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2005 Jeep WRANGLER TJ COMPLETE Service Repair Manual – PDF DOWNLOAD
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Description
2005 Jeep WRANGLER TJ COMPLETE Service Repair Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:1500+
DOWNLOADABLE:YES
FILE TYPE:PDF
2005 JEEP WRANGLER TJ COMPLETE SERVICE REPAIR MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2005 Jeep WRANGLER TJ COMPLETE Service Repair Manual
FOREWORD:
The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations. Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle. Information in this manual is divided into groups. These groups contain description, operation, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components. To assist in locating a group title page, use the Group Tab Locator by clicking to the following page. The solid bar after the group title is aligned to a solid tab on the first page of each group.
- The first page of the group has a contents section that lists major topics within the group. If you are not sure which Group contains the information you need, look up the Component/System in the alphabetical index located in the rear of this manual. A Service Manual Comment form is included at the rear of this manual. Use the form to provide DaimlerChrysler Corporation with your comments and suggestions. Tightening torques are provided as a specific value throughout this manual.
- This value represents the midpoint of the acceptable engineering torque range for a given fastener application. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners.
- When replacing fasteners, always use the same type (part number) fastener as removed. DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
TABLE OF CONTENTS:
2005 Jeep WRANGLER TJ COMPLETE Service Repair Manual
MAIN WELCOME PAGE......................................................................................... 0 TJ Powertrain............................................................................................. 0 TJ Body................................................................................................... 0 TJ Chassis................................................................................................ 0 TJ Service Manual......................................................................................... 1 FOREWORD.............................................................................................. 0 GROUP TAB LOCATOR..................................................................................... 1 in-INTRODUCTION....................................................................................... 3 VEHICLE IDENTIFICATION NUMBER..................................................................... 3 DESCRIPTION................................................................................... 3 VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL................................................. 4 DESCRIPTION................................................................................... 4 VEHICLE CERTIFICATION LABEL....................................................................... 4 DESCRIPTION................................................................................... 4 BODY CODE PLATE................................................................................... 5 DESCRIPTION................................................................................... 5 BODY CODE PLATE........................................................................... 5 BODY CODE PLATE—LINE 3................................................................ 5 BODY CODE PLATE—LINE 2................................................................ 5 BODY CODE PLATE—LINE 1................................................................ 6 INTERNATIONAL SYMBOLS............................................................................. 6 DESCRIPTION................................................................................... 6 FASTENER IDENTIFICATION........................................................................... 7 DESCRIPTION................................................................................... 7 FASTENER USAGE.................................................................................... 9 DESCRIPTION................................................................................... 9 DESCRIPTION - FASTENER USAGE.............................................................. 9 DESCRIPTION - THREADED HOLE REPAIR........................................................ 9 METRIC SYSTEM..................................................................................... 9 DESCRIPTION................................................................................... 9 TORQUE REFERENCES................................................................................. 11 DESCRIPTION................................................................................... 11 0-LUBRICATION & MAINTENANCE........................................................................... 13 INTERNATIONAL SYMBOLS............................................................................. 13 DESCRIPTION................................................................................... 13 PARTS & LUBRICANT RECOMMENDATION.................................................................. 13 DESCRIPTION................................................................................... 13 LUBRICANT RECOMMENDATIONS................................................................. 13 Chassis............................................................................... 13 Body.................................................................................. 14 FLUID TYPES............................................................................... 14 API QUALITY CLASSIFICATION ........................................................... 14 GEAR LUBRICANTS....................................................................... 14 FLUID TYPES....................................................................................... 14 DESCRIPTION................................................................................... 14 ENGINE OIL................................................................................ 14 API SERVICE GRADE CERTIFIED........................................................... 14 SAE VISCOSITY......................................................................... 15 ACEA Categories....................................................................... 15 ENERGY CONSERVING OIL................................................................. 15 CONTAINER IDENTIFICATION.............................................................. 15 FUEL REQUIREMENTS......................................................................... 15 REFORMULATED GASOLINE................................................................. 15 GASOLINE/OXYGENATE BLENDS............................................................. 15 MMT IN GASOLINE....................................................................... 15 SULFUR IN GASOLINE.................................................................... 16 MATERIALS ADDED TO FUEL............................................................... 16 FUEL SYSTEM CAUTIONS.................................................................. 16 HOAT COOLANT.............................................................................. 16 COOLANT PERFORMANCE................................................................... 17 COOLANT SELECTION AND ADDITIVES....................................................... 17 TRANSFER CASE - NV231..................................................................... 17 TRANSFER CASE - NV241..................................................................... 17 AXLE LUBRICATION.......................................................................... 17 MANUAL TRANSMISSION....................................................................... 18 AUTOMATIC TRANSMISSION FLUID.............................................................. 18 FLUID ADDITIVES....................................................................... 18 POWER STEERING FLUID...................................................................... 18 OPERATION - AUTOMATIC TRANSMISSION FLUID...................................................... 18 FLUID CAPACITIES.................................................................................. 19 SPECIFICATIONS - FLUID CAPACITIES............................................................. 19 MAINTENANCE SCHEDULES............................................................................. 19 DESCRIPTION................................................................................... 19 MAINTENANCE SCHEDULES..................................................................... 19 Schedule “B”.......................................................................... 20 Schedule “A”.......................................................................... 25 MAINTENANCE SCHEDULES – EXPORT............................................................ 27 Schedule “A”.......................................................................... 27 Schedule “B”.......................................................................... 30 HOISTING.......................................................................................... 34 STANDARD PROCEDURE - HOISTING RECOMMENDATIONS................................................. 34 HOIST..................................................................................... 34 TOWING............................................................................................ 34 STANDARD PROCEDURE - TOWING RECOMMENDATIONS................................................... 34 SAFETY PRECAUTIONS........................................................................ 34 GROUND CLEARANCE.......................................................................... 35 FLAT-BED TOWING RAMP ANGLE................................................................ 35 VEHICLE TOWING............................................................................ 35 TOWING-FRONT END LIFTED (WHEEL LIFT)...................................................... 35 TOWING-REAR END LIFTED (WHEEL LIFT ONLY).................................................. 35 TOWING-FRONT END LIFTED (SLING-TYPE)...................................................... 35 RECREATIONAL TOWING....................................................................... 36 EMERGENCY TOW HOOKS....................................................................... 36 JUMP STARTING..................................................................................... 