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2005 Dodge Viper SRT-10 Service Manual - Full Workshop Repair & Diagnostic Guide
2005 Dodge Viper SRT-10 Service Manual - Full Workshop Repair & Diagnostic Guide - Image 2
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2005 Dodge Viper SRT-10 Service Manual – Full Workshop Repair & Diagnostic Guide

Original price was: $49.95.Current price is: $27.95.

The complete 2005 Dodge Viper SRT-10 Service Manual covering the 8.3L V10 engine, T-56 six-speed transmission, ABS brakes, suspension, Hydra-Lok differential, convertible top, wiring diagrams, and every major system on the ZB Viper. Instant PDF download for owners and professional technicians.

SKU: dodge-viper-srt10-2005-sm-hd Category: Tags: , , , Vendor: OEM Service PDFs
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Description

2005 Dodge Viper SRT-10 Service Manual — Complete Workshop Documentation for the ZB Viper

This is the comprehensive 2005 Dodge Viper SRT-10 Service Manual, the factory-issued workshop documentation covering every major mechanical, electrical, and body system on the ZB-generation Viper. Written by DaimlerChrysler for use by dealership technicians, this manual provides the same step-by-step procedures, torque specifications, diagnostic routines, and component illustrations used in professional Viper service. Whether you are performing routine maintenance, rebuilding the 8.3L V10, servicing the Tremec T-56 six-speed, or diagnosing an ABS fault, this manual provides the technical foundation you need.

What This 2005 Dodge Viper SRT-10 Service Manual Covers

The manual is organized into factory service groups, each covering a distinct vehicle system with removal, disassembly, inspection, assembly, and installation procedures. Sections include:

  • Lubrication & Maintenance — Fluid types and capacities, maintenance schedules A and B, hoisting, jump starting, towing, and long-term vehicle storage preparation.
  • Suspension — Front and rear suspension specifications, hub/bearing service, knuckle removal, ball joints, control arms, shock assemblies, stabilizer bars, toe links, and wheel alignment including design height measurement and dynamic toe pattern.
  • Differential & Driveline — Propeller shaft service, single Cardan universal joints, half shaft removal, and the 226RIA rear axle with Hydra-Lok differential operation and diagnosis.
  • Brakes — Base brake system, ABS with electronic variable brake proportioning, disc brake calipers, rotors, master cylinder, power brake booster, adjustable pedals, parking brake, and bleeding procedures.
  • Clutch — Clutch disc, release bearing, flywheel, hydraulic linkage, master cylinder, and clutch pedal position switch diagnostics.
  • Cooling — Accessory drive belt and tensioner, cooling system diagnosis, coolant service, pressure cap testing, radiator fan, radiator, water pump, and thermostat.
  • Engine — 8.3L V10 — Complete engine service including cylinder heads, camshaft, timing chain, hydraulic tappets, pistons and connecting rods, crankshaft, main bearings, oil pump, and lubrication system.
  • Fuel System — Fuel delivery, fuel injection operation, fuel pump module, fuel rail, fuel injectors, throttle body, and quick-connect fittings.
  • Steering — Power steering gear, pump, column, intermediate shaft, and hydraulic flow and pressure testing.
  • Transmission — T-56 — Tremec six-speed manual transmission disassembly, assembly, adjustment, and specifications.
  • Exhaust System — Catalytic converters, resonators, H-pipe, spout assemblies, and exhaust system alignment.
  • Frame & Bumpers — Frame dimensions, damage repair, welding specifications, front and rear fascia, and bumper reinforcements.
  • Body — Convertible top, decklid, doors, exterior panels, hood, instrument panel, interior, paint codes, seats, stationary glass, and weatherstrip.
  • Heating & Air Conditioning — HVAC housing, controls, distribution, plumbing, A/C compressor, condenser, evaporator, and refrigerant service.
  • Emissions Control — On-board diagnostics, monitored systems, evaporative emissions, CCV system, ORVR, and leak detection pump.
  • Electrical Systems — Battery, charging, starting, ignition control, instrument cluster, lamps, power systems, restraints, vehicle theft security, wipers/washers, and complete wiring diagrams.

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the “2005 Dodge Viper SRT-10 Service Manual – Full Workshop Repair & Diagnostic Guide” are as follows:

