2005 Jeep KJ Diesel Service Manual – PDF DOWNLOAD
$36.95
2005 Jeep KJ Diesel Service Manual – PDF DOWNLOAD
Description
2005 Jeep KJ Diesel Service Manual – PDF DOWNLOAD
FILE DETAILS:
2005 Jeep KJ Diesel Service Manual – PDF DOWNLOAD
Language : English
Pages : 2401
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
2005 Jeep KJ Diesel Service Manual – PDF DOWNLOAD
KJ Diesel Service Manual 1
GROUP TAB LOCATOR 1
in-INTRODUCTION 2
FASTENER IDENTIFICATION 2
DESCRIPTION 2
FASTENER USAGE 5
DESCRIPTION 5
DESCRIPTION 5
DESCRIPTION 5
INTERNATIONAL SYMBOLS 5
DESCRIPTION 5
METRIC SYSTEM 5
DESCRIPTION 5
TORQUE REFERENCES 7
DESCRIPTION 7
VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL 9
DESCRIPTION 9
VEHICLE IDENTIFICATION NUMBER 9
DESCRIPTION 9
VEHICLE CERTIFICATION LABEL 10
DESCRIPTION 10
0-LUBRICATION & MAINTENANCE 12
INTERNATIONAL SYMBOLS 12
DESCRIPTION 12
PARTS & LUBRICANT RECOMMENDATION 12
DESCRIPTION 12
LUBRICANT RECOMMENDATIONS 12
Chassis 12
Body 13
FLUID TYPES 13
API QUALITY CLASSIFICATION 13
GEAR LUBRICANTS 13
FLUID TYPES 13
DESCRIPTION 13
ENGINE OIL 13
API SERVICE GRADE CERTIFIED 13
SAE VISCOSITY 13
ACEA Categories 13
ENERGY CONSERVING OIL 13
CONTAINER IDENTIFICATION 14
ENGINE OIL – DIESEL ENGINES 14
SAE VISCOSITY GRADE 14
ENGINE OIL – DIESEL ENGINES – EXPORT 14
SAE VISCOSITY GRADE 14
AXLE 14
MANUAL TRANSMISSION 14
AUTOMATIC TRANSMISSION FLUID 14
FLUID ADDITIVES 15
TRANSFER CASE – NV231 15
TRANSFER CASE – NV241 GENII 15
TRANSFER CASE – NV242 15
ENGINE COOLANT 15
COOLANT PERFORMANCE 15
POWER STEERING FLUID 16
OPERATION – AUTOMATIC TRANSMISSION FLUID 16
FLUID CAPACITIES 16
SPECIFICATIONS – FLUID CAPACITIES 16
MAINTENANCE SCHEDULES 17
DESCRIPTION 17
MAINTENANCE SCHEDULES – GASOLINE ENGINES 17
Schedule “B” 17
Schedule “A” 21
MAINTENANCE SCHEDULES – DIESEL ENGINE 23
Schedule “B” 23
Schedule “A” 25
MAINTENANCE SCHEDULES – GASOLINE ENGINES – EXPORT 25
Schedule “A” 26
Schedule “B” 28
DESCRIPTION – DIESEL ENGINES – EXPORT SCHEDULES 30
Schedule “A” 31
Schedule “B” 32
FLUID FILL/CHECK LOCATIONS 34
DESCRIPTION 34
HOISTING 34
STANDARD PROCEDURE – HOISTING RECOMMENDATIONS 34
HOIST 34
JUMP STARTING 34
STANDARD PROCEDURE – JUMP STARTING PROCEDURE 34
TO JUMP START A DISABLED VEHICLE: 35
DISCONNECT CABLE CLAMPS AS FOLLOWS: 35
TOWING 35
STANDARD PROCEDURE – TOWING 35
SAFETY PRECAUTIONS 36
TWO-WHEEL-DRIVE VEHICLE TOWING 36
TWO WHEEL DRIVE TOWING-REAR END LIFTED 36
TWO WHEEL DRIVE TOWING-FRONT END LIFTED 36
FOUR-WHEEL-DRIVE VEHICLE TOWING 36
FOUR WHEEL DRIVE TOWING—REAR END LIFTED 36
FOUR WHEEL DRIVE TOWING—FRONT END LIFTED 37
2-SUSPENSION 38
SUSPENSION 38
DIAGNOSIS AND TESTING – SUSPENSION AND STEERING SYSTEM 38
WHEEL ALIGNMENT 40
WHEEL ALIGNMENT 40
DESCRIPTION 40
OPERATION 40
STANDARD PROCEDURE 41
STANDARD PROCEDURE – HEIGHT MEASUREMENT 41
RIDE HEIGHT 41
STANDARD PROCEDURE – CAMBER AND CASTER ADJUSTMENT 42
STANDARD PROCEDURE – TOE ADJUSTMENT 42
STANDARD PROCEDURE – CAMBER, CASTER AND TOE ADJUSTMENT 42
CASTER 42
CAMBER 43
TOE ADJUSTMENT 43
SPECIFICATIONS 43
ALIGNMENT 43
FRONT 43
REAR 43
FRONT 44
FRONT 44
DESCRIPTION 44
WARNING 45
SPECIFICATIONS 45
TORQUE CHART 45
SPECIAL TOOLS 46
FRONT SUSPENSION 46
BUSHINGS 47
REMOVAL 47
REMOVAL – STABILIZER BAR BUSHINGS 47
REMOVAL – LOWER CONTROL ARM BUSHING 47
REMOVAL – CLEVIS BRACKET BUSHING 47
REMOVAL – UPPER CONTROL ARM BUSHINGS 47
INSTALLATION 47
INSTALLATION – STABILIZER BAR BUSHINGS 47
INSTALLATION – LOWER CONTROL ARM BUSHING 48
INSTALLATION – CLEVIS BRACKET BUSHING 48
INSTALLATION – UPPER CONTROL ARM BUSHINGS 49
HUB / BEARING 49
REMOVAL 49
INSTALLATION 49
KNUCKLE 49
REMOVAL 49
INSTALLATION 50
LOWER BALL JOINT 50
DIAGNOSIS AND TESTING – LOWER BALL JOINT 50
REMOVAL 50
INSTALLATION 51
LOWER CONTROL ARM 51
REMOVAL 51
INSTALLATION 52
SHOCK 52
REMOVAL 52
REMOVAL – LEFT SIDE 52
REMOVAL – RIGHT SIDE 52
INSTALLATION 53
INSTALLATION – LEFT SIDE 53
INSTALLATION – RIGHT SIDE 53
SPRING 54
REMOVAL 54
INSTALLATION 54
CLEVIS BRACKET 54
REMOVAL 54
INSTALLATION 54
STABILIZER BAR 55
REMOVAL 55
INSTALLATION 55
STABILIZER LINK 55
REMOVAL 55
INSTALLATION 55
UPPER CONTROL ARM 55
REMOVAL 55
REMOVAL – RIGHT SIDE 55
REMOVAL – LEFT SIDE 56
INSTALLATION 56
INSTALLATION – RIGHT SIDE 56
INSTALLATION – LEFT SIDE 56
REAR 57
REAR 57
DESCRIPTION 57
WARNING 58
DIAGNOSIS AND TESTING – REAR SUSPENSION 58
SPECIFICATIONS 58
TORQUE CHART 58
SPECIAL TOOLS 59
REAR SUSPENSION 59
SHOCK 59
REMOVAL 59
INSTALLATION 59
SPRING 60
REMOVAL 60
INSTALLATION 60
JOUNCE BUMPER 60
REMOVAL 60
INSTALLATION 60
STABILIZER BAR 61
REMOVAL 61
INSTALLATION 61
UPPER BALL JOINT 61
REMOVAL 61
INSTALLATION 62
UPPER CONTROL ARM 62
DESCRIPTION – UPPER SUSPENSION ARM, BUSHINGS, AND BALL JOINT 62
OPERATION – UPPER SUSPENSION ARM, BUSHINGS, AND BALL JOINT 62
REMOVAL 62
INSTALLATION 62
LOWER CONTROL ARM 63
DESCRIPTION 63
OPERATION 63
REMOVAL 63
INSTALLATION 63
BUSHINGS 63
REMOVAL 63
REMOVAL – LOWER SUSPENSION ARM BUSHING 63
REMOVAL – UPPER SUSPENSION ARM BUSHING 64
INSTALLATION 64
INSTALLATION – LOWER SUSPENSION ARM BUSHING 64
INSTALLATION – UPPER SUSPENSION ARM BUSHING 65
3-DIFFERENTIAL & DRIVELINE 66
PROPELLER SHAFT 66
PROPELLER SHAFT 66
DIAGNOSIS AND TESTING 66
PROPELLER SHAFT 66
PROPELLER SHAFT VIBRATION 66
BALANCE 67
RUNOUT 68
STANDARD PROCEDURE 68
PROPELLER SHAFT ANGLE 68
RULES 69
SPECIFICATIONS 70
SPECIAL TOOLS 70
SHAFT-PROPELLER FRONT 70
REMOVAL 70
2 8L DIESEL 70
GAS ENGINES 71
INSTALLATION 71
2 8L DIESEL 71
GAS ENGINES 71
SHAFT-PROPELLER REAR 71
REMOVAL 71
INSTALLATION 72
UNIVERSAL JOINT-SINGLE CARDAN 73
DISASSEMBLY – WITH SNAP RINGS 73
ASSEMBLY – WITH SNAP RINGS 74
HALF SHAFT 75
HALF SHAFT 75
CAUTION 75
DIAGNOSIS AND TESTING 75
HALF SHAFT 75
NOISE/VIBRATION IN TURNS 75
CLUNKING NOISE DURING ACCELERATION 75
SHUDDER/VIBRATION DURING ACCELERATION 75
VIBRATION AT HIGHWAY SPEEDS 75
REMOVAL 75
INSTALLATION 76
SPECIFICATIONS 77
SPECIAL TOOLS 77
JOINT/BOOT-C/V OUTER 78
REMOVAL 78
INSTALLATION 79
JOINT/BOOT-C/V INNER 81
REMOVAL 81
INSTALLATION 83
FRONT AXLE – 186FIA 85
FRONT AXLE – 186FIA 85
DIAGNOSIS AND TESTING 85
FRONT AXLE – 186FIA 85
GEAR NOISE 85
BEARING NOISE 85
LOW SPEED KNOCK 85
VIBRATION 85
DRIVELINE SNAP 86
REMOVAL 89
INSTALLATION 91
ADJUSTMENTS 92
PINION DEPTH MEASUREMENT 93
DIFFERENTIAL SIDE BEARING PRELOAD AND GEAR BACKLASH 94
PRELOAD SHIM SELECTION 95
GEAR BACKLASH 97
GEAR CONTACT PATTERN 98
DIFFERENTIAL BEARING PRELOAD CHECK 98
SPECIFICATIONS 98
SPECIAL TOOLS 100
COVER-DIFFERENTIAL 103
REMOVAL 103
INSTALLATION 103
SHAFT-AXLE 105
REMOVAL 105
INSTALLATION 105
SEAL-AXLE SHAFT 105
REMOVAL 105
INSTALLATION 106
BEARING-AXLE 106
REMOVAL 106
INSTALLATION 106
SEAL-PINION 107
REMOVAL 107
INSTALLATION 107
DIFFERENTIAL 108
REMOVAL 108
DISASSEMBLY 109
ASSEMBLY 110
INSTALLATION 110
BEARING-DIFFERENTIAL CASE 111
REMOVAL 111
INSTALLATION 112
GEAR-PINION/RING 112
REMOVAL 112
INSTALLATION 114
REAR AXLE – 8 1/4 117
REAR AXLE – 8 1/4 117
DIAGNOSIS AND TESTING 117
GEAR NOISE 117
BEARING NOISE 117
LOW SPEED KNOCK 117
VIBRATION 117
DRIVELINE SNAP 118
REMOVAL 120
INSTALLATION 121
ADJUSTMENTS 122
PINION DEPTH MEASUREMENT 123
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH 123
GEAR CONTACT PATTERN 125
SIDE GEAR CLEARANCE 127
SPECIFICATIONS 128
SPECIAL TOOLS 128
COVER-DIFFERENTIAL 131
REMOVAL 131
INSTALLATION 131
SHAFT-AXLE 131
REMOVAL 131
INSTALLATION 132
SEAL-AXLE SHAFT 132
REMOVAL 132
INSTALLATION 132
BEARING-AXLE 133
REMOVAL 133
INSTALLATION 133
SEAL-PINION 134
REMOVAL 134
INSTALLATION 134
DIFFERENTIAL 136
REMOVAL 136
DISASSEMBLY 137
ASSEMBLY 138
INSTALLATION 138
DIFFERENTIAL-TRAC-LOK 139
OPERATION 139
DIAGNOSIS AND TESTING 139
DIFFERENTIAL-TRAC-LOK 139
DIFFERENTIAL TEST 139
BEARING-DIFFERENTIAL CASE 140
REMOVAL 140
INSTALLATION 140
GEAR-PINION/RING 140
REMOVAL 140
INSTALLATION 143
5-BRAKES 146
BRAKES – BASE 146
BRAKES – BASE 147
DESCRIPTION 147
WARNING 148
DIAGNOSIS AND TESTING – BASE BRAKE SYSTEM 148
PRELIMINARY BRAKE CHECK 148
ROAD TESTING 149
BRAKE NOISES 150
STANDARD PROCEDURE 150
STANDARD PROCEDURE – PRESSURE BLEEDING 150
STANDARD PROCEDURE – MANUAL BLEEDING 151
SPECIFICATIONS 152
BRAKE COMPONENTS 152
TORQUE 152
SPECIAL TOOLS 153
BASE BRAKES 153
BRAKE LINES 153
DESCRIPTION 153
DIAGNOSIS AND TESTING – BRAKE LINE AND HOSES 153
STANDARD PROCEDURE 153
STANDARD PROCEDURE – DOUBLE INVERTED FLARING 153
STANDARD PROCEDURE – ISO FLARING 154
REMOVAL 154
FRONT BRAKE CALIPER HOSE 154
REAR BRAKE HOSE 155
INSTALLATION 155
FRONT BRAKE CALIPER HOSE 155
INSTALLATION – REAR BRAKE HOSE 156
BRAKE PADS / SHOES 156
REMOVAL 156
REMOVAL – FRONT BRAKE PADS 156
REMOVAL – REAR DISC BRAKE PADS 156
INSTALLATION 157
INSTALLATION – FRONT BRAKE PADS 157
INSTALLATION – REAR DISC BRAKE PADS 157
DISC BRAKE CALIPERS 158
DESCRIPTION 158
OPERATION 158
REMOVAL 159
FRONT 159
REAR 159
DISASSEMBLY 159
CLEANING 160
INSPECTION 160
ASSEMBLY 161
INSTALLATION 162
FRONT 162
REAR 163
DISC BRAKE CALIPER ADAPTER 163
REMOVAL 163
INSTALLATION 163
ROTORS 164
DIAGNOSIS AND TESTING 164
DIAGNOSIS AND TESTING – DISC BRAKE ROTOR 164
ROTOR MINIMUM THICKNESS 164
ROTOR RUNOUT 164
ROTOR THICKNESS VARIATION 164
DIAGNOSIS AND TESTING – BRAKE DRUM IN HAT ROTOR 164
BRAKE DRUM RUNOUT 164
STANDARD PROCEDURE 165
STANDARD PROCEDURE – DISC BRAKE ROTOR 165
STANDARD PROCEDURE – BRAKE DRUM IN HAT ROTOR MACHINING 165
REMOVAL 165
FRONT 165
REAR 165
INSTALLATION 166
FRONT 166
REAR 166
BRAKE JUNCTION BLOCK 166
DESCRIPTION 166
OPERATION 166
PROPORTIONING VALVE 166
DIAGNOSIS AND TESTING – PROPORTIONING VALVE 166
REMOVAL 167
INSTALLATION 167
PEDAL 167
DESCRIPTION 167
OPERATION 168
REMOVAL 168
INSTALLATION 168
POWER BRAKE BOOSTER 168
DESCRIPTION 168
OPERATION 169
DIAGNOSIS AND TESTING – MASTER CYLINDER/POWER BOOSTER 169
POWER BOOSTER VACUUM TEST 169
POWER BOOSTER CHECK VALVE TEST 170
REMOVAL 170
LEFT HAND DRIVE (LHD) 170
RIGHT HAND DRIVE (RHD) 171
INSTALLATION 171
LEFT HAND DRIVE (LHD) 171
RIGHT HAND DRIVE (RHD) 172
MASTER CYLINDER 173
DESCRIPTION 173
OPERATION 173
DIAGNOSIS AND TESTING – MASTER CYLINDER/POWER BOOSTER 173
POWER BOOSTER VACUUM TEST 173
POWER BOOSTER CHECK VALVE TEST 173
STANDARD PROCEDURE – MASTER CYLINDER BLEEDING 173
REMOVAL 174
INSTALLATION 175
FLUID 175
DIAGNOSIS AND TESTING 175
BRAKE FLUID CONTAMINATION 175
STANDARD PROCEDURE – MASTER CYLINDER FLUID LEVEL 175
SPECIFICATIONS 175
BRAKE FLUID 175
FLUID RESERVOIR 176
REMOVAL 176
INSTALLATION 176
SUPPORT PLATE 176
REMOVAL 176
INSTALLATION 177
PARKING BRAKE 177
DESCRIPTION 177
OPERATION 177
ADJUSTMENTS 178
ADJUSTMENT – LOCK OUT 178
CABLES 178
REMOVAL 178
INSTALLATION 179
LEVER 180
REMOVAL 180
INSTALLATION 181
SHOES 181
DESCRIPTION 181
OPERATION 181
REMOVAL 181
CLEANING – REAR DRUM IN HAT BRAKE 182
INSPECTION – REAR DRUM IN HAT BRAKE 182
INSTALLATION 183
ADJUSTMENTS 183
ADJUSTMENT – WITH ADJUSTING TOOL 183
ADJUSTMENT – REAR DRUM IN HAT PARK BRAKE (ROTOR REMOVED) 184
BRAKES – ABS 186
BRAKES – ABS 186
DESCRIPTION 186
ANTILOCK BRAKING SYSTEM 186
ELECTRONIC BRAKE DISTRIBUTION 186
OPERATION 186
ANTILOCK BRAKING SYSTEM 186
ELECTRONIC BRAKE DISTRIBUTION 187
DIAGNOSIS AND TESTING – ANTILOCK BRAKING SYSTEM 187
STANDARD PROCEDURE – ABS BRAKE BLEEDING 187
SPECIFICATIONS 187
ELECTRICAL 188
DESCRIPTION 188
OPERATION 188
FRONT WHEEL SPEED SENSOR 188
REMOVAL 188
INSTALLATION 188
REAR WHEEL SPEED SENSOR 189
REMOVAL 189
INSTALLATION 189
HCU (HYDRAULIC CONTROL UNIT) 189
DESCRIPTION 189
OPERATION 189
PRESSURE DECREASE 190
PRESSURE HOLD 190
PRESSURE INCREASE 190
REMOVAL 190
DISASSEMBLY 190
ASSEMBLY 191
INSTALLATION 192
6-CLUTCH 194
CLUTCH 194
WARNING 194
DIAGNOSIS AND TESTING 194
CLUTCH 194
CLUTCH CONTAMINATION 194
IMPROPER RELEASE OR CLUTCH ENGAGEMENT 195
CLUTCH MISALIGNMENT 195
PRESSURE PLATE AND DISC RUNOUT 195
FLYWHEEL RUNOUT 195
DIAGNOSIS CHART 195
SPECIFICATIONS 198
CLUTCH DISC 198
REMOVAL 198
INSTALLATION 198
CLUTCH RELEASE BEARING 199
REMOVAL 199
INSTALLATION 200
FLYWHEEL 200
DESCRIPTION 200
STANDARD FLYWHEEL 200
DUAL MASS FLYWHEEL 200
DIAGNOSIS AND TESTING 201
FLYWHEEL 201
PILOT BEARING 201
REMOVAL 201
INSTALLATION 201
LINKAGE 202
REMOVAL 202
INSTALLATION 202
MASTER CYLINDER 203
INSPECTION 203
CLUTCH PEDAL 203
REMOVAL 203
INSTALLATION 204
CLUTCH SWITCH OVERRIDE RELAY 204
DESCRIPTION 204
OPERATION 204
REMOVAL 204
INSTALLATION 204
CLUTCH PEDAL POSITION SWITCH 205
DESCRIPTION 205
OPERATION 205
DIAGNOSIS AND TESTING 205
CLUTCH PEDAL POSITION SWITCH 205
7-COOLING 206
COOLING 206
DESCRIPTION 206
2 4L ENGINE 206
3 7L ENGINE 206
DESCRIPTION – COOLING SYSTEM ROUTING 3 7L ENGINE 206
DESCRIPTION – HOSE CLAMPS 208
OPERATION 208
OPERATION – COOLING SYSTEM 208
OPERATION – HOSE CLAMPS 208
DIAGNOSIS AND TESTING 208
DIAGNOSIS AND TESTING – ON-BOARD DIAGNOSTICS (OBD) 208
COOLING SYSTEM RELATED DIAGNOSTICS 208
ACCESSING DIAGNOSTIC TROUBLE CODES 208
ERASING TROUBLE CODES 208
PRELIMINARY CHECKS 208
ENGINE COOLING SYSTEM OVERHEATING 208
COOLING SYSTEM LEAKS 209
ULTRAVIOLET LIGHT METHOD 209
PRESSURE TESTER METHOD 209
INTERNAL LEAKAGE INSPECTION 210
COMBUSTION LEAKAGE TEST – WITHOUT PRESSURE TESTER 210
COOLING SYSTEM DIAGNOSIS CHART – GAS ENGINE 211
COOLING SYSTEM AERATION 217