36 STANDARD PROCEDURE - JUMP STARTING PROCEDURE.................................................. 36 TO JUMP START A DISABLED VEHICLE:......................................................... 36 DISCONNECT CABLE CLAMPS AS FOLLOWS:....................................................... 37 EMERGENCY TOW HOOKS............................................................................... 37 DESCRIPTION — EMERGENCY TOW HOOKS............................................................. 37 2-SUSPENSION.......................................................................................... 39 WHEEL ALIGNMENT................................................................................... 39 WHEEL ALIGNMENT............................................................................... 39 DESCRIPTION............................................................................... 39 OPERATION................................................................................. 39 DIAGNOSIS AND TESTING - SUSPENSION AND STEERING SYSTEM.................................... 40 STANDARD PROCEDURE........................................................................ 42 STANDARD PROCEDURE - CAMBER........................................................... 42 STANDARD PROCEDURE - CASTER........................................................... 42 STANDARD PROCEDURE - TOE POSITION..................................................... 42 SPECIFICATIONS............................................................................ 43 ALIGNMENT SPECIFICATIONS.............................................................. 43 FRONT............................................................................................. 44 FRONT......................................................................................... 44 DESCRIPTION............................................................................... 44 STANDARD PROCEDURE - LUBRICATION.......................................................... 44 SPECIFICATIONS............................................................................ 45 TORQUE CHART.......................................................................... 45 SPECIAL TOOLS............................................................................. 45 FRONT SUSPENSION...................................................................... 45 BUSHINGS...................................................................................... 46 REMOVAL................................................................................... 46 INSTALLATION.............................................................................. 46 HUB / BEARING................................................................................. 46 DESCRIPTION............................................................................... 46 OPERATION................................................................................. 47 REMOVAL................................................................................... 47 INSTALLATION.............................................................................. 47 JOUNCE BUMPER................................................................................. 48 DESCRIPTION............................................................................... 48 KNUCKLE....................................................................................... 48 REMOVAL................................................................................... 48 INSTALLATION.............................................................................. 48 LOWER BALL JOINT.............................................................................. 48 REMOVAL................................................................................... 48 LOWER CONTROL ARM............................................................................. 49 DESCRIPTION............................................................................... 49 OPERATION................................................................................. 49 REMOVAL................................................................................... 49 INSTALLATION.............................................................................. 49 SHOCK......................................................................................... 50 DESCRIPTION............................................................................... 50 OPERATION................................................................................. 50 DIAGNOSIS AND TESTING - SHOCK ABSORBER.................................................... 50 REMOVAL................................................................................... 50 INSTALLATION.............................................................................. 50 SPRING........................................................................................ 51 DESCRIPTION............................................................................... 51 OPERATION................................................................................. 51 REMOVAL................................................................................... 51 INSTALLATION.............................................................................. 51 STABILIZER BAR................................................................................ 52 DESCRIPTION............................................................................... 52 OPERATION................................................................................. 52 REMOVAL................................................................................... 52 INSTALLATION.............................................................................. 52 TRACK BAR..................................................................................... 52 DESCRIPTION............................................................................... 52 OPERATION................................................................................. 52 REMOVAL................................................................................... 52 INSTALLATION.............................................................................. 52 UPPER BALL JOINT.............................................................................. 53 REMOVAL................................................................................... 53 UPPER CONTROL ARM............................................................................. 53 DESCRIPTION............................................................................... 53 OPERATION................................................................................. 53 REMOVAL................................................................................... 53 INSTALLATION.............................................................................. 53 REAR.............................................................................................. 54 REAR.......................................................................................... 54 DESCRIPTION............................................................................... 54 SPECIFICATIONS............................................................................ 54 TORQUE CHART.......................................................................... 54 JOUNCE BUMPER................................................................................. 55 DESCRIPTION............................................................................... 55 OPERATION................................................................................. 55 LOWER CONTROL ARM............................................................................. 55 DESCRIPTION............................................................................... 55 OPERATION................................................................................. 55 REMOVAL................................................................................... 55 INSTALLATION.............................................................................. 55 SHOCK......................................................................................... 56 DESCRIPTION............................................................................... 56 OPERATION................................................................................. 56 DIAGNOSIS AND TESTING - SHOCK ABSORBER.................................................... 56 REMOVAL................................................................................... 56 INSTALLATION.............................................................................. 56 SPRING........................................................................................ 56 DESCRIPTION............................................................................... 56 OPERATION................................................................................. 56 REMOVAL................................................................................... 56 INSTALLATION.............................................................................. 57 STABILIZER BAR................................................................................ 57 DESCRIPTION............................................................................... 57 OPERATION................................................................................. 57 REMOVAL................................................................................... 57 INSTALLATION.............................................................................. 57 TRACK BAR..................................................................................... 58 DESCRIPTION............................................................................... 58 OPERATION................................................................................. 58 REMOVAL................................................................................... 58 INSTALLATION.............................................................................. 58 UPPER CONTROL ARM............................................................................. 58 REMOVAL................................................................................... 58 INSTALLATION.............................................................................. 58 3-DIFFERENTIAL & DRIVELINE............................................................................ 59 PROPELLER SHAFT................................................................................... 59 PROPELLER SHAFT............................................................................... 59 DIAGNOSIS AND TESTING..................................................................... 59 VIBRATION............................................................................. 