MAIN WELCOME PAGE
ZB SRT-10 BUX Powertrain
ZB SRT-10 BUX Body
ZB SRT-10 BUX Chassis
2005 ZB SRT-10 Service Manualp. 1
FOREWORD
GROUP TAB LOCATORp. 1
in-INTRODUCTIONp. 2
BODY CODE PLATEp. 2
DESCRIPTIONp. 2
E-MARK LABELp. 2
DESCRIPTIONp. 2
FASTENER IDENTIFICATIONp. 3
DESCRIPTIONp. 3
FASTENER USAGEp. 5
DESCRIPTIONp. 5
FASTENER USAGEp. 5
THREADED HOLE REPAIRp. 5
INTERNATIONAL SYMBOLSp. 5
DESCRIPTIONp. 5
MANUFACTURE PLATEp. 6
DESCRIPTIONp. 6
METRIC SYSTEMp. 6
DESCRIPTIONp. 6
TORQUE REFERENCESp. 8
DESCRIPTIONp. 8
VECI LABELp. 10
DESCRIPTIONp. 10
VEHICLE IDENTIFICATION NUMBERp. 10
DESCRIPTIONp. 10
VIN CHECK DIGITp. 11
VEHICLE CERTIFICATION LABELp. 11
DESCRIPTIONp. 11
0-LUBRICATION & MAINTENANCEp. 12
INTERNATIONAL SYMBOLSp. 12
DESCRIPTIONp. 12
PARTS & LUBRICANT RECOMMENDATIONp. 12
DESCRIPTIONp. 12
LUBRICANT RECOMMENDATIONSp. 12
Chassisp. 12
Bodyp. 13
FLUID TYPESp. 13
API QUALITY CLASSIFICATIONp. 13
GEAR LUBRICANTSp. 13
FLUID TYPESp. 13
DESCRIPTIONp. 13
ENGINE OILp. 13
API SERVICE GRADE CERTIFIEDp. 13
SAE VISCOSITYp. 13
SYNTHETIC ENGINE OILSp. 13
ENERGY CONSERVING OILp. 14
CONTAINER IDENTIFICATIONp. 14
ENGINE OIL ADDITIVES/SUPPLEMENTSp. 14
ENGINE COOLANTp. 14
AXLEp. 15
POWER STEERING FLUIDp. 15
MANUAL TRANSMISSIONp. 15
FLUID CAPACITIESp. 15
SPECIFICATIONSp. 15
FLUID CAPACITIESp. 15
FLUID CAPACITIES – EXPORTp. 15
FLUID FILL/CHECK LOCATIONSp. 15
DESCRIPTIONp. 15
LUBRICATION POINTSp. 15
DESCRIPTIONp. 15
MAINTENANCE SCHEDULESp. 15
DESCRIPTIONp. 15
MAINTENANCE SCHEDULESp. 15
SCHEDULE Bp. 16
SCHEDULE Ap. 19
HOISTINGp. 21
STANDARD PROCEDURE – HOISTINGp. 21
JUMP STARTINGp. 21
STANDARD PROCEDURE – JUMP STARTINGp. 21
TO JUMP START A DISABLED VEHICLEp. 21
DISCONNECT CABLE CLAMPS AS FOLLOWSp. 21
TOWINGp. 22
STANDARD PROCEDURE – TOWINGp. 22
VEHICLE STORAGEp. 22
STANDARD PROCEDUREp. 22
VEHICLE PREPARATIONp. 22
ENGINE COMPONENT PREPARATIONp. 22
FUEL SYSTEM PREPARATIONp. 23
BRAKE SYSTEM PREPARATIONp. 23
REAR AXLE PREPARATIONp. 23
WHEELS AND TIRES PREPARATIONp. 23
INTERIOR TRIM PREPARATIONp. 23
BODY PREPARATIONp. 23
RETURNING VEHICLE FROM LONG TERM STORAGEp. 24
2-SUSPENSIONp. 26
SUSPENSIONp. 26
WARNINGS AND CAUTIONSp. 26
STANDARD PROCEDURE – LUBRICATIONp. 26
FRONT SUSPENSIONp. 28
SPECIFICATIONSp. 29
FRONT SUSPENSION FASTENER TORQUEp. 29
SPECIAL TOOLSp. 29
FRONT SUSPENSIONp. 29
HUB / BEARINGp. 30
DESCRIPTIONp. 30
DIAGNOSIS AND TESTING – HUB AND BEARING (FRONT)p. 30
REMOVALp. 31
INSTALLATIONp. 32
KNUCKLEp. 32
REMOVALp. 32
INSTALLATIONp. 33
KNUCKLE/ABS TONE WHEEL SEALp. 34
REMOVALp. 34
INSTALLATIONp. 35
LOWER BALL JOINTp. 36
DESCRIPTIONp. 36
DIAGNOSIS AND TESTING – LOWER BALL JOINT (FRONT)p. 36
LOWER BALL JOINT SEAL BOOTp. 36
REMOVALp. 36
INSTALLATIONp. 37
LOWER CONTROL ARMp. 38
REMOVALp. 38
DISASSEMBLY – LOWER CONTROL ARM (ISOLATOR BUSHINGS)p. 39
ASSEMBLY – LOWER CONTROL ARM (ISOLATOR BUSHINGS)p. 40
INSTALLATIONp. 41
SHOCK ASSEMBLYp. 41
REMOVALp. 41
DISASSEMBLYp. 41
ASSEMBLYp. 43
INSTALLATIONp. 43
STABILIZER BARp. 45
REMOVALp. 45
INSTALLATIONp. 46
STABILIZER BAR BUSHINGSp. 46
REMOVALp. 46
INSTALLATIONp. 46
STABILIZER LINKp. 47
REMOVALp. 47
INSTALLATIONp. 47
UPPER BALL JOINTp. 47
DESCRIPTIONp. 47
DIAGNOSIS AND TESTING – UPPER BALL JOINT (FRONT)p. 48
UPPER BALL JOINT SEAL BOOTp. 48
REMOVALp. 48
INSTALLATIONp. 48
UPPER CONTROL ARMp. 49
REMOVALp. 49
DISASSEMBLY – UPPER CONTROL ARM (ISOLATOR BUSHINGS)p. 50
ASSEMBLY – UPPER CONTROL ARM (ISOLATOR BUSHINGS)p. 51
INSTALLATIONp. 51
REAR SUSPENSIONp. 53
SPECIFICATIONSp. 54
REAR SUSPENSION FASTENER TORQUEp. 54
SPECIAL TOOLSp. 54
REAR SUSPENSIONp. 54
HUB / BEARINGp. 55
DESCRIPTIONp. 55
OPERATIONp. 55
DIAGNOSIS AND TESTING – HUB AND BEARING (REAR)p. 56
REMOVALp. 56
INSTALLATIONp. 58
KNUCKLEp. 58
REMOVALp. 58
INSTALLATIONp. 60
LOWER BALL JOINTp. 60
DESCRIPTIONp. 60
OPERATIONp. 61
DIAGNOSIS AND TESTING – LOWER BALL JOINT (REAR)p. 61
WEAR INSPECTION PROCEDUREp. 61
LOWER BALL JOINT SEAL BOOTp. 61
REMOVALp. 61
INSTALLATIONp. 61
LOWER CONTROL ARMp. 62
REMOVALp. 62
DISASSEMBLY – ISOLATOR BUSHINGSp. 64
INSPECTION – LOWER CONTROL ARMp. 64
ASSEMBLY – ISOLATOR BUSHINGSp. 65
INSTALLATIONp. 65
SHOCK ASSEMBLYp. 66
REMOVALp. 66
DISASSEMBLYp. 67
ASSEMBLYp. 68
INSTALLATIONp. 70
STABILIZER BARp. 72
REMOVALp. 72
INSTALLATIONp. 72
STABILIZER BAR BUSHINGSp. 73
REMOVALp. 73
INSTALLATIONp. 73
STABILIZER LINKp. 73
REMOVALp. 73
INSTALLATIONp. 74
TOE LINKp. 74
DESCRIPTIONp. 74
OPERATIONp. 74
REMOVALp. 74
INSTALLATIONp. 75
UPPER BALL JOINTp. 76
DESCRIPTIONp. 76
OPERATIONp. 76
DIAGNOSIS AND TESTING – UPPER BALL JOINT (REAR)p. 76
WEAR INSPECTION PROCEDUREp. 76
UPPER BALL JOINT SEAL BOOTp. 77
REMOVALp. 77
INSTALLATIONp. 77
UPPER CONTROL ARMp. 77
REMOVALp. 77
DISASSEMBLY – ISOLATOR BUSHINGSp. 77
INSPECTION – UPPER CONTROL ARMp. 78
ASSEMBLY – ISOLATOR BUSHINGSp. 79
INSTALLATIONp. 79
3-DIFFERENTIAL & DRIVELINEp. 102
PROPELLER SHAFTp. 102
WARNINGp. 102
DIAGNOSIS AND TESTING – PROPELLER SHAFTp. 102
PROPELLER SHAFT VIBRATIONp. 102
PROPELLER SHAFT BALANCEp. 103
PROPELLER SHAFT RUNOUTp. 104
PROPELLER SHAFT ANGLEp. 104
PROPELLER SHAFT MEASUREMENTp. 105
REMOVALp. 105
INSTALLATIONp. 105
SPECIFICATIONSp. 107
SPECIAL TOOLSp. 107
SINGLE CARDAN UNIVERSAL JOINTSp. 107
REMOVALp. 107
INSTALLATIONp. 107
HALF SHAFTp. 109
CAUTIONp. 109
DIAGNOSIS AND TESTING – HALF SHAFTp. 109
CLUNKING NOISE DURING ACCELERATIONp. 109
SHUDDER/VIBRATION DURING ACCELERATIONp. 109
VIBRATION AT HIGHWAY SPEEDSp. 109
REMOVALp. 109
INSTALLATIONp. 110
SPECIFICATIONSp. 111
SPECIAL TOOLSp. 111
REAR AXLE – 226RIAp. 112
DESCRIPTIONp. 112
OPERATIONp. 112
HYDRA-LOK DIFFERENTIALp. 112
DIAGNOSIS AND TESTING – REAR AXLEp. 112
GEAR NOISEp. 112
BEARING NOISEp. 113
LOW SPEED KNOCKp. 113
VIBRATIONp. 113
DRIVELINE SNAPp. 113
HYDRA-LOKp. 115
STANDARD PROCEDURE – DRAIN AND REFILLp. 115
REMOVALp. 116
INSTALLATIONp. 116
SPECIFICATIONSp. 117
SPECIAL TOOLSp. 117
AXLE SHAFT SEALSp. 118
REMOVALp. 118
INSTALLATIONp. 118
PINION SEALp. 118
REMOVALp. 118
INSTALLATIONp. 119
5-BRAKESp. 122
BRAKES – BASEp. 122
DESCRIPTION – BASE BRAKE SYSTEMp. 123
WARNINGS AND CAUTIONSp. 123
DIAGNOSIS AND TESTING – BASE BRAKE SYSTEM DIAGNOSIS CHARTSp. 124
RED BRAKE WARNING INDICATOR LAMPp. 124
BRAKE NOISEp. 124
OTHER BRAKE CONDITIONSp. 125
STANDARD PROCEDURE – BASE BRAKE BLEEDINGp. 126
PRESSURE BLEEDING METHODp. 126
MANUAL BLEEDING METHODp. 128
SPECIFICATIONSp. 128
BRAKE ACTUATING SYSTEMp. 128
BRAKE FASTENER TORQUEp. 129
SPECIAL TOOLSp. 129
BASE BRAKE SYSTEMp. 129
ADJUSTABLE PEDALS SWITCHp. 130
DESCRIPTIONp. 130
REMOVALp. 130
INSTALLATIONp. 130
BRAKE FLUID LEVEL SWITCHp. 130
DESCRIPTIONp. 130
OPERATIONp. 130
REMOVALp. 130
INSTALLATIONp. 131
HYDRAULIC/MECHANICALp. 131
DESCRIPTION – HYDRAULIC DISC BRAKESp. 131
BRAKE LINESp. 132
DESCRIPTION – BRAKE TUBES AND HOSESp. 132
INSPECTION – BRAKE TUBES AND HOSESp. 132
BRAKE PADS/SHOES – FRONT/REARp. 133
STANDARD PROCEDURE – BRAKE SHOE BURNISHINGp. 133
REMOVALp. 133
CLEANINGp. 135
INSPECTIONp. 135
INSTALLATIONp. 136
DISC BRAKE CALIPER – FRONTp. 137
REMOVALp. 137
DISASSEMBLYp. 138
ASSEMBLYp. 141
INSTALLATIONp. 142
DISC BRAKE CALIPER – REARp. 142
REMOVALp. 142
DISASSEMBLYp. 143
ASSEMBLYp. 143
INSTALLATIONp. 143
FLUIDp. 144
DIAGNOSIS AND TESTING – BRAKE FLUID CONTAMINATIONp. 144
STANDARD PROCEDURE – BRAKE FLUID LEVEL CHECKINGp. 144
SPECIFICATIONSp. 144
BRAKE FLUIDp. 144
MASTER CYLINDERp. 145
STANDARD PROCEDURE – MASTER CYLINDER BLEEDINGp. 145
REMOVALp. 145
INSTALLATIONp. 146
PEDALS – ADJUSTABLEp. 146
DESCRIPTIONp. 146
REMOVALp. 146
INSTALLATIONp. 148
POWER BRAKE BOOSTERp. 149
DESCRIPTIONp. 149
DIAGNOSIS AND TESTING – POWER BRAKE BOOSTERp. 150
BASIC TESTp. 150
VACUUM LEAK TESTp. 150
REMOVALp. 150
INSTALLATIONp. 151
ROTORp. 152
DIAGNOSIS AND TESTING – BRAKE ROTORp. 152
BRAKING SURFACE INSPECTIONp. 152
ROTOR MINIMUM THICKNESSp. 152
ROTOR THICKNESS VARIATIONp. 152
ROTOR RUNOUTp. 153
STANDARD PROCEDURE – BRAKE ROTOR MACHININGp. 154
REMOVALp. 155
REMOVAL – BRAKE ROTOR (FRONT)p. 155
REMOVAL – BRAKE ROTOR (REAR)p. 155
INSTALLATIONp. 156
INSTALLATION – BRAKE ROTOR (FRONT)p. 156
INSTALLATION – BRAKE ROTOR (REAR)p. 156
SPECIFICATIONSp. 157
BRAKE ROTOR LIMITS/SPECIFICATIONSp. 157
PARKING BRAKEp. 157
DESCRIPTIONp. 157
OPERATIONp. 157
STANDARD PROCEDUREp. 158
STANDARD PROCEDURE – AUTOMATIC ADJUSTER LOCKING OUTp. 158
STANDARD PROCEDURE – AUTOMATIC ADJUSTER UNLOCKINGp. 158
CABLE – PARKING BRAKEp. 158
REMOVALp. 158
INSTALLATIONp. 160
CALIPER – PARKING BRAKEp. 161
REMOVALp. 161
DISASSEMBLYp. 162
ASSEMBLYp. 162
INSTALLATIONp. 162
LEVER – PARKING BRAKEp. 164
REMOVALp. 164
INSTALLATIONp. 165
PADS/SHOES – PARKING BRAKEp. 165
REMOVALp. 165
INSTALLATIONp. 165
BRAKES – ABSp. 167
DESCRIPTIONp. 167
DESCRIPTION – ANTILOCK BRAKE SYSTEMp. 167
DESCRIPTION – ELECTRONIC VARIABLE BRAKE PROPORTIONINGp. 167
OPERATIONp. 167
OPERATION – ANTILOCK BRAKE SYSTEMp. 167
NORMAL BRAKINGp. 168
ABS BRAKINGp. 168
NOISE AND BRAKE PEDAL FEELp. 168
TIRE NOISE AND MARKSp. 168
START-UP CYCLEp. 168