STANDARD PROCEDURE 217
DRAINING COOLING SYSTEM 217
REFILLING COOLING SYSTEM 218
COOLING SYSTEM – REVERSE FLUSHING 218
CHEMICAL CLEANING 218
REVERSE FLUSHING RADIATOR 218
REVERSE FLUSHING ENGINE 218
INSPECTION 219
SPECIFICATIONS 219
FILL VOLUMES 219
TORQUE 219
SPECIAL TOOLS 220
COOLING 220
ACCESSORY DRIVE 221
ACCESSORY DRIVE 221
DIAGNOSIS AND TESTING – SERPENTINE DRIVE BELT DIAGNOSIS 221
BELT TENSIONERS 223
DESCRIPTION 223
OPERATION 223
REMOVAL 223
2 4L ENGINE 223
3 7L ENGINE 224
INSTALLATION 224
2 4L ENGINE 224
3 7L ENGINE 224
DRIVE BELTS 224
REMOVAL 224
2 4L ENGINE 224
3 7L ENGINE 225
INSTALLATION 225
2 4L ENGINE 225
3 7L ENGINE 226
ENGINE 227
COOLANT 228
DESCRIPTION 228
HOAT COOLANT 228
COOLANT PERFORMANCE 228
COOLANT SELECTION AND ADDITIVES 228
ENGINE COOLANT 229
ETHYLENE-GLYCOL MIXTURES 229
PROPYLENE-GLYCOL MIXTURES 229
OPERATION 229
COOLANT RECOVERY CONTAINER 229
DESCRIPTION 229
COOLANT RECOVERY PRESSURE SYSTEM – 3 7L/2 8L DIESEL 229
COOLANT RECOVERY NON-PRESSURE SYSTEM – 2 4L 229
OPERATION 230
COOLANT RECOVERY PRESSURE SYSTEM – 3 7L/2 8L DIESEL 230
COOLANT RECOVERY NON-PRESSURE SYSTEM – 2 4L 230
REMOVAL 231
PRESSURE SYSTEM – 3 7L/2 8L DIESEL 231
NON-PRESSURE SYSTEM – 2 4L 231
INSTALLATION 231
PRESSURE SYSTEM – 3 7L/2 8L DIESEL 231
NON-PRESSURE SYSTEM – 2 4L 231
ENGINE BLOCK HEATER 231
DESCRIPTION 231
OPERATION 232
REMOVAL 232
REMOVAL – 2 4L 232
REMOVAL – 3 7L 232
INSTALLATION 232
INSTALLATION – 2 4L 232
INSTALLATION – 3 7L 232
ENGINE COOLANT TEMPERATURE SENSOR 233
DESCRIPTION 233
OPERATION 233
REMOVAL 233
2 4L ENGINE 233
3 7L ENGINE 234
INSTALLATION 234
2 4L ENGINE 234
3 7L ENGINE 234
ENGINE COOLANT THERMOSTAT 234
DESCRIPTION 234
DESCRIPTION – 3 7L ENGINE 234
DESCRIPTION 235
OPERATION 235
DIAGNOSIS AND TESTING – THERMOSTAT 235
ON-BOARD DIAGNOSTICS 235
REMOVAL 235
2 4L ENGINE 235
3 7L ENGINE 235
INSTALLATION 236
2 4L ENGINE 236
3 7L ENGINE 236
HOSE CLAMPS 236
DESCRIPTION – HOSE CLAMPS 236
OPERATION – HOSE CLAMPS 236
RADIATOR 238
DESCRIPTION 238
REMOVAL 238
2 4L ENGINE 238
CLEANING 239
INSPECTION 239
INSTALLATION 240
2 4L ENGINE 240
RADIATOR PRESSURE CAP 240
DESCRIPTION0 – 2 KJ (Continued) 240
OPERATION 240
DIAGNOSIS AND TESTING 240
RADIATOR PRESSURE CAP – GAS ENGINES 240
CLEANING 241
INSPECTION 241
RADIATOR FAN – ELECTRIC 241
DESCRIPTION 241
OPERATION 241
REMOVAL 241
REMOVAL 241
REMOVAL 242
INSTALLATION 243
INSTALLATION 243
INSTALLATION 243
RADIATOR – FAN – VISCOUS 243
DESCRIPTION 243
OPERATION 243
DIAGNOSIS AND TESTING 243
VISCOUS FAN DRIVE 243
REMOVAL 244
3 7L ENGINE 244
CLEANING 244
INSPECTION 244
INSTALLATION 245
3 7L ENGINE 245
THERMOSTAT HOUSING 245
REMOVAL 245
INSTALLATION 245
WATER PUMP 245
DESCRIPTION 245
3 7L ENGINE 245
2 4L ENGINE 246
DESCRIPTION – WATER PUMP BYPASS – 3 7L 246
OPERATION 246
2 4L/3 7L ENGINES 246
REMOVAL 246
2 4L ENGINE 246
3 7L 247
CLEANING 248
INSPECTION 248
INSTALLATION 248
2 4L ENGINE 248
3 7L ENGINE 248
TRANSMISSION 250
TRANSMISSION 250
STANDARD PROCEDURE – TRANSMISSION COOLER LINE QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLY 250
DISCONNECT 250
CONNECT 251
TRANS COOLER 251
DESCRIPTION 251
REMOVAL 251
INSTALLATION 251
8a-AUDIO/VIDEO 252
AUDIO/VIDEO 252
DESCRIPTION 252
OPERATION 253
DIAGNOSIS AND TESTING – AUDIO 253
AMPLIFIER CHOKE AND RELAY 255
DESCRIPTION 255
OPERATION 255
DIAGNOSIS AND TESTING – AMPLIFIER CHOKE AND RELAY 255
REMOVAL 255
INSTALLATION 256
ANTENNA BODY & CABLE 256
DESCRIPTION 256
DOMESTIC 256
EXPORT 256
OPERATION 256
DIAGNOSIS AND TESTING – ANTENNA BODY AND CABLE 256
TEST 1 257
TEST 2 257
TEST 3 257
TEST 4 257
REMOVAL 258
DOMESTIC 258
EXPORT 258
INSTALLATION 258
DOMESTIC 258
EXPORT 259
ANTENNA CABLE – SATELLITE RADIO 259
REMOVAL 259
INSTALLATION 260
ANTENNA MODULE 260
DESCRIPTION 260
OPERATION 260
DIAGNOSIS AND TESTING 260
ANTENNA MODULE 260
REMOVAL 261
INSTALLATION 261
ANTENNA-SATELLITE RADIO 261
DESCRIPTION 261
OPERATION 261
REMOVAL 261
INSTALLATION 261
CD CHANGER 262
DESCRIPTION 262
OPERATION 262
REMOVAL 262
INSTALLATION 262
INSTRUMENT PANEL ANTENNA CABLE 262
REMOVAL 262
DOMESTIC 262
EXPORT 263
INSTALLATION 264
DOMESTIC 264
EXPORT 264
QUARTER GLASS INTEGRAL ANTENNA 264
DESCRIPTION 264
OPERATION 264
DIAGNOSIS AND TESTING – QUARTER GLASS INTEGRAL ANTENNA 264
RADIO 265
DESCRIPTION 265
RADIO 265
COUNTRY CODE AND CABIN EQ SETTING – REK RADIO ONLY 265
OPERATION 268
REMOVAL 268
INSTALLATION 268
RADIO NOISE SUPPRESSION COMPONENTS 268
DESCRIPTION 268
OPERATION 269
REMOVAL 269
2 4L ENGINE 269
2 5L ENGINE 270
3 7L ENGINE 270
INSTALLATION 270
2 4L ENGINE 270
2 5L ENGINE 270
3 7L ENGINE 270
RECEIVER-SATELLITE 271
DESCRIPTION 271
OPERATION 271
REMOVAL 271
INSTALLATION 271
REMOTE SWITCHES 271
DESCRIPTION 271
OPERATION 272
DIAGNOSIS AND TESTING – REMOTE SWITCHES 272
REMOVAL 273
INSTALLATION 273
SPEAKER 273
DESCRIPTION 273
STANDARD 273
PREMIUM 273
OPERATION 273
DIAGNOSIS AND TESTING – SPEAKER 274
REMOVAL 274
FRONT DOOR 274
INSTRUMENT PANEL 274
REAR DOOR 275
INSTALLATION 275
FRONT DOOR 275
INSTRUMENT PANEL 275
REAR DOOR 275
8b-CHIME/BUZZER 276
CHIME WARNING SYSTEM 276
DESCRIPTION 276
OPERATION 276
DIAGNOSIS AND TESTING 280
CHIME WARNING SYSTEM 280
8e-ELECTRONIC CONTROL MODULES 282
ELECTRONIC CONTROL MODULES 282
STANDARD PROCEDURE – PCM/SKREEM PROGRAMMING 282
PROGRAMMING THE PCM/SKREEM 283
PROGRAMMING IGNITION KEYS TO THE SKREEM 283
ANTILOCK BRAKE MODULE 283
DESCRIPTION 283
OPERATION 284
REMOVAL 284
INSTALLATION 285
BODY CONTROL MODULE 286
DESCRIPTION 286
OPERATION 288
INPUT AND OUTPUT CIRCUITS 289
DIAGNOSIS AND TESTING 290
BODY CONTROL MODULE 290
REMOVAL 290
INSTALLATION 291
COMMUNICATION 291
DESCRIPTION 291
OPERATION 291
DATA LINK CONNECTOR 292
DESCRIPTION 292
OPERATION 293
FRONT CONTROL MODULE 293
DESCRIPTION 293
REMOVAL 293
INSTALLATION 293
ENGINE CONTROL MODULE-DIESEL ENGINE 294
DESCRIPTION 294
OPERATION 294
ECM OPERATING MODES 294
MONITORED CIRCUITS 294
DIAGNOSTIC TROUBLE CODES 295
STANDARD PROCEDURE – PCM/ECM/SKIM PROGRAMMING – DIESEL 295
PCM/SKIM PROGRAMMING 295
ECM/SKIM PROGRAMMING 295
PROGRAMMING THE ECM (Bosch) 295
PROGRAMMING THE PCM (JTEC) 296
PROGRAMMING THE SKIM 296
PROGRAMMING IGNITION KEYS TO THE SKIM 296
REMOVAL 297
INSTALLATION 297
POWERTRAIN CONTROL MODULE 297
DESCRIPTION 297
DESCRIPTION – PCM 297
DESCRIPTION – MODES OF OPERATION 297
DESCRIPTION – 5 VOLT SUPPLIES 300
DESCRIPTION – IGNITION CIRCUIT SENSE 300
DESCRIPTION – POWER GROUNDS 300
DESCRIPTION – SENSOR RETURN 300
OPERATION 300
OPERATION – PCM 300
OPERATION – 5 VOLT SUPPLIES 301
OPERATION – IGNITION CIRCUIT SENSE 301
REMOVAL 301
INSTALLATION 302
TRANSMISSION CONTROL MODULE 302
DESCRIPTION 302
TRANSMISSION CONTROL MODULE – GASOLINE ENGINES 302
TRANSMISSION CONTROL MODULE – DIESEL ENGINE 302
OPERATION 302
TRANSMISSION CONTROL MODULE – GASOLINE ENGINES 302
CLUTCH VOLUME INDEX (CVI) 303
SHIFT SCHEDULES 304
TRANSMISSION CONTROL MODULE – DIESEL ENGINE 305
BATTERY FEED 306
CLUTCH VOLUME INDEXES (CVI) 306
SHIFT SCHEDULES 306
STANDARD PROCEDURE 307
TCM QUICK LEARN 307
DRIVE LEARN 307
LEARN A SMOOTH 1ST NEUTRAL TO DRIVE SHIFT 308
LEARN A SMOOTH NEUTRAL TO DRIVE GARAGE SHIFT 308
LEARN THE 1ST 2-3 SHIFT AFTER A RESTART OR SHIFT TO REVERSE 308
LEARN A SMOOTH 2-3 AND 3-4 UPSHIFT 308
LEARN A SMOOTH 4-3 COASTDOWN AND PART THROTTLE 4-3 KICKDOWN 309
LEARN A SMOOTH 1-2 UPSHIFT AND 3-2 KICKDOWN 309
LEARN A SMOOTH MANUAL 2-1 PULLDOWN SHIFT AS WELL AS A NEUTRAL TO REVERSE SHIFT 309
LEARN A SMOOTH NEUTRAL TO REVERSE SHIFT 309
LEARN A SMOOTH 4-5 UPSHIFT 309
HEATED SEAT MODULE 309
DESCRIPTION 309
OPERATION 310
DIAGNOSIS AND TESTING – HEATED SEAT MODULE 310
RIGHT SEAT HEATER INOPERATIVE 310
LEFT SEAT HEATER INOPERATIVE 311
BOTH SEATS INOPERATIVE 312
REMOVAL 312
INSTALLATION 312
8f-ENGINE SYSTEMS 314
BATTERY SYSTEM 314
BATTERY SYSTEM 314
DESCRIPTION 314
OPERATION 315
DIAGNOSIS AND TESTING – BATTERY SYSTEM 315
MICRO 420 BATTERY TESTER 315
ABNORMAL BATTERY DISCHARGING 317
CLEANING 317
INSPECTION 319
SPECIFICATIONS 319
BATTERY 319
DESCRIPTION 319
CONVENTIONAL BATTERY – GASOLINE ENGINES 319
SPIRAL PLATE BATTERY – DIESEL ENGINE 320
OPERATION 320
DIAGNOSIS AND TESTING – BATTERY 321
STANDARD PROCEDURE 322
STANDARD PROCEDURE – CONVENTIONAL BATTERY CHARGING 322
CHARGING A COMPLETELY DISCHARGED BATTERY 322
CHARGING TIME REQUIRED 323
STANDARD PROCEDURE – SPIRAL PLATE BATTERY CHARGING 323
CHARGING A COMPLETELY DISCHARGED BATTERY – SPIRAL PLATE BATTERY 324
CHARGING TIME REQUIRED 324
STANDARD PROCEDURE – BUILT-IN INDICATOR TEST 325
STANDARD PROCEDURE – HYDROMETER TEST 325
STANDARD PROCEDURE – OPEN-CIRCUIT VOLTAGE TEST 326
STANDARD PROCEDURE – IGNITION-OFF DRAW TEST 327
STANDARD PROCEDURE – USING MICRO 420 BATTERY TESTER 329
BATTERY TESTING 329
REMOVAL 330
INSTALLATION 330
BATTERY HOLDDOWN 331
DESCRIPTION 331
OPERATION 331
REMOVAL 331
INSTALLATION 331
BATTERY CABLES 331
DESCRIPTION 331
OPERATION 332
DIAGNOSIS AND TESTING – BATTERY CABLES 332
VOLTAGE DROP TEST 332
BATTERY TRAY 334
DESCRIPTION 334
OPERATION 334
REMOVAL 334
INSTALLATION 334
CHARGING SYSTEM 335
CHARGING SYSTEM 335
DESCRIPTION 335
OPERATION 335
DIAGNOSIS AND TESTING – CHARGING SYSTEM 335
SPECIFICATIONS 336
TORQUE – EXCEPT DIESEL 336
GENERATOR RATINGS – GAS ENGINES 336
SPECIAL TOOLS 337
BATTERY TEMPERATURE SENSOR 337
DESCRIPTION 337
OPERATION 337
REMOVAL 337
INSTALLATION 337
GENERATOR 338
DESCRIPTION 338
OPERATION 338
REMOVAL 338
INSTALLATION 339
GENERATOR DECOUPLER PULLEY 339
DESCRIPTION 339
OPERATION 340
DIAGNOSIS AND TESTING – GENERATOR DECOUPLER 340
REMOVAL 340
INSTALLATION 343
VOLTAGE REGULATOR 344
DESCRIPTION 344
OPERATION 344
STARTING SYSTEM 345
STARTING SYSTEM 345
DESCRIPTION 345
OPERATION 345
DIAGNOSIS AND TESTING – STARTING SYSTEM 346
INSPECTION 347
TESTING 347
INSPECTION – STARTING SYSTEM 350
SPECIFICATIONS 351
TORQUE – GAS POWERED 351
STARTER MOTOR – GAS POWERED 352
STARTER MOTOR 352
DIAGNOSIS AND TESTING – STARTER MOTOR 352
REMOVAL 353
2 4L 4–Cylinder 353
3 7L V-6 353
INSTALLATION 353
2 4L 4–Cylinder 353
3 7L V-6 354
STARTER MOTOR RELAY 354
DESCRIPTION 354
OPERATION 354
DIAGNOSIS AND TESTING – STARTER RELAY 355
RELAY TEST 355
RELAY CIRCUIT TEST 355
REMOVAL 356
INSTALLATION 356
8g-HEATED SYSTEMS 358
HEATED GLASS 358
HEATED GLASS 358
DESCRIPTION 358
OPERATION 359
DIAGNOSIS AND TESTING 359
ELECTRIC BACKLIGHT (EBL) SYSTEM 359
REAR WINDOW DEFOGGER RELAY 360
DESCRIPTION 360
OPERATION 360
REMOVAL 361
INSTALLATION 361
REAR WINDOW DEFOGGER SWITCH 361
DESCRIPTION 361
OPERATION 362
DIAGNOSIS AND TESTING 362
REAR WINDOW DEFOGGER SWITCH 362
HEATED GLASS 362
STANDARD PROCEDURE 362
GRID LINE AND TERMINAL REPAIR 362
HEATED MIRRORS 364
HEATED MIRRORS 364
DESCRIPTION 364
OPERATION 364
HEATED SEAT SYSTEM 365
HEATED SEAT SYSTEM 365
DESCRIPTION 365
OPERATION 365
DIAGNOSIS AND TESTING – HEATED SEAT SYSTEM 366
HEATED SEAT SYSTEM SELF-DIAGNOSIS 366
HEATED SEAT SYSTEM TESTING 366
DRIVER HEATED SEAT SWITCH 366
DESCRIPTION 366
OPERATION 366
DIAGNOSIS AND TESTING – DRIVER HEATED SEAT SWITCH 367
REMOVAL 367
INSTALLATION 368
PASSENGER HEATED SEAT SWITCH 368
DESCRIPTION 368
OPERATION 368
DIAGNOSIS AND TESTING – PASSENGER HEATED SEAT SWITCH 368
REMOVAL 369
INSTALLATION 369
HEATED SEAT ELEMENT 369
DESCRIPTION 369
OPERATION 369
DIAGNOSIS AND TESTING – HEATED SEAT ELEMENT 369
SEAT CUSHION ELEMENT 369
SEAT BACK ELEMENT 370
HEATED SEAT SENSOR 370
DESCRIPTION 370
OPERATION 370
DIAGNOSIS AND TESTING – HEATED SEAT SENSOR 370
REMOVAL 370
8h-HORN 372
HORN SYSTEM 372
DESCRIPTION 372
OPERATION 372
DIAGNOSIS AND TESTING – HORN SYSTEM 372
HORN 373
DIAGNOSIS AND TESTING – HORN 373
REMOVAL 373
INSTALLATION 373
HORN RELAY 373
REMOVAL 373
INSTALLATION 374
HORN SWITCH 374
DESCRIPTION 374
DIAGNOSIS AND TESTING – HORN SWITCH 374
8i-IGNITION CONTROL 376
IGNITION CONTROL 376
DESCRIPTION 376
OPERATION 376
2 4L 376
3 7L 377
SPECIFICATIONS 377
SPECIFICATIONS – IGNITION TIMING 377
ENGINE FIRING ORDER – 2 4L 4-CYLINDER 377
ENGINE FIRING ORDER – 3 7L V-6 377
IGNITION COIL RESISTANCE – 2 4L 377
IGNITION COIL RESISTANCE – 3 7L V-6 377
SPARK PLUGS 378
SPARK PLUG CABLE RESISTANCE – 2 4L 378
TORQUE – IGNITION SYSTEM 378
AUTO SHUT DOWN RELAY 379
DESCRIPTION – PCM OUTPUT 379
OPERATION 379
OPERATION – ASD SENSE – PCM INPUT 379
OPERATION – PCM OUTPUT 379
DIAGNOSIS AND TESTING – ASD AND FUEL PUMP RELAYS 379
REMOVAL 380
INSTALLATION 380
CAMSHAFT POSITION SENSOR 380
DESCRIPTION 380
2 4L 380
3 7L 381
2 8L TURBODIESEL 381
OPERATION 382
2 4L 382
3 7L 382
2 8L TURBODIESEL 382
REMOVAL 383
GAS ENGINES 383
2 4L 383
3 7L 383
2 8L TURBODIESEL 383
INSTALLATION 384
GAS ENGINES 384
2 4L 384
3 7L 385
2 8L TURBODIESEL 385
GLOW PLUG 385
DESCRIPTION 385
OPERATION 385
REMOVAL 386
INSTALLATION 386
GLOW PLUG MODULE 387
DESCRIPTION 387
OPERATION 387
REMOVAL 388
INSTALLATION 388
IGNITION COIL 388
DESCRIPTION 388
2 4L 388
3 7L 388
OPERATION 388
2 4L 388
3 7L 389
REMOVAL 389
2 4L 389
3 7L 389
INSTALLATION 390
2 4L 390
3 7L 390
KNOCK SENSOR 390
DESCRIPTION 390
OPERATION 390
REMOVAL 391
INSTALLATION 391
SPARK PLUG 391
DESCRIPTION 391
OPERATION 392
DIAGNOSIS AND TESTING – SPARK PLUG CONDITIONS 392
REMOVAL 394
2 4L 394
3 7L 395