59 BALANCE............................................................................... 61 RUNOUT................................................................................ 61 STANDARD PROCEDURE........................................................................ 62 PROPELLER SHAFT ANGLE................................................................. 62 ADJUSTMENTS............................................................................... 64 SPECIFICATIONS............................................................................ 64 PROPELLER SHAFT....................................................................... 64 SPECIAL TOOLS............................................................................. 65 PROPELLER SHAFT - FRONT....................................................................... 65 REMOVAL................................................................................... 65 INSTALLATION.............................................................................. 65 PROPELLER SHAFT - REAR........................................................................ 65 REMOVAL................................................................................... 65 INSTALLATION.............................................................................. 66 PROPELLER SHAFT - REAR RUBICON................................................................ 66 REMOVAL................................................................................... 66 INSTALLATION.............................................................................. 67 SINGLE CARDAN UNIVERSAL JOINTS................................................................ 67 DISASSEMBLY............................................................................... 67 ASSEMBLY.................................................................................. 68 DOUBLE CARDAN UNIVERSAL JOINTS................................................................ 69 DISASSEMBLY............................................................................... 69 ASSEMBLY.................................................................................. 70 FRONT AXLE - 181FBI............................................................................... 73 FRONT AXLE - 181FBI........................................................................... 73 DIAGNOSIS AND TESTING..................................................................... 73 GEAR NOISE............................................................................ 73 BEARING NOISE......................................................................... 73 LOW SPEED KNOCK....................................................................... 74 VIBRATION............................................................................. 74 DRIVELINE SNAP........................................................................ 74 REMOVAL................................................................................... 77 INSTALLATION.............................................................................. 77 ADJUSTMENTS............................................................................... 79 PINION DEPTH MEASUREMENT AND ADJUSTMENT............................................... 80 DIFFERENTIAL SIDE BEARING PRELOAD AND GEAR BACKLASH................................... 81 PRELOAD SHIM SELECTION................................................................ 82 GEAR CONTACT PATTERN.................................................................. 85 DIFFERENTIAL BEARING PRELOAD CHECK.................................................... 86 SPECIFICATIONS............................................................................ 87 FRONT AXLE............................................................................ 87 SPECIAL TOOLS............................................................................. 87 AXLE SHAFTS................................................................................... 90 REMOVAL................................................................................... 90 INSTALLATION.............................................................................. 91 AXLE SHAFT SEALS.............................................................................. 91 REMOVAL................................................................................... 91 INSTALLATION.............................................................................. 91 SINGLE CARDAN UNIVERSAL JOINT................................................................. 92 REMOVAL................................................................................... 92 INSTALLATION.............................................................................. 93 PINION SEAL................................................................................... 93 REMOVAL................................................................................... 93 INSTALLATION.............................................................................. 93 COLLAPSIBLE SPACER............................................................................ 95 REMOVAL................................................................................... 95 INSTALLATION.............................................................................. 95 DIFFERENTIAL COVER............................................................................ 96 REMOVAL................................................................................... 96 INSTALLATION.............................................................................. 96 DIFFERENTIAL.................................................................................. 97 REMOVAL................................................................................... 97 DISASSEMBLY............................................................................... 98 ASSEMBLY.................................................................................. 99 INSTALLATION.............................................................................. 99 DIFFERENTIAL CASE BEARINGS.................................................................... 101 REMOVAL................................................................................... 101 INSTALLATION.............................................................................. 101 PINION GEAR/RING GEAR......................................................................... 102 REMOVAL................................................................................... 102 INSTALLATION.............................................................................. 104 FRONT AXLE - 216FBI............................................................................... 107 FRONT AXLE - 216FBI........................................................................... 107 DIAGNOSIS AND TESTING..................................................................... 107 GEAR NOISE............................................................................ 107 BEARING NOISE......................................................................... 107 LOW SPEED KNOCK....................................................................... 108 VIBRATION............................................................................. 108 DRIVELINE SNAP........................................................................ 108 REMOVAL................................................................................... 111 INSTALLATION.............................................................................. 111 ADJUSTMENTS............................................................................... 113 PINION DEPTH MEASUREMENT AND ADJUSTMENT............................................... 114 PRELOAD SHIM SELECTION................................................................ 115 GEAR CONTACT PATTERN.................................................................. 119 DIFFERENTIAL BEARING PRELOAD CHECK.................................................... 119 SPECIFICATIONS............................................................................ 121 FRONT AXLE............................................................................ 121 SPECIAL TOOLS............................................................................. 121 AXLE SHAFTS................................................................................... 124 REMOVAL................................................................................... 124 INSTALLATION.............................................................................. 125 AXLE SHAFT SEALS.............................................................................. 125 REMOVAL................................................................................... 125 INSTALLATION.............................................................................. 125 SINGLE CARDAN UNIVERSAL JOINT................................................................. 126 REMOVAL................................................................................... 126 INSTALLATION.............................................................................. 126 PINION SEAL................................................................................... 127 REMOVAL................................................................................... 127 INSTALLATION.............................................................................. 127 DIFFERENTIAL COVER............................................................................ 128 REMOVAL................................................................................... 128 INSTALLATION.............................................................................. 128 DIFFERENTIAL - TRU-LOK........................................................................ 129 DESCRIPTION............................................................................... 129 OPERATION................................................................................. 129 DIAGNOSIS AND TESTING..................................................................... 129 UNLOCKED.............................................................................. 129 LOCKED................................................................................ 130 TRU-LOK INDICATOR SWITCH.............................................................. 130 TRU-LOK PUMPS......................................................................... 130 REMOVAL................................................................................... 130 DISASSEMBLY............................................................................... 133 ASSEMBLY.................................................................................. 134 INSTALLATION.............................................................................. 