DRIVE-OFF CYCLEp. 168
PREMATURE ABS CYCLINGp. 168
OPERATION – ELECTRONIC VARIABLE BRAKE PROPORTIONINGp. 169
CAUTIONp. 169
DIAGNOSIS AND TESTING – INSPECTION AND ROAD TESTp. 170
STANDARD PROCEDURE – ANTILOCK BRAKE SYSTEM BLEEDINGp. 170
SPECIFICATIONSp. 171
ANTILOCK BRAKE SYSTEM FASTENER TORQUEp. 171
TONE WHEEL RUNOUTp. 171
WHEEL SPEED SENSOR AIR GAPp. 171
TONE WHEELp. 171
REMOVAL – FRONT TONE WHEELp. 171
INSPECTION – TONE WHEELp. 171
INSTALLATION – FRONT TONE WHEELp. 172
WHEEL SPEED SENSOR – FRONTp. 172
REMOVALp. 172
INSTALLATIONp. 172
WHEEL SPEED SENSOR – REARp. 173
REMOVALp. 173
INSTALLATIONp. 173
HCU (HYDRAULIC CONTROL UNIT)p. 174
DESCRIPTION – HYDRAULIC CONTROL UNIT (HCU)p. 174
VALVES AND SOLENOIDSp. 174
BRAKE FLUID ACCUMULATORSp. 174
PUMP/MOTORp. 174
OPERATION – HYDRAULIC CIRCUITS AND VALVESp. 174
NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTIONp. 175
ABS HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTIONp. 176
ICU (INTEGRATED CONTROL UNIT)p. 177
DESCRIPTIONp. 177
OPERATIONp. 177
REMOVALp. 177
DISASSEMBLYp. 178
ASSEMBLYp. 179
INSTALLATIONp. 179
6-CLUTCHp. 180
CLUTCHp. 180
DESCRIPTIONp. 180
OPERATIONp. 181
WARNINGp. 182
DIAGNOSIS AND TESTING – CLUTCHp. 182
ROAD TESTp. 182
CLUTCH CONTAMINATIONp. 182
IMPROPER RELEASE OR CLUTCH ENGAGEMENTp. 182
CLUTCH MISALIGNMENTp. 182
PRESSURE PLATEp. 182
CLUTCH DISCp. 183
DIAGNOSIS CHARTp. 183
STANDARD PROCEDURE – CLUTCH SYSTEM BLEEDp. 185
LINKAGE BLEEDp. 185
MASTER CYLINDER BLEEDp. 186
SPECIFICATIONSp. 186
SPECIAL TOOLSp. 186
CLUTCH DISCp. 187
REMOVALp. 187
CLEANINGp. 187
INSTALLATIONp. 187
CLUTCH RELEASE BEARINGp. 188
REMOVALp. 188
INSTALLATIONp. 188
FLYWHEELp. 188
DIAGNOSIS AND TESTINGp. 188
LINKAGEp. 189
DESCRIPTIONp. 189
OPERATIONp. 189
MASTER CYLINDERp. 189
REMOVALp. 189
INSTALLATIONp. 189
CLUTCH PEDAL POSITION SWITCHp. 189
DESCRIPTIONp. 189
OPERATIONp. 189
DIAGNOSIS AND TESTINGp. 190
REMOVALp. 190
INSTALLATIONp. 191
7-COOLINGp. 192
COOLINGp. 192
WARNINGp. 192
COOLING SYSTEM WARNINGSp. 192
SPECIFICATIONSp. 192
TORQUEp. 192
SPECIAL TOOLSp. 193
COOLINGp. 193
ACCESSORY DRIVEp. 194
ACCESSORY DRIVE BELT AND TENSIONERp. 194
DIAGNOSIS AND TESTING – ACCESSORY DRIVE BELT DIAGNOSISp. 194
REMOVALp. 195
INSPECTIONp. 195
INSTALLATIONp. 196
8a-AUDIO/VIDEOp. 218
AUDIOp. 218
DESCRIPTIONp. 218
OPERATIONp. 218
DIAGNOSIS AND TESTING – AUDIOp. 218
AMPLIFIERp. 220
DESCRIPTIONp. 220
OPERATIONp. 220
REMOVALp. 221
INSTALLATIONp. 221
ANTENNAp. 221
DESCRIPTIONp. 221
OPERATIONp. 221
DIAGNOSIS AND TESTING – ANTENNAp. 221
REMOVALp. 222
ANTENNA MODULEp. 222
DESCRIPTIONp. 222
OPERATIONp. 222
DIAGNOSIS AND TESTING – ANTENNA MODULEp. 222
REMOVALp. 222
INSTALLATIONp. 223
INSTRUMENT PANEL ANTENNA CABLEp. 223
REMOVALp. 223
INSTALLATIONp. 223
RADIOp. 223
DESCRIPTIONp. 223
OPERATIONp. 224
REMOVALp. 224
INSTALLATIONp. 224
RADIO NOISE SUPPRESSION COMPONENTSp. 224
DESCRIPTIONp. 224
OPERATIONp. 225
REMOVALp. 225
SPEAKERp. 225
DESCRIPTIONp. 225
OPERATIONp. 225
DIAGNOSIS AND TESTING – SPEAKERp. 225
REMOVALp. 227
DOOR SPEAKERp. 227
INSTRUMENT PANEL SPEAKERp. 227
REAR SPEAKERp. 227
SUB WOOFERp. 227
INSTALLATIONp. 227
DOOR SPEAKERp. 227
INSTRUMENT PANEL SPEAKERp. 228
REAR SPEAKERp. 228
SUB WOOFERp. 228
8b-CHIME/BUZZERp. 230
CHIME/BUZZERp. 230
DESCRIPTIONp. 230
OPERATIONp. 230
AIRBAG WARNINGp. 230
ANTILOCK BRAKE WARNINGp. 230
CRITICAL COOLANT TEMPERATURE WARNINGp. 230
CRITICAL OIL TEMPERATURE WARNINGp. 230
DECK LID AJAR REMINDERp. 230
DOME LAMPS ON REMINDERp. 230
DOOR AJAR WARNINGp. 230
ENHANCED SEAT BELT REMINDERp. 231
FASTEN SEAT BELT REMINDERp. 231
HEADLAMPS REMINDERp. 231
KEY IN IGNITION REMINDERp. 231
LOW FUEL REMINDERp. 231
PARK BRAKE/LOW BRAKE FLUID WARNINGp. 231
SERVICE ENGINE SOON WARNINGp. 232
TIRE PRESSURE SYSTEM WARNINGp. 232
UNDER/OVER VOLTAGE WARNINGp. 232
WARNING LAMP ANNOUNCEMENTp. 232
DIAGNOSIS AND TESTING – CHIME CONDITIONSp. 232
8e-ELECTRONIC CONTROL MODULESp. 234
BODY CONTROL MODULEp. 234
DESCRIPTIONp. 234
BATTERY SAVE MODEp. 234
OPERATIONp. 234
BATTERY SAVE MODEp. 235
REMOVALp. 236
INSTALLATIONp. 236
CONTROLLER ANTILOCK BRAKEp. 236
DESCRIPTIONp. 236
OPERATIONp. 236
CONTROLLER ANTILOCK BRAKE INPUTSp. 237
CONTROLLER ANTILOCK BRAKE OUTPUTSp. 237
REMOVALp. 237
INSTALLATIONp. 237
DATA LINK CONNECTORp. 237
DESCRIPTIONp. 237
OPERATIONp. 237
POWERTRAIN CONTROL MODULEp. 237
DESCRIPTIONp. 237
OPERATION – SENSOR RETURN – PCM INPUTp. 237
OPERATION – DATA BUS COMMUNICATION RECEIVE – PCM INPUTp. 238
OPERATION – IGNITION SENSE – PCM INPUTp. 238
OPERATION – PCM GROUNDp. 238
OPERATIONp. 238
OPERATION – 5 VOLT SUPPLY – PCM OUTPUTp. 239
STANDARD PROCEDURE – OBTAINING DIAGNOSTIC TROUBLE CODESp. 239
BULB CHECKp. 239
OBTAINING DTC'S USING DRB SCAN TOOLp. 239
REMOVALp. 239
INSTALLATIONp. 240
8f-ENGINE SYSTEMSp. 242
BATTERY SYSTEMp. 242
DESCRIPTIONp. 242
OPERATIONp. 242
WARNINGp. 243
SAFETY PRECAUTIONS AND WARNINGSp. 243
DIAGNOSIS AND TESTING – BATTERY SYSTEM0 – 2 ZB (Continued)p. 243
MICRO 420 BATTERY TESTERp. 243
ABNORMAL BATTERY DISCHARGINGp. 245
CLEANINGp. 245
INSPECTIONp. 246
SPECIFICATIONSp. 246
BATTERY SYSTEM SPECIFICATIONSp. 246
SPECIAL TOOLSp. 247
BATTERY SPECIAL TOOLSp. 247
BATTERYp. 247
DESCRIPTIONp. 247
OPERATIONp. 247
DIAGNOSIS AND TESTING – BATTERYp. 248
MICRO 420 BATTERY TESTERp. 248
STANDARD PROCEDUREp. 248
BATTERY CHARGINGp. 248
CHARGING A COMPLETELY DISCHARGED BATTERYp. 249
CHARGING TIME REQUIREDp. 250
OPEN-CIRCUIT VOLTAGE TESTp. 250
IGNITION-OFF DRAW TESTp. 250
USING MICRO 420 BATTERY TESTERp. 252
BATTERY TESTINGp. 252
REMOVALp. 253
INSTALLATIONp. 253
BATTERY HOLDDOWNp. 253
REMOVALp. 253
INSTALLATIONp. 253
BATTERY CABLESp. 253
DESCRIPTIONp. 253
OPERATIONp. 253
DIAGNOSIS AND TESTING – BATTERY CABLESp. 254
VOLTAGE DROP TESTp. 254
REMOVALp. 255
INSTALLATIONp. 255
BATTERY TRAYp. 256
DESCRIPTIONp. 256
OPERATIONp. 256
CHARGINGp. 257
BATTERY TEMPERATURE SENSORp. 257
OPERATIONp. 257
REMOVALp. 257
INSTALLATIONp. 257
GENERATORp. 257
DESCRIPTIONp. 257
OPERATIONp. 258
REMOVALp. 258
INSTALLATIONp. 259
VOLTAGE REGULATORp. 259
DESCRIPTIONp. 259
OPERATIONp. 259
STARTINGp. 260
DESCRIPTIONp. 260
OPERATIONp. 260
DIAGNOSIS AND TESTINGp. 260
DIAGNOSIS AND TESTING – STARTING SYSTEM TESTp. 260
INSPECTIONp. 260
DIAGNOSIS AND TESTING – CONTROL CIRCUIT TESTp. 262
STARTER SOLENOIDp. 262
STARTER RELAYp. 262
RELAY TESTp. 263
RELAY CIRCUIT TESTp. 263
SAFETY SWITCHESp. 263
IGNITION SWITCHp. 263
STARTER BUTTONp. 263
BATTERYp. 263
ALL RELATED WIRING AND CONNECTORSp. 263
DIAGNOSIS AND TESTING – FEED CIRCUIT RESISTANCE TESTp. 264
DIAGNOSIS AND TESTING – CLUTCH PEDAL POSITION SWITCHp. 264
SPECIFICATIONSp. 264
STARTERp. 264
TORQUEp. 264
STARTER MOTORp. 265
REMOVALp. 265
INSTALLATIONp. 265
STARTER MOTOR RELAYp. 265
DESCRIPTIONp. 265
OPERATIONp. 265
STARTER SOLENOIDp. 265
DESCRIPTIONp. 265
OPERATIONp. 265
8g-HEATED SYSTEMSp. 266
HEATED GLASSp. 266
DESCRIPTIONp. 266
OPERATIONp. 266
DIAGNOSIS AND TESTINGp. 267
ELECTRIC BACKLIGHT (EBL) SYSTEMp. 267
REAR WINDOW DEFOGGER RELAYp. 267
DESCRIPTIONp. 267
OPERATIONp. 268
REMOVALp. 268
INSTALLATIONp. 268
REAR WINDOW DEFOGGER SWITCHp. 269
DESCRIPTIONp. 269
OPERATIONp. 269
REAR WINDOW DEFOGGER GRIDp. 269
STANDARD PROCEDUREp. 269
GRID LINE AND TERMINAL REPAIRp. 269
8h-HORNp. 272
HORN SYSTEMp. 272
DESCRIPTIONp. 272
OPERATIONp. 272
DIAGNOSIS AND TESTING – HORN SYSTEMp. 272
HORNp. 273
DIAGNOSIS AND TESTING – HORNp. 273
REMOVALp. 273
INSTALLATIONp. 273
HORN SWITCHp. 273
DESCRIPTIONp. 273
8i-IGNITION CONTROLp. 274
IGNITION CONTROLp. 274
DESCRIPTION – IGNITION SYSTEMp. 274
OPERATION – IGNITION SYSTEMp. 274
SPECIFICATIONSp. 274
TORQUEp. 274
SPARK PLUGp. 275
CABLES RESISTANCE CHARTp. 275
IGNITION COIL RESISTANCE – 8.3Lp. 275
8.3L – FIRING ORDERp. 275
CAMSHAFT POSITION SENSORp. 276
OPERATION – 8.3Lp. 276
REMOVALp. 276
REPLACING WITH NEW SENSORp. 276
REPLACING OLD SENSOR WITH ORIGINALp. 277
INSTALLATIONp. 277
INSTALLATION – WITH NEW SENSORp. 277
REPLACING OLD SENSOR WITH ORIGINALp. 277
IGNITION COILp. 278
OPERATIONp. 278
REMOVALp. 278
INSTALLATIONp. 279
SPARK PLUGp. 280
DESCRIPTIONp. 280
OPERATIONp. 280
REMOVALp. 280
INSTALLATIONp. 280
SPARK PLUG CABLEp. 280
DESCRIPTIONp. 280
REMOVALp. 280
INSTALLATIONp. 281
STARTER BUTTONp. 282
REMOVALp. 282
INSTALLATIONp. 283
8j-INSTRUMENT CLUSTERp. 284
INSTRUMENT CLUSTERp. 284
DESCRIPTIONp. 284
DESCRIPTION – EXPORTp. 284
OPERATIONp. 285
OPERATION – EXPORTp. 286
DIAGNOSIS AND TESTING – INSTRUMENT CLUSTER WARNING/INDICATOR LAMPSp. 287
STANDARD PROCEDUREp. 287
STANDARD PROCEDURE – ENHANCED SEAT BELT REMINDERp. 287
STANDARD PROCEDURE – SELF-DIAGNOSTICSp. 287
REMOVALp. 287
INSTALLATIONp. 287
AIRBAG INDICATORp. 288
DESCRIPTIONp. 288
OPERATIONp. 288
INSTRUMENT CLUSTER GAUGE PACKp. 288
REMOVALp. 288
INSTALLATIONp. 289
INSTRUMENT CLUSTER GAUGE PACK LENSp. 289
REMOVALp. 289
INSTALLATIONp. 289
INSTRUMENT CLUSTER LENSp. 289
REMOVALp. 289
INSTALLATIONp. 290
PASS AIRBAG OFF INDICATORp. 290
DESCRIPTIONp. 290
OPERATIONp. 290
