................2084
REMOVAL...................................................................................2084
INSTALLATION..............................................................................2084
ACCUMULATOR...................................................................................2085
DESCRIPTION...............................................................................2085
OPERATION.................................................................................2085
REMOVAL...................................................................................2085
INSTALLATION..............................................................................2086
HEATER CORE...................................................................................2086
DESCRIPTION...............................................................................2086
OPERATION.................................................................................2086
REMOVAL...................................................................................2086
INSTALLATION..............................................................................2087
REFRIGERANT...................................................................................2087
DESCRIPTION...............................................................................2087
OPERATION.................................................................................2087
REFRIGERANT OIL...............................................................................2087
DESCRIPTION...............................................................................2087
OPERATION.................................................................................2088
STANDARD PROCEDURE - REFRIGERANT OIL LEVEL................................................2088
25-EMISSIONS CONTROL..................................................................................2090
EMISSIONS CONTROL.................................................................................2090
DESCRIPTION...................................................................................2090
DESCRIPTION - EMISSION CONTROL SYSTEM.....................................................2090
DESCRIPTION - STATE DISPLAY TEST MODE.....................................................2091
DESCRIPTION - CIRCUIT ACTUATION TEST MODE.................................................2091
DESCRIPTION - DIAGNOSTIC TROUBLE CODES....................................................2091
DESCRIPTION - TASK MANAGER................................................................2091
DESCRIPTION - MONITORED SYSTEMS...........................................................2091
OXYGEN SENSOR (O2S) MONITOR...........................................................2091
OXYGEN SENSOR HEATER MONITOR..........................................................2092
LEAK DETECTION PUMP MONITOR (IF EQUIPPED).............................................2092
MISFIRE MONITOR.......................................................................2093
FUEL SYSTEM MONITOR...................................................................2093
CATALYST MONITOR......................................................................2093
DESCRIPTION - TRIP DEFINITION.............................................................2093
DESCRIPTION - COMPONENT MONITORS..........................................................2094
DESCRIPTION - NON-MONITORED CIRCUITS......................................................2094
DESCRIPTION - HIGH AND LOW LIMITS.........................................................2095
DESCRIPTION - LOAD VALUE..................................................................2095
OPERATION - TASK MANAGER......................................................................2095
Test Sequence.............................................................................2095
MIL Illumination..........................................................................2096
Diagnostic Trouble Codes (DTCs)...........................................................2096
DTC Self Erasure..........................................................................2096
Trip Indicator............................................................................2096
Freeze Frame Data Storage.................................................................2097
Similar Conditions Window.................................................................2097
EVAPORATIVE EMISSIONS.............................................................................2099
EVAPORATIVE EMISSIONS.........................................................................2099
DESCRIPTION - EVAPORATION CONTROL SYSTEM..................................................2099
SPECIFICATIONS............................................................................2101
TORQUE................................................................................2101
EVAP/PURGE SOLENOID...........................................................................2102
DESCRIPTION...............................................................................2102
OPERATION.................................................................................2102
REMOVAL...................................................................................2102
INSTALLATION..............................................................................2102
FUEL FILLER CAP...............................................................................2102
DESCRIPTION...............................................................................2102
OPERATION.................................................................................2102
LEAK DETECTION PUMP...........................................................................2103
DESCRIPTION...............................................................................2103
OPERATION.................................................................................2103
REMOVAL...................................................................................2103
INSTALLATION..............................................................................2103
ORVR..........................................................................................2104
DESCRIPTION...............................................................................2104
OPERATION.................................................................................2104
PCV VALVE.....................................................................................2104
DESCRIPTION...............................................................................2104
2.4L..................................................................................2104
3.7L..................................................................................2105
OPERATION.................................................................................2105
DIAGNOSIS AND TESTING - PCV VALVE.........................................................2106
REMOVAL...................................................................................2107
INSTALLATION..............................................................................2107
VACUUM LINES..................................................................................2107
DESCRIPTION...............................................................................2107
VAPOR CANISTER................................................................................2108
DESCRIPTION...............................................................................2108
OPERATION.................................................................................2108
REMOVAL...................................................................................2108
INSTALLATION..............................................................................2108
INDEX.................................................................................................2110
COMMENTS..............................................................................................2144
–
Very good service !