134 DIFFERENTIAL - TRU-LOK PUMP................................................................... 135 REMOVAL................................................................................... 135 INSTALLATION.............................................................................. 136 PINION GEAR/RING GEAR......................................................................... 137 REMOVAL................................................................................... 137 INSTALLATION.............................................................................. 139 REAR AXLE - 194RBI................................................................................ 142 REAR AXLE - 194RBI............................................................................ 142 DIAGNOSIS AND TESTING..................................................................... 142 GEAR NOISE............................................................................ 142 BEARING NOISE......................................................................... 142 LOW SPEED KNOCK....................................................................... 143 VIBRATION............................................................................. 143 DRIVELINE SNAP........................................................................ 143 REMOVAL................................................................................... 146 INSTALLATION.............................................................................. 146 ADJUSTMENTS............................................................................... 147 RING AND PINION GEAR.................................................................. 147 PINION DEPTH MEASUREMENT.............................................................. 148 DIFFERENTIAL BEARING PRELOAD.......................................................... 149 PRELOAD SHIM SELECTION................................................................ 150 GEAR CONTACT PATTERN.................................................................. 152 DIFFERENTIAL BEARING PRELOAD CHECK.................................................... 153 SPECIFICATIONS............................................................................ 154 REAR AXLE............................................................................. 154 SPECIAL TOOLS............................................................................. 155 AXLE SHAFTS................................................................................... 158 REMOVAL................................................................................... 158 INSTALLATION.............................................................................. 158 AXLE SHAFT SEALS.............................................................................. 158 REMOVAL................................................................................... 158 INSTALLATION.............................................................................. 158 AXLE BEARINGS................................................................................. 159 REMOVAL................................................................................... 159 INSTALLATION.............................................................................. 159 PINION SEAL................................................................................... 159 REMOVAL................................................................................... 159 INSTALLATION.............................................................................. 160 COLLAPSIBLE SPACER............................................................................ 161 REMOVAL................................................................................... 161 INSTALLATION.............................................................................. 161 DIFFERENTIAL COVER............................................................................ 163 REMOVAL................................................................................... 163 INSTALLATION.............................................................................. 163 DIFFERENTIAL.................................................................................. 163 REMOVAL................................................................................... 163 DISASSEMBLY............................................................................... 164 ASSEMBLY.................................................................................. 164 INSTALLATION.............................................................................. 165 DIFFERENTIAL - TRAC-LOK....................................................................... 166 DESCRIPTION............................................................................... 166 OPERATION................................................................................. 166 DIAGNOSIS AND TESTING..................................................................... 166 DIFFERENTIAL TEST..................................................................... 166 DISASSEMBLY............................................................................... 167 ASSEMBLY.................................................................................. 168 DIFFERENTIAL CASE BEARINGS.................................................................... 170 REMOVAL................................................................................... 170 INSTALLATION.............................................................................. 171 PINION GEAR/RING GEAR......................................................................... 171 REMOVAL................................................................................... 171 INSTALLATION.............................................................................. 173 REAR AXLE - 216RBI................................................................................ 176 REAR AXLE - 216RBI............................................................................ 176 DIAGNOSIS AND TESTING..................................................................... 176 GEAR NOISE............................................................................ 176 BEARING NOISE......................................................................... 176 LOW SPEED KNOCK....................................................................... 177 VIBRATION............................................................................. 177 DRIVELINE SNAP........................................................................ 177 REMOVAL................................................................................... 180 INSTALLATION.............................................................................. 180 ADJUSTMENTS............................................................................... 181 RING AND PINION GEAR.................................................................. 181 PINION DEPTH MEASUREMENT AND ADJUSTMENT............................................... 182 PRELOAD SHIM SELECTION................................................................ 183 GEAR CONTACT PATTERN.................................................................. 186 DIFFERENTIAL BEARING PRELOAD CHECK.................................................... 187 SPECIFICATIONS............................................................................ 189 REAR AXLE............................................................................. 189 SPECIAL TOOLS............................................................................. 189 AXLE SHAFTS................................................................................... 192 REMOVAL................................................................................... 192 INSTALLATION.............................................................................. 192 AXLE BEARINGS................................................................................. 193 REMOVAL................................................................................... 193 INSTALLATION.............................................................................. 194 PINION SEAL................................................................................... 194 REMOVAL................................................................................... 194 INSTALLATION.............................................................................. 195 DIFFERENTIAL COVER............................................................................ 196 REMOVAL................................................................................... 196 INSTALLATION.............................................................................. 196 DIFFERENTIAL.................................................................................. 197 REMOVAL................................................................................... 197 DISASSEMBLY............................................................................... 198 ASSEMBLY.................................................................................. 198 INSTALLATION.............................................................................. 199 DIFFERENTIAL -TRAC-LOK........................................................................ 199 DESCRIPTION............................................................................... 199 OPERATION................................................................................. 199 DIAGNOSIS AND TESTING..................................................................... 200 DIFFERENTIAL TEST..................................................................... 200 DISASSEMBLY............................................................................... 200 ASSEMBLY.................................................................................. 202 DIFFERENTIAL - TRU-LOK........................................................................ 204 DESCRIPTION............................................................................... 204 OPERATION................................................................................. 204 DIAGNOSIS AND TESTING..................................................................... 204 UNLOCKED.............................................................................. 204 LOCKED................................................................................ 204 TRU-LOK INDICATOR SWITCH.............................................................. 204 TRU-LOK PUMPS......................................................................... 205 REMOVAL................................................................................... 205 DISASSEMBLY............................................................................... 