SEAT BELT WARNING INDICATORp. 290
DESCRIPTIONp. 290
OPERATIONp. 290
8l-LAMPSp. 292
LAMPS/LIGHTING – EXTERIORp. 293
WARNINGp. 293
DIAGNOSIS AND TESTING – LAMPS/LIGHTING – EXTERIORp. 293
SPECIFICATIONSp. 293
EXTERIOR LAMPSp. 293
EXTERIOR LAMPS – EXPORTp. 293
BACKUP LAMPp. 294
REMOVALp. 294
INSTALLATIONp. 294
BACK UP LAMP UNITp. 294
REMOVALp. 294
INSTALLATIONp. 294
BRAKE LAMP SWITCHp. 295
DESCRIPTIONp. 295
OPERATIONp. 295
DIAGNOSIS AND TESTING – BRAKE LAMP SWITCHp. 295
REMOVALp. 296
INSTALLATIONp. 296
CENTER HIGH MOUNTED STOP LAMP UNITp. 297
REMOVALp. 297
INSTALLATIONp. 297
FOG LAMP – FRONTp. 297
REMOVALp. 297
INSTALLATIONp. 297
FOG LAMP UNIT – FRONTp. 297
REMOVALp. 297
INSTALLATIONp. 297
FOG LAMP – REAR (EXPORT)p. 298
DESCRIPTIONp. 298
FOG LAMP UNIT – REAR (EXPORT)p. 298
REMOVALp. 298
INSTALLATIONp. 298
HEADLAMPp. 299
DESCRIPTIONp. 299
OPERATIONp. 299
DIAGNOSIS AND TESTING – HIGH INTENSITY DISCHARGE HEADLAMPSp. 300
REMOVALp. 301
HIGH INTENSITY DISCHARGE (HID) HEADLAMPS – LOW BEAMp. 301
HIGH BEAMp. 301
INSTALLATIONp. 301
HIGH INTENSITY DISCHARGE (HID) HEADLAMPS – LOW BEAMp. 301
HIGH BEAMp. 302
HEADLAMP UNITp. 302
STANDARD PROCEDUREp. 302
STANDARD PROCEDURE – HEADLAMP UNIT AIMINGp. 302
STANDARD PROCEDURE – HEADLAMP UNIT AIMING – EXPORTp. 302
REMOVALp. 305
INSTALLATIONp. 305
LICENSE PLATE LAMPp. 305
REMOVALp. 305
INSTALLATIONp. 305
LICENSE PLATE LAMP UNITp. 306
REMOVALp. 306
INSTALLATIONp. 306
MULTI-FUNCTION SWITCHp. 306
DESCRIPTIONp. 306
HAZARD WARNING SYSTEMp. 306
OPERATIONp. 307
LIGHTINGp. 307
WIPERSp. 308
HAZARD WARNING SYSTEMp. 308
DIAGNOSIS AND TESTING – MULTI-FUNCTION SWITCHp. 308
FLASHER DIAGNOSISp. 308
SWITCH DIAGNOSISp. 310
REMOVALp. 312
INSTALLATIONp. 312
MULTI-FUNCTION SWITCH – EXPORTp. 314
DESCRIPTIONp. 314
HAZARD WARNING SYSTEMp. 315
OPERATIONp. 315
LIGHTINGp. 315
WIPERSp. 316
HAZARD WARNING SYSTEMp. 316
DIAGNOSIS AND TESTING – MULTI-FUNCTION SWITCHp. 316
FLASHER DIAGNOSISp. 316
SWITCH DIAGNOSISp. 318
REMOVALp. 321
INSTALLATIONp. 321
FRONT SIDE MARKER LAMPp. 322
REMOVALp. 322
INSTALLATIONp. 322
REAR SIDE MARKER LAMPp. 322
REMOVALp. 322
INSTALLATIONp. 322
REPEATER LAMP – EXPORTp. 322
REMOVALp. 322
INSTALLATIONp. 323
TAIL LAMPp. 323
REMOVALp. 323
INSTALLATIONp. 323
TAIL LAMP UNITp. 323
REMOVALp. 323
INSTALLATIONp. 323
8n-POWER SYSTEMSp. 324
POWER LOCKSp. 324
DESCRIPTIONp. 324
POWER LOCKSp. 324
DOOR ENTRY INHIBITp. 324
DOOR EXITp. 325
REMOTE KEYLESS ENTRYp. 325
OPERATIONp. 325
DOOR ENTRYp. 325
DOOR EXITp. 325
DOOR LOCK SWITCHp. 325
DOOR LOCK INHIBITp. 325
AUTOMATIC DOOR LOCKSp. 325
KEY CYLINDER FUNCTIONp. 325
REMOTE KEYLESS ENTRYp. 326
DIAGNOSIS AND TESTING – POWER LOCKSp. 326
DOOR CYLINDER UNLOCK SWITCHp. 326
DIAGNOSIS AND TESTING – DOOR CYLINDER UNLOCK SWITCHp. 326
EXTERIOR DOOR HANDLE SWITCHp. 326
DIAGNOSIS AND TESTING – EXTERIOR DOOR HANDLE SWITCHp. 326
INTERIOR DOOR HANDLE SWITCHp. 326
DIAGNOSIS AND TESTING – INTERIOR DOOR HANDLE SWITCHp. 326
POWER LOCK SWITCHp. 327
DIAGNOSIS AND TESTING – POWER LOCK SWITCHp. 327
REMOVALp. 327
INSTALLATIONp. 327
REMOTE KEYLESS ENTRY MODULEp. 327
DIAGNOSIS AND TESTING – REMOTE KEYLESS ENTRY MODULEp. 327
REMOVALp. 327
INSTALLATIONp. 328
REMOTE KEYLESS ENTRY TRANSMITTERp. 328
DIAGNOSIS AND TESTING – REMOTE KEYLESS ENTRY TRANSMITTERp. 328
STANDARD PROCEDUREp. 328
STANDARD PROCEDURE – RKE TRANSMITTER BATTERIESp. 328
STANDARD PROCEDURE – RKE TRANSMITTER CUSTOMER PREFERENCESp. 328
AUTOMATIC (ROLLING) LOCKSp. 328
HORN CHIRP DISABLING / ENABLINGp. 328
OPTICAL CHIRP (FLASH) DISABLING / ENABLINGp. 328
UNLOCK SEQUENCEp. 329
STANDARD PROCEDURE – RKE TRANSMITTER PROGRAMINGp. 329
STANDARD PROCEDURE – TRANSMITTER SYNCHRONIZATIONp. 329
SPECIFICATIONS – REMOTE KEYLESS ENTRY TRANSMITTERp. 329
RANGEp. 329
POWER MIRRORSp. 330
DESCRIPTIONp. 330
OPERATIONp. 330
DIAGNOSIS AND TESTING – POWER MIRRORSp. 330
POWER MIRROR SWITCHp. 330
DIAGNOSIS AND TESTING – POWER MIRROR SWITCHp. 330
REMOVALp. 331
INSTALLATIONp. 331
SIDEVIEW MIRRORp. 331
DESCRIPTIONp. 331
OPERATIONp. 331
POWER WINDOWSp. 332
DESCRIPTIONp. 332
OPERATIONp. 332
POWER WINDOWSp. 332
SMART GLASS FEATUREp. 332
DIAGNOSIS AND TESTING – POWER WINDOWSp. 332
POWER WINDOW SWITCHp. 333
DESCRIPTIONp. 333
OPERATIONp. 333
DIAGNOSIS AND TESTING – POWER WINDOW SWITCHp. 333
REMOVALp. 333
INSTALLATIONp. 333
WINDOW MOTORp. 333
DESCRIPTIONp. 333
OPERATIONp. 334
DIAGNOSIS AND TESTING – WINDOW MOTORp. 334
8o-RESTRAINTSp. 336
RESTRAINTSp. 337
WARNINGp. 337
AIRBAG SYSTEM0 – 4 ZB (Continued)p. 337
CHILD RESTRAINTSp. 337
AIRBAG/TENSIONER DISPOSALp. 337
DIAGNOSIS AND TESTING – AIRBAG SYSTEMp. 337
STANDARD PROCEDUREp. 338
STANDARD PROCEDURE – HANDLING AIRBAGSp. 338
DEPLOYED AIRBAGp. 338
UNDEPLOYED AIRBAGp. 338
STANDARD PROCEDURE – SERVICE AFTER AN AIRBAG DEPLOYMENTp. 338
DRIVER AIRBAGp. 338
PASSENGER AIRBAGp. 338
SEAT BELTS AND TENSIONERSp. 338
CLEAN UP PROCEDUREp. 338
CHILD TETHERp. 338
REMOVALp. 338
INSTALLATIONp. 339
CLOCKSPRINGp. 339
DESCRIPTIONp. 339
OPERATIONp. 339
STANDARD PROCEDURE – CLOCK SPRING CENTERINGp. 339
REMOVALp. 340
INSTALLATIONp. 340
DRIVER AIRBAGp. 341
DESCRIPTIONp. 341
OPERATIONp. 341
REMOVALp. 341
INSTALLATIONp. 341
OCCUPANT RESTRAINT CONTROLLERp. 341
DESCRIPTIONp. 341
OPERATIONp. 342
REMOVALp. 342
INSTALLATIONp. 343
PASSENGER AIRBAGp. 343
DESCRIPTIONp. 343
OPERATIONp. 343
REMOVALp. 344
INSTALLATIONp. 345
PASSENGER AIRBAG ON / OFF SWITCHp. 346
DESCRIPTIONp. 346
OPERATIONp. 346
REMOVALp. 346
INSTALLATIONp. 347
SEAT BELT & RETRACTORp. 347
REMOVALp. 347
INSTALLATIONp. 347
SEAT BELT BUCKLEp. 348
REMOVALp. 348
INSTALLATIONp. 348
SEAT BELT SWITCHp. 349
DESCRIPTIONp. 349
OPERATIONp. 349
SEAT BELT TENSIONERp. 349
DESCRIPTIONp. 349
OPERATIONp. 349
8q-VEHICLE THEFT SECURITYp. 352
VEHICLE THEFT SECURITYp. 352
DESCRIPTIONp. 352
OPERATIONp. 352
DIAGNOSIS AND TESTING – VEHICLE THEFT SECURITYp. 353
HOOD AJAR SWITCHp. 353
REMOVALp. 353
INSTALLATIONp. 353
VTSS DISARM SWITCHp. 353
DESCRIPTIONp. 353
OPERATIONp. 353
VTSS INDICATORp. 353
DESCRIPTIONp. 353
OPERATIONp. 353
8r-WIPERS/WASHERSp. 354
WIPERS/WASHERSp. 354
DESCRIPTIONp. 354
WIPER SYSTEMp. 354
WASHER SYSTEMp. 354
OPERATIONp. 355
WIPER SYSTEMp. 355
WASHER SYSTEMp. 355
DIAGNOSIS AND TESTING – WIPERS/WASHERSp. 356
MOTOR WILL NOT OPERATE ALL SWITCH POSITIONSp. 356
MOTOR OPERATES SLOWLY AT ALL SPEEDSp. 356
WIPERS RUN AT HIGH SPEED WITH SWITCH IN LOW SPEED POSITION OR WIPERS RUN AT LOW SPEED WITH SWITCH IN HIGH SPEED POSITION.p. 356
WIPERS WILL OPERATE CONTINUOUSLY WITH THE SWITCH IN THE INTERMITTENT POSITION – WHEN WIPER SWITCH IS TURNED OFF, WIPERS STOP WHEREVER THEY ARE WITHOUT RETURNING TO PARK POSITION.p. 357
WIPERS DO NOT OPERATE WHEN WASHER MOTOR IS ENGAGED (PULSE WIPE) OR WIPERS DO OPERATE IN INTERMITTENT POSITION.p. 357
WASHER SYSTEM DIAGNOSISp. 357
WASHER HOSES / TUBESp. 358
REMOVALp. 358
INSTALLATIONp. 358
WASHER NOZZLEp. 358
REMOVALp. 358
INSTALLATIONp. 358
WASHER PUMP MOTORp. 358
REMOVALp. 358
INSTALLATIONp. 358
WASHER RESERVOIRp. 358
REMOVALp. 358
INSTALLATIONp. 358
WIPER ARMSp. 358
REMOVALp. 358
INSTALLATIONp. 358
ADJUSTMENTSp. 359
ADJUSTMENTp. 359
WIPER BLADESp. 359
DESCRIPTIONp. 359
OPERATIONp. 359
REMOVALp. 359
CLEANINGp. 359
INSTALLATIONp. 360
WIPER MODULEp. 360
REMOVALp. 360
INSTALLATIONp. 360
WIPER MOTORp. 360
DIAGNOSIS AND TESTING – WIPER MOTORp. 360
REMOVALp. 361
INSTALLATIONp. 361
WIPER/WASHER SWITCHp. 362
REMOVALp. 362
INSTALLATIONp. 362
HEADLAMP WASHERS – EXPORTp. 363
DESCRIPTIONp. 363
OPERATIONp. 363
DIAGNOSIS AND TESTING – HEADLAMP WASHERS – EXPORTp. 363
HEADLAMP WASHER HOSES / TUBES – EXPORTp. 365
REMOVALp. 365
INSTALLATIONp. 365
HEADLAMP WASHER NOZZLE – EXPORTp. 365
REMOVALp. 365
REMOVAL – NOZZLEp. 365
REMOVAL – NOZZLE COVERp. 365
INSTALLATIONp. 366
INSTALLATION – NOZZLEp. 366
INSTALLATION – NOZZLE COVERp. 366
HEADLAMP WASHER PUMP MOTOR – EXPORTp. 366
REMOVALp. 366
INSTALLATIONp. 366
WASHER PUMP MOTOR – EXPORTp. 367
REMOVALp. 367
INSTALLATIONp. 367
HEADLAMP WASHER RESERVOIR – EXPORTp. 367
REMOVALp. 367
REMOVAL – LOWER RESERVOIRp. 367
REMOVAL – UPPER RESERVOIRp. 368
INSTALLATIONp. 368
INSTALLATION – LOWER RESERVOIRp. 368
INSTALLATION – UPPER RESERVOIRp. 368
8w-WIRINGp. 370
8W-01 WIRING DIAGRAM INFORMATIONp. 372
WIRING DIAGRAM INFORMATIONp. 372
DESCRIPTIONp. 372
DESCRIPTION – HOW TO USE WIRING DIAGRAMSp. 372
DESCRIPTION – CIRCUIT INFORMATIONp. 376
DESCRIPTION – CIRCUIT FUNCTIONSp. 377
DESCRIPTION – SECTION IDENTIFICATION AND INFORMATIONp. 377
DESCRIPTION – CONNECTOR, GROUND AND SPLICE INFORMATIONp. 378
WARNINGS – GENERALp. 378
DIAGNOSIS AND TESTING – WIRING HARNESSp. 378
STANDARD PROCEDUREp. 379
STANDARD PROCEDURE – ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICESp. 379
STANDARD PROCEDURE – TESTING OF VOLTAGE POTENTIALp. 380
STANDARD PROCEDURE – TESTING FOR CONTINUITYp. 380
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUNDp. 380
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADSp. 381
STANDARD PROCEDURE – TESTING FOR A VOLTAGE DROPp. 381