CLEANING SPARK PLUGS 395
INSTALLATION 395
2 4L 395
3 7L 395
IGNITION COIL CAPACITOR 395
DESCRIPTION 395
OPERATION 395
REMOVAL 395
INSTALLATION 395
8j-INSTRUMENT CLUSTER 396
INSTRUMENT CLUSTER 397
DESCRIPTION 397
OPERATION 400
INPUT AND OUTPUT CIRCUITS 403
DIAGNOSIS AND TESTING 403
INSTRUMENT CLUSTER 403
ACTUATOR TEST 403
CLUSTER ILLUMINATION DIAGNOSIS 404
REMOVAL 404
DISASSEMBLY 405
CLUSTER BULB 405
CLUSTER LENS, HOOD, AND MASK 405
ASSEMBLY 406
CLUSTER BULB 406
CLUSTER LENS, HOOD, AND MASK 406
INSTALLATION 406
ABS INDICATOR 407
DESCRIPTION 407
OPERATION 407
AIRBAG INDICATOR 408
DESCRIPTION 408
OPERATION 408
BRAKE/PARK BRAKE INDICATOR 409
DESCRIPTION 409
OPERATION 409
CHARGING INDICATOR 410
DESCRIPTION 410
OPERATION 410
COOLANT LOW INDICATOR 411
DESCRIPTION 411
OPERATION 411
CRUISE INDICATOR 412
DESCRIPTION 412
OPERATION 412
DOOR AJAR INDICATOR 412
DESCRIPTION 412
OPERATION 413
ENGINE TEMPERATURE GAUGE 413
DESCRIPTION 413
OPERATION 413
ETC INDICATOR 414
DESCRIPTION 414
OPERATION 414
FRONT FOG LAMP INDICATOR 415
DESCRIPTION 415
OPERATION 415
FUEL GAUGE 416
DESCRIPTION 416
OPERATION 416
GATE AJAR INDICATOR 417
DESCRIPTION 417
OPERATION 417
GLASS AJAR INDICATOR 418
DESCRIPTION 418
OPERATION 418
HIGH BEAM INDICATOR 419
DESCRIPTION 419
OPERATION 419
LIGHT BAR LAMP INDICATOR 419
DESCRIPTION 419
OPERATION 420
LOW FUEL INDICATOR 420
DESCRIPTION 420
OPERATION 420
LOW OIL PRESSURE INDICATOR 421
DESCRIPTION 421
OPERATION 421
MALFUNCTION INDICATOR LAMP (MIL) 422
DESCRIPTION 422
OPERATION 422
ODOMETER 423
DESCRIPTION 423
OPERATION 423
OVERDRIVE OFF INDICATOR 424
DESCRIPTION 424
OPERATION 424
REAR FOG LAMP INDICATOR 425
DESCRIPTION 425
OPERATION 425
SEATBELT INDICATOR 426
DESCRIPTION 426
OPERATION 426
STANDARD PROCEDURE – ENHANCED SEATBELT REMINDER PROGRAMMING 427
CUSTOMER PROGRAMMING SEQUENCE 427
SECURITY INDICATOR 427
DESCRIPTION 427
OPERATION 427
SHIFT INDICATOR (TRANSFER CASE) 428
DESCRIPTION 428
PART TIME INDICATOR 428
FULL TIME INDICATOR 428
FOUR LOW MODE INDICATOR 429
OPERATION 429
PART TIME INDICATOR 429
FULL TIME INDICATOR 429
FOUR LOW MODE INDICATOR 430
SPEEDOMETER 431
DESCRIPTION 431
OPERATION 431
TACHOMETER 432
DESCRIPTION 432
OPERATION 432
TIRE PRESSURE MONITOR INDICATOR 433
DESCRIPTION 433
OPERATION 433
TRANS TEMP INDICATOR 433
DESCRIPTION 433
OPERATION 434
TURN SIGNAL INDICATOR 434
DESCRIPTION 434
OPERATION 434
WAIT-TO-START INDICATOR 435
DESCRIPTION 435
OPERATION 435
WASHER FLUID INDICATOR 436
DESCRIPTION 436
OPERATION 436
WATER-IN-FUEL INDICATOR 436
DESCRIPTION 436
OPERATION 437
8l-LAMPS 438
LAMPS/LIGHTING – EXTERIOR 438
LAMPS/LIGHTING – EXTERIOR 440
DESCRIPTION 440
OPERATION 443
BACKUP LAMPS 443
BRAKE LAMPS 443
DAYTIME RUNNING LAMPS 443
FRONT FOG LAMPS 443
HAZARD WARNING LAMPS 444
HEADLAMPS 444
HEADLAMP LEVELING 444
LIGHT BAR LAMPS 444
PARK LAMPS 445
REAR FOG LAMPS 445
TURN SIGNAL LAMPS 445
WARNINGS – LAMPS/LIGHTING – EXTERIOR 445
DIAGNOSIS AND TESTING 446
LAMPS/LIGHTING – EXTERIOR 446
BACKUP LAMPS 447
BRAKE LAMPS 447
DAYTIME RUNNING LAMPS 448
FRONT FOG LAMPS 448
HAZARD WARNING LAMPS 449
HEADLAMPS 449
HEADLAMP LEVELING 451
LIGHT BAR LAMPS 451
PARK LAMPS 453
REAR FOG LAMPS 454
TURN SIGNAL LAMPS 455
SPECIFICATIONS 455
LAMPS/LIGHTING – EXTERIOR 455
BACKUP LAMP SWITCH 456
DESCRIPTION 456
OPERATION 456
DIAGNOSIS AND TESTING 456
BACKUP LAMP SWITCH 456
BRAKE LAMP SWITCH 456
DESCRIPTION 456
OPERATION 457
DIAGNOSIS AND TESTING 457
BRAKE LAMP SWITCH 457
REMOVAL 458
INSTALLATION 458
LAMP-HIGH MOUNTED STOP 459
REMOVAL 459
BULB 459
LAMP 459
INSTALLATION 459
BULB 459
LAMP0 – 4 KJ (Continued) 460
COMBINATION FLASHER 460
DESCRIPTION 460
OPERATION 460
DAYTIME RUNNING LAMP RELAY 460
DESCRIPTION 460
OPERATION 461
REMOVAL 461
INSTALLATION 462
FOG LAMP RELAY 462
DESCRIPTION 462
FRONT 462
REAR 462
OPERATION 463
FRONT 463
REAR 463
FRONT FOG LAMP 464
REMOVAL 464
BULB – GRILLE MOUNTED 464
BULB – FASCIA MOUNTED 464
LAMP – GRILLE MOUNTED 465
LAMP – FASCIA MOUNTED 465
INSTALLATION 466
BULB – GRILLE MOUNTED 466
BULB – FASCIA MOUNTED 466
LAMP – GRILLE MOUNTED 466
LAMP – FASCIA MOUNTED 467
ADJUSTMENTS 467
FRONT FOG LAMP UNIT 467
VEHICLE PREPARATION FOR FOG LAMP ALIGNMENT 467
FOG LAMP ALIGNMENT SCREEN PREPARATION 467
FOG LAMP ADJUSTMENT 468
FRONT POSITION LAMP 468
REMOVAL – BULB 468
INSTALLATION – BULB 469
HAZARD SWITCH 469
DESCRIPTION 469
OPERATION 470
REMOVAL 470
INSTALLATION 471
HEADLAMP HIGH BEAM RELAY 471
DESCRIPTION 471
OPERATION 471
REMOVAL 472
INSTALLATION 473
HEADLAMP LEVELING MOTOR 473
DESCRIPTION 473
OPERATION 473
REMOVAL 474
INSTALLATION 474
HEADLAMP LEVELING SWITCH 475
DESCRIPTION 475
OPERATION 475
DIAGNOSIS AND TESTING 475
HEADLAMP LEVELING SWITCH 475
REMOVAL 476
INSTALLATION 476
HEADLAMP LOW BEAM RELAY 477
DESCRIPTION 477
OPERATION 477
HEADLAMP UNIT 477
REMOVAL 477
LAMP 477
BULB – NORTH AMERICA 478
BULB – EXPORT 479
INSTALLATION 480
LAMP 480
BULB – NORTH AMERICA 480
BULB – EXPORT 480
ADJUSTMENTS 481
HEADLAMP UNIT 481
VEHICLE PREPARATION FOR HEADLAMP ALIGNMENT 481
HEADLAMP ALIGNMENT SCREEN PREPARATION 481
HEADLAMP ADJUSTMENT 482
LICENSE PLATE LAMP 482
REMOVAL 482
BULB – NORTH AMERICA 482
BULB – EXPORT 482
LAMP – NORTH AMERICA 483
LAMP – EXPORT 483
INSTALLATION 484
BULB – NORTH AMERICA 484
BULB – EXPORT 484
LAMP – NORTH AMERICA 484
LAMP – EXPORT 484
LAMP BAR 484
REMOVAL 484
BULB 484
LAMP 485
COVER 485
REINFORCEMENT 485
INSTALLATION 486
BULB 486
LAMP 487
COVER 487
REINFORCEMENT 487
ADJUSTMENTS 488
LIGHT BAR LAMP 488
VEHICLE PREPARATION FOR LIGHT BAR LAMP ALIGNMENT 488
LIGHT BAR LAMP ALIGNMENT SCREEN PREPARATION 488
LIGHT BAR LAMP ADJUSTMENT 488
LAMP BAR SWITCH 488
DESCRIPTION 488
OPERATION 489
REMOVAL 489
INSTALLATION 490
MARKER LAMP 490
REMOVAL 490
BULB 490
LAMP 490
INSTALLATION 491
BULB 491
LAMP 491
MULTI-FUNCTION SWITCH 492
DESCRIPTION 492
LEFT CONTROL STALK 493
RIGHT CONTROL STALK 493
OPERATION 493
LEFT CONTROL STALK 494
RIGHT CONTROL STALK 495
DIAGNOSIS AND TESTING 496
MULTI-FUNCTION SWITCH 496
REMOVAL 498
INSTALLATION 498
PARK BRAKE SWITCH 499
DESCRIPTION 499
OPERATION 499
DIAGNOSIS AND TESTING 499
PARK BRAKE SWITCH 499
REMOVAL 500
INSTALLATION 500
PARK LAMP RELAY 501
DESCRIPTION 501
OPERATION 501
PARK/TURN SIGNAL LAMP 502
REMOVAL 502
BULB 502
LAMP 502
INSTALLATION 503
BULB 503
LAMP 503
REAR LAMP UNIT 503
REMOVAL 503
BULB 503
LAMP 503
INSTALLATION 504
BULB 504
LAMP 504
REPEATER LAMP 504
REMOVAL 504
BULB 504
LAMP 504
INSTALLATION 505
BULB 505
LAMP 505
TRAILER TOW CONNECTOR 505
REMOVAL 505
INSTALLATION 506
TRAILER TOW RELAY 506
DESCRIPTION 506
OPERATION 506
REMOVAL 507
INSTALLATION 508
TRAILER TOW WIRING 508
DESCRIPTION 508
TURN SIGNAL CANCEL CAM 509
DESCRIPTION 509
OPERATION 509
LAMPS/LIGHTING – INTERIOR 510
LAMPS/LIGHTING – INTERIOR 510
DESCRIPTION 510
OPERATION 512
COURTESY LAMP CIRCUIT 512
PANEL LAMPS DIMMER CIRCUIT 513
WARNINGS – LAMPS/LIGHTING – INTERIOR 513
DIAGNOSIS AND TESTING 513
LAMPS/LIGHTING – INTERIOR 513
COURTESY LAMP CIRCUIT 514
PANEL LAMPS DIMMER CIRCUIT 515
SPECIFICATIONS 516
LAMPS/LIGHTING – INTERIOR 516
COURTESY LAMPS 516
PANEL LAMPS 516
AJAR SWITCH 516
DESCRIPTION 516
DOOR 516
FLIP-UP GLASS 516
TAILGATE 516
OPERATION 516
DOOR 516
FLIP-UP GLASS 517
TAILGATE 517
ASH RECEIVER LAMP 517
REMOVAL 517
BULB 517
LAMP 518
INSTALLATION 518
BULB 518
LAMP 519
CARGO LAMP 519
REMOVAL 519
BULB 519
LAMP 519
INSTALLATION 520
BULB 520
LAMP 520
COURTESY LAMP 520
REMOVAL 520
BULB 520
LAMP 520
INSTALLATION 521
BULB 521
LAMP 521
DOME LAMP 521
REMOVAL 521
BULB – REAR 521
LAMP – REAR 522
INSTALLATION 522
BULB – REAR 522
LAMP – REAR 522
ILLUMINATION LAMP 523
REMOVAL 523
BULB – CMTC CONTROL 523
BULB – A/C-HEAT CONTROL 523
BULB – TRANSMISSION RANGE INDICATOR 524
INSTALLATION 524
BULB – CMTC CONTROL 524
BULB – A/C-HEAT CONTROL 525
BULB – TRANSMISSION RANGE INDICATOR 525
VANITY LAMP 525
REMOVAL – BULB 525
INSTALLATION – BULB 526
8m-MESSAGE SYSTEMS 528
OVERHEAD CONSOLE 528
DESCRIPTION 528
OPERATION 528
DIAGNOSIS AND TESTING – OVERHEAD CONSOLE 529
TESTING VOLTAGE AND GROUND SUPPLY TO OVERHEAD CONSOLE 529
STANDARD PROCEDURE 530
STANDARD PROCEDURE – MODULE LAMP REPLACEMENT 530
STANDARD PROCEDURE – COURTESY LAMP REPLACEMENT 530
STANDARD PROCEDURE – COMPASS CALIBRATION 530
STANDARD PROCEDURE – COMPASS DEMAGNETIZING 531
STANDARD PROCEDURE – COMPASS VARIATION ADJUSTMENT 531
STANDARD PROCEDURE – ELECTRONIC VEHICLE INFORMATION CENTER PROGRAMMING 532
EVIC PROGRAMMING MODE 532
PROGRAMMABLE FEATURES 533
REMOVAL 535
OVERHEAD CONSOLE – REMOVAL 535
INSTALLATION 535
SPECIAL TOOLS 535
ELECTRONIC VEHICLE INFO CENTER 535
DESCRIPTION 535
DESCRIPTION – COMPASS 536
DESCRIPTION – TEMPERATURE 537
OPERATION 537
DIAGNOSIS AND TESTING – ELECTRONIC VEHICLE INFORMATION CENTER 537
SELF-DIAGNOSTIC TEST 538
REMOVAL 538
INSTALLATION 538
UNIVERSAL TRANSMITTER 539
DESCRIPTION 539
OPERATION 539
DIAGNOSIS AND TESTING – UNIVERSAL TRANSMITTER 539
STANDARD PROCEDURE 540
STANDARD PROCEDURE – ERASING TRANSMITTER CODES 540
STANDARD PROCEDURE – PROGRAMMING TRANSMITTER CODES 540
AMBIENT TEMP SENSOR 541
DESCRIPTION 541
OPERATION 541
DIAGNOSIS AND TESTING 541
DIAGNOSIS AND TESTING – AMBIENT TEMPERATURE SENSOR 541
DIAGNOSIS AND TESTING – AMBIENT TEMPERATURE SENSOR CIRCUIT 541
REMOVAL 542
INSTALLATION 542
8n-POWER SYSTEMS 544
POWER LOCKS 544
POWER LOCKS 544
DESCRIPTION 544
POWER LOCKS 544
REMOTE KEYLESS ENTRY 545
TAILGATE / FLIP-UP GLASS POWER RELEASE SYSTEM 545
COMBINATION FLASHER 546
HORN RELAY 546
LOW BEAM HEADLAMP RELAY 546
OPERATION 546
POWER LOCKS 546
AUTOMATIC DOOR LOCKS 546
DOOR LOCK INHIBIT 546
DOOR LOCK CIRCUIT PROTECTION 546
REMOTE KEYLESS ENTRY 546
DIAGNOSIS AND TESTING – POWER LOCKS 546
PRELIMINARY DIAGNOSIS 547
DOOR LOCK / UNLOCK SWITCH 547
DIAGNOSIS AND TESTING – DOOR LOCK/UNLOCK SWITCH 547
REMOVAL 547
INSTALLATION 548
DOOR LOCK MOTOR 548
DESCRIPTION 548
OPERATION 548
DIAGNOSIS AND TESTING – DOOR LOCK MOTOR 548
FLIP-UP GLASS RELEASE SWITCH 548
DIAGNOSIS AND TESTING – FLIP-UP GLASS RELEASE SWITCH 548
DOOR LOCK RELAY 549
REMOVAL 549
INSTALLATION 549
REMOTE KEYLESS ENTRY MODULE 549
DESCRIPTION 549
OPERATION 549
DIAGNOSIS AND TESTING – REMOTE KEYLESS ENTRY MODULE 549
REMOVAL 549
INSTALLATION 549
REMOTE KEYLESS ENTRY TRANSMITTER 550
DIAGNOSIS AND TESTING – REMOTE KEYLESS ENTRY TRANSMITTER 550
STANDARD PROCEDURE 550
STANDARD PROCEDURE – RKE TRANSMITTER CUSTOMER PREFERENCES 550
AUTOMATIC (ROLLING) LOCKS 550
HORN CHIRP DISABLING / ENABLING 550
OPTICAL CHIRP (FLASH) DISABLING / ENABLING 550
TAIL GATE RELEASE DELAY 550
UNLOCK SEQUENCE 550
STANDARD PROCEDURE – RKE TRANSMITTER PROGRAMING 550
STANDARD PROCEDURE – RKE TRANSMITTER BATTERIES 551
SPECIFICATIONS – REMOTE KEYLESS ENTRY TRANSMITTER 551
RANGE 551
TAILGATE CYLINDER LOCK SWITCH 551
DESCRIPTION 551
OPERATION 551
DIAGNOSIS AND TESTING – TAILGATE CYLINDER LOCK SWITCH 551
REMOVAL 551
INSTALLATION 552
POWER MIRRORS 553
POWER MIRRORS 553
DESCRIPTION 553
OPERATION 553
DIAGNOSIS AND TESTING – POWER MIRRORS 553
WIRING VOLTAGE TEST 553
POWER MIRROR MOTOR TEST 553
AUTOMATIC DAY / NIGHT MIRROR 554
DESCRIPTION – REAR VIEW MIRROR 554
OPERATION – REAR VIEW MIRROR 554
DIAGNOSIS AND TESTING – AUTOMATIC DAY / NIGHT MIRROR 554
POWER FOLDAWAY MIRROR SWITCH – EXPORT 555
DESCRIPTION 555
OPERATION 555
DIAGNOSIS AND TESTING – POWER FOLDAWAY MIRROR SWITCH – EXPORT 556
REMOVAL 556
POWER MIRROR SWITCH 556
DIAGNOSIS AND TESTING – POWER MIRROR SWITCH 556
REMOVAL 557
INSTALLATION 557
SIDEVIEW MIRROR 557
REMOVAL 557
POWER SEATS 558
POWER SEATS 558
DESCRIPTION 558
OPERATION 559
DIAGNOSIS AND TESTING – POWER SEATS 559
LEFT POWER SEAT SWITCH 559
DESCRIPTION 559
OPERATION 559
DIAGNOSIS AND TESTING – LEFT POWER SEAT SWITCH 560
REMOVAL 561
INSTALLATION 561
RIGHT POWER SEAT SWITCH 561
DESCRIPTION 561
OPERATION 561
DIAGNOSIS AND TESTING – RIGHT POWER SEAT SWITCH 562
REMOVAL 563
INSTALLATION 563
POWER SEAT TRACK 563
DESCRIPTION 563
OPERATION 563
DIAGNOSIS AND TESTING – POWER SEAT TRACK 564
REMOVAL 564
INSTALLATION 564
POWER TOP – SUNROOF 565
POWER TOP – SUNROOF 565
DESCRIPTION 565
OPERATION 565
DIAGNOSIS AND TESTING 565
SUNROOF 565
MOTOR/MODULE – SUNROOF 567
DIAGNOSIS AND TESTING – 567
STANDARD PROCEDURE 568
STANDARD PROCEDURE – POWER SUNROOF TIMING 568
STANDARD PROCEDURE – RE-INITIALIZATION 568
STANDARD PROCEDURE – INITIALIZATION 568
REMOVAL 569
INSTALLATION 569
SWITCH – SUNROOF 570
DESCRIPTION 570
OPERATION 570
DIAGNOSIS AND TESTING 570
SUNROOF SWITCH 570
REMOVAL 571
INSTALLATION 571
POWER WINDOWS 572
POWER WINDOWS 572
DESCRIPTION 572
OPERATION 572
WINDOW SWITCH 572
WINDOW MOTOR 572
DIAGNOSIS AND TESTING – POWER WINDOWS 572
WIRING VOLTAGE TEST 572
POWER WINDOW MOTOR TEST 572
WINDOW MOTOR 573
REMOVAL 573
WINDOW SWITCH 573
DIAGNOSIS AND TESTING – WINDOW SWITCH 573
REMOVAL 574
FRONT 574
REAR 574
INSTALLATION 574
FRONT 574
REAR 574
8o-RESTRAINTS 576
RESTRAINTS 577
DESCRIPTION 577
ACTIVE RESTRAINTS 577
PASSIVE RESTRAINTS 577
OPERATION 580
ACTIVE RESTRAINTS 580
PASSIVE RESTRAINTS 580
WARNINGS – RESTRAINT SYSTEM 581
DIAGNOSIS AND TESTING 582
SUPPLEMENTAL RESTRAINT SYSTEM 582
STANDARD PROCEDURE 582
STANDARD PROCEDURE – HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS 582