206 ASSEMBLY.................................................................................. 209 INSTALLATION.............................................................................. 209 DIFFERENTIAL - TRU-LOK PUMP................................................................... 210 REMOVAL................................................................................... 210 INSTALLATION.............................................................................. 211 DIFFERENTIAL CASE BEARINGS.................................................................... 212 REMOVAL................................................................................... 212 INSTALLATION.............................................................................. 212 PINION GEAR/RING GEAR/TONE RING............................................................... 213 REMOVAL................................................................................... 213 INSTALLATION.............................................................................. 215 5-BRAKES.............................................................................................. 219 BRAKES - BASE..................................................................................... 219 BRAKES - BASE................................................................................. 220 DESCRIPTION............................................................................... 220 DESCRIPTION - BRAKE SYSTEM............................................................ 220 DESCRIPTION - SERVICE WARNINGS & CAUTIONS............................................. 221 DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM................................................. 221 PRELIMINARY BRAKE CHECK............................................................... 221 ROAD TESTING.......................................................................... 221 STANDARD PROCEDURE........................................................................ 223 STANDARD PROCEDURE - MANUAL BLEEDING.................................................. 223 STANDARD PROCEDURE - PRESSURE BLEEDING................................................ 223 SPECIFICATIONS............................................................................ 224 BRAKE COMPONENTS...................................................................... 224 TORQUE CHART.......................................................................... 225 SPECIAL TOOLS............................................................................. 226 BASE BRAKES........................................................................... 226 BRAKE LINES................................................................................... 226 DESCRIPTION............................................................................... 226 OPERATION................................................................................. 226 DIAGNOSIS AND TESTING - BRAKE LINE AND HOSES.............................................. 226 STANDARD PROCEDURE........................................................................ 226 STANDARD PROCEDURE - BRAKE TUBE FLARING............................................... 226 STANDARD PROCEDURE - DOUBLE INVERTED FLARING.......................................... 226 STANDARD PROCEDURE - ISO FLARING...................................................... 227 DISC BRAKE CALIPERS........................................................................... 228 DESCRIPTION............................................................................... 228 OPERATION................................................................................. 228 REMOVAL................................................................................... 228 REMOVAL - FRONT....................................................................... 228 REMOVAL - REAR........................................................................ 229 DISASSEMBLY............................................................................... 230 CLEANING.................................................................................. 231 INSPECTION................................................................................ 231 ASSEMBLY.................................................................................. 231 INSTALLATION.............................................................................. 233 INSTALLATION - FRONT.................................................................. 233 INSTALLATION - REAR................................................................... 234 BRAKE PADS/SHOES.............................................................................. 234 REMOVAL................................................................................... 234 REMOVAL - FRONT PADS.................................................................. 234 REMOVAL - DRUM BRAKE SHOES............................................................ 235 REMOVAL - REAR DISC BRAKE PADS........................................................ 235 INSTALLATION.............................................................................. 235 INSTALLATION - FRONT PADS............................................................. 235 INSTALLATION - DRUM BRAKE SHOES....................................................... 235 INSTALLATION - REAR DISC BRAKE PADS................................................... 237 DRUM.......................................................................................... 237 DESCRIPTION............................................................................... 237 OPERATION................................................................................. 237 DIAGNOSIS AND TESTING - BRAKE DRUM RUNOUT................................................. 237 BRAKE DRUM RUNOUT..................................................................... 237 STANDARD PROCEDURE - BRAKE DRUM MACHINING................................................. 237 CLEANING.................................................................................. 237 INSPECTION................................................................................ 237 ADJUSTMENTS - REAR DRUM BRAKE............................................................. 238 ADJUSTMENT WITH BRAKE GAUGE........................................................... 238 ADJUSTMENT WITH ADJUSTING TOOL........................................................ 239 FLUID......................................................................................... 239 DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION......................................... 239 STANDARD PROCEDURE - BRAKE FLUID LEVEL.................................................... 239 SPECIFICATIONS............................................................................ 239 BRAKE FLUID........................................................................... 239 FLUID RESERVOIR............................................................................... 240 REMOVAL................................................................................... 240 INSTALLATION.............................................................................. 241 MASTER CYLINDER............................................................................... 241 DESCRIPTION............................................................................... 241 OPERATION................................................................................. 241 DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER..................................... 241 POWER BOOSTER VACUUM TEST............................................................. 241 POWER BOOSTER CHECK VALVE TEST........................................................ 241 STANDARD PROCEDURE - MASTER CYLINDER BLEEDING............................................. 242 REMOVAL................................................................................... 242 INSTALLATION.............................................................................. 243 PEDAL......................................................................................... 243 DESCRIPTION............................................................................... 243 OPERATION................................................................................. 243 REMOVAL................................................................................... 243 INSTALLATION.............................................................................. 243 POWER BRAKE BOOSTER........................................................................... 244 DESCRIPTION............................................................................... 244 OPERATION................................................................................. 244 REMOVAL................................................................................... 245 INSTALLATION.............................................................................. 245 COMBINATION VALVE............................................................................. 245 DESCRIPTION............................................................................... 245 OPERATION................................................................................. 245 PRESSURE DIFFERENTIAL VALVE........................................................... 245 PROPORTIONING VALVE................................................................... 246 DIAGNOSIS AND TESTING - COMBINATION VALVE................................................. 246 Pressure Differential Switch.......................................................... 246 REMOVAL................................................................................... 246 INSTALLATION.............................................................................. 246 ROTORS........................................................................................ 246 DIAGNOSIS AND TESTING..................................................................... 246 DIAGNOSIS AND TESTING - DISC BRAKE ROTOR.............................................. 246 ROTOR MINIMUM THICKNESS........................................................... 247 ROTOR RUNOUT...................................................................... 247 ROTOR THICKNESS VARIATION......................................................... 247 DIAGNOSIS AND TESTING - BRAKE DRUM IN HAT ROTOR....................................... 247 BRAKE DRUM RUNOUT................................................................. 247 STANDARD PROCEDURE........................................................................ 247 STANDARD PROCEDURE - DISC ROTOR MACHINING............................................. 