SPECIAL TOOLSp. 381
WIRING/TERMINALp. 381
CONNECTORp. 382
REMOVALp. 382
INSTALLATIONp. 382
DIODEp. 385
REMOVALp. 385
INSTALLATIONp. 385
TERMINALp. 385
REMOVALp. 385
INSTALLATIONp. 385
WIREp. 386
STANDARD PROCEDURE – WIRE SPLICINGp. 386
8W-02 COMPONENT INDEXp. 388
8W-10 POWER DISTRIBUTIONp. 390
8W-15 GROUND DISTRIBUTIONp. 410
8W-18 BUS COMMUNICATIONSp. 422
8W-20 CHARGING SYSTEMp. 426
8W-21 STARTING SYSTEMp. 430
8W-30 FUEL/IGNITION SYSTEMp. 434
8W-35 ANTILOCK BRAKESp. 450
8W-39 VEHICLE THEFT SECURITY SYSTEMp. 454
8W-40 INSTRUMENT CLUSTERp. 460
8W-41 HORN/CIGAR LIGHTER/POWER OUTLETp. 468
8W-42 AIR CONDITIONING/HEATERp. 472
8W-43 OCCUPANT RESTRAINT SYSTEMp. 480
8W-44 INTERIOR LIGHTINGp. 484
8W-45 BODY CONTROL MODULEp. 490
8W-47 AUDIO SYSTEMp. 508
8W-48 REAR WINDOW DEFOGGERp. 514
8W-50 FRONT LIGHTINGp. 516
8W-51 REAR LIGHTINGp. 522
8W-52 TURN SIGNALSp. 528
8W-53 WIPERSp. 532
8W-56 CONVENIENCE SYSTEMSp. 536
8W-60 POWER WINDOWSp. 538
8W-61 POWER DOOR LOCKSp. 542
8W-62 POWER MIRRORSp. 548
8W-70 SPLICE INFORMATIONp. 550
8W-80 CONNECTOR PIN-OUTSp. 554
8W-91 CONNECTOR/GROUND/SPLICE LOCATIONp. 622
CONNECTOR/GROUND/SPLICE LOCATION DESCRIPTIONp. 622
8W-97 POWER DISTRIBUTIONp. 656
POWER DISTRIBUTIONp. 656
DESCRIPTIONp. 656
OPERATIONp. 656
CIGAR LIGHTER OUTLETp. 656
REMOVALp. 656
INSTALLATIONp. 656
POWER DISTRIBUTION CENTERp. 656
REMOVALp. 656
INSTALLATIONp. 656
POWER OUTLETp. 657
REMOVALp. 657
INSTALLATIONp. 657
9-ENGINEp. 658
ENGINE – 8.3Lp. 660
DESCRIPTIONp. 660
Vehicle Identification Numberp. 660
Engine Serial Numberp. 660
DIAGNOSIS AND TESTINGp. 660
INTRODUCTIONp. 660
ENGINE DIAGNOSIS – PERFORMANCEp. 661
ENGINE DIAGNOSIS – MECHANICALp. 662
CYLINDER COMPRESSION PRESSURE TESTp. 664
CYLINDER COMBUSTION PRESSURE LEAKAGE TESTp. 664
CYLINDER HEAD GASKET FAILURE DIAGNOSISp. 665
CYLINDER-TO-CYLINDER LEAKAGE TESTp. 665
CYLINDER-TO-WATER JACKET LEAKAGE TESTp. 665
INTAKE MANIFOLD LEAKSp. 665
HYDRAULIC TAPPET NOISE DIAGNOSISp. 666
PRELIMINARY STEP TO CHECKING THE HYDRAULIC TAPPETSp. 666
OIL LEVEL TOO HIGHp. 666
OIL LEVEL TOO LOWp. 666
VALVE TRAIN NOISE DIAGNOSISp. 666
ENGINE OIL LEAK INSPECTIONp. 666
INSPECTION FOR REAR SEAL AREA LEAKSp. 667
STANDARD PROCEDUREp. 667
ENGINE CORE AND OIL GALLERY PLUGSp. 667
FORM-IN-PLACE GASKETS AND SEALERSp. 667
FORM-IN-PLACE GASKET AND SEALER APPLICATIONp. 668
ENGINE GASKET SURFACE PREPARATIONp. 669
HYDROSTATIC LOCKED ENGINEp. 669
REMOVAL – ENGINE ASSEMBLYp. 669
INSTALLATION – ENGINE ASSEMBLYp. 673
SPECIFICATIONSp. 674
ENGINEp. 674
TORQUEp. 677
SPECIAL TOOLSp. 678
ENGINEp. 678
AIR CLEANER ELEMENTp. 681
REMOVALp. 681
INSTALLATIONp. 681
AIR CLEANER HOUSINGp. 682
REMOVALp. 682
INSTALLATIONp. 682
ENGINE MOUNTSp. 683
REMOVALp. 683
INSTALLATIONp. 683
INTAKE MANIFOLDp. 684
REMOVALp. 684
INSPECTIONp. 686
INSTALLATIONp. 686
EXHAUST MANIFOLDp. 687
REMOVALp. 687
INSPECTIONp. 687
INSTALLATIONp. 688
CYLINDER HEAD(S)p. 688
REMOVAL – CYLINDER HEAD(S)p. 688
CLEANING / INSPECTIONp. 689
INSTALLATION – CYLINDER HEAD(S)p. 689
CYLINDER HEAD COVER(S)p. 690
REMOVALp. 690
LEFT CYLINDER HEAD COVERp. 690
RIGHT CYLINDER HEAD COVERp. 690
INSTALLATIONp. 691
LEFT CYLINDER HEAD COVERp. 691
RIGHT CYLINDER HEAD COVERp. 691
ROCKER ARMSp. 691
REMOVALp. 691
INSTALLATIONp. 692
VALVE SPRINGS/SEALSp. 692
DESCRIPTIONp. 692
DIAGNOSIS AND TESTINGp. 692
VALVE SPRING TESTINGp. 692
STANDARD PROCEDURE – VALVE SPRING/SEAL SERVICE IN-CARp. 693
REMOVALp. 694
INSTALLATIONp. 694
INTAKE/EXHAUST – VALVES/SEATS/GUIDESp. 695
STANDARD PROCEDURE – VALVE AND VALVE SEAT – REFACINGp. 695
VALVE SEATSp. 695
INSPECTIONp. 696
Valvep. 696
Valve Guidep. 696
TIMING CHAIN COVERp. 697
REMOVALp. 697
INSTALLATIONp. 697
TIMING CHAIN AND SPROCKETSp. 699
REMOVALp. 699
TIMING CHAIN AND CAMSHAFT SPROCKET REMOVALp. 699
CRANKSHAFT SPROCKET REMOVALp. 699
INSTALLATIONp. 700
CRANKSHAFT SPROCKET INSTALLATIONp. 700
TIMING CHAIN AND CAMSHAFT SPROCKET INSTALLATIONp. 700
LUBRICATIONp. 700
DESCRIPTIONp. 700
OPERATIONp. 700
DIAGNOSIS AND TESTINGp. 701
CHECKING ENGINE OIL PRESSUREp. 701
ENGINE OIL LEAKp. 701
Air Leak Detection Test Methodp. 701
INSPECTION FOR REAR SEAL AREA LEAKSp. 701
OILp. 702
STANDARD PROCEDUREp. 702
CHECKING ENGINE OIL LEVELp. 702
ENGINE OIL AND FILTER CHANGEp. 703
OIL FILTER SPECIFICATIONp. 703
USED ENGINE OIL DISPOSALp. 703
OIL COOLER & LINESp. 703
DESCRIPTIONp. 703
OPERATIONp. 703
STANDARD PROCEDURE – OIL COOLER LINE QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLYp. 703
DISASSEMBLYp. 703
ASSEMBLYp. 704
REMOVALp. 705
INSTALLATIONp. 705
OIL PANp. 706
REMOVALp. 706
INSTALLATIONp. 706
OIL PUMPp. 707
REMOVALp. 707
DISASSEMBLYp. 707
CLEANINGp. 708
INSPECTIONp. 708
ASSEMBLYp. 709
INSTALLATIONp. 710
OIL PRESSURE SENSORp. 710
REMOVALp. 710
INSTALLATIONp. 710
SENSOR-OIL TEMPERATUREp. 710
REMOVALp. 710
INSTALLATIONp. 710
ENGINE BLOCKp. 710
DESCRIPTIONp. 710
STANDARD PROCEDURE – CYLINDER BORE HONINGp. 710
CLEANINGp. 711
INSPECTIONp. 711
HYDRAULIC TAPPETSp. 712
DESCRIPTIONp. 712
REMOVALp. 712
INSTALLATIONp. 712
CAMSHAFTp. 713
REMOVALp. 713
INSTALLATIONp. 713
PISTON & CONNECTING RODp. 714
DESCRIPTIONp. 714
STANDARD PROCEDUREp. 714
PISTON FITTINGp. 714
MEASURING CONNECTING ROD SIDE CLEARANCEp. 714
REMOVALp. 715
INSPECTIONp. 716
CONNECTING RODp. 716
PISTON PINp. 716
PISTONp. 716
INSTALLATIONp. 716
PISTON RINGSp. 717
STANDARD PROCEDURE – MEASURING PISTON RING CLEARANCESp. 717
REMOVALp. 717
INSTALLATIONp. 717
CONNECTING ROD BEARINGSp. 718
DESCRIPTIONp. 718
STANDARD PROCEDUREp. 718
CONNECTING ROD BEARING – FITTINGp. 718
MEASURING CONNECTING ROD BEARING CLEARANCEp. 719
CRANKSHAFT DAMPERp. 719
REMOVALp. 719
INSTALLATIONp. 721
CRANKSHAFT OIL SEAL – FRONTp. 721
REMOVALp. 721
INSTALLATIONp. 721
CRANKSHAFT OIL SEAL AND RETAINER – REARp. 722
REMOVALp. 722
INSTALLATIONp. 722
CRANKSHAFT MAIN BEARINGSp. 723
DESCRIPTIONp. 723
STANDARD PROCEDUREp. 723
MEASURING CRANKSHAFT MAIN BEARING CLEARANCE IN-CARp. 723
PLASTIGAGE METHODp. 723
PREFERRED METHODp. 723
ALTERNATIVE METHODp. 723
CRANKSHAFTp. 724
STANDARD PROCEDUREp. 724
MEASURING CRANKSHAFT END PLAYp. 724
CRANKSHAFT END PLAY CHECK – OPTIONALp. 724
CRANKSHAFT JOURNAL MEASUREMENTp. 724
REMOVALp. 725
INSPECTIONp. 726
INSTALLATIONp. 727
CRANKSHAFT PILOT BEARINGp. 729
REMOVALp. 729
INSTALLATIONp. 729
11-EXHAUST SYSTEMp. 730
EXHAUST SYSTEMp. 730
DESCRIPTION – EXPORTp. 730
OPERATION – EXPORTp. 730
DIAGNOSIS AND TESTING – EXHAUST SYSTEM RESTRICTION CHECKp. 731
INSPECTIONp. 732
EXHAUST SYSTEM INSPECTIONp. 732
ADJUSTMENTSp. 732
EXHAUST SYSTEM ALIGNMENTp. 732
SPECIFICATIONS0 – 6 ZB (Continued)p. 733
TORQUEp. 733
SPECIAL TOOLSp. 733
EXHAUST SYSTEMp. 733
PIPE CLAMPSp. 733
DESCRIPTIONp. 733
HEAT SHIELDSp. 734
DESCRIPTIONp. 734
CATALYTIC CONVERTER(S)p. 734
OPERATIONp. 734
REMOVALp. 734
INSPECTIONp. 737
INSTALLATIONp. 737
RESONATOR(S)p. 737
REMOVALp. 737
INSTALLATIONp. 737
SPOUT ASSEMBLY – LEFT/RIGHTp. 738
REMOVALp. 738
INSTALLATIONp. 738
H-PIPEp. 740
REMOVALp. 740
INSTALLATIONp. 740
HEAT SHIELDS – EXPORTp. 740
REMOVAL – AUXILIARY RESONATOR HEAT SHEILDp. 740
INSTALLATION – AUXILIARY RESONATOR HEAT SHIELDp. 740
RESONATOR(S) – EXPORTp. 741
REMOVALp. 741
INSTALLATIONp. 741
SPOUT ASSEMBLY – EXPORTp. 741
REMOVALp. 741
INSTALLATIONp. 741
H-PIPE – EXPORTp. 742
REMOVALp. 742
REMOVAL – H-PIPEp. 742
REMOVAL – H-PIPE EXTENSION PIPESp. 743
INSTALLATIONp. 743
INSTALLATION – H-PIPEp. 743
INSTALLATION – H-PIPE EXTENSION PIPESp. 743
EXHAUST PIPE – EXPORTp. 744
REMOVAL – DIVERTER PIPEp. 744
INSTALLATION – DIVERTER PIPEp. 744
SUPPORT BRACKET AND ISOLATOR – EXPORTp. 745
REMOVALp. 745
REMOVAL – AUXILIARY RESONATOR – UPPER LEFTp. 745
REMOVAL – AUXILIARY RESONATOR – LOWER LEFT HANGERp. 745
INSTALLATIONp. 745
INSTALLATION – AUXILIARY RESONATOR – UPPER LEFTp. 745
INSTALLATION – AUXILIARY RESONATOR – LOWER LEFT HANGERp. 745
EXHAUST SOLENOID – EXPORTp. 746
REMOVALp. 746
INSTALLATIONp. 746
13-FRAME & BUMPERSp. 748
FRAME & BUMPERSp. 748
SPECIFICATIONS – TORQUEp. 748
FRONT FASCIAp. 748
REMOVALp. 748
INSTALLATIONp. 750
FRONT FASCIA – EXPORTp. 750
REMOVAL – EXPORTp. 750
INSTALLATION – EXPORTp. 750
FRONT BUMPER REINFORCEMENTp. 751
REMOVALp. 751
INSTALLATIONp. 751
FRONT BUMPER REINFORCEMENT – EXPORTp. 752
REMOVAL – EXPORTp. 752
INSTALLATION – EXPORTp. 752
REAR FASCIAp. 752
REMOVALp. 752
INSTALLATIONp. 752
REAR BUMPER FOAMp. 754
REMOVALp. 754
INSTALLATIONp. 754
REAR BUMPERp. 754
REMOVALp. 754
INSTALLATIONp. 754
FRONT TOW EYE BRACKET – EXPORTp. 755
REMOVAL – EXPORTp. 755
INSTALLATION – EXPORTp. 755
BRACKET – REAR LICENSE PLATE EXPORTp. 755
REMOVAL – EXPORTp. 755
INSTALLATION – EXPORTp. 755
FRAMEp. 756
WARNINGp. 756
STANDARD PROCEDUREp. 756
FRAME DAMAGE REPAIRp. 756
FRONT FRAME ASSEMBLYp. 757
WARNINGS AND CAUTIONSp. 757
Removalp. 757
Installationp. 757
FRONT UPPER FRAME RAIL ASSEMBLYp. 757
WARNINGS AND CAUTIONSp. 757
Removalp. 757
Installationp. 758
FRAME SIDE SILL ASSEMBLYp. 758
WARNINGS AND CAUTIONSp. 758
Removalp. 758
Installationp. 758