SUPPLEMENTAL RESTRAINT STORAGE 583
STANDARD PROCEDURE – SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT 583
AIRBAG SQUIB STATUS 583
CLEANUP PROCEDURE 584
STANDARD PROCEDURE – VERIFICATION TEST 585
AIRBAG CONTROL MODULE 586
DESCRIPTION 586
OPERATION 586
REMOVAL 588
INSTALLATION 589
BELT TENSION SENSOR 590
DESCRIPTION 590
OPERATION 590
CHILD RESTRAINT ANCHOR 590
DESCRIPTION 590
OPERATION 592
CLOCKSPRING 592
DESCRIPTION 592
OPERATION 593
STANDARD PROCEDURE – CLOCKSPRING CENTERING 593
REMOVAL 594
INSTALLATION 595
CURTAIN AIRBAG 596
DESCRIPTION 596
OPERATION 596
REMOVAL 596
INSTALLATION 599
DRIVER AIRBAG 600
DESCRIPTION 600
OPERATION 601
REMOVAL 601
INSTALLATION 603
IMPACT SENSOR 603
DESCRIPTION 603
FRONT 603
SIDE 604
OPERATION 604
FRONT 604
SIDE 605
REMOVAL 605
FRONT 605
SIDE 605
INSTALLATION 606
FRONT 606
SIDE 607
OCCUPANT CLASSIFICATION MODULE 607
DESCRIPTION 607
OPERATION 608
REMOVAL 609
INSTALLATION 610
PASSENGER AIRBAG 611
DESCRIPTION 611
OPERATION 612
REMOVAL 612
AIRBAG 612
DOOR 613
BRACKETS 614
INSTALLATION 614
AIRBAG 614
DOOR 615
BRACKETS 616
PASSENGER AIRBAG ON/OFF INDICATOR 616
DESCRIPTION 616
OPERATION 616
REMOVAL 617
INSTALLATION 618
SEAT BELT BUCKLE 618
REMOVAL 618
FRONT 618
REAR 620
INSTALLATION 620
FRONT 620
REAR 621
SEAT BELT & RETRACTOR 621
REMOVAL 621
FRONT 621
REAR CENTER 623
REAR OUTBOARD 624
INSTALLATION 624
FRONT 624
REAR CENTER 626
REAR OUTBOARD 626
SEAT BELT SWITCH 627
DESCRIPTION 627
OPERATION 627
SEAT BELT TENSIONER 627
DESCRIPTION 627
OPERATION 628
SEAT BELT TURNING LOOP ADJUSTER 628
REMOVAL 628
INSTALLATION 629
SEAT WEIGHT SENSOR 629
DESCRIPTION 629
OPERATION 630
REMOVAL 630
INSTALLATION 631
8p-SPEED CONTROL 634
SPEED CONTROL 634
DESCRIPTION 634
OPERATION 634
DIAGNOSIS AND TESTING – ROAD TEST 635
SPECIFICATIONS 635
TORQUE – SPEED CONTROL 635
CABLE 636
DESCRIPTION 636
OPERATION 636
REMOVAL – 3 7L 636
INSTALLATION – 3 7L 637
SERVO 637
DESCRIPTION 637
OPERATION 637
REMOVAL 637
INSTALLATION 638
SWITCH 638
DESCRIPTION 638
OPERATION 638
Multiplexing 639
REMOVAL 639
INSTALLATION 639
VACUUM RESERVOIR 639
DESCRIPTION 639
OPERATION 639
DIAGNOSIS AND TESTING – VACUUM RESERVOIR 640
REMOVAL 640
INSTALLATION 641
8q-VEHICLE THEFT SECURITY 642
VEHICLE THEFT SECURITY 642
DESCRIPTION 642
OPERATION 644
VEHICLE THEFT ALARM 644
SENTRY KEY IMMOBILIZER SYSTEM 646
DIAGNOSIS AND TESTING 647
VEHICLE THEFT SECURITY SYSTEM 647
VEHICLE THEFT ALARM 647
SENTRY KEY IMMOBILIZER SYSTEM 647
STANDARD PROCEDURE 648
STANDARD PROCEDURE – SKIS INITIALIZATION 648
STANDARD PROCEDURE – SENTRY KEY TRANSPONDER PROGRAMMING 648
SECURED ACCESS METHOD 649
CUSTOMER LEARN METHOD 649
HOOD AJAR SWITCH 649
DESCRIPTION 649
OPERATION 650
REMOVAL 650
SWITCH 650
BRACKET 651
STRIKER 651
INSTALLATION 651
SWITCH 651
BRACKET 651
STRIKER 652
UK SECURITY SYSTEM MODULE 652
DESCRIPTION 652
OPERATION 653
REMOVAL 654
INSTALLATION 654
SENTRY KEY REMOTE ENTRY MODULE 654
DESCRIPTION 654
OPERATION 655
REMOVAL 656
INSTALLATION 657
SIREN 657
DESCRIPTION 657
OPERATION 658
REMOVAL 658
INSTALLATION 659
TRANSPONDER KEY 659
DESCRIPTION 659
OPERATION 659
8r-WIPERS/WASHERS 662
WIPERS/WASHERS 663
DESCRIPTION 663
FRONT 663
REAR 664
OPERATION 666
FRONT 666
OPERATING MODES 666
REAR 668
OPERATING MODES 668
DIAGNOSIS AND TESTING 669
FRONT 669
REAR 669
WIPER SYSTEM 669
WASHER SYSTEM 670
CLEANING 671
FRONT 671
WIPER SYSTEM 671
WASHER SYSTEM 671
REAR 671
WIPER SYSTEM 671
WASHER SYSTEM 672
INSPECTION 672
FRONT 672
WIPER SYSTEM 672
WASHER SYSTEM 673
REAR 673
WIPER SYSTEM 673
WASHER SYSTEM 674
CHECK VALVE 674
DESCRIPTION 674
OPERATION 674
REMOVAL 674
INSTALLATION 675
REAR WIPER MOTOR 675
DESCRIPTION 675
OPERATION 676
REMOVAL 676
INSTALLATION 677
WASHER FLUID LEVEL SWITCH 677
DESCRIPTION 677
OPERATION 678
REMOVAL 678
INSTALLATION 678
WASHER HOSES/TUBES 679
DESCRIPTION 679
FRONT 679
REAR 680
OPERATION 680
FRONT 680
REAR 680
WASHER NOZZLE 680
DESCRIPTION 680
FRONT 680
REAR 681
OPERATION 681
FRONT 681
REAR 681
REMOVAL 681
FRONT 681
REAR 682
INSTALLATION 682
FRONT 682
REAR 683
WASHER PUMP/MOTOR 683
DESCRIPTION 683
OPERATION 683
REMOVAL 684
INSTALLATION 684
WASHER RESERVOIR 685
DESCRIPTION 685
OPERATION 685
REMOVAL 685
INSTALLATION 686
WIPER ARM 687
DESCRIPTION 687
FRONT 687
REAR 688
OPERATION 688
FRONT 688
REAR0 – 6 KJ (Continued) 688
REMOVAL 689
FRONT 689
REAR 689
INSTALLATION 690
FRONT 690
REAR 690
WIPER ARM PARK RAMP 691
REMOVAL 691
INSTALLATION 691
WIPER BLADE 691
DESCRIPTION 691
FRONT 691
REAR 692
OPERATION 692
FRONT 692
REAR 692
REMOVAL 693
FRONT 693
REAR 693
INSTALLATION 694
FRONT 694
REAR 694
WIPER HIGH/LOW RELAY 694
DESCRIPTION 694
OPERATION 695
WIPER MODULE 695
DESCRIPTION 695
OPERATION 696
REMOVAL 696
INSTALLATION 697
WIPER ON/OFF RELAY 697
DESCRIPTION 697
OPERATION 697
8t-NAVIGATION/TELECOMMUNICATION 700
NAVIGATION/TELECOMMUNICATION 700
DESCRIPTION 700
TELECOMMUNICATIONS 700
OPERATION 700
TELECOMMUNICATION 700
HANDS FREE MODULE 700
REMOVAL 700
INSTALLATION 701
8w-WIRING 702
8W-01 WIRING DIAGRAM INFORMATION 704
WIRING DIAGRAM INFORMATION 704
DESCRIPTION 704
DESCRIPTION – HOW TO USE WIRING DIAGRAMS 704
SYMBOLS 704
TERMINOLOGY 704
DESCRIPTION – CIRCUIT INFORMATION 708
DESCRIPTION – CIRCUIT FUNCTIONS 709
DESCRIPTION – SECTION IDENTIFICATION AND INFORMATION 709
DESCRIPTION – CONNECTOR, GROUND AND SPLICE INFORMATION 710
IDENTIFICATION 710
LOCATIONS 710
WARNINGS – GENERAL 710
DIAGNOSIS AND TESTING – WIRING HARNESS 710
TROUBLESHOOTING TOOLS 710
INTERMITTENT AND POOR CONNECTIONS 711
TROUBLESHOOTING WIRING PROBLEMS 711
STANDARD PROCEDURE 711
STANDARD PROCEDURE – ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES 711
STANDARD PROCEDURE – TESTING OF VOLTAGE POTENTIAL 712
STANDARD PROCEDURE – TESTING FOR CONTINUITY 712
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND 712
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 712
STANDARD PROCEDURE – TESTING FOR A VOLTAGE DROP 713
SPECIAL TOOLS 713
WIRING/TERMINAL 713
CONNECTOR 714
REMOVAL 714
INSTALLATION 714
DIODE 717
REMOVAL 717
INSTALLATION 717
TERMINAL 717
REMOVAL 717
INSTALLATION 717
WIRE 718
STANDARD PROCEDURE – WIRE SPLICING 718
8W-02 COMPONENT INDEX 720
8W-10 POWER DISTRIBUTION 722
8W-12 JUNCTION BLOCK 748
8W-15 GROUND DISTRIBUTION 784
8W-18 BUS COMMUNICATIONS 806
8W-20 CHARGING SYSTEM 812
8W-21 STARTING SYSTEM 816
8W-30 FUEL/IGNITION SYSTEM 820
8W-31 TRANSMISSION CONTROL SYSTEM 858
8W-33 VEHICLE SPEED CONTROL 874
8W-35 ANTILOCK BRAKES 880
8W-39 VEHICLE THEFT SECURITY SYSTEM 886
8W-40 INSTRUMENT CLUSTER 898
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 906
8W-42 AIR CONDITIONING-HEATER 910
8W-43 AIRBAG SYSTEM 918
8W-44 INTERIOR LIGHTING 924
8W-45 BODY CONTROL MODULE 928
8W-47 AUDIO SYSTEM 938
8W-48 REAR WINDOW DEFOGGER 950
8W-49 OVERHEAD CONSOLE 952
8W-50 FRONT LIGHTING 958
8W-51 REAR LIGHTING 976
8W-52 TURN SIGNALS 982
8W-53 WIPERS 990
8W-54 TRAILER TOW 996
8W-55 NAVIGATION/TELECOMMUNICATIONS 1002
8W-60 POWER WINDOWS 1006
8W-61 POWER DOOR LOCKS 1010
8W-62 POWER MIRRORS 1018
8W-63 POWER SEAT 1024
8W-64 POWER SUNROOF 1030
8W-70 SPLICE INFORMATION 1032
8W-80 CONNECTOR PIN-OUTS 1042
8W-91 CONNECTOR/GROUND/SPLICE LOCATION 1162
CONNECTOR/GROUND/SPLICE LOCATION 1162
DESCRIPTION 1162
8W-97 POWER DISTRIBUTION 1232
POWER DISTRIBUTION 1232
DESCRIPTION 1232
OPERATION 1232
SPECIAL TOOLS 1233
POWER DISTRIBUTION SYSTEMS 1233
CIGAR LIGHTER OUTLET 1233
DESCRIPTION 1233
OPERATION 1233
DIAGNOSIS AND TESTING – CIGAR LIGHTER OUTLET 1233
IOD FUSE 1234
DESCRIPTION 1234
CIRCUITS INCLUDED WITH IOD FUSE 1234
OPERATION 1234
REMOVAL 1234
INSTALLATION 1234
JUNCTION BLOCK 1235
DESCRIPTION 1235
OPERATION 1235
DIAGNOSIS AND TESTING – JUNCTION BLOCK 1235
REMOVAL 1236
REMOVAL – LHD 1236
REMOVAL – RHD 1236
INSTALLATION 1237
INSTALLATION – LHD 1237
INSTALLATION – RHD 1237
POWER DISTRIBUTION CENTER 1237
DESCRIPTION 1237
OPERATION 1237
REMOVAL 1238
DISASSEMBLY 1238
POWER DISTRIBUTION CENTER DISASSEMBLY 1238
PDC HOUSING LOWER COVER 1238
PDC B+ TERMINAL MODULE 1239
PDC RELAY WEDGE 1239
PDC RELAY CASSETTE 1239
ASSEMBLY 1240
POWER DISTRIBUTION CENTER ASSEMBLY 1240
PDC B(+) TERMINAL MODULE 1240
RELAY WEDGE 1240
RELAY CASSETTE 1241
PDC LOWER COVER 1241
INSTALLATION 1241
POWER OUTLET 1242
DESCRIPTION 1242
OPERATION 1242
DIAGNOSIS AND TESTING – POWER OUTLET 1242
REMOVAL 1243
INSTALLATION 1243
RELAY 1244
DESCRIPTION 1244
OPERATION 1244
DIAGNOSIS AND TESTING – RELAY 1244
DIAGNOSIS & TESTING – RELAY CIRCUIT TEST 1244
REMOVAL 1245
INSTALLATION 1245
MICRO-RELAY 1245
DESCRIPTION 1245
OPERATION 1245
DIAGNOSIS AND TESTING – MICRO-RELAY 1245
REMOVAL 1245
INSTALLATION 1245
9-ENGINE 1246
ENGINE – 2 4L 1246
ENGINE – 2 4L 1248
DESCRIPTION 1248
DIAGNOSIS AND TESTING 1248
CYLINDER COMBUSTION PRESSURE LEAKAGE TEST 1248
CYLINDER COMPRESSION PRESSURE TEST 1248
ENGINE OIL LEAK INSPECTION 1249
INSPECTION FOR REAR SEAL AREA LEAKS 1249
ENGINE DIAGNOSIS 1250
ENGINE DIAGNOSIS – PERFORMANCE 1251
DIAGNOSIS AND TESTING – ENGINE MECHANICAL 1253
STANDARD PROCEDURE 1255
ENGINE CORE AND OIL GALLERY PLUGS 1255
REPAIR OF DAMAGED OR WORN THREADS 1255
HYDROSTATIC LOCKED ENGINE 1255
FORM-IN-PLACE GASKETS AND SEALERS 1256
SEALER APPLICATION 1256
ENGINE GASKET SURFACE PREPARATION 1257
MEASURING BEARING CLEARANCE USING PLASTIGAGE 1257
REMOVAL – ENGINE ASSEMBLY 1258
INSTALLATION – ENGINE ASSEMBLY 1258
SPECIFICATIONS 1259
SPECIFICATIONS – 2 4L ENGINE 1259
SPECIFICATIONS – TORQUE 1264
SPECIAL TOOLS 1265
2 4L ENGINE 1265
AIR CLEANER ELEMENT 1267
REMOVAL – 2 4L 1267
INSTALLATION – 2 4L 1267
AIR CLEANER HOUSING 1267
REMOVAL 1267
INSTALLATION 1267
CYLINDER HEAD 1267
DESCRIPTION 1267
OPERATION 1267
DIAGNOSIS AND TESTING 1268
CYLINDER HEAD GASKET 1268
CYLINDER-TO-CYLINDER LEAKAGE TEST 1268
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1268
REMOVAL – CYLINDER HEAD 1268
CLEANING 1269
INSPECTION 1269
INSTALLATION – CYLINDER HEAD 1269
CAMSHAFT OIL SEAL(S) 1271
REMOVAL 1271
INSTALLATION 1271
CAMSHAFT(S) 1272
DESCRIPTION 1272
OPERATION 1272
STANDARD PROCEDURE – CAMSHAFT END-PLAY 1272
REMOVAL 1272
CLEANING 1273
INSPECTION 1273
INSTALLATION 1273
CYLINDER HEAD COVER 1274
REMOVAL 1274
CLEANING 1274
INSPECTION 1274
INSTALLATION 1274
INTAKE/EXHAUST VALVES & SEATS 1275
DESCRIPTION 1275
CLEANING 1275
VALVE SPRINGS 1276
REMOVAL 1276
REMOVAL – CYLINDER HEAD ON 1276
REMOVAL – CYLINDER HEAD OFF 1276
INSPECTION 1276
INSTALLATION 1276
INSTALLATION – CYLINDER HEAD ON 1276
INSTALLATION – CYLINDER HEAD OFF 1277
HYDRAULIC LIFTERS 1277
DIAGNOSIS AND TESTING 1277
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS 1277
REMOVAL 1278
INSTALLATION 1278
ROCKER ARMS 1278
REMOVAL 1278
INSPECTION 1279
INSTALLATION 1279
ENGINE BLOCK 1279
DESCRIPTION 1279
STANDARD PROCEDURE 1279
STANDARD PROCEDURE – PISTON TO CYLINDER BORE FITTING 1279
CYLINDER BORE HONING 1280
CLEANING 1280
INSPECTION 1280
ENGINE BLOCK 1280
CYLINDER BORE 1281
CONNECTING ROD BEARINGS 1281
STANDARD PROCEDURE 1281
CONNECTING ROD – FITTING 1281
CRANKSHAFT 1281
DESCRIPTION 1281
OPERATION 1281
STANDARD PROCEDURE – CRANKSHAFT END PLAY 1281
REMOVAL 1282
INSPECTION 1283
INSTALLATION 1283
CRANKSHAFT MAIN BEARINGS 1284
STANDARD PROCEDURE – MAIN BEARING – FITTING 1284
CRANKSHAFT MAIN BEARINGS 1284
MAIN BEARING INSTALLATION 1285
CRANKSHAFT OIL SEAL – FRONT 1286
REMOVAL 1286
INSTALLATION 1287
CRANKSHAFT OIL SEAL – REAR 1288
REMOVAL 1288
INSTALLATION 1288
PISTON & CONNECTING ROD 1289
DESCRIPTION 1289
OPERATION 1289
REMOVAL 1289
INSTALLATION 1290
PISTON RINGS 1291
STANDARD PROCEDURE 1291
PISTON RING – FITTING 1291
PISTON RINGS – INSTALLATION 1292
VIBRATION DAMPER 1293
REMOVAL 1293
INSTALLATION 1293
STRUCTURAL COLLAR 1293
REMOVAL 1293
INSTALLATION 1293
ENGINE MOUNTING 1293
DESCRIPTION 1293
FRONT MOUNT 1293
REMOVAL 1293
INSTALLATION 1294
REAR MOUNT 1294
REMOVAL 1294
MANUAL TRANSMISSION 1294
AUTOMATIC TRANSMISSION 1294
INSTALLATION 1294
MANUAL TRANSMISSION: 1294
AUTOMATIC TRANSMISSION: 1294
LUBRICATION 1296
DESCRIPTION 1296
OPERATION 1296
DIAGNOSIS AND TESTING 1296
ENGINE OIL PRESSURE CHECKING 1296
OIL 1296
STANDARD PROCEDURE 1296
ENGINE OIL LEVEL CHECK 1296
ENGINE OIL AND FILTER CHANGE 1296
OIL FILTER 1297
DESCRIPTION 1297
REMOVAL 1297
INSTALLATION 1297
OIL PAN 1297
REMOVAL 1297
INSTALLATION 1298
OIL PRESSURE SENSOR/SWITCH 1298
DESCRIPTION 1298
OPERATION 1298
OIL PUMP 1298
REMOVAL 1298
REMOVAL 1298
REMOVAL 1299
DISASSEMBLY 1300
CLEANING 1300
INSPECTION 1301
ASSEMBLY 1301
INSTALLATION 1302
INTAKE MANIFOLD 1303
DESCRIPTION 1303
OPERATION 1303
DIAGNOSIS AND TESTING 1303
INTAKE MANIFOLD LEAKS 1303
REMOVAL 1303
REMOVAL 1303
REMOVAL — LOWER 1303
INSPECTION 1304
INSTALLATION 1304
INSTALLATION — UPPER 1304
INSTALLATION — LOWER 1304
EXHAUST MANIFOLD 1305
DESCRIPTION 1305
OPERATION 1305
REMOVAL 1305
CLEANING 1305
INSPECTION 1305
INSTALLATION 1305
TIMING BELT COVER(S) 1305
REMOVAL 1305
FRONT COVER 1305
REAR COVER 1306
INSTALLATION 1306
REAR COVER 1306
FRONT COVER 1306
TIMING BELT AND SPROCKET(S) 1306
REMOVAL 1306
TIMING BELT 1306
CRANKSHAFT SPROCKET 1307
CLEANING 1307
INSTALLATION 1308
CRANKSHAFT SPROCKET 1308
TIMING BELT 1308