247 STANDARD PROCEDURE - BRAKE DRUM IN HAT ROTOR MACHINING................................ 248 REMOVAL................................................................................... 248 REMOVAL - FRONT....................................................................... 248 REMOVAL - REAR........................................................................ 248 INSTALLATION.............................................................................. 249 INSTALLATION - FRONT.................................................................. 249 INSTALLATION - REAR................................................................... 249 WHEEL CYLINDERS............................................................................... 249 REMOVAL................................................................................... 249 DISASSEMBLY............................................................................... 249 CLEANING.................................................................................. 249 INSPECTION................................................................................ 249 ASSEMBLY.................................................................................. 249 INSTALLATION.............................................................................. 250 SUPPORT PLATE................................................................................. 250 REMOVAL................................................................................... 250 INSTALLATION.............................................................................. 250 PARKING BRAKE................................................................................. 251 DESCRIPTION............................................................................... 251 OPERATION................................................................................. 251 DIAGNOSIS AND TESTING - PARKING BRAKE..................................................... 251 SHOES......................................................................................... 252 DESCRIPTION............................................................................... 252 OPERATION................................................................................. 252 REMOVAL................................................................................... 252 CLEANING - REAR DRUM IN HAT BRAKE......................................................... 252 INSPECTION - REAR DRUM IN HAT BRAKE....................................................... 252 INSTALLATION.............................................................................. 253 ADJUSTMENTS............................................................................... 253 ADJUSTMENT - REAR DRUM IN HAT PARK BRAKE (ROTOR REMOVED).............................. 253 ADJUSTMENT - WITH ADJUSTING TOOL...................................................... 255 CABLES........................................................................................ 255 REMOVAL................................................................................... 255 REMOVAL - DRUM BRAKES................................................................. 255 REMOVAL - DISC BRAKES................................................................. 256 INSTALLATION.............................................................................. 256 INSTALLATION - DRUM BRAKES............................................................ 256 INSTALLATION - DISC BRAKES............................................................ 256 BRAKES - ABS...................................................................................... 257 BRAKES - ABS.................................................................................. 257 DESCRIPTION............................................................................... 257 OPERATION................................................................................. 257 DIAGNOSIS AND TESTING - ANTILOCK BRAKES................................................... 257 STANDARD PROCEDURE - BLEEDING ABS BRAKE SYSTEM............................................ 258 SPECIFICATIONS............................................................................ 258 T0RQUE CHART.......................................................................... 258 FRONT WHEEL SPEED SENSOR...................................................................... 259 DESCRIPTION............................................................................... 259 OPERATION................................................................................. 259 FRONT SENSOR AIR GAP.................................................................. 259 REAR SENSOR AIR GAP................................................................... 259 REMOVAL................................................................................... 259 INSTALLATION.............................................................................. 259 G-SWITCH...................................................................................... 260 DESCRIPTION............................................................................... 260 OPERATION................................................................................. 260 REMOVAL................................................................................... 260 INSTALLATION.............................................................................. 260 REAR WHEEL SPEED SENSOR....................................................................... 260 DESCRIPTION............................................................................... 260 OPERATION................................................................................. 260 REMOVAL................................................................................... 261 INSTALLATION.............................................................................. 261 HCU (HYDRAULIC CONTROL UNIT).................................................................. 261 DESCRIPTION............................................................................... 261 OPERATION................................................................................. 261 PRESSURE DECREASE..................................................................... 262 PRESSURE HOLD......................................................................... 262 PRESSURE INCREASE..................................................................... 262 REMOVAL................................................................................... 262 INSTALLATION.............................................................................. 262 6-CLUTCH.............................................................................................. 263 CLUTCH............................................................................................ 263 WARNING....................................................................................... 263 DIAGNOSIS AND TESTING......................................................................... 263 CLUTCH CONTAMINATION...................................................................... 263 IMPROPER RELEASE OR CLUTCH ENGAGEMENT..................................................... 263 CLUTCH MISALIGNMENT....................................................................... 264 PRESSURE PLATE AND DISC RUNOUT............................................................ 264 FLYWHEEL RUNOUT........................................................................... 264 DIAGNOSIS CHART........................................................................... 264 SPECIFICATIONS................................................................................ 267 CLUTCH.................................................................................... 267 CLUTCH DISC....................................................................................... 268 REMOVAL....................................................................................... 268 INSTALLATION.................................................................................. 268 CLUTCH RELEASE BEARING............................................................................ 268 REMOVAL....................................................................................... 268 INSTALLATION.................................................................................. 268 FLYWHEEL.......................................................................................... 269 DESCRIPTION................................................................................... 269 STANDARD FLYWHEEL......................................................................... 269 DUAL MASS FLYWHEEL........................................................................ 269 OPERATION..................................................................................... 269 DIAGNOSIS AND TESTING......................................................................... 270 PILOT BEARING..................................................................................... 270 REMOVAL....................................................................................... 270 INSTALLATION.................................................................................. 270 LINKAGE........................................................................................... 270 REMOVAL....................................................................................... 270 INSTALLATION.................................................................................. 271 MASTER CYLINDER................................................................................... 271 INSPECTION.................................................................................... 271 CLUTCH PEDAL...................................................................................... 272 REMOVAL....................................................................................... 272 INSTALLATION.................................................................................. 272 CLUTCH PEDAL POSITION SWITCH...................................................................... 272 DESCRIPTION................................................................................... 272 OPERATION..................................................................................... 273 DIAGNOSIS AND TESTING......................................................................... 273 7-COOLING............................................................................................. 275 COOLING........................................................................................... 275 DESCRIPTION................................................................................... 