REAR UPPER FRAME RAIL ASSEMBLYp. 758
WARNINGS AND CAUTIONSp. 758
Removalp. 758
Installationp. 758
SPECIFICATIONSp. 759
FRAME DIMENSIONSp. 759
VEHICLE PREPARATIONp. 759
SPECIFICATIONS – WELDINGp. 767
REAR TRANSMISSION CROSSMEMBERp. 768
REMOVALp. 768
INSTALLATIONp. 768
14-FUEL SYSTEMp. 770
FUEL DELIVERYp. 770
DESCRIPTIONp. 771
FUEL DELIVERY SYSTEMp. 771
LONG-TERM STORAGEp. 771
OPERATION – FUEL DELIVERY SYSTEMp. 771
STANDARD PROCEDUREp. 771
FUEL SYSTEM PRESSURE RELEASE PROCEDUREp. 771
DRAINING FUEL TANKp. 771
SPECIFICATIONSp. 771
FUEL SYSTEM PRESSUREp. 771
TORQUEp. 771
SPECIAL TOOLSp. 772
FUELp. 772
FUEL FILTERp. 772
DESCRIPTIONp. 772
REMOVALp. 772
INSTALLATIONp. 772
FUEL LEVEL SENSORp. 773
DESCRIPTIONp. 773
OPERATIONp. 773
REMOVALp. 773
INSTALLATIONp. 773
FUEL TUBES/LINES/HOSES AND CLAMPSp. 774
DESCRIPTION – FUEL TUBES/LINES/HOSES AND CLAMPSp. 774
STANDARD PROCEDURE – HOSES AND CLAMPSp. 775
FUEL PRESSURE REGULATORp. 775
DESCRIPTIONp. 775
OPERATIONp. 775
REMOVALp. 775
INSTALLATIONp. 776
ELECTRIC FUEL PUMPp. 776
DESCRIPTIONp. 776
OPERATIONp. 776
FUEL PUMP ELECTRICAL CONTROLp. 776
STANDARD PROCEDURE – FUEL PUMP REPLACEMENTp. 776
FUEL PUMP MODULEp. 776
DESCRIPTIONp. 776
REMOVALp. 776
INSTALLATIONp. 778
FUEL RAILp. 779
OPERATIONp. 779
REMOVALp. 779
INSTALLATIONp. 781
FUEL TANKp. 781
OPERATIONp. 781
STANDARD PROCEDURE – FUEL TANK CLOSEOUT PANELp. 782
INSTALLATIONp. 782
REMOVALp. 782
INSTALLATIONp. 790
FUEL FILLER TUBEp. 791
REMOVALp. 791
INSTALLATIONp. 791
FUEL PUMP INLET STRAINERp. 791
DESCRIPTIONp. 791
QUICK CONNECT FITTINGp. 791
STANDARD PROCEDURE – QUICK-CONNECT FITTINGSp. 791
REMOVALp. 791
INSTALLATIONp. 791
TWO-TAB TYPE FITTINGp. 792
PLASTIC RETAINER RING TYPE FITTINGp. 793
PRESSURE VACUUM FILLER CAPp. 793
DESCRIPTIONp. 793
OPERATIONp. 793
FUEL INJECTIONp. 794
OPERATIONp. 794
OPERATION – INJECTION SYSTEMp. 794
OPERATION – MODES OF OPERATIONp. 795
IGNITION SWITCH ON (ZERO RPM) MODEp. 795
ENGINE START-UP MODEp. 795
ENGINE WARM-UP MODEp. 796
CRUISE OR IDLE MODEp. 796
ACCELERATION MODEp. 796
DECELERATION MODEp. 796
WIDE-OPEN-THROTTLE MODEp. 797
IGNITION SWITCH OFF MODEp. 797
FUEL CORRECTION or ADAPTIVE MEMORIESp. 797
DESCRIPTIONp. 797
OPERATIONp. 797
SPECIFICATIONSp. 798
TORQUEp. 798
SPECIAL TOOLSp. 799
FUELp. 799
ACCELERATOR PEDALp. 799
DESCRIPTIONp. 799
REMOVALp. 799
CRANKSHAFT POSITION SENSORp. 800
DESCRIPTIONp. 800
OPERATIONp. 800
REMOVALp. 800
INSTALLATIONp. 800
FUEL INJECTORSp. 800
DESCRIPTIONp. 800
OPERATIONp. 801
REMOVALp. 801
INSTALLATIONp. 803
FUEL PUMP RELAYp. 803
DESCRIPTIONp. 803
OPERATIONp. 803
IDLE AIR CONTROL MOTORp. 803
DESCRIPTIONp. 803
OPERATIONp. 804
REMOVALp. 804
INSTALLATIONp. 804
INLET AIR TEMPERATURE SENSORp. 804
DESCRIPTIONp. 804
REMOVALp. 804
INSTALLATIONp. 804
MAP SENSORp. 805
DESCRIPTIONp. 805
OPERATIONp. 805
REMOVALp. 806
INSTALLATIONp. 806
O2 SENSORp. 806
DESCRIPTIONp. 806
OPERATIONp. 806
UPSTREAM OXYGEN SENSORp. 807
DOWNSTREAM OXYGEN SENSORp. 807
REMOVALp. 807
8.3L – UPSTREAM 1/1, 2/1p. 807
8.3L – DOWNSTREAM 1/2, 2/2p. 807
INSTALLATIONp. 807
8.3L – UPSTREAM 1/1, 2/1p. 807
8.3L – DOWNSTREAM 1/2, 2/2p. 807
THROTTLE BODYp. 808
DESCRIPTIONp. 808
OPERATIONp. 808
REMOVALp. 808
INSTALLATIONp. 809
THROTTLE CABLEp. 809
REMOVALp. 809
INSTALLATIONp. 810
THROTTLE POSITION SENSORp. 810
DESCRIPTIONp. 810
OPERATIONp. 810
REMOVALp. 810
INSTALLATIONp. 811
19-STEERINGp. 812
STEERINGp. 812
WARNINGS AND CAUTIONSp. 812
DIAGNOSIS AND TESTINGp. 812
DIAGNOSIS AND TESTING – HYDRAULIC FLOW AND PRESSUREp. 812
FLOW AND PRESSURE TEST – AT POWER STEERING PUMPp. 812
FLOW AND PRESSURE TEST – AT POWER STEERING GEARp. 813
DIAGNOSIS AND TESTING – STEERING SYSTEM DIAGNOSIS CHARTSp. 814
POWER STEERING NOISEp. 814
STEERING WHEEL FEELp. 816
POWER STEERING FLUIDp. 819
SPECIFICATIONSp. 819
POWER STEERING FASTENER TORQUEp. 819
SPECIAL TOOLSp. 820
POWER STEERINGp. 820
COLUMNp. 821
WARNINGS AND CAUTIONSp. 821
REMOVALp. 822
INSTALLATIONp. 824
SPECIFICATIONSp. 826
STEERING COLUMN FASTENER TORQUEp. 826
IGNITION SWITCHp. 826
REMOVALp. 826
INSTALLATIONp. 827
START BUTTONp. 828
REMOVALp. 828
INSTALLATIONp. 828
INTERMEDIATE SHAFTp. 828
DIAGNOSIS AND TESTING – STEERING COLUMN INTERMEDIATE SHAFTp. 828
REMOVALp. 828
INSTALLATIONp. 829
INTERMEDIATE SHAFT – EXTENSIONp. 829
DIAGNOSIS AND TESTING – STEERING COLUMN INTERMEDIATE SHAFT – EXTENSIONp. 829
REMOVALp. 829
INSTALLATIONp. 829
STEERING WHEELp. 830
REMOVALp. 830
INSTALLATIONp. 831
GEARp. 833
REMOVALp. 833
INSTALLATIONp. 834
TIE ROD – OUTERp. 835
REMOVALp. 835
INSTALLATIONp. 836
21-TRANSMISSION/TRANSAXLEp. 848
MANUAL TRANSMISSION – T56p. 848
DESCRIPTIONp. 848
IDENTIFICATIONp. 848
OPERATIONp. 849
NEUTRALp. 849
1ST GEARp. 849
2ND GEARp. 849
3RD GEARp. 849
4TH GEARp. 849
5TH GEARp. 849
6TH GEARp. 849
REVERSEp. 850
DIAGNOSIS AND TESTING – MANUAL TRANSMISSIONp. 850
LOW LUBRICANT LEVELp. 850
HARD SHIFTINGp. 851
TRANSMISSION NOISEp. 851
STANDARD PROCEDURE – DRAIN AND FILLp. 851
REMOVALp. 851
DISASSEMBLYp. 852
MAINSHAFTp. 861
COUNTERSHAFTp. 864
INPUT SHAFTp. 864
EXTENSION HOUSINGp. 865
TRANSMISSION CASEp. 866
TRANSMISSION ADAPTERp. 867
CLEANINGp. 867
INSPECTIONp. 867
ASSEMBLYp. 867
TRANSMISSION ADAPTERp. 867
TRANSMISSION CASEp. 868
EXTENSION HOUSINGp. 869
INPUT SHAFTp. 869
COUNTERSHAFTp. 869
MAINSHAFTp. 871
TRANSMISSION HOUSINGp. 873
INSTALLATIONp. 881
ADJUSTMENTSp. 881
ADUSTMENTSp. 881
MAINSHAFT BEARINGS PRELOADp. 881
COUNTERSHAFT BEARINGS PRELOADp. 882
SPECIFICATIONSp. 883
SPECIAL TOOLSp. 883
EXTENSION HOUSING SEALp. 883
REMOVALp. 883
INSTALLATIONp. 883
INPUT SHAFTp. 884
REMOVALp. 884
INSTALLATIONp. 885
REVERSE LOCKOUT SOLENOIDp. 885
DESCRIPTIONp. 885
OPERATIONp. 885
SHIFT MECHANISMp. 886
REMOVAL0 – 8 ZB (Continued)p. 886
INSTALLATIONp. 886
SKIP SHIFT SOLENOIDp. 886
DESCRIPTIONp. 886
OPERATIONp. 886
22-TIRES/WHEELSp. 888
TIRES/WHEELSp. 888
DIAGNOSIS AND TESTING – TIRE AND WHEEL RUNOUTp. 888
METHOD 1 (RELOCATE WHEEL ON HUB)p. 888
METHOD 2 (RELOCATE TIRE ON WHEEL)p. 889
STANDARD PROCEDUREp. 890
TIRE AND WHEEL BALANCEp. 890
TIRE AND WHEEL MATCH MOUNTINGp. 890
REMOVAL – TIRE AND WHEEL ASSEMBLYp. 893
INSTALLATION – TIRE AND WHEEL ASSEMBLYp. 893
TIRE PRESSURE MONITORING (TPM)p. 893
DESCRIPTIONp. 893
OPERATIONp. 893
POWER UP INITIALIZATIONp. 893
TIRE DIAGNOSTIC FAULTp. 894
TIRE LOW PRESSUREp. 894
TIRE CRITICAL PRESSUREp. 894
DIAGNOSIS AND TESTING – TIRE PRESSURE MONITORING SYSTEMp. 894
SPECIFICATIONSp. 894
TIRE PRESSURE MONITORING SYSTEMp. 894
MODULE – TPMp. 894
DESCRIPTIONp. 894
OPERATIONp. 895
STANDARD PROCEDURE – TPM MODULE PROGRAMMINGp. 895
REMOVALp. 895
INSTALLATIONp. 895
SENSOR – TPMp. 896
DESCRIPTIONp. 896
VALVE STEM CORE AND CAPp. 896
OPERATIONp. 896
REMOVALp. 897
INSTALLATIONp. 898
TIRESp. 899
DESCRIPTION – TIRESp. 899
DIAGNOSIS AND TESTINGp. 900
TIRE NOISE AND VIBRATIONp. 900
TIRE TREAD WEAR INDICATORSp. 900
TIRE TREAD WEAR PATTERNSp. 900
TIRE/VEHICLE LEADp. 901
STANDARD PROCEDUREp. 903
TIRE INFLATION PRESSURESp. 903
TIRE PRESSURE FOR HIGH SPEED OPERATIONp. 903
TIRE LEAK REPAIRINGp. 903
SPECIFICATIONSp. 904
TIRESp. 904
WHEELSp. 904
DESCRIPTION – WHEELp. 904
DIAGNOSIS AND TESTING – WHEEL INSPECTIONp. 904
CLEANING – ALUMINUM WHEEL CAREp. 905
SPECIFICATIONSp. 905
WHEELSp. 905
WHEEL MOUNTING STUDS – FRONTp. 905
REMOVALp. 905
INSTALLATIONp. 906
WHEEL MOUNTING STUDS – REARp. 906
REMOVALp. 906
INSTALLATIONp. 906
23-BODYp. 908
BODYp. 908
WARNINGp. 908
SAFETY PRECAUTIONS AND WARNINGSp. 908
DIAGNOSIS AND TESTINGp. 908
WATER LEAKSp. 908
VISUAL INSPECTION BEFORE WATER LEAK TESTSp. 909
WATER LEAK TESTSp. 909
WATER LEAK DETECTIONp. 909
WIND NOISEp. 909
VISUAL INSPECTION BEFORE TESTSp. 909
STANDARD PROCEDUREp. 910
STANDARD PROCEDURE – PLASTIC BODY PANEL REPAIRp. 910
Rigid Plastics:p. 910
Semi-Rigid Plastics:p. 910
Flexible Plastics:p. 910
Repair Procedure:p. 910
Adhesion Promoter/Surface Modifier:p. 910
SAFETY PRECAUTION AND WARNINGSp. 910
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPESp. 911
PANEL SECTIONINGp. 913
PANEL REINFORCEMENTp. 913
VISUAL INSPECTIONp. 914
PANEL SURFACE PREPARATIONp. 914
PATCHING PANELSp. 914
PANEL PATCH FABRICATIONSp. 914
PANEL PATCH INSTALLATIONp. 915
PATCHED PANEL SURFACINGp. 917
STANDARD PROCEDURE – HEAT STAKINGp. 917
SPECIFICATIONSp. 917
BODY PANELS AND MATERIALSp. 917
BODY LUBRICATIONp. 917
LUBRICATION REQUIREMENTSp. 917
LUBRICANT APPLICATIONp. 917
LUBRICANT USAGE – BODYp. 918
SPECIFICATIONS – TORQUEp. 918
SPECIAL TOOLSp. 919
BODYp. 919
CONVERTIBLE TOPp. 920
DESCRIPTIONp. 920
FOLDING TOP COVERp. 922
REMOVALp. 922
INSTALLATIONp. 922
FOLDING TOP – ASSEMBLYp. 923
REMOVALp. 923
INSTALLATIONp. 923
REAR WINDOWp. 924
REMOVALp. 924
INSTALLATIONp. 924
STAY PADS – STRAPSp. 924
REMOVALp. 924
INSTALLATIONp. 925
BOW – CENTER/3p. 925
REMOVALp. 925
INSTALLATIONp. 925
BOW – REAR/4p. 925
REMOVALp. 925
INSTALLATIONp. 925
CLOTH SUPPORT PANELp. 926
REMOVALp. 926
INSTALLATIONp. 926
HEADER ASSEMBLYp. 926
REMOVALp. 926
INSTALLATIONp. 926
TACK STRIPp. 926