TIMING BELT TENSIONER & PULLEY 1310
REMOVAL 1310
INSTALLATION 1310
BALANCE SHAFTS AND CARRIER ASSEMBLY 1311
DESCRIPTION 1311
OPERATION 1311
REMOVAL 1312
BALANCE SHAFTS 1312
BALANCE SHAFT CARRIER 1313
INSTALLATION 1313
BALANCE SHAFT TIMING 1313
BALANCE SHAFT INSTALLATION 1313
BALANCE SHAFT CARRIER 1315
DESCRIPTION 1315
OPERATION 1315
REMOVAL 1316
INSTALLATION 1316
BALANCE SHAFT CHAIN 1316
REMOVAL 1316
INSTALLATION 1316
ENGINE – 3 7L 1317
ENGINE – 3 7L 1319
DESCRIPTION 1319
DIAGNOSIS AND TESTING 1320
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – INTRODUCTION 1320
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – PERFORMANCE 1320
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – MECHANICAL 1322
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – LUBRICATION 1323
DIAGNOSIS AND TESTING – CYLINDER COMPRESSION PRESSURE 1324
DIAGNOSIS AND TESTING – CYLINDER COMBUSTION PRESSURE LEAKAGE 1324
STANDARD PROCEDURE 1325
ENGINE GASKET SURFACE PREPARATION 1325
STANDARD PROCEDURE – REPAIR DAMAGED OR WORN THREADS 1326
ENGINE CORE AND OIL GALLERY PLUGS 1326
REMOVAL 1326
INSTALLATION 1327
SPECIFICATIONS 1328
TORQUE 1328
SPECIFICATIONS – 3 7L ENGINE 1328
SPECIAL TOOLS 1332
3 7L ENGINE 1332
AIR CLEANER ELEMENT 1336
REMOVAL – 3 7L 1336
INSTALLATION – 3 7L 1336
CYLINDER HEAD – LEFT 1336
DESCRIPTION – VALVE GUIDES 1336
DIAGNOSIS AND TESTING 1336
DIAGNOSIS AND TESTING – HYDRAULIC LASH ADJUSTER 1336
CYLINDER HEAD GASKET 1336
CYLINDER-TO-CYLINDER LEAKAGE TEST 1337
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1337
REMOVAL 1337
CLEANING 1339
INSTALLATION 1339
CAMSHAFT 1340
DESCRIPTION 1340
REMOVAL 1340
INSTALLATION 1341
COVER – CYLINDER HEAD 1342
DESCRIPTION 1342
REMOVAL 1342
INSTALLATION 1343
INTAKE/EXHAUST VALVES & SEATS 1343
DESCRIPTION 1343
STANDARD PROCEDURE – REFACING 1343
REMOVAL 1344
TESTING VALVE SPRINGS 1345
INSTALLATION 1345
ROCKER ARM 1346
DESCRIPTION 1346
REMOVAL 1346
SEALS – VALVE GUIDE 1346
DESCRIPTION 1346
SPRINGS VALVE 1346
DESCRIPTION 1346
REMOVAL 1346
INSTALLATION 1347
CYLINDER HEAD – RIGHT 1347
DESCRIPTION 1347
DESCRIPTION – CYLINDER HEAD 1347
DESCRIPTION – VALVE GUIDES 1347
DESCRIPTION 1347
DIAGNOSIS AND TESTING 1347
DIAGNOSIS AND TESTING – HYDRAULIC LASH ADJUSTER 1347
DIAGNOSIS AND TESTING – CYLINDER HEAD GASKET 1347
CYLINDER-TO-CYLINDER LEAKAGE TEST 1348
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1348
REMOVAL 1348
CLEANING 1350
INSPECTION 1350
INSTALLATION 1350
CAMSHAFT 1352
DESCRIPTION 1352
REMOVAL 1352
INSTALLATION 1354
COVER – CYLINDER HEAD 1354
REMOVAL 1354
INSTALLATION 1354
INTAKE/EXHAUST VALVES & SEATS 1355
STANDARD PROCEDURE – REFACING 1355
REMOVAL 1356
TESTING VALVE SPRINGS 1356
INSTALLATION 1356
ROCKER ARM 1357
DESCRIPTION 1357
REMOVAL 1357
INSTALLATION 1358
SEALS – VALVE GUIDE 1358
DESCRIPTION 1358
SPRINGS – VALVE 1358
DESCRIPTION 1358
REMOVAL 1358
INSTALLATION 1359
ENGINE BLOCK 1359
DESCRIPTION 1359
STANDARD PROCEDURE – CYLINDER BORE HONING 1359
CLEANING 1360
INSPECTION 1360
CRANKSHAFT 1361
DESCRIPTION 1361
REMOVAL 1361
INSPECTION 1361
INSTALLATION 1362
CRANKSHAFT MAIN BEARINGS 1364
STANDARD PROCEDURE 1364
MAIN BEARING – FITTING 1364
SELECT FIT IDENTIFICATION 1364
INSPECTION 1364
MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED) 1364
CRANKSHAFT MAIN BEARING SELECTION 1364
CRANKSHAFT OIL SEAL – FRONT 1365
REMOVAL 1365
INSTALLATION 1366
CRANKSHAFT OIL SEAL – REAR 1366
DIAGNOSIS AND TESTING – REAR SEAL AREA LEAKS 1366
REMOVAL 1367
INSTALLATION 1367
FLEX PLATE 1368
REMOVAL 1368
INSTALLATION 1368
PISTON & CONNECTING ROD 1368
DESCRIPTION 1368
STANDARD PROCEDURE 1369
CONNECTING ROD BEARING FITTING 1369
STANDARD PROCEDURE – PISTON FITTING 1371
REMOVAL 1371
CLEANING 1372
INSPECTION 1372
INSTALLATION 1372
PISTON RINGS 1373
STANDARD PROCEDURE – PISTON RING FITTING 1373
VIBRATION DAMPER 1375
REMOVAL 1375
INSTALLATION 1376
STRUCTURAL COVER 1376
DESCRIPTION 1376
OPERATION 1376
REMOVAL 1376
INSTALLATION 1376
FRONT MOUNT 1377
REMOVAL 1377
INSTALLATION 1377
REAR MOUNT 1378
REMOVAL 1378
MANUAL TRANSMISSION 1378
AUTOMATIC TRANSMISSION 1378
INSTALLATION 1378
MANUAL TRANSMISSION: 1378
AUTOMATIC TRANSMISSION: 1379
LUBRICATION 1379
DESCRIPTION 1379
OPERATION 1380
DIAGNOSIS AND TESTING 1382
DIAGNOSIS AND TESTING – ENGINE OIL LEAK 1382
Air Leak Detection Test Method 1382
INSPECTION FOR REAR SEAL AREA LEAKS 1382
DIAGNOSIS AND TESTING – CHECKING ENGINE OIL PRESSURE 1383
DIAGNOSIS AND TESTING – REAR SEAL AREA LEAKS 1383
OIL 1384
STANDARD PROCEDURE – ENGINE OIL SERVICE 1384
CRANKCASE OIL LEVEL INSPECTION 1384
ENGINE OIL CHANGE 1384
OIL FILTER 1385
REMOVAL 1385
INSTALLATION 1385
OIL PAN 1385
DESCRIPTION 1385
REMOVAL 1386
REMOVAL 1386
REMOVAL – 4×4 1386
CLEANING 1387
INSPECTION 1387
INSTALLATION 1387
INSTALLATION 1387
INSTALLATION – 4×4 1387
SWITCH – OIL PRESSURE 1388
DESCRIPTION 1388
OPERATION 1388
REMOVAL 1388
INSTALLATION 1388
PUMP – ENGINE OIL 1389
REMOVAL 1389
DISASSEMBLY 1389
INSPECTION 1389
ASSEMBLY 1390
INSTALLATION 1390
MANIFOLD – INTAKE 1391
DESCRIPTION 1391
DIAGNOSIS AND TESTING – INTAKE MANIFOLD LEAKS 1391
REMOVAL 1391
INSTALLATION 1392
MANIFOLD – EXHAUST 1393
DESCRIPTION 1393
REMOVAL 1393
RIGHT EXHAUST MANIFOLD 1393
LEFT EXHAUST MANIFOLD 1393
INSTALLATION 1393
RIGHT EXHAUST MANIFOLD 1393
LEFT EXHAUST MANIFOLD 1394
VALVE TIMING 1394
DESCRIPTION 1394
OPERATION 1394
STANDARD PROCEDURE 1396
MEASURING TIMING CHAIN WEAR 1396
SERVICE PROCEDURE – TIMING VERIFICATION 1396
COUNTER BALANCE SHAFT TIMING 1397
TIMING – SINGLE CAMSHAFT 1398
BALANCE SHAFT 1398
REMOVAL 1398
INSTALLATION 1400
TIMING BELT / CHAIN COVER(S) 1400
REMOVAL 1400
INSTALLATION 1401
IDLER SHAFT 1402
REMOVAL 1402
INSTALLATION 1402
TIMING BELT/CHAIN AND SPROCKET(S) 1402
REMOVAL 1402
INSPECTION 1404
INSTALLATION 1404
2 8L COMMON RAIL DIESEL ENGINE 1408
2 8L COMMON RAIL DIESEL ENGINE 1410
DESCRIPTION 1410
2 8L COMMON RAIL DIESEL ENGINE 1410
ENGINE COVER 1411
DIAGNOSIS AND TESTING 1411
ENGINE DIAGNOSIS – MECHANICAL 1411
SMOKE DIAGNOSIS CHARTS 1414
STANDARD PROCEDURE 1416
FORM-IN-PLACE GASKETS AND SEALERS 1416
FORM-IN-PLACE GASKET AND SEALER APPLICATION 1417
REPAIR DAMAGED OR WORN THREADS 1417
HYDROSTATIC LOCK 1417
REMOVAL 1417
2 8L COMMON RAIL DIESEL ENGINE 1417
ENGINE COVER 1422
INSTALLATION 1422
2 8L COMMON RAIL DIESEL ENGINE 1422
ENGINE COVER 1426
SPECIFICATIONS 1427
ENGINE SPECIFICATIONS 1427
TORQUE 1430
SPECIAL TOOLS 1432
AIR CLEANER ELEMENT 1436
REMOVAL 1436
INSTALLATION 1436
AIR CLEANER HOUSING 1436
REMOVAL 1436
INSTALLATION 1436
CYLINDER HEAD 1437
DESCRIPTION 1437
STANDARD PROCEDURE 1437
VALVE SEALS – IN VEHICLE 1437
VALVE SERVICE 1438
DISASSEMBLY 1438
VALVE CLEANING 1438
INSPECTION 1438
VALVE SEAT REFACING 1438
VALVE GUIDES 1438
VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT 1438
STANDARD PROCEDURE – MEASURING PISTON PROTRUSION 1439
REMOVAL – CYLINDER HEAD 1440
CLEANING 1441
INSPECTION 1442
INSTALLATION – CYLINDER HEAD 1442
CAMSHAFT OIL SEAL(S) 1444
REMOVAL 1444
INSTALLATION 1445
CAMSHAFT(S) 1445
DESCRIPTION 1445
OPERATION 1445
REMOVAL – CAMSHAFTS 1445
INSTALLATION – CAMSHAFTS 1446
CHECKING CAMSHAFT ENDPLAY 1446
CYLINDER HEAD COVER 1447
DESCRIPTION 1447
REMOVAL – CYLINDER HEAD COVER 1447
INSTALLATION 1449
CYLINDER HEAD COVER/INTAKE MANIFOLD TIGHTENING PROCEDURE 1449
ROCKER ARMS 1451
DESCRIPTION0 – 8 KJ (Continued) 1451
OPERATION 1451
REMOVAL 1451
INSTALLATION 1451
HYDRAULIC LIFTERS 1452
DESCRIPTION 1452
REMOVAL 1452
INSPECTION 1453
INSTALLATION 1453
ENGINE BLOCK 1453
DESCRIPTION 1453
CRANKSHAFT 1453
DESCRIPTION 1453
OPERATION 1453
STANDARD PROCEDURE – CHECKING CRANKSHAFT END PLAY 1453
REMOVAL – CRANKSHAFT 1453
INSTALLATION – CRANKSHAFT 1456
CRANKSHAFT MAIN BEARINGS 1458
REMOVAL 1458
CRANKSHAFT MAIN BEARINGS 1458
CRANKSHAFT FRONT MAIN BEARING 1458
INSTALLATION 1459
CRANKSHAFT MAIN BEARINGS 1459
FRONT CRANKSHAFT MAIN BEARING 1461
CRANKSHAFT OIL SEAL – FRONT 1461
REMOVAL 1461
INSTALLATION 1461
CRANKSHAFT OIL SEAL – REAR 1463
DESCRIPTION 1463
REMOVAL 1463
INSTALLATION 1464
FLEX PLATE 1464
REMOVAL 1464
INSTALLATION 1464
CYLINDER LINERS 1465
DESCRIPTION 1465
REMOVAL 1465
INSPECTION 1465
INSTALLATION 1466
PISTON & CONNECTING ROD 1467
DESCRIPTION 1467
STANDARD PROCEDURE – PISTON RING FITTING 1468
REMOVAL 1468
PISTON PIN – REMOVAL 1469
PISTON RING – REMOVAL 1469
INSPECTION 1469
PISTONS 1469
CONNECTING RODS 1470
PISTON PINS 1470
INSTALLATION 1470
PISTON PIN INSTALLATION 1470
PISTON RINGS – INSTALLATION 1471
INSTALLATION 1471
VIBRATION DAMPER 1473
REMOVAL 1473
INSTALLATION 1473
INTERNAL VACUUM PUMP 1473
DESCRIPTION 1473
REMOVAL 1473
INSTALLATION 1474
ENGINE COVER – FRONT 1475
DESCRIPTION 1475
REMOVAL 1475
INSTALLATION 1475
LEFT MOUNT 1476
REMOVAL 1476
INSTALLATION 1476
RIGHT MOUNT 1477
REMOVAL 1477
INSTALLATION 1477
OIL 1478
DESCRIPTION 1478
OIL PAN 1478
REMOVAL 1478
INSTALLATION 1478
OIL PRESSURE RELIEF VALVE 1479
DESCRIPTION 1479
REMOVAL 1479
INSTALLATION 1479
OIL PRESSURE SENDING UNIT 1480
DESCRIPTION 1480
OPERATION 1480
REMOVAL 1480
INSTALLATION 1481
OIL PUMP 1482
REMOVAL 1482
REMOVAL – OIL PUMP PICKUP TUBE 1482
REMOVAL – OIL PUMP 1482
INSTALLATION 1483
INSTALLATION – OIL PUMP PICKUP TUBE 1483
INSTALLATION – OIL PUMP 1483
OIL JET 1484
DESCRIPTION 1484
REMOVAL 1484
INSTALLATION 1485
OIL SEPARATOR 1485
REMOVAL 1485
INSTALLATION 1486
OIL COOLER 1486
DESCRIPTION 1486
REMOVAL 1486
INSTALLATION 1487
INTAKE MANIFOLD 1487
DESCRIPTION 1487
REMOVAL 1487
INSTALLATION 1487
EXHAUST MANIFOLD 1487
REMOVAL 1487
INSTALLATION 1487
VALVE TIMING 1487
STANDARD PROCEDURE – LOCKING ENGINE 90 DEGREES AFTER TDC 1487
BALANCE SHAFT 1490
DESCRIPTION 1490
OPERATION 1490
REMOVAL 1490
INSTALLATION 1490
TIMING BELT / CHAIN COVER(S) 1492
REMOVAL 1492
REMOVAL – TIMING BELT INNER COVER 1492
REMOVAL – TIMING BELT OUTER COVER 1493
INSTALLATION 1493
INSTALLATION – TIMING BELT INNER COVER 1493
INSTALLATION – TIMING BELT OUTER COVER 1494
TIMING BELT IDLER PULLEY 1494
REMOVAL 1494
INSTALLATION 1495
TIMING BELT/CHAIN AND SPROCKET(S) 1496
REMOVAL 1496
INSTALLATION 1497
TIMING BELT/CHAIN TENSIONER & PULLEY 1498
REMOVAL 1498
INSTALLATION 1499
ADJUSTMENTS 1500
ADJUSTMENT – TIMING BELT TENSIONER 1500
11-EXHAUST SYSTEM 1502
EXHAUST SYSTEM AND TURBOCHARGER 1502
DESCRIPTION 1502
GAS ENGINES 1502
2 8L DIESEL 1503
DIAGNOSIS AND TESTING 1504
DIAGNOSIS AND TESTING – EXHAUST SYSTEM 1504
DIESEL ENGINE 1505
SPECIFICATIONS 1505
TORQUE 1505
CATALYTIC CONVERTER 1506
DESCRIPTION – CATALYTIC CONVERTER 1506
REMOVAL 1506
2 4L ENGINE 1506
3 7L ENGINE 1506
2 8L DIESEL ENGINE 1507
INSPECTION 1507
INSTALLATION 1507
2 4L ENGINE 1507
3 7L ENGINE 1508
2 8L DIESEL 1508
MUFFLER 1509
REMOVAL 1509
INSTALLATION 1509
HEAT SHIELDS 1510
DESCRIPTION 1510
TURBOCHARGER SYSTEM 1510
DIAGNOSIS AND TESTING 1510
TURBOCHARGER BOOST PRESSURE 1510
CHARGE AIR COOLER AND PLUMBING 1510
DIAGNOSIS AND TESTING 1510
CHARGE AIR COOLER SYSTEM – LEAKS 1510
REMOVAL 1511
REMOVAL – CAC INLET HOSE 1511
REMOVAL – CAC OUTLET HOSE 1511
INSTALLATION 1511
INSTALLATION – CAC INLET HOSE 1511
INSTALLATION – CAC OUTLET HOSE 1511
TURBOCHARGER 1512
DESCRIPTION 1512
OPERATION 1512
REMOVAL 1514
CLEANING 1515
INSTALLATION 1515
13-FRAME & BUMPERS 1518
FRONT FASCIA 1518
REMOVAL 1518
INSTALLATION 1518
REAR FASCIA 1519
REMOVAL 1519
INSTALLATION 1519
REAR FASCIA SUPPORT 1519
REMOVAL 1519
INSTALLATION 1520
REAR FASCIA – STEP PAD 1520
REMOVAL 1520
INSTALLATION 1520
REAR FASCIA – RAIN DIVERTER 1520
REMOVAL 1520
INSTALLATION 1520
FRAME 1520
SPECIFICATIONS 1520
SPECIFICATIONS – FRAME DIMENSIONS 1520
VEHICLE PREPARATION 1520
DIMENSION ILLUSTRATIONS 1520
SPECIFICATIONS – TORQUE 1522
FRONT SKID PLATE 1523
REMOVAL 1523
INSTALLATION 1523
ENGINE CRADLE CROSSMEMBER 1523
REMOVAL 1523
INSTALLATION 1523
TRANSFER CASE SKID PLATE 1524
REMOVAL 1524
INSTALLATION 1524
REAR CROSSMEMBER 1524
REMOVAL 1524
INSTALLATION 1524
FRONT TOW HOOK 1525
REMOVAL 1525
INSTALLATION 1525
REAR TOW HOOK 1525
REMOVAL 1525
INSTALLATION 1525
TRAILER HITCH 1525
REMOVAL 1525
INSTALLATION 1525
FUEL TANK SKID PLATE 1525
REMOVAL 1525
INSTALLATION 1526
14-FUEL SYSTEM 1528
FUEL DELIVERY – 2 4L/3 7L GAS 1528
FUEL DELIVERY – 2 4L/3 7L GAS 1529
DESCRIPTION 1529
OPERATION 1529
STANDARD PROCEDURE – FUEL SYSTEM PRESSURE RELEASE 1529
SPECIFICATIONS 1531
FUEL SYSTEM PRESSURE 1531
TORQUE 1531
SPECIAL TOOLS 1532
FUEL SYSTEM 1532
FLOW MANAGEMENT VALVE 1533
DESCRIPTION 1533
OPERATION 1533
FUEL FILTER 1533
DESCRIPTION 1533
FUEL LEVEL SENDING UNIT / SENSOR 1533
DESCRIPTION 1533
OPERATION 1533
FUEL LINES 1533
DESCRIPTION 1533
QUICK CONNECT FITTING 1534
DESCRIPTION 1534
STANDARD PROCEDURE – QUICK-CONNECT FITTINGS 1534
DISCONNECTING 1534
CONNECTING 1537
FUEL PRESSURE REGULATOR 1538
DESCRIPTION 1538
OPERATION 1538
FUEL PUMP 1539
DESCRIPTION 1539
OPERATION 1539
FUEL PUMP MODULE 1539
DESCRIPTION 1539
OPERATION 1539
REMOVAL 1540
INSTALLATION 1540
FUEL RAIL 1541
DESCRIPTION 1541
OPERATION 1541
REMOVAL 1542
INSTALLATION 1544
FUEL TANK 1545
DESCRIPTION 1545
OPERATION 1545
REMOVAL 1545
Fuel Tank Draining 1545
Tank Removal 1547
INSTALLATION 1547
FUEL INJECTION – 2 4L/3 7L GAS 1551
FUEL INJECTION – 2 4L/3 7L GAS 1551