275 DESCRIPTION - COOLING SYSTEM 2.4L ENGINE.................................................. 275 DESCRIPTION - 4.0L ENGINE................................................................. 275 DESCRIPTION - HOSE CLAMPS................................................................. 276 OPERATION - HOSE CLAMPS....................................................................... 276 DIAGNOSIS AND TESTING......................................................................... 276 ON-BOARD DIAGNOSTICS - OBD................................................................ 276 COOLING SYSTEM RELATED DIAGNOSTICS.................................................... 276 ACCESSING DIAGNOSTIC TROUBLE CODES.................................................... 276 DIAGNOSIS AND TESTING - PRELIMINARY CHECKS................................................ 276 ENGINE COOLING SYSTEM OVERHEATING..................................................... 276 DIAGNOSIS AND TESTING - COOLING SYSTEM - TESTING FOR LEAKS................................ 283 ULTRAVIOLET LIGHT METHOD.............................................................. 283 PRESSURE TESTER METHOD................................................................ 283 INTERNAL LEAKAGE INSPECTION........................................................... 284 COMBUSTION LEAKAGE TEST (WITHOUT PRESSURE TESTER)..................................... 284 DIAGNOSIS AND TESTING - RADIATOR COOLANT FLOW CHECK....................................... 284 STANDARD PROCEDURE0 - 2 TJ (Continued).................................................... 284 STANDARD PROCEDURE - DRAINING COOLING SYSTEM - 2.4L....................................... 284 STANDARD PROCEDURE - REFILLING COOLING SYSTEM - 2.4L...................................... 285 STANDARD PROCEDURE - COOLANT LEVEL CHECK.................................................. 285 STANDARD PROCEDURE - COOLING SYSTEM - DRAINING............................................ 285 STANDARD PROCEDURE - COOLING SYSTEM - REFILLING........................................... 286 STANDARD PROCEDURE - COOLING SYSTEM - REVERSE FLUSHING.................................... 286 CHEMICAL CLEANING..................................................................... 286 REVERSE FLUSHING RADIATOR............................................................. 286 REVERSE FLUSHING ENGINE............................................................... 286 SPECIFICATIONS................................................................................ 287 TORQUE.................................................................................... 287 SPECIAL TOOLS................................................................................. 287 COOLING................................................................................... 287 ACCESSORY DRIVE................................................................................... 288 ACCESSORY DRIVE............................................................................... 288 SPECIFICATIONS............................................................................ 288 BELT TENSION.......................................................................... 288 BELT TENSIONERS............................................................................... 288 DESCRIPTION............................................................................... 288 REMOVAL................................................................................... 289 REMOVAL - 2.4L ENGINE................................................................. 289 REMOVAL............................................................................... 289 INSTALLATION.............................................................................. 289 INSTALLATION - 2.4L ENGINE............................................................ 289 INSTALLATION.......................................................................... 290 DRIVE BELTS - 2.4L............................................................................ 290 DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT.............................................. 290 VISUAL DIAGNOSIS...................................................................... 290 NOISE DIAGNOSIS....................................................................... 291 REMOVAL................................................................................... 293 REMOVAL............................................................................... 293 REMOVAL............................................................................... 293 INSTALLATION.............................................................................. 293 INSTALLATION.......................................................................... 293 INSTALLATION.......................................................................... 295 ENGINE............................................................................................ 296 COOLANT....................................................................................... 297 DESCRIPTION............................................................................... 297 DESCRIPTION - HOAT COOLANT............................................................ 297 COOLANT PERFORMANCE............................................................... 297 COOLANT SELECTION AND ADDITIVES................................................... 297 DESCRIPTION - ENGINE COOLANT.......................................................... 298 ETHYLENE-GLYCOL MIXTURES.......................................................... 298 PROPYLENE-GLYCOL MIXTURES......................................................... 298 OPERATION................................................................................. 298 COOLANT RECOVERY CONTAINER.................................................................... 298 DESCRIPTION............................................................................... 298 OPERATION................................................................................. 299 REMOVAL................................................................................... 299 INSTALLATION.............................................................................. 299 ENGINE BLOCK HEATER........................................................................... 299 DESCRIPTION............................................................................... 299 OPERATION................................................................................. 299 REMOVAL................................................................................... 300 REMOVAL - 4.0L........................................................................ 300 REMOVAL - 2.4L........................................................................ 300 INSTALLATION.............................................................................. 300 INSTALLATION 4.0L..................................................................... 300 INSTALLATION - 2.4L................................................................... 300 ENGINE COOLANT TEMPERATURE SENSOR............................................................. 301 DESCRIPTION............................................................................... 301 OPERATION................................................................................. 301 REMOVAL................................................................................... 301 INSTALLATION.............................................................................. 301 ENGINE COOLANT THERMOSTAT..................................................................... 302 DESCRIPTION............................................................................... 302 OPERATION................................................................................. 302 REMOVAL................................................................................... 302 REMOVAL............................................................................... 302 REMOVAL............................................................................... 303 INSTALLATION.............................................................................. 303 INSTALLATION.......................................................................... 303 INSTALLATION.......................................................................... 303 FAN DRIVE VISCOUS CLUTCH...................................................................... 304 DESCRIPTION............................................................................... 304 OPERATION................................................................................. 305 DIAGNOSIS AND TESTING..................................................................... 305 VISCOUS FAN DRIVE..................................................................... 305 NOISE............................................................................. 305 LEAKS............................................................................. 305 TESTING........................................................................... 305 REMOVAL................................................................................... 306 INSTALLATION.............................................................................. 306 RADIATOR...................................................................................... 307 DESCRIPTION............................................................................... 307 OPERATION................................................................................. 307 DIAGNOSIS AND TESTING - RADIATOR COOLANT FLOW............................................. 307 REMOVAL................................................................................... 307 CLEANING.................................................................................. 309 INSPECTION................................................................................ 309 INSTALLATION.............................................................................. 310 WATER PUMP - 2.4L............................................................................. 310 DESCRIPTION............................................................................... 310 OPERATION................................................................................. 310 DIAGNOSIS AND TESTING..................................................................... 310 WATER PUMP............................................................................ 310 REMOVAL - 2.4L............................................................................ 311 INSTALLATION.............................................................................. 