REMOVALp. 926
INSTALLATIONp. 926
TENSION CABLEp. 927
REMOVALp. 927
INSTALLATIONp. 928
LATCHp. 928
REMOVALp. 928
INSTALLATIONp. 928
HINGE – SIDEARM/LINKAGE ASSEMBLYp. 928
REMOVALp. 928
INSTALLATIONp. 928
DECKLIDp. 930
GAS PROPp. 930
REMOVALp. 930
INSTALLATIONp. 930
HINGEp. 930
REMOVALp. 930
INSTALLATIONp. 930
LATCHp. 932
REMOVALp. 932
INSTALLATIONp. 932
LATCH STRIKERp. 932
REMOVALp. 932
INSTALLATIONp. 932
LOCK CYLINDERp. 933
REMOVALp. 933
INSTALLATIONp. 933
SLAM BUMPERp. 933
REMOVALp. 933
INSTALLATIONp. 933
DOOR – FRONTp. 934
DOORp. 934
REMOVALp. 934
INSTALLATIONp. 934
ADJUSTMENTSp. 935
ADJUSTMENTp. 935
FORE/AFTp. 935
UP/DOWNp. 935
IN/OUTp. 935
DOOR GLASSp. 936
REMOVALp. 936
INSTALLATIONp. 936
ADJUSTMENTSp. 936
ADJUSTMENTp. 936
TOP OF GLASS – INBOARD/OUTBOARD ADJUSTMENTSp. 936
UP/DOWN AND FORE/AFT ADJUSTMENTSp. 937
DOOR GLASS ALIGNMENT VERIFICATIONp. 938
OUTSIDE DOOR HANDLEp. 938
REMOVALp. 938
INSTALLATIONp. 939
HINGEp. 939
REMOVALp. 939
INSTALLATIONp. 939
LOCK CYLINDERp. 940
REMOVALp. 940
INSTALLATIONp. 940
LATCHp. 940
REMOVALp. 940
INSTALLATIONp. 941
LATCH STRIKERp. 941
REMOVALp. 941
INSTALLATIONp. 941
TRIM PANELp. 942
REMOVALp. 942
INSTALLATIONp. 942
WINDOW REGULATORp. 944
REMOVALp. 944
INSTALLATIONp. 945
HINGE COVER – EXPORTp. 945
REMOVALp. 945
INSTALLATIONp. 945
EXTERIORp. 946
BELLY PANp. 946
REMOVALp. 946
REMOVALp. 946
REMOVAL – FRONT EXTENSION BELLY PANp. 946
REMOVAL – REAR EXTENSION BELLY PANp. 948
INSTALLATIONp. 948
INSTALLATION – BELLY PANp. 948
INSTALLATION – FRONT EXTENSION BELLY PANp. 948
INSTALLATION – REAR EXTENSION BELLY PANp. 948
COWL SCREEN PANELp. 948
REMOVALp. 948
INSTALLATIONp. 948
FUEL FILL DOORp. 949
REMOVALp. 949
INSTALLATIONp. 949
FUEL FILLER HOUSINGp. 949
REMOVALp. 949
INSTALLATIONp. 949
FRONT WHEELHOUSE SPLASH SHIELDp. 949
REMOVALp. 949
INSTALLATIONp. 950
REAR QUARTER PANELp. 950
REMOVALp. 950
INSTALLATIONp. 950
REAR WHEELHOUSE SPLASH SHIELDp. 953
REMOVALp. 953
INSTALLATIONp. 953
SILL PANELp. 953
REMOVALp. 953
INSTALLATIONp. 954
SILL PANEL – EXPORTp. 955
REMOVALp. 955
INSTALLATIONp. 955
SIDE VIEW MIRRORp. 957
REMOVALp. 957
INSTALLATIONp. 957
GLASS-OUTSIDE REARVIEW MIRRORp. 957
REMOVALp. 957
INSTALLATIONp. 957
TRUNK PANp. 958
REMOVALp. 958
INSTALLATIONp. 958
FRONT FENDERp. 959
REMOVALp. 959
Fenderp. 959
Fender Supportp. 960
INSTALLATIONp. 961
Fender Supportp. 961
Fenderp. 961
FRONT FENDER – EXPORTp. 962
REMOVALp. 962
Fenderp. 962
Fender Supportp. 962
INSTALLATIONp. 963
Fender Supportp. 963
Fenderp. 964
FRONT STRUT TOWER TO TOWER BRACEp. 964
REMOVALp. 964
INSTALLATIONp. 964
HOODp. 966
ADJUSTMENT BUMPERp. 966
REMOVALp. 966
INSTALLATIONp. 966
HINGEp. 966
REMOVALp. 966
INSTALLATIONp. 966
REMOVALp. 967
INSTALLATIONp. 967
ADJUSTMENTSp. 967
ADJUSTMENTp. 967
HOOD AIR CLEANER SEALp. 967
REMOVALp. 967
INSTALLATIONp. 967
HOOD LATCH AND SAFETY CATCHp. 967
REMOVALp. 967
INSTALLATIONp. 968
LATCH RELEASE HANDLEp. 968
REMOVALp. 968
INSTALLATIONp. 968
SILENCER PADp. 969
REMOVALp. 969
INSTALLATIONp. 969
GAS PROPp. 970
REMOVALp. 970
INSTALLATIONp. 970
INSTRUMENT PANELp. 971
CLUSTER BEZELp. 971
REMOVALp. 971
INSTALLATIONp. 971
GLOVE BOXp. 971
REMOVALp. 971
INSTALLATIONp. 972
GLOVE BOX LATCH STRIKERp. 972
REMOVALp. 972
INSTALLATIONp. 972
INSTRUMENT PANEL RIGHT LOWER TRIMp. 972
REMOVALp. 972
INSTALLATIONp. 972
INSTRUMENT PANEL CENTER BEZELp. 972
REMOVALp. 972
INSTALLATIONp. 973
INSTRUMENT PANEL STEERING COLUMN COVERp. 973
REMOVALp. 973
INSTALLATIONp. 973
INSTRUMENT PANEL & PAD ASSEMBLYp. 973
REMOVALp. 973
INSTALLATIONp. 976
INSTRUMENT PANEL COVER/PADp. 978
REMOVALp. 978
INSTALLATIONp. 978
INTERIORp. 979
A-PILLAR TRIMp. 979
REMOVALp. 979
INSTALLATIONp. 979
BULKHEAD QUARTER TRIM PANELp. 979
REMOVALp. 979
INSTALLATIONp. 980
CARPETSp. 981
REMOVALp. 981
Floor Carpetsp. 981
Top Stack Carpetp. 981
INSTALLATIONp. 981
Floor Carpetsp. 981
Top Stack Carpetp. 981
CENTER CONSOLE BEZELp. 982
REMOVALp. 982
INSTALLATIONp. 982
DOOR SURROUND PANELp. 983
REMOVALp. 983
INSTALLATIONp. 983
REAR VIEW MIRRORp. 983
REMOVALp. 983
INSTALLATIONp. 983
INSTALLATION – REAR VIEW MIRROR SUPPORT BRACKETp. 983
SIDE COWL TRIMp. 984
REMOVALp. 984
INSTALLATIONp. 984
SPORT HOOPp. 984
REMOVALp. 984
Sport Hoopp. 984
Sport Hoop Mounting Bracketsp. 985
INSTALLATIONp. 985
Sport Hoop Mounting Bracketsp. 985
Sport Hoopp. 985
SUN VISORp. 985
REMOVALp. 985
INSTALLATIONp. 986
FRONT TUNNEL CONSOLEp. 986
REMOVAL0 – 10 ZB (Continued)p. 986
INSTALLATIONp. 986
PAINTp. 987
SPECIFICATIONS – PAINT CODESp. 987
PAINT CODEp. 987
DESCRIPTIONp. 987
BASE COAT/CLEAR COAT FINISHp. 987
DESCRIPTIONp. 987
PAINT TOUCH-UPp. 988
DESCRIPTIONp. 988
TOUCH UP PROCEDUREp. 988
FINESSE SANDING/BUFFING & POLISHINGp. 988
DESCRIPTIONp. 988
SEATSp. 989
SEATp. 989
REMOVALp. 989
INSTALLATIONp. 989
SEAT ADJUSTERSp. 990
REMOVALp. 990
INSTALLATIONp. 990
SEAT BACKp. 991
REMOVALp. 991
INSTALLATIONp. 991
SEAT BACK COVERp. 991
REMOVALp. 991
INSTALLATIONp. 992
SEAT BACK RECLINERp. 992
REMOVALp. 992
INSTALLATIONp. 993
SEAT CUSHION ASSEMBLYp. 993
REMOVALp. 993
INSTALLATIONp. 994
SEAT CUSHION COVERp. 994
REMOVALp. 994
INSTALLATIONp. 994
STATIONARY GLASSp. 995
WINDSHIELDp. 995
WARNINGp. 995
WINDSHIELD SAFETY PRECAUTIONSp. 995
REMOVALp. 995
INSTALLATIONp. 996
WEATHERSTRIP/SEALSp. 998
DOOR INNER BELT WEATHERSTRIPp. 998
REMOVALp. 998
INSTALLATIONp. 998
DOOR OPENING PRIMARY SEAL WEATHERSTRIPp. 998
REMOVALp. 998
INSTALLATIONp. 998
DOOR OUTER BELT WEATHERSTRIPp. 999
REMOVALp. 999
INSTALLATIONp. 999
DOOR SECONDARY SEAL WEATHERSTRIPp. 999
REMOVALp. 999
INSTALLATIONp. 999
WINDSHIELD HEADER & A-PILLAR WEATHERSTRIPp. 999
REMOVALp. 999
INSTALLATIONp. 999
SIDE RAIL WEATHERSTRIPp. 999
REMOVALp. 999
INSTALLATIONp. 999
DECKLID OPENING WEATHERSTRIPp. 1000
REMOVALp. 1000
INSTALLATIONp. 1000
24-HEATING & AIR CONDITIONINGp. 1026
HEATING & AIR CONDITIONINGp. 1026
DESCRIPTIONp. 1026
OPERATIONp. 1027
DIAGNOSIS AND TESTINGp. 1027
A/C PERFORMANCEp. 1027
A/C PERFORMANCE TESTp. 1028
HEATER PERFORMANCEp. 1031
SPECIFICATIONSp. 1032
HEATING-A/C SYSTEMp. 1032
CONTROLSp. 1034
A/C COMPRESSOR CLUTCHp. 1034
DESCRIPTIONp. 1034
OPERATIONp. 1034
DIAGNOSIS AND TESTINGp. 1035
A/C COMPRESSOR CLUTCH COILp. 1035
STANDARD PROCEDUREp. 1036
A/C CLUTCH INSPECTIONp. 1036
A/C CLUTCH BREAK-INp. 1036
REMOVALp. 1036
INSTALLATIONp. 1038
A/C COMPRESSOR CLUTCH RELAYp. 1039
DESCRIPTIONp. 1039
OPERATIONp. 1039
REMOVALp. 1039
INSTALLATIONp. 1039
A/C HEATER CONTROLp. 1040
DESCRIPTIONp. 1040
REMOVALp. 1040
INSTALLATIONp. 1040
A/C LOW PRESSURE SWITCHp. 1041
DESCRIPTIONp. 1041
OPERATIONp. 1041
DIAGNOSIS AND TESTINGp. 1041
A/C LOW PRESSURE SWITCHp. 1041
REMOVALp. 1041
INSTALLATIONp. 1042
A/C PRESSURE TRANSDUCERp. 1042
DESCRIPTIONp. 1042
OPERATIONp. 1042
DIAGNOSIS AND TESTINGp. 1043
A/C PRESSURE TRANSDUCERp. 1043
REMOVALp. 1043
INSTALLATIONp. 1043
BLEND DOOR ACTUATORp. 1044
DESCRIPTIONp. 1044
OPERATIONp. 1044
REMOVALp. 1044
INSTALLATIONp. 1045
BLOWER MOTOR RELAYp. 1045
DESCRIPTIONp. 1045
OPERATIONp. 1045
REMOVALp. 1046
INSTALLATIONp. 1046
BLOWER MOTOR RESISTOR BLOCKp. 1046
DESCRIPTIONp. 1046
OPERATIONp. 1046
DIAGNOSIS AND TESTINGp. 1047
BLOWER MOTOR RESISTORp. 1047
REMOVALp. 1047
INSTALLATIONp. 1048
MODE DOOR ACTUATORSp. 1048
DESCRIPTIONp. 1048
OPERATIONp. 1048
REMOVALp. 1048
INSTALLATIONp. 1049
RECIRCULATION DOOR ACTUATORp. 1049
DESCRIPTIONp. 1049
OPERATIONp. 1049
REMOVALp. 1050
INSTALLATIONp. 1050
DISTRIBUTIONp. 1051
AIR OUTLETSp. 1051
DESCRIPTIONp. 1051
REMOVALp. 1051
INSTALLATIONp. 1051
BLOWER MOTORp. 1052
DESCRIPTIONp. 1052
OPERATIONp. 1052
DIAGNOSIS AND TESTINGp. 1052
BLOWER MOTORp. 1052
REMOVALp. 1053
INSTALLATIONp. 1053
DEFROSTER DUCTSp. 1053
REMOVALp. 1053
INSTALLATIONp. 1054
FLOOR DISTRIBUTION DUCTp. 1055
REMOVALp. 1055
INSTALLATIONp. 1055
HVAC HOUSINGp. 1055
REMOVALp. 1055
DISASSEMBLYp. 1056
ASSEMBLYp. 1057
INSTALLATIONp. 1057
INSTRUMENT PANEL DUCTSp. 1058
REMOVALp. 1058
INSTALLATIONp. 1058
25-EMISSIONS CONTROLp. 1086
EMISSIONS CONTROLp. 1086
DESCRIPTIONp. 1086
DESCRIPTION – MONITORED COMPONENTp. 1086
DESCRIPTION – VEHICLE EMISSION CONTROL INFORMATION LABELp. 1089
DESCRIPTION – TRIP DEFINITIONp. 1090
OPERATION – NON-MONITORED CIRCUITSp. 1090
DESCRIPTION – MONITORED SYSTEMSp. 1091
DESCRIPTION – HIGH AND LOW LIMITSp. 1093
OPERATIONp. 1093
OPERATION – SYSTEMp. 1093
DRB III STATE DISPLAY TEST MODEp. 1094
OPERATIONp. 1094
EVAPORATIVE EMISSIONSp. 1095
OPERATION – EVAPORATION CONTROL SYSTEMp. 1095
CCV SYSTEMp. 1095
DESCRIPTIONp. 1095
OPERATIONp. 1095
DIAGNOSIS AND TESTING – CRANKCASE VENTILATION SYSTEMp. 1096
TESTING/CLEANINGp. 1096
EVAP/PURGE SOLENOIDp. 1096
OPERATIONp. 1096
REMOVALp. 1097
INSTALLATIONp. 1098
FUEL FILLER CAPp. 1098
DESCRIPTIONp. 1098
OPERATIONp. 1098
LEAK DETECTION PUMPp. 1098
REMOVALp. 1098
INSTALLATIONp. 1099
ORVRp. 1100
DESCRIPTIONp. 1100
OPERATIONp. 1100
VAPOR CANISTERp. 1101
DESCRIPTIONp. 1101
OPERATIONp. 1101
Purge Free Cellsp. 1101
REMOVALp. 1101
INSTALLATIONp. 1102
INDEXp. 1108
COMMENTSp. 1110