DESCRIPTION 1551
ACCELERATOR PEDAL 1552
REMOVAL 1552
INSTALLATION 1552
CRANKSHAFT POSITION SENSOR 1552
DESCRIPTION 1552
2 4L 1552
3 7L 1553
OPERATION 1553
2 4L 1553
3 7L 1553
REMOVAL 1554
2 4L 1554
3 7L 1554
INSTALLATION 1554
2 4L 1554
3 7L 1555
FUEL INJECTOR 1555
DESCRIPTION 1555
OPERATION 1555
OPERATION – FUEL INJECTOR 1555
OPERATION – PCM OUTPUT 1555
REMOVAL 1556
INSTALLATION 1556
FUEL PUMP RELAY 1556
DESCRIPTION 1556
OPERATION 1556
REMOVAL 1556
INSTALLATION 1556
IDLE AIR CONTROL MOTOR 1557
DESCRIPTION 1557
OPERATION 1557
REMOVAL 1558
2 4L 1558
3 7L 1558
INSTALLATION 1558
2 4L 1558
3 7L 1558
INTAKE AIR TEMPERATURE SENSOR 1558
DESCRIPTION 1558
OPERATION 1558
REMOVAL 1559
2 4L 1559
3 7L 1559
INSTALLATION 1560
2 4L 1560
3 7L 1560
MAP SENSOR 1560
DESCRIPTION 1560
2 4L 1560
3 7L 1560
OPERATION 1560
REMOVAL 1561
2 4L 1561
3 7L 1561
INSTALLATION 1562
2 4L 1562
3 7L 1562
OXYGEN SENSOR 1562
DESCRIPTION 1562
OPERATION 1562
REMOVAL 1563
INSTALLATION 1565
THROTTLE BODY 1565
DESCRIPTION 1565
OPERATION 1565
REMOVAL 1565
2 4L 1565
3 7L 1565
INSTALLATION 1566
2 4L 1566
3 7L 1566
THROTTLE CONTROL CABLE 1566
REMOVAL 1566
2 4L 1566
3 7L 1567
INSTALLATION 1568
THROTTLE POSITION SENSOR 1568
DESCRIPTION 1568
OPERATION 1568
REMOVAL 1569
2 4L 1569
3 7L 1569
INSTALLATION 1570
2 4L 1570
3 7L 1570
FUEL DELIVERY – 2 8L DIESEL 1571
FUEL DELIVERY – 2 8L DIESEL 1571
DESCRIPTION – DIESEL FUEL DELIVERY SYSTEM 1571
WARNING – HIGH FUEL SYSTEM PRESSURE 1572
DIAGNOSIS AND TESTING 1572
FUEL SYSTEM SUPPLY 1572
HIGH PRESSURE FUEL LEAKS 1573
AIR IN FUEL SYSTEM 1573
FUEL SUPPLY RESTRICTIONS 1574
LOW-PRESSURE LINES 1574
HIGH-PRESSURE LINES 1574
FUEL FILTER 1574
Testing The Filter For Restrictions 1574
INJECTOR LEAK QUANTITY 1574
Cranking Test 1575
Engine Running 1575
STANDARD PROCEDURE 1576
PRIMING FUEL SYSTEM 1576
CLEANING FUEL SYSTEM COMPONENTS 1576
DRAINING WATER IN FUEL 1576
SPECIFICATIONS – TORQUE 1578
SPECIAL TOOLS – DIESEL 1578
FUEL FILTER / WATER SEPARATOR 1579
DESCRIPTION 1579
OPERATION 1579
REMOVAL 1580
REMOVAL – FUEL FILTER/WATER SEPARATOR ASSEMBLY 1580
REMOVAL – FUEL FILTER 1580
INSTALLATION 1581
INSTALLATION – FUEL FILTER / WATER SEPARATOR ASSEMBLY 1581
INSTALLATION – FUEL FILTER 1582
WATER IN FUEL SENSOR 1583
DESCRIPTION 1583
OPERATION 1584
REMOVAL 1584
INSTALLATION 1585
FUEL RAIL 1586
DESCRIPTION 1586
OPERATION 1586
REMOVAL 1587
INSTALLATION 1587
FUEL LINES 1588
DESCRIPTION 1588
DESCRIPTION 1588
DESCRIPTION – HIGH PRESSURE FUEL LINES 1588
OPERATION – HIGH PRESSURE FUEL LINES 1588
FUEL INJECTION PUMP 1588
DESCRIPTION 1588
OPERATION 1589
REMOVAL 1589
INSTALLATION 1592
FUEL LEVEL SENDING UNIT / SENSOR 1592
DESCRIPTION 1592
OPERATION 1592
DIAGNOSIS AND TESTING – FUEL LEVEL SENDING UNIT 1592
REMOVAL 1593
INSTALLATION 1593
FUEL HEATER 1594
DESCRIPTION 1594
OPERATION 1594
REMOVAL 1594
INSTALLATION 1595
FUEL QUANTITY SOLENOID 1596
DESCRIPTION 1596
OPERATION 1596
REMOVAL 1596
INSTALLATION 1597
FUEL TANK 1597
REMOVAL – DIESEL 1597
Fuel Tank Draining 1597
Tank Removal 1597
INSTALLATION – DIESEL 1599
FUEL TANK MODULE 1601
DESCRIPTION 1601
REMOVAL 1602
INSTALLATION 1603
FUEL INJECTION – 2 8L DIESEL 1604
ACCELERATOR PEDAL POSITION SENSOR 1605
DESCRIPTION 1605
REMOVAL 1605
INSTALLATION 1605
BOOST PRESSURE SENSOR 1605
DESCRIPTION 1605
OPERATION 1606
DIAGNOSIS AND TESTING – BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR 1606
REMOVAL 1606
INSTALLATION 1606
CAMSHAFT POSITION SENSOR 1606
DESCRIPTION 1606
OPERATION 1607
REMOVAL 1607
INSTALLATION 1607
CRANKSHAFT POSITION SENSOR 1607
DESCRIPTION 1607
OPERATION 1607
REMOVAL 1608
INSTALLATION 1608
FUEL INJECTOR 1609
DESCRIPTION 1609
FUEL INJECTOR 1609
OPERATION 1609
Injector closed (with high pressure applied) 1609
Injector opens (start of injection) 1610
Injector opens fully 1610
Injector closes (end of injection) 1610
STANDARD PROCEDURE 1610
STANDARD PROCEDURE – CLEANING FUEL INJECTORS 1610
STANDARD PROCEDURE – INJECTOR CLASSIFICATION 1610
INJECTOR CLASSIFICATION PROCEDURE 1611
REMOVAL 1611
INSTALLATION 1612
FUEL PRESSURE SENSOR 1613
DESCRIPTION 1613
OPERATION 1613
REMOVAL 1613
INSTALLATION 1613
FUEL PRESSURE SOLENOID 1613
DESCRIPTION 1613
OPERATION 1613
REMOVAL 1614
INSTALLATION 1615
FUEL TEMPERATURE SENSOR 1616
DESCRIPTION 1616
OPERATION 1616
REMOVAL 1616
INSTALLATION 1616
INTAKE AIR TEMPERATURE SENSOR 1617
DESCRIPTION 1617
OPERATION 1617
REMOVAL 1617
INSTALLATION 1617
MASS AIR FLOW SENSOR 1617
DESCRIPTION 1617
OPERATION 1618
REMOVAL 1618
INSTALLATION 1618
19-STEERING 1620
STEERING 1620
DESCRIPTION 1620
OPERATION 1620
DIAGNOSIS AND TESTING 1621
DIAGNOSIS AND TESTING – POWER STEERING SYSTEM 1621
DIAGNOSIS AND TESTING – POWER STEERING FLOW AND PRESSURE 1623
FLOW AND PRESSURE TEST 1623
COLUMN 1624
COLUMN 1624
DESCRIPTION 1624
OPERATION – SERVICE PRECAUTIONS 1624
REMOVAL 1625
INSTALLATION 1626
SPECIFICATIONS 1628
TORQUE CHART 1628
SPECIAL TOOLS 1628
STEERING COLUMN 1628
IGNITION SWITCH 1628
DESCRIPTION 1628
DIAGNOSIS AND TESTING – IGNITION SWITCH 1628
ELECTRICAL DIAGNOSIS 1628
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE) 1628
REMOVAL – IGNITION SWITCH 1629
INSTALLATION 1629
IGNITION SWITCH INSTALLATION 1629
KEY-IN IGNITION SWITCH 1630
DESCRIPTION 1630
DIAGNOSIS AND TESTING – KEY-IN IGNITION SWITCH 1630
KEY CYLINDER 1630
REMOVAL 1630
INSTALLATION 1631
INTERMEDIATE SHAFT 1631
REMOVAL 1631
INSTALLATION 1632
STEERING WHEEL 1633
REMOVAL 1633
INSTALLATION 1633
GEAR 1634
GEAR 1634
DESCRIPTION 1634
OPERATION 1634
REMOVAL 1634
4WD 1634
2WD 1635
DIESEL 1636
REMOVAL – RHD – 4X2 & 4X4 1637
INSTALLATION 1637
4WD 1637
2WD 1638
DIESEL 1639
INSTALLATION – RHD – 4X2 & 4X4 1640
SPECIFICATIONS 1641
TORQUE CHART 1641
SPECIAL TOOLS 1641
OUTER TIE ROD END REMOVAL TOOL 1641
LINKAGE 1642
LINKAGE 1642
STANDARD PROCEDURE – STEERING LINKAGE 1642
TIE ROD END 1642
REMOVAL 1642
INSTALLATION 1642
PUMP 1643
PUMP 1644
DESCRIPTION 1644
DESCRIPTION 1644
DESCRIPTION 1644
OPERATION 1644
STANDARD PROCEDURE 1644
POWER STEERING PUMP – INITIAL OPERATION – GAS ENGINE 1644
POWER STEERING PUMP – INITIAL OPERATION – DIESEL ENGINE 1645
PRE AIR EVACUATION PROCEDURE 1645
AIR EVACUATION AND FILL PROCEDURE 1645
REMOVAL 1646
2 8L- DIESEL 1646
3 7L 1646
2 4L 1647
INSTALLATION 1647
2 8L–DIESEL 1647
3 7L 1647
2 4L 1648
SPECIFICATIONS 1648
TORQUE CHART 1648
SPECIAL TOOLS 1649
POWER STEERING PUMP 1649
FLUID 1649
DESCRIPTION 1649
STANDARD PROCEDURE – POWER STEERING FLUID LEVEL CHECKING 1649
FLUID COOLER 1650
DESCRIPTION 1650
OPERATION 1650
REMOVAL 1650
INSTALLATION 1651
HOSES 1651
REMOVAL 1651
PRESSURE HOSE 1651
RETURN HOSE (GEAR TO THE COOLER) 1651
RETURN HOSE (RESERVOIR TO THE COOLER) 1652
PRESSURE / RETURN HOSE ASSEMBLY – DIESEL 1652
INSTALLATION 1654
PRESSURE HOSE 1654
RETURN HOSE (GEAR TO THE COOLER) 1654
RETURN HOSE (RESERVOIR TO THE COOLER) 1655
PRESSURE / RETURN HOSE ASSEMBLY – DIESEL 1655
POWER STEERING PRESSURE SWITCH 1657
DESCRIPTION 1657
OPERATION 1657
REMOVAL 1657
INSTALLATION 1657
PULLEY 1658
REMOVAL 1658
DIESEL 1658
GAS 1658
INSTALLATION 1659
DIESEL 1659
GAS 1659
RESERVOIR 1659
REMOVAL 1659
DIESEL 1659
3 7L 1660
2 4L 1660
INSTALLATION 1660
DIESEL 1660
3 7L 1660
2 4L 1661
21-TRANSMISSION AND TRANSFER CASE 1662
MANUAL TRANSMISSION – NSG370 1662
MANUAL TRANSMISSION – NSG370 1662
DIAGNOSIS AND TESTING 1662
MANUAL TRANSMISSION – NSG370 1662
LOW LUBRICANT LEVEL 1662
HARD SHIFTING 1662
TRANSMISSION NOISE 1662
STANDARD PROCEDURE – DRAIN AND FILL 1663
REMOVAL 1663
DISASSEMBLY 1665
MAINSHAFT 1668
COUNTERSHAFT 1672
FRONT HOUSING 1672
INPUT SHAFT 1673
REAR HOUSING 1674
CLEANING 1676
INSPECTION 1676
ASSEMBLY 1678
MAINSHAFT 1678
REAR HOUSING 1684
INPUT SHAFT 1686
FRONT HOUSING 1687
FINAL ASSEMBLY 1688
INSTALLATION 1693
SPECIFICATIONS – NSG370 1696
SPECIAL TOOLS 1696
AUTOMATIC TRANSMISSION – 42RLE 1699
AUTOMATIC TRANSMISSION – 42RLE 1700
DESCRIPTION 1700
TRANSMISSION IDENTIFICATION 1702
OPERATION 1702
FIRST GEAR POWERFLOW 1703
SECOND GEAR POWERFLOW 1704
THIRD GEAR POWERFLOW 1705
FOURTH GEAR POWERFLOW 1706
REVERSE GEAR POWERFLOW 1707
DIAGNOSIS AND TESTING 1708
AUTOMATIC TRANSMISSION 1708
ROAD TEST 1708
HYDRAULIC PRESSURE TESTS 1709
TEST ONE – SELECTOR IN MANUAL 1 (1st Gear) 1710
TEST TWO – SELECTOR IN MANUAL 2 (Second Gear) 1710
TEST TWO A – SELECTOR IN DRIVE (OD ON – Fourth Gear) 1710
TEST THREE – SELECTOR IN DRIVE (OD OFF – Third and Second Gear) 1710
TEST FOUR – SELECTOR IN DRIVE (OD ON – Fourth Gear) 1710
TEST FIVE-SELECTOR IN DRIVE (OD ON – Fourth Gear, CC on) 1710
TEST SIX-SELECTOR IN REVERSE 1710
TEST RESULT INDICATIONS 1711
CLUTCH AIR PRESSURE TESTS 1712
2/4 CLUTCH 1712
OVERDRIVE CLUTCH 1712
REVERSE CLUTCH 1712
LOW/REVERSE CLUTCH 1712
UNDERDRIVE CLUTCH 1712
FLUID LEAKAGE 1712
FLUID LEAKAGE – TORQUE CONVERTER HOUSING AREA 1712
TORQUE CONVERTER LEAKAGE 1713
STANDARD PROCEDURE – ALUMINUM THREAD REPAIR0 – 10 KJ (Continued) 1713
REMOVAL 1713
DISASSEMBLY 1715
ASSEMBLY 1731
INSTALLATION 1747
SCHEMATICS AND DIAGRAMS – 42RLE TRANSMISSION 1750
SPECIFICATIONS 1763
42RLE AUTOMATIC TRANSMISSION 1763
SPECIAL TOOLS 1764
42RLE AUTOMATIC TRANSMISSION 1764
ACCUMULATOR 1768
DESCRIPTION 1768
OPERATION 1768
ADAPTER HOUSING SEAL 1768
REMOVAL 1768
INSTALLATION 1768
BEARINGS 1769
ADJUSTMENTS 1769
BEARING ADJUSTMENT PROCEDURES 1769
BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM 1769
DESCRIPTION 1769
OPERATION 1769
DIAGNOSIS AND TESTING – BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM 1769
DRIVING CLUTCHES 1769
DESCRIPTION 1769
OPERATION 1769
UNDERDRIVE CLUTCH 1770
OVERDRIVE CLUTCH 1770
REVERSE CLUTCH 1770
EXTENSION HOUSING SEAL 1770
REMOVAL 1770
INSTALLATION 1770
FLUID AND FILTER 1771
DIAGNOSIS AND TESTING 1771
DIAGNOSIS AND TESTING – CAUSES OF BURNT FLUID 1771
EFFECTS OF INCORRECT FLUID LEVEL 1771
FLUID CONTAMINATION 1771
STANDARD PROCEDURE 1771
FLUID LEVEL CHECK 1771
FLUID LEVEL CHECK USING SCAN TOOL 1771
FLUID/FILTER SERVICE 1772
STANDARD PROCEDURE – TRANSMISSION FILL 1773
GEARSHIFT CABLE 1773
DIAGNOSIS AND TESTING 1773
GEARSHIFT CABLE 1773
REMOVAL 1774
INSTALLATION 1775
ADJUSTMENTS – GEARSHIFT CABLE 1775
Gearshift Adjustment Procedure 1775
HOLDING CLUTCHES 1776
DESCRIPTION 1776
OPERATION 1776
2/4 CLUTCH 1777
LOW/REVERSE CLUTCH 1777
INPUT CLUTCH ASSEMBLY 1777
DISASSEMBLY 1777
ASSEMBLY 1784
INPUT SPEED SENSOR 1793
DESCRIPTION 1793
OPERATION 1793
REMOVAL 1794
INSTALLATION 1794
OIL PUMP 1794
DESCRIPTION 1794
OPERATION 1795
DISASSEMBLY 1795
ASSEMBLY 1796
OUTPUT SPEED SENSOR 1796
DESCRIPTION 1796
OPERATION 1796
REMOVAL 1796
INSTALLATION 1797
OVERDRIVE SWITCH 1797
DESCRIPTION 1797
OPERATION 1797
PARK INTERLOCK CABLE 1797
REMOVAL 1797
INSTALLATION 1798
ADJUSTMENTS – PARK-INTERLOCK CABLE 1798
PLANETARY GEARTRAIN 1799
DESCRIPTION 1799
OPERATION 1799
OIL PUMP SEAL 1799
REMOVAL 1799
INSTALLATION 1799
SHIFT MECHANISM 1800
DESCRIPTION 1800
OPERATION 1800
REMOVAL 1800
INSTALLATION 1801
SOLENOID 1801
DESCRIPTION 1801
OPERATION 1802
SOLENOID/PRESSURE SWITCH ASSY 1802
DESCRIPTION 1802
OPERATION 1802
SOLENOIDS 1802
PRESSURE SWITCHES 1803
REMOVAL 1803
INSTALLATION 1804
TORQUE CONVERTER 1804
DESCRIPTION 1804
IMPELLER 1805
TURBINE 1806
STATOR 1807
TORQUE CONVERTER CLUTCH (TCC) 1807
OPERATION 1808
TURBINE 1808
STATOR 1808
TORQUE CONVERTER CLUTCH (TCC) 1808
REMOVAL 1809
INSTALLATION 1809
TRANSMISSION CONTROL RELAY 1809
DESCRIPTION 1809
OPERATION 1810
TRANSMISSION RANGE SENSOR 1810
DESCRIPTION 1810
OPERATION 1810
REMOVAL 1811
INSTALLATION 1811
TRANSMISSION TEMPERATURE SENSOR 1812
DESCRIPTION 1812
OPERATION 1812
CALCULATED TEMPERATURE 1812
VALVE BODY 1812
DESCRIPTION 1812
OPERATION 1813
THERMAL VALVE 1813
REGULATOR VALVE 1814
SOLENOID SWITCH VALVE 1814
MANUAL VALVE 1815
CONVERTER CLUTCH SWITCH VALVE 1815
CONVERTER CLUTCH CONTROL VALVE 1816
T/C REGULATOR VALVE 1816
LOW/REVERSE SWITCH VALVE 1816
REMOVAL 1816
DISASSEMBLY 1818
ASSEMBLY 1823
INSTALLATION 1827
AUTOMATIC TRANSMISSION – 545RFE 1829
AUTOMATIC TRANSMISSION – 545RFE 1830
DESCRIPTION 1830
TRANSMISSION IDENTIFICATION 1831
GEAR RATIOS 1831
OPERATION 1831
DIAGNOSIS AND TESTING 1832
AUTOMATIC TRANSMISSION 1832
PRELIMINARY 1832
VEHICLE IS DRIVABLE 1832
VEHICLE IS DISABLED 1832
ROAD TESTING 1832
HYDRAULIC PRESSURE TEST 1833
Pressure Test Port Locations 1833
TEST PROCEDURE 1833
AIR CHECKING TRANSMISSION CLUTCH OPERATION 1834
CONVERTER HOUSING FLUID LEAK 1835
TORQUE CONVERTER LEAK POINTS 1835
STANDARD PROCEDURE – ALUMINUM THREAD REPAIR 1835
REMOVAL 1835
DISASSEMBLY 1838
CLEANING 1844
INSPECTION 1844
ASSEMBLY 1845
INSTALLATION 1852
SCHEMATICS AND DIAGRAMS 1855
HYDRAULIC SCHEMATICS 1855
SPECIFICATIONS 1876
TRANSMISSION 1876
SPECIAL TOOLS 1877
AUTOMATIC TRANSMISSION – RFE 1877
4C RETAINER/BULKHEAD 1880
DISASSEMBLY 1880
ASSEMBLY 1881
ADAPTER HOUSING SEAL 1883
REMOVAL 1883
INSTALLATION 1883
BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM 1883
DESCRIPTION 1883
OPERATION 1883
DIAGNOSIS AND TESTING – BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM 1884
FLUID AND FILTER 1884
DIAGNOSIS AND TESTING 1884
EFFECTS OF INCORRECT FLUID LEVEL 1884
CAUSES OF BURNT FLUID 1884
FLUID CONTAMINATION 1884