311 INSTALLATION 2.4L..................................................................... 311 WATER PUMP - 4.0L............................................................................. 311 DESCRIPTION............................................................................... 311 OPERATION................................................................................. 312 REMOVAL................................................................................... 312 INSTALLATION.............................................................................. 313 RADIATOR PRESSURE CAP......................................................................... 314 DESCRIPTION............................................................................... 314 OPERATION................................................................................. 314 DIAGNOSIS AND TESTING..................................................................... 315 DIAGNOSIS AND TESTING - RADIATOR CAP-TO-FILLER NECK SEAL.............................. 315 DIAGNOSIS AND TESTING - RADIATOR CAP.................................................. 315 CLEANING.................................................................................. 315 INSPECTION................................................................................ 315 RADIATOR FAN.................................................................................. 316 DESCRIPTION............................................................................... 316 REMOVAL................................................................................... 316 REMOVAL............................................................................... 316 REMOVAL - 4.0L........................................................................ 316 CLEANING.................................................................................. 316 INSPECTION................................................................................ 316 INSTALLATION.............................................................................. 317 INSTALLATION.......................................................................... 317 INSTALLATION - 4.0L................................................................... 317 RADIATOR FAN RELAY............................................................................ 317 DESCRIPTION............................................................................... 317 TRANSMISSION...................................................................................... 318 TRANSMISSION COOLER........................................................................... 318 DESCRIPTION............................................................................... 318 OPERATION................................................................................. 318 8a-AUDIO/VIDEO........................................................................................ 319 AUDIO............................................................................................. 319 DESCRIPTION................................................................................... 319 OPERATION..................................................................................... 319 DIAGNOSIS AND TESTING - AUDIO................................................................. 319 AMPLIFIED SUBWOOFER............................................................................... 321 DESCRIPTION................................................................................... 321 OPERATION..................................................................................... 321 DIAGNOSIS AND TESTING - AMPLIFIED SUBWOOFER................................................... 321 REMOVAL....................................................................................... 321 INSTALLATION.................................................................................. 321 ANTENNA BODY & CABLE.............................................................................. 322 DESCRIPTION................................................................................... 322 DIAGNOSIS AND TESTING - ANTENNA BODY AND CABLE................................................ 322 TEST 1.................................................................................... 322 TEST 2.................................................................................... 322 TEST 3.................................................................................... 322 TEST 4.................................................................................... 323 REMOVAL....................................................................................... 323 INSTALLATION.................................................................................. 323 RADIO............................................................................................. 324 DESCRIPTION................................................................................... 324 OPERATION..................................................................................... 324 REMOVAL....................................................................................... 324 INSTALLATION.................................................................................. 325 RADIO NOISE SUPPRESSION COMPONENTS................................................................ 325 DESCRIPTION................................................................................... 325 DIAGNOSIS AND TESTING - RADIO NOISE SUPPRESSION COMPONENTS.................................... 325 REMOVAL....................................................................................... 326 ENGINE-TO-BODY GROUND STRAP............................................................... 326 INSTALLATION.................................................................................. 326 ENGINE-TO-BODY GROUND STRAP............................................................... 326 SPEAKER........................................................................................... 326 DESCRIPTION................................................................................... 326 OPERATION..................................................................................... 326 DIAGNOSIS AND TESTING - SPEAKER............................................................... 326 REMOVAL....................................................................................... 327 FRONT..................................................................................... 327 REAR...................................................................................... 327 INSTALLATION.................................................................................. 328 FRONT..................................................................................... 328 REAR...................................................................................... 328 8b-CHIME/BUZZER....................................................................................... 329 CHIME WARNING SYSTEM.............................................................................. 329 DESCRIPTION................................................................................... 329 OPERATION..................................................................................... 329 DIAGNOSIS AND TESTING - CHIME WARNING SYSTEM.................................................. 331 8e-ELECTRONIC CONTROL MODULES......................................................................... 335 ELECTRONIC CONTROL MODULES........................................................................ 335 STANDARD PROCEDURE - PCM/SKIM PROGRAMMING..................................................... 335 PROGRAMMING THE PCM (JTEC)................................................................ 335 PROGRAMMING THE SKIM...................................................................... 336 PROGRAMMING IGNITION KEYS TO THE SKIM..................................................... 336 COMMUNICATION..................................................................................... 336 DESCRIPTION................................................................................... 336 OPERATION..................................................................................... 337 CONTROLLER ANTILOCK BRAKE......................................................................... 338 DESCRIPTION................................................................................... 338 OPERATION..................................................................................... 338 REMOVAL....................................................................................... 338 INSTALLATION.................................................................................. 338 DATA LINK CONNECTOR............................................................................... 338 DESCRIPTION - DATA LINK CONNECTOR............................................................. 338 OPERATION - DATA LINK CONNECTOR............................................................... 338 POWERTRAIN CONTROL MODULE......................................................................... 339 DESCRIPTION................................................................................... 339 DESCRIPTION............................................................................... 339 DESCRIPTION - MODES OF OPERATION.......................................................... 339 DESCRIPTION - 5 VOLT SUPPLIES......................................................... 342 DESCRIPTION - IGNITION CIRCUIT SENSE.................................................. 342 DESCRIPTION - POWER GROUNDS............................................................... 342 DESCRIPTION - SENSOR RETURN............................................................... 342 OPERATION................................................................................. 342 OPERATION............................................................................. 342 OPERATION - 5 VOLT SUPPLIES........................................................... 343 OPERATION - IGNITION CIRCUIT SENSE.................................................... 343 REMOVAL................................................................................... 343 INSTALLATION.................................................................................. 344 SENTRY KEY IMMOBILIZER MODULE................................................................. 344 DESCRIPTION............................................................................... 344 OPERATION................................................................................. 344 REMOVAL................................................................................... 346 INSTALLATION.............................................................................