Beyond the chapter list above, this 2005 Dodge Viper SRT-10 Service Manual is a fully integrated service reference. Every section includes component-specific diagnosis charts, fastener torque tables, exploded illustrations, and wiring or hydraulic diagrams where applicable. The electrical portion includes connector pin-outs, ground distribution, splice locations, and component indexes — essential for tracking down intermittent faults or performing a full vehicle electrical repair.

Why the Factory Service Manual Matters for the Viper SRT-10

The Viper SRT-10 is not a typical passenger car. Its 8.3L aluminum V10, T-56 six-speed transaxle, fully independent suspension, four-piston opposed calipers, and Hydra-Lok limited-slip differential all demand procedures and torque values that generic repair guides simply do not provide. The factory service manual is the only reliable source for critical specifications such as camshaft end play, connecting rod side clearance, pinion rotating torque, dynamic toe pattern, and ABS hydraulic circuit bleeding sequences. Without the correct values, even a minor repair can lead to premature wear, poor handling, or brake system malfunction.

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2005 Dodge Viper SRT-10 Service Manual - Full Workshop Repair & Diagnostic Guide — PDF page 1 preview
2005 Dodge Viper SRT-10 Service Manual - Full Workshop Repair & Diagnostic Guide — PDF page 27 preview
2005 Dodge Viper SRT-10 Service Manual - Full Workshop Repair & Diagnostic Guide — PDF page 132 preview

For owners performing their own maintenance, this 2005 Viper SRT-10 workshop manual makes it possible to handle oil changes, brake pad replacement, fluid services, and scheduled maintenance with confidence. For professional technicians, it provides the complete disassembly and reassembly procedures for engine, transmission, differential, suspension, and body systems — the same documentation a Dodge dealer would reference.

Get Your 2005 Dodge Viper SRT-10 Service Manual Instantly

This complete 2005 Dodge Viper SRT-10 Service Manual is delivered as an instant PDF download. There is no shipping, no waiting, and no physical media to lose. Once downloaded, the manual can be viewed on any computer, tablet, or smartphone, and individual pages or sections can be printed for use in the garage. Whether you are diagnosing a drivability complaint, rebuilding a differential, or adjusting the convertible top, this manual gives you the factory procedures, specifications, and illustrations needed to do the job correctly.

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