STANDARD PROCEDURE 1885
FLUID LEVEL CHECK 1885
FLUID AND FILTER REPLACEMENT 1885
REMOVAL 1885
INSPECTION 1885
CLEANING 1885
INSTALLATION 1886
TRANSMISSION FILL 1886
GEARSHIFT CABLE 1887
DIAGNOSIS AND TESTING 1887
GEARSHIFT CABLE 1887
REMOVAL 1887
INSTALLATION 1887
ADJUSTMENTS – GEARSHIFT CABLE 1889
Gearshift Adjustment Procedure 1889
HOLDING CLUTCHES 1889
DESCRIPTION 1889
OPERATION 1889
2C CLUTCH 1889
4C CLUTCH 1889
LOW/REVERSE CLUTCH 1890
INPUT CLUTCH ASSEMBLY 1891
DESCRIPTION 1891
OPERATION 1891
UNDERDRIVE CLUTCH 1891
OVERDRIVE CLUTCH 1892
REVERSE CLUTCH 1892
DISASSEMBLY 1893
ASSEMBLY 1896
INPUT SPEED SENSOR 1901
DESCRIPTION 1901
OPERATION 1901
REMOVAL 1902
INSTALLATION 1902
LINE PRESSURE (LP) SENSOR 1902
DESCRIPTION 1902
OPERATION 1903
REMOVAL 1903
INSTALLATION 1903
LOW/REVERSE CLUTCH 1904
DISASSEMBLY 1904
CLEANING 1905
INSPECTION 1905
ASSEMBLY 1905
OIL PUMP 1908
DESCRIPTION 1908
OPERATION 1908
CONVERTER CLUTCH SWITCH VALVE 1908
CONVERTER CLUTCH REGULATOR VALVE 1909
TORQUE CONVERTER LIMIT VALVE 1909
STANDARD PROCEDURE – OIL PUMP VOLUME CHECK 1909
DISASSEMBLY 1910
CLEANING 1912
INSPECTION 1912
ASSEMBLY 1912
OIL PUMP FRONT SEAL 1916
REMOVAL 1916
INSTALLATION 1916
OUTPUT SPEED SENSOR 1916
DESCRIPTION 1916
OPERATION 1916
REMOVAL 1916
INSTALLATION 1917
OVERDRIVE SWITCH 1917
DESCRIPTION 1917
OPERATION 1917
PARK INTERLOCK CABLE 1917
REMOVAL 1917
INSTALLATION 1917
ADJUSTMENTS – PARK-INTERLOCK CABLE 1918
PLANETARY GEARTRAIN 1919
DESCRIPTION 1919
OPERATION 1919
REACTION PLANETARY GEARTRAIN 1919
REVERSE PLANETARY GEARTRAIN 1919
INPUT PLANETARY GEARTRAIN 1922
DISASSEMBLY 1922
CLEANING 1922
INSPECTION 1922
ASSEMBLY 1922
SHIFT MECHANISM 1923
DESCRIPTION 1923
OPERATION 1923
REMOVAL 1924
INSTALLATION 1924
SOLENOID SWITCH VALVE 1925
DESCRIPTION 1925
OPERATION 1925
TORQUE CONVERTER 1925
DESCRIPTION 1925
IMPELLER 1926
TURBINE 1927
STATOR 1928
TORQUE CONVERTER CLUTCH (TCC) 1928
OPERATION 1929
TURBINE 1929
STATOR 1929
TORQUE CONVERTER CLUTCH (TCC) 1929
REMOVAL 1930
INSTALLATION 1930
TRANSMISSION CONTROL RELAY 1931
DESCRIPTION 1931
OPERATION 1931
TRANSMISSION RANGE SENSOR 1931
DESCRIPTION 1931
OPERATION 1931
TRANSMISSION SOLENOID/TRS ASSEMBLY 1932
DESCRIPTION 1932
OPERATION 1932
SOLENOIDS 1932
PRESSURE SWITCHES 1932
REMOVAL 1932
INSTALLATION 1933
TRANSMISSION TEMPERATURE SENSOR 1933
DESCRIPTION 1933
OPERATION 1933
Calculated Temperature 1933
VALVE BODY 1934
DESCRIPTION 1934
OPERATION 1935
SOLENOID SWITCH VALVE 1935
MANUAL VALVE 1935
LOW/REVERSE SWITCH VALVE 1935
REMOVAL 1935
DISASSEMBLY 1936
CLEANING 1938
INSPECTION 1938
ASSEMBLY 1940
INSTALLATION 1942
TRANSFER CASE – NV231 1943
TRANSFER CASE – NV231 1943
DESCRIPTION 1943
OPERATING RANGES 1943
SHIFT MECHANISM 1943
IDENTIFICATION 1944
OPERATION 1944
DIAGNOSIS AND TESTING – TRANSFER CASE – NV231 1944
REMOVAL 1945
DISASSEMBLY 1946
REAR RETAINER AND OIL PUMP 1946
COMPANION FLANGE AND RANGE LEVER 1948
FRONT OUTPUT SHAFT AND DRIVE CHAIN 1949
SHIFT FORKS AND MAINSHAFT 1950
MAINSHAFT 1951
INPUT GEAR AND LOW RANGE GEAR 1952
INPUT AND LOW RANGE GEAR 1953
CLEANING 1954
INSPECTION 1954
MAINSHAFT/SPROCKET/HUB 1954
INPUT GEAR AND PLANETARY CARRIER 1954
SHIFT FORKS/HUBS/SLEEVES 1956
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT 1956
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN 1956
LOW RANGE ANNULUS GEAR 1956
FRONT/REAR CASES AND FRONT RETAINER 1956
OIL PUMP/OIL PICKUP 1957
ASSEMBLY 1958
BEARINGS AND SEALS 1958
INPUT AND LOW RANGE GEAR 1962
MAINSHAFT 1963
SHIFT FORKS, SECTOR, AND MAINSHAFT 1963
FRONT OUTPUT SHAFT AND DRIVE CHAIN 1965
OIL PUMP AND REAR CASE 1966
COMPANION FLANGE AND RANGE LEVER 1967
REAR RETAINER 1967
INSTALLATION 1968
SPECIFICATIONS 1968
TRANSFER CASE – NV231 1968
SPECIAL TOOLS 1969
TRANSFER CASE – NV231 1969
FLUID 1971
STANDARD PROCEDURE – FLUID DRAIN AND FILL 1971
FRONT OUTPUT SHAFT SEAL 1971
REMOVAL 1971
INSTALLATION 1971
POSITION SENSOR 1971
DESCRIPTION 1971
OPERATION 1972
REMOVAL 1972
INSTALLATION 1973
REAR OUTPUT SHAFT SEAL 1973
REMOVAL 1973
INSTALLATION 1974
SHIFT LEVER 1975
REMOVAL 1975
INSTALLATION 1975
TRANSFER CASE – NV241 GENII 1976
TRANSFER CASE – NV241 GENII 1976
DESCRIPTION 1976
IDENTIFICATION 1976
OPERATION 1976
OPERATING RANGE 1976
SHIFT MECHANISM 1977
SHIFTING 1977
DIAGNOSIS AND TESTING – TRANSFER CASE – NV241 GENII 1977
REMOVAL 1979
DISASSEMBLY 1980
COMPANION FLANGE AND RANGE LEVER 1980
REAR EXTENSION 1981
OIL PUMP AND REAR CASE 1981
FRONT OUTPUT SHAFT AND DRIVE CHAIN 1982
SHIFT FORKS AND MAINSHAFT 1983
MAINSHAFT 1985
INPUT AND PLANETARY GEAR 1986
INPUT AND PLANETARY GEAR 1987
CLEANING 1988
INSPECTION 1988
MAINSHAFT/SPROCKET/HUB 1988
INPUT GEAR AND PLANETARY CARRIER 1988
SHIFT FORKS/HUBS/SLEEVES 1988
REAR RETAINER COMPONENTS 1988
DRIVE CHAIN 1988
LOW RANGE ANNULUS GEAR 1990
FRONT CASE AND REAR CASE 1990
OIL PUMP/OIL PICKUP 1990
ASSEMBLY 1990
BEARINGS AND SEALS 1990
INPUT AND PLANETARY GEAR 1992
SHIFT FORKS AND MAINSHAFT 1993
FRONT OUTPUT SHAFT AND DRIVE CHAIN 1996
OIL PUMP AND REAR CASE 1998
REAR EXTENSION 1999
COMPANION FLANGE AND RANGE LEVER 1999
INSTALLATION 2000
SPECIFICATIONS 2001
TRANSFER CASE – NV241 GENII 2001
SPECIAL TOOLS 2002
TRANSFER CASE – NV241 GENII 2002
EXTENSION HOUSING SEAL0 – 12 KJ (Continued) 2004
REMOVAL 2004
INSTALLATION 2004
FLUID 2004
STANDARD PROCEDURE – FLUID DRAIN AND FILL 2004
FRONT OUTPUT SHAFT SEAL 2004
REMOVAL 2004
INSTALLATION 2005
POSITION SENSOR 2005
DESCRIPTION 2005
OPERATION 2005
REMOVAL 2006
INSTALLATION 2006
SHIFT LEVER 2006
REMOVAL 2006
INSTALLATION 2007
TRANSFER CASE – NV242 2008
TRANSFER CASE – NV242 2008
DESCRIPTION 2008
TRANSFER CASE IDENTIFICATION 2008
OPERATING RANGES 2008
SHIFT MECHANISM 2008
OPERATION 2009
DIAGNOSIS AND TESTING – TRANSFER CASE – NV242 2009
REMOVAL 2010
DISASSEMBLY 2011
REAR RETAINER 2011
COMPANION FLANGE AND RANGE LEVER 2013
FRONT OUTPUT SHAFT AND DRIVE CHAIN 2014
SHIFT FORKS AND MAINSHAFT 2015
INPUT GEAR/LOW RANGE ASSEMBLY 2018
DIFFERENTIAL 2019
CLEANING 2020
INSPECTION 2020
MAINSHAFT/SPROCKET/HUB 2020
INPUT GEAR AND PLANETARY CARRIER 2021
SHIFT FORKS/HUBS/SLEEVES 2021
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT 2021
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN 2022
LOW RANGE ANNULUS GEAR 2023
FRONT-REAR CASES AND FRONT RETAINER 2023
OIL PUMP/OIL PICKUP 2023
ASSEMBLY 2023
BEARINGS AND SEALS 2023
DIFFERENTIAL 2026
INPUT GEAR/LOW RANGE ASSEMBLY 2027
SHIFT FORKS, SECTOR, AND MAINSHAFT 2029
FRONT OUTPUT SHAFT AND DRIVE CHAIN 2033
OIL PUMP AND REAR CASE 2033
REAR RETAINER 2034
COMPANION FLANGE AND RANGE LEVER 2036
INSTALLATION 2036
SPECIFICATIONS 2037
NV242 TRANSFER CASE 2037
SPECIAL TOOLS 2037
TRANSFER CASE – NV242 2037
FLUID 2040
STANDARD PROCEDURE – FLUID DRAIN AND FILL 2040
FRONT OUTPUT SHAFT SEAL 2040
REMOVAL 2040
INSTALLATION 2040
POSITION SENSOR 2040
DESCRIPTION 2040
OPERATION 2041
REMOVAL 2042
INSTALLATION 2042
REAR OUTPUT SHAFT SEAL 2042
REMOVAL 2042
INSTALLATION 2043
SHIFT LEVER 2043
REMOVAL 2043
INSTALLATION 2044
22-TIRES/WHEELS 2046
TIRES/WHEELS 2046
DIAGNOSIS AND TESTING 2046
TIRE AND WHEEL RUNOUT 2046
METHOD 1 (RELOCATE WHEEL ON HUB) 2047
METHOD 2 (RELOCATE TIRE ON WHEEL) 2047
STANDARD PROCEDURE 2047
TIRE ROTATION 2047
MATCH MOUNTING 2048
WHEEL BALANCING 2049
TIRES 2051
DESCRIPTION 2051
TIRES 2051
TIRE IDENTIFICATION 2051
TIRE CHAINS 2051
RADIAL-PLY TIRES 2051
TIRE PRESSURE FOR HIGH SPEED 2051
SPARE / TEMPORARY TIRE 2052
FULL SIZE, SPARE WHEEL WITH MATCHING TIRE 2052
REPLACEMENT TIRES 2052
DIAGNOSIS AND TESTING 2052
PRESSURE GAUGES 2052
TIRE INFLATION 2052
TREAD WEAR INDICATORS 2053
TIRE WEAR PATTERNS 2053
TIRE NOISE OR VIBRATION 2053
TIRE/VEHICLE LEAD 2053
STANDARD PROCEDURE 2055
TIRE REPAIR AREA 2055
CLEANING 2055
TIRES 2055
SPECIFICATIONS 2055
TIRE SIZE CHART 2055
SPARE TIRE CARRIER 2055
REMOVAL 2055
INSTALLATION 2055
WHEELS 2055
DESCRIPTION 2055
WHEEL DESIGN 2055
DIAGNOSIS AND TESTING 2056
WHEEL INSPECTION 2056
STANDARD PROCEDURE 2056
WHEEL INSTALLATION 2056
WHEEL REPLACEMENT 2056
SPECIFICATIONS 2057
STUDS 2057
REMOVAL 2057
INSTALLATION 2057
TIRE PRESSURE MONITORING SYSTEM 2058
DESCRIPTION 2058
BASE TIRE PRESSURE MONITORING 2058
PREMIUM TIRE PRESSURE MONITORING 2058
WIRELESS CONTROL MODULE (WCM) 2058
OPERATION 2058
BASE TIRE PRESSURE MONITORING 2058
PREMIUM TIRE PRESSURE MONITORING 2059
DIAGNOSIS AND TESTING – TIRE PRESSURE MONITORING SYSTEM 2059
SPECIFICATIONS 2059
TORQUE CHART 2059
SENSOR 2060
DESCRIPTION 2060
OPERATION 2061
CAUTION 2061
DIAGNOSIS AND TESTING 2061
TIRE PRESSURE SENSOR 2061
REMOVAL 2062
INSTALLATION 2063
TRANSPONDER 2065
DESCRIPTION 2065
OPERATION 2065
REMOVAL 2065
FRONT TRANSPONDER 2065
REAR TRANSPONDER 2065
INSTALLATION 2066
FRONT TRANSPONDER 2066
REAR TRANSPONDER 2066
23-BODY 2068
BODY 2068
WARNING 2068
SAFETY PRECAUTIONS AND WARNINGS 2068
DIAGNOSIS AND TESTING 2068
WATER LEAKS 2068
VISUAL INSPECTION BEFORE WATER LEAK TESTS 2069
WATER LEAK TESTS 2069
WATER LEAK DETECTION 2069
WIND NOISE 2069
VISUAL INSPECTION BEFORE TESTS 2069
STANDARD PROCEDURE 2070
STANDARD PROCEDURE – BODY LUBRICATION 2070
HEAT STAKING 2070
STANDARD PROCEDURE – PLASTIC BODY PANEL REPAIR 2070
Rigid Plastics: 2071
Semi-Rigid Plastics: 2071
Flexible Plastics: 2071
Repair Procedure: 2071
Adhesion Promoter/Surface Modifier: 2071
SAFETY PRECAUTION AND WARNINGS 2071
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES 2071
PANEL SECTIONING 2073
PANEL REINFORCEMENT 2074
VISUAL INSPECTION 2074
PANEL SURFACE PREPARATION 2075
PATCHING PANELS 2075
PANEL PATCH FABRICATIONS 2075
PANEL PATCH INSTALLATION 2076
PATCHED PANEL SURFACING 2078
BUZZ, SQUEAK & RATTLE 2078
SPECIFICATIONS 2080
SPECIAL TOOLS 2081
BODY 2081
HOOD 2082
HINGE 2082
REMOVAL 2082
INSTALLATION 2082
HOOD 2082
REMOVAL 2082
INSTALLATION 2082
ADJUSTMENTS 2082
ADJUSTMENT 2082
LATCH 2082
REMOVAL 2082
INSTALLATION 2083
LATCH RELEASE CABLE 2083
REMOVAL 2083
INSTALLATION 2083
SUPPORT CYLINDER 2083
REMOVAL 2083
INSTALLATION 2084
LATCH RELEASE HANDLE 2084
REMOVAL 2084
INSTALLATION 2084
DOOR – FRONT 2085
CHECK STRAP 2085
REMOVAL 2085
INSTALLATION 2085
DOOR 2086
REMOVAL 2086
INSTALLATION 2086
ADJUSTMENTS 2086
ADJUSTMENT 2086
FORE/AFT 2086
UP/DOWN 2086
IN/OUT 2087
DOOR GLASS 2087
REMOVAL 2087
INSTALLATION 2087
EXTERIOR HANDLE 2087
REMOVAL 2087
INSTALLATION 2088
GLASS RUN CHANNEL 2088
REMOVAL 2088
INSTALLATION 2088
HINGE 2088
REMOVAL 2088
INSTALLATION 2088
LATCH 2088
REMOVAL 2088
INSTALLATION 2089
LATCH STRIKER 2089
REMOVAL 2089
INSTALLATION 2089
LOCK CYLINDER 2089
REMOVAL 2089
INSTALLATION 2089
TRIM PANEL 2090
REMOVAL 2090
INSTALLATION 2090
WATERDAM 2090
REMOVAL 2090
INSTALLATION 2091
WINDOW REGULATOR – MANUAL 2091
REMOVAL 2091
INSTALLATION 2092
WINDOW REGULATOR – POWER 2092
REMOVAL 2092
INSTALLATION 2093
DOORS – REAR 2094
CHECK STRAP 2094
REMOVAL 2094
INSTALLATION 2094
DOOR 2095
REMOVAL 2095
INSTALLATION 2095
ADJUSTMENTS 2095
ADJUSTMENT 2095
FORE/AFT 2095
UP/DOWN 2095
IN/OUT 2096
DOOR GLASS 2096
REMOVAL 2096
INSTALLATION 2096
EXTERIOR HANDLE 2097
REMOVAL 2097
INSTALLATION 2097
GLASS RUN CHANNEL 2097
REMOVAL 2097
INSTALLATION 2098
HINGE 2098
REMOVAL 2098
INSTALLATION 2098
LATCH 2098
REMOVAL 2098
INSTALLATION 2098
ADJUSTMENTS 2099
ADJUSTMENT 2099
LATCH STRIKER 2099
REMOVAL 2099
INSTALLATION 2099
TRIM PANEL 2099
REMOVAL 2099
INSTALLATION 2100
WATERDAM 2100
REMOVAL 2100
INSTALLATION 2100
WINDOW REGULATOR – MANUAL 2100
REMOVAL 2100
INSTALLATION 2101
WINDOW REGULATOR – POWER 2101
REMOVAL 2101
INSTALLATION 2102
SWING GATE 2103
FLIP-UP GLASS 2103
REMOVAL 2103
INSTALLATION 2103
ADJUSTMENTS 2103
ADJUSTMENT 2103
FLIP-UP GLASS LATCH 2104
REMOVAL 2104
INSTALLATION 2104
FLIP-UP GLASS – HINGE 2104
REMOVAL 2104
INSTALLATION 2105
FLIP-UP GLASS – HINGE COVER 2105
REMOVAL 2105
INSTALLATION 2105
FLIP-UP GLASS SUPPORT CYLINDER 2106
REMOVAL 2106
INSTALLATION 2106
TRIM PANEL 2107
REMOVAL 2107
INSTALLATION 2107
LATCH 2107
REMOVAL 2107
INSTALLATION 2107
LATCH STRIKER 2108
REMOVAL 2108
INSTALLATION 2108
ADJUSTMENTS 2108
ADJUSTMENT 2108
LATCH – ACCESS PANEL 2108
DESCRIPTION 2108
REMOVAL 2108
INSTALLATION 2108
EXTERIOR HANDLE 2108
REMOVAL 2108
INSTALLATION 2108
LOCK CYLINDER 2109
REMOVAL 2109
INSTALLATION 2109
CHECK STRAP 2109
REMOVAL 2109
INSTALLATION 2109
STABILIZER WEDGE/INSERT 2110
REMOVAL 2110
INSTALLATION 2110
ADJUSTMENTS 2111
ADJUSTMENT 2111
HINGE0 – 14 KJ (Continued) 2111
REMOVAL 2111
INSTALLATION 2111
SWING GATE 2112
REMOVAL 2112
INSTALLATION 2112
ADJUSTMENTS 2112
ADJUSTMENT 2112
IN/OUT 2112
UP/DOWN 2113
LEFT/RIGHT 2113
EXTERIOR 2114
BODY SIDE MOLDINGS 2114
REMOVAL 2114
INSTALLATION 2114
COWL GRILLE 2114
REMOVAL 2114
INSTALLATION 2114
EXTERIOR NAME PLATES 2115
REMOVAL 2115
INSTALLATION 2115
FRONT FENDER 2115
REMOVAL 2115
INSTALLATION 2115
FUEL FILL DOOR/HOUSING 2116
REMOVAL 2116
INSTALLATION 2116
GRILLE 2116
REMOVAL 2116
INSTALLATION 2117
GRILLE OPENING REINFORCEMENT 2117
REMOVAL 2117
INSTALLATION 2117
FRONT WHEELHOUSE SPLASH SHIELD 2118
REMOVAL 2118
INSTALLATION 2118
LUGGAGE RACK 2119
REMOVAL 2119
INSTALLATION 2119
REAR WHEELHOUSE SPLASH SHIELD 2119
REMOVAL 2119
INSTALLATION 2119
FRONT WHEEL OPENING FLARE MOLDINGS 2120
REMOVAL 2120
INSTALLATION 2120
REAR WHEEL OPENING FLARE MOLDINGS 2120
REMOVAL 2120
INSTALLATION 2120
RADIATOR CROSSMEMBER 2121
REMOVAL 2121
INSTALLATION 2121
SIDE VIEW MIRROR 2121
REMOVAL 2121
INSTALLATION 2121
GLASS-OUTSIDE REARVIEW MIRROR 2121
REMOVAL 2121
INSTALLATION 2122
SIDE STEP 2122
REMOVAL 2122
INSTALLATION 2122
ROCK RAIL 2122
REMOVAL 2122
INSTALLATION 2123
MOLDING – SILL 2123
REMOVAL 2123
Front Sill Molding 2123
Rear Sill Molding 2124
INSTALLATION 2124
Rear Sill Molding 2124
Front Sill Molding 2124
INSTRUMENT PANEL 2126
CLUSTER BEZEL 2126
REMOVAL 2126
INSTALLATION 2126
GLOVE BOX 2127
REMOVAL 2127
INSTALLATION 2127
GLOVE BOX LATCH 2127
REMOVAL 2127
INSTALLATION 2127
GLOVE BOX LATCH STRIKER 2127
REMOVAL 2127
INSTALLATION 2128
INSTRUMENT PANEL ASSEMBLY 2128
REMOVAL 2128
INSTALLATION 2131
INSTRUMENT PANEL TOP COVER 2132
REMOVAL 2132
INSTALLATION 2133
INSTRUMENT PANEL END CAP 2133
REMOVAL 2133
INSTALLATION 2133
INSTRUMENT PANEL DRIVER SIDE BEZELS 2133
REMOVAL 2133
INSTALLATION 2134
INSTRUMENT PANEL CENTER BEZEL 2134
REMOVAL 2134
INSTALLATION 2134
INSTRUMENT PANEL PASSENGER SIDE BEZEL 2134
REMOVAL 2134
On vehicles equipped with a grab handle: 2135
On vehicles without a grab handle: 2135
INSTALLATION 2135
On vehicles without a grab handle: 2135
On vehicles equipped with a grab handle: 2135
KNEE BLOCKER 2135
REMOVAL 2135
INSTALLATION 2136
INTERIOR 2137
4WD FLOOR SHIFT BOOT 2137
REMOVAL 2137
INSTALLATION 2137
A-PILLAR TRIM AND GRAB HANDLE 2137
REMOVAL 2137
INSTALLATION 2137
COWL TRIM COVER 2138
REMOVAL 2138
INSTALLATION 2138
DOOR SILL SCUFF PLATE 2138
REMOVAL 2138
INSTALLATION 2138
ASSIST HANDLE 2138
REMOVAL 2138
INSTALLATION 2138
B-PILLAR LOWER TRIM 2138
REMOVAL 2138
INSTALLATION 2138
B-PILLAR UPPER TRIM 2138
REMOVAL 2138
INSTALLATION 2139
CARPETS AND FLOOR MATS 2139
REMOVAL 2139
Front Carpet 2139
Rear Cargo Carpet 2139
INSTALLATION 2139
Front Carpet 2139
Rear Cargo Carpet 2139
SHIFT BEZEL 2139
REMOVAL 2139
INSTALLATION 2139
FLOOR CONSOLE 2139
REMOVAL 2139
INSTALLATION 2139
FLOOR CONSOLE LID LATCH 2140
REMOVAL 2140
INSTALLATION 2140
HEADLINER 2140
REMOVAL 2140
INSTALLATION 2140
QUARTER TRIM PANEL 2140
REMOVAL 2140
INSTALLATION 2141
REAR DOOR SCUFF PLATE 2141
REMOVAL 2141
INSTALLATION 2141
SUN VISOR 2141
REMOVAL 2141
INSTALLATION 2141
SUN VISOR SUPPORT 2141
REMOVAL 2141
INSTALLATION 2141
REAR VIEW MIRROR 2142
REMOVAL 2142
INSTALLATION 2142
INSTALLATION 2142
INSTALLATION – REAR VIEW MIRROR SUPPORT BRACKET 2142
PAINT 2143
PAINT 2143
SPECIFICATIONS – PAINT CODES 2143
PAINT CODE 2143
DESCRIPTION 2143
BASE COAT/CLEAR COAT FINISH 2144
DESCRIPTION 2144
PAINT TOUCH-UP 2144
DESCRIPTION 2144
OPERATION 2144
FINESSE SANDING/BUFFING & POLISHING 2144
DESCRIPTION 2144
SEATS 2145
HEADREST 2145
REMOVAL 2145
INSTALLATION 2145
HEADREST SLEEVE 2145
REMOVAL 2145
INSTALLATION 2145
SEAT – FRONT 2146
REMOVAL 2146
INSTALLATION 2146
SEAT BACK – FRONT 2148
REMOVAL 2148
INSTALLATION 2149
SEAT BACK RECLINER – FRONT 2149
REMOVAL 2149
INSTALLATION 2150
SEAT BACK COVER – FRONT 2150
REMOVAL 2150
INSTALLATION 2151
SEAT BACK CUSHION – FRONT 2152
REMOVAL 2152
INSTALLATION 2152
SEAT CUSHION – FRONT 2153
REMOVAL 2153
INSTALLATION 2154
SEAT CUSHION COVER – FRONT 2155
REMOVAL 2155
INSTALLATION 2156
MANUAL SEAT RISER 2157
REMOVAL 2157
INSTALLATION 2158
SEAT TRACK 2158
REMOVAL 2158
INSTALLATION 2159
SEAT – REAR 2159
REMOVAL 2159
INSTALLATION 2160
SEAT BACK – REAR 2160
REMOVAL 2160
60/40 Split Seat – Left 2160
60/40 Split Seat – Right 2160
INSTALLATION 2161
60/40 Split Seat – Left 2161
60/40 Split Seat – Right 2161
SEAT BACK COVER – REAR 2162
REMOVAL 2162
INSTALLATION 2162
SEAT BACK CUSHION – REAR 2162
REMOVAL 2162
INSTALLATION 2162
FOLDING REAR SEAT BACK LATCH / LOCK 2162
REMOVAL 2162
INSTALLATION 2162
REAR SEAT BACK LATCH STRIKER 2163
REMOVAL 2163
INSTALLATION 2163
SEAT BACK FRAME – REAR 2163
REMOVAL 2163
INSTALLATION 2163
SEAT CUSHION – REAR 2163
REMOVAL 2163
INSTALLATION 2163
STATIONARY GLASS 2164
DOOR GLASS 2164
REMOVAL 2164
INSTALLATION 2164
QUARTER WINDOW 2164
REMOVAL 2164
INSTALLATION 2164
WINDSHIELD 2165
WARNING 2165
WINDSHIELD SAFETY PRECAUTIONS 2165
REMOVAL 2165
INSTALLATION 2165
SUNROOF 2167
SUNROOF 2167
DESCRIPTION 2167
SUNROOF OPERATION INSTRUCTIONS 2168
DIAGNOSIS AND TESTING 2168
WATER DRAINAGE AND WIND NOISE DIAGNOSIS 2168
DIAGNOSTIC PROCEDURES 2168
GLASS PANEL 2170
REMOVAL 2170
INSTALLATION 2170
ADJUSTMENTS 2170
SUNROOF GLASS PANEL ADJUSTMENT 2170
GLASS PANEL SEAL 2170
REMOVAL 2170
INSTALLATION 2171
SUNSHADE 2171
REMOVAL 2171
INSTALLATION 2171
TROUGH 2171
REMOVAL 2171
INSTALLATION 2171
TROUGH GUIDE ASSEMBLY 2171
REMOVAL 2171
INSTALLATION 2172
WIND DEFLECTOR 2172
REMOVAL 2172
INSTALLATION 2172
OPENING TRIM LACE 2172
REMOVAL 2172
INSTALLATION 2172
DRAIN TUBE 2172
REMOVAL 2172
FRONT DRAIN TUBES 2172
REAR DRAIN TUBES 2173
INSTALLATION 2173
FRONT DRAIN TUBES 2173
REAR DRAIN TUBES 2173
MODULE/FRAME ASSEMBLY 2173
REMOVAL 2173
INSTALLATION 2174
WIRE HARNESS 2175
REMOVAL 2175
INSTALLATION 2175
DRIVE MOTOR 2175
STANDARD PROCEDURE 2175
DRIVE MOTOR TEACH PROCEDURE 2175
REPLACEMENT DRIVE MOTOR 2175
ORIGINAL DRIVE MOTOR 2175
REMOVAL 2176
INSTALLATION 2176
CONTROL SWITCH 2176
DESCRIPTION 2176
OPERATION 2176
DIAGNOSIS AND TESTING – CONTROL SWITCH 2177
REMOVAL 2177
INSTALLATION 2177
WEATHERSTRIP/SEALS 2178
A-PILLAR SEAL 2178
REMOVAL 2178
INSTALLATION 2178
COWL WEATHERSTRIP 2178
REMOVAL 2178
INSTALLATION 2178
DOOR PRIMARY WEATHERSTRIP 2178
REMOVAL 2178
INSTALLATION 2178
DOOR LOWER WEATHERSTRIP 2179
REMOVAL 2179
INSTALLATION 2179
FRONT DOOR OUTER BELT MOLDING 2179
REMOVAL 2179
INSTALLATION 2179
SWING GATE BELTLINE WEATHERSTRIP 2179
REMOVAL 2179
INSTALLATION 2179
SWING GATE OPENING WEATHERSTRIP 2179
REMOVAL 2179
INSTALLATION 2180
REAR DOOR OUTER BELT MOLDING 2180
REMOVAL 2180
INSTALLATION 2180
SIDE RAIL WEATHERSTRIP/RETAINER 2180
REMOVAL 2180
INSTALLATION 2181
WINDSHIELD A-PILLAR WEATHERSTRIP/RETAINER 2181
REMOVAL 2181
INSTALLATION 2181
COWL/PLENUM SEAL0 – 16 KJ (Continued) 2181
REMOVAL 2181
INSTALLATION 2181
COWL/PLENUM WINDOW BAFFLE SEAL 2181
REMOVAL 2181
INSTALLATION 2181
AIR INLET SEAL 2181
REMOVAL 2181
INSTALLATION 2181
FRONT DOOR INNER BELT WEATHERSTRIP 2181
REMOVAL 2181
INSTALLATION 2181
REAR DOOR INNER BELT WEATHERSTRIP 2181
REMOVAL 2181
INSTALLATION 2181
BODY STRUCTURE 2182
ASSEMBLY 2182
SPECIFICATIONS 2182
SPECIFICATION 2182
WELD AND STRUCTURAL ADHESIVE LOCATIONS 2185
SPECIFICATIONS 2185
FRONT END ASSEMBLY 2189
FRONT END ASSEMBLY/UNDERBODY 2206
REAR FRAME RAILS 2211
REAR FLOOR PAN ASSEMBLY 2217
FULL FLOOR PAN ASSEMBLY 2224
BODY SIDE PANELS AND SUB ASSEMBLIES 2230
BODY SIDE PANELS 2237
FENDER ASSEMBLIES 2249
ROOF PANEL ASSEMBLIES 2253
BODY SIDE PANELS & FLOOR PAN ASSEMBLIES 2257
SEALER LOCATIONS 2263
SPECIFICATIONS 2263
OPENING DIMENSIONS 2287
SPECIFICATIONS 2287
GAP AND FLUSH 2292
SPECIFICATIONS 2292
24-HEATING & AIR CONDITIONING 2296
HEATING & AIR CONDITIONING 2296
DESCRIPTION 2296
OPERATION 2297
DIAGNOSIS AND TESTING 2298
A/C PERFORMANCE 2298
PERFORMANCE TEST PROCEDURE 2298
HEATER PERFORMANCE 2302
SPECIFICATIONS 2303
HEATING-A/C SYSTEM 2303
CONTROLS 2305
A/C COMPRESSOR CLUTCH 2306
DESCRIPTION 2306
OPERATION 2306
DIAGNOSIS AND TESTING 2306
A/C COMPRESSOR CLUTCH COIL 2306
STANDARD PROCEDURE 2307
DIODE REPLACEMENT 2307
A/C CLUTCH INSPECTION 2307
A/C CLUTCH BREAK-IN 2308
REMOVAL 2308
INSTALLATION 2309
A/C CLUTCH RELAY 2311
DESCRIPTION 2311
OPERATION 2311
REMOVAL 2312
INSTALLATION 2312
A/C HEATER CONTROL 2312
DESCRIPTION 2312
DIAGNOSIS AND TESTING 2313
VACUUM CONTROL SYSTEM 2313
VACUUM CHECK VALVE 2313
A/C HEATER CONTROLS 2313
LOCATING VACUUM LEAKS 2314
STANDARD PROCEDURE 2316
A/C-HEATER CONTROL CALIBRATION 2316
REMOVAL 2316
INSTALLATION 2317
A/C HIGH PRESSURE SWITCH 2317
DESCRIPTION 2317
OPERATION 2317
DIAGNOSIS AND TESTING 2317
A/C HIGH PRESSURE SWITCH 2317
REMOVAL 2318
INSTALLATION 2318
A/C LOW PRESSURE SWITCH 2318
DESCRIPTION 2318
OPERATION 2318
DIAGNOSIS AND TESTING 2319
A/C LOW PRESSURE SWITCH 2319
REMOVAL 2319
INSTALLATION 2319
A/C PRESSURE TRANSDUCER 2320
DESCRIPTION 2320
OPERATION 2320
DIAGNOSIS AND TESTING 2320
A/C PRESSURE TRANSDUCER 2320
REMOVAL 2321
INSTALLATION 2321
BLEND DOOR ACTUATOR 2321
DESCRIPTION 2321
OPERATION 2321
REMOVAL 2322
INSTALLATION 2322
BLOWER MOTOR RELAY 2323
DESCRIPTION 2323
OPERATION 2323
REMOVAL 2324
INSTALLATION 2324
BLOWER MOTOR RESISTOR 2324
DESCRIPTION 2324
OPERATION 2324
DIAGNOSIS AND TESTING 2325
BLOWER MOTOR RESISTOR 2325
REMOVAL 2325
INSTALLATION 2325
MODE DOOR ACTUATOR 2326
DESCRIPTION 2326
REMOVAL 2326
INSTALLATION 2327
RECIRCULATION DOOR ACTUATOR 2327
DESCRIPTION 2327
REMOVAL 2328
INSTALLATION 2329
VACUUM CHECK VALVE 2329
DESCRIPTION 2329
OPERATION 2329
REMOVAL 2329
INSTALLATION 2329
DISTRIBUTION 2330
AIR OUTLETS 2330
DESCRIPTION 2330
REMOVAL 2330
INSTALLATION 2330
BLEND DOOR 2331
REMOVAL 2331
INSTALLATION 2331
BLOWER MOTOR 2332
DESCRIPTION 2332
OPERATION 2332
DIAGNOSIS AND TESTING 2332
BLOWER MOTOR 2332
REMOVAL 2333
INSTALLATION 2333
DEFROSTER DUCT 2334
REMOVAL 2334
INSTALLATION 2334
FLOOR DISTRIBUTION DUCT 2334
REMOVAL 2334
INSTALLATION 2334
HVAC HOUSING 2334
REMOVAL 2334
DISASSEMBLY 2335
ASSEMBLY 2336
INSTALLATION 2337
MODE DOOR 2337
REMOVAL 2337
PANEL-AIR DOOR 2337
FLOOR/DEFROST-AIR DOOR 2338
INSTALLATION 2339
PANEL-AIR DOOR 2339
FLOOR/DEFROST-AIR DOOR 2339
REAR FLOOR HEAT DUCT 2339
REMOVAL 2339
INSTALLATION 2339
RECIRCULATION DOOR 2340
REMOVAL 2340
INSTALLATION 2340
PLUMBING 2341
PLUMBING 2342
DESCRIPTION 2342
OPERATION 2342
WARNINGS 2342
CAUTIONS 2342
DIAGNOSIS AND TESTING 2343
REFRIGERANT SYSTEM LEAKS 2343
STANDARD PROCEDURE 2344
REFRIGERANT SYSTEM SERVICE EQUIPMENT 2344
REFRIGERANT SYSTEM CHARGE LEVEL 2345
REFRIGERANT SYSTEM RECOVERY 2346
REFRIGERANT SYSTEM EVACUATE 2346
REFRIGERANT SYSTEM CHARGE 2347
A/C COMPRESSOR 2348
DESCRIPTION 2348
A/C COMPRESSOR 2348
HIGH PRESSURE RELIEF VALVE 2348
OPERATION 2348
A/C COMPRESSOR 2348
HIGH PRESSURE RELIEF VALVE 2348
DIAGNOSIS AND TESTING 2348
A/C COMPRESSOR NOISE 2348
REMOVAL 2349
INSTALLATION 2350
A/C CONDENSER 2351
DESCRIPTION 2351
OPERATION 2351
REMOVAL 2351
INSTALLATION 2351
A/C DISCHARGE LINE 2352
DESCRIPTION 2352
REMOVAL 2352
INSTALLATION 2353
A/C EVAPORATOR 2354
DESCRIPTION 2354
OPERATION 2354
REMOVAL 2355
INSTALLATION 2355
A/C ORIFICE TUBE 2355
DESCRIPTION 2355
OPERATION 2355
DIAGNOSIS AND TESTING 2356
A/C ORIFICE TUBE 2356
ACCUMULATOR 2356
DESCRIPTION 2356
OPERATION 2356
REMOVAL 2357
INSTALLATION 2357
HEATER CORE 2358
DESCRIPTION 2358
OPERATION 2358
REMOVAL 2358
INSTALLATION 2359
LIQUID LINE 2359
DESCRIPTION 2359
REMOVAL 2359
INSTALLATION 2360
REFRIGERANT 2360
DESCRIPTION 2360
OPERATION 2360
REFRIGERANT OIL 2360
DESCRIPTION 2360
OPERATION 2360
STANDARD PROCEDURE 2361
REFRIGERANT OIL LEVEL 2361
SERVICE PORT VALVE CORE 2361
DESCRIPTION 2361
REMOVAL 2361
INSTALLATION 2362
SUCTION LINE 2362
DESCRIPTION 2362
REMOVAL 2363
INSTALLATION 2363
CABIN HEATER 2364
DESCRIPTION 2364
OPERATION 2364
REMOVAL 2364
INSTALLATION 2365
25-EMISSIONS CONTROL 2366
EMISSIONS CONTROL 2366
DESCRIPTION 2366
GAS ENGINES 2366
2 8L TURBODIESEL 2367
ECM MONITORED SYSTEMS 2367
ECM NON-MONITORED SYSTEMS 2367
HIGH AND LOW LIMITS 2367
DESCRIPTION – STATE DISPLAY TEST MODE 2367
DESCRIPTION – CIRCUIT ACTUATION TEST MODE 2367
DESCRIPTION – DIAGNOSTIC TROUBLE CODES 2368
DESCRIPTION – TASK MANAGER 2368
DESCRIPTION – MONITORED SYSTEMS 2368
OXYGEN SENSOR (O2S) MONITOR 2368
OXYGEN SENSOR HEATER MONITOR 2369
LEAK DETECTION PUMP MONITOR (IF EQUIPPED) 2369
MISFIRE MONITOR 2369
FUEL SYSTEM MONITOR 2370
CATALYST MONITOR 2370
DESCRIPTION – TRIP DEFINITION 2370
DESCRIPTION – COMPONENT MONITORS 2371
DESCRIPTION – NON-MONITORED CIRCUITS 2371
DESCRIPTION – HIGH AND LOW LIMITS 2372
DESCRIPTION – LOAD VALUE 2372
OPERATION – TASK MANAGER 2372
Test Sequence 2372
MIL Illumination 2372
Diagnostic Trouble Codes (DTCs) 2373
DTC Self Erasure 2373
Trip Indicator 2373
Freeze Frame Data Storage 2374
Similar Conditions Window 2374
EVAPORATIVE EMISSIONS 2376
EVAPORATIVE EMISSIONS 2376
DESCRIPTION – EVAPORATION CONTROL SYSTEM 2376
SPECIFICATIONS 2378
TORQUE 2378
EVAP/PURGE SOLENOID 2379
DESCRIPTION 2379
OPERATION 2379
REMOVAL 2379
INSTALLATION 2379
FUEL FILLER CAP 2379
DESCRIPTION 2379
OPERATION 2379
ORVR 2379
DESCRIPTION 2379
OPERATION 2379
PUMP-NATURAL VAC LEAK DETECTION 2380
DESCRIPTION 2380
OPERATION 2380
REMOVAL 2381
INSTALLATION 2381
PCV VALVE 2382
DESCRIPTION 2382
2 4L 2382
3 7L 2382
OPERATION 2383
DIAGNOSIS AND TESTING – PCV VALVE 2383
REMOVAL 2384
INSTALLATION 2384
VACUUM LINES 2385
DESCRIPTION 2385
VAPOR CANISTER 2385
DESCRIPTION 2385
OPERATION 2385
REMOVAL 2386
INSTALLATION 2386
EXHAUST GAS RECIRCULATION 2388
EXHAUST GAS RECIRCULATION 2388
DESCRIPTION 2388
OPERATION 2388
SPECIFICATIONS – TORQUE 2389
VALVE 2390
DESCRIPTION 2390
OPERATION 2390
REMOVAL 2391
INSTALLATION 2391
EGR VALVE COOLER 2391
DESCRIPTION 2391
REMOVAL 2391
INSTALLATION 2391
EGR AIR FLOW CONTROL VALVE 2392
DESCRIPTION 2392
OPERATION 2393
REMOVAL 2393
INSTALLATION 2394
INDEX 2396
COMMENTS 2400
S.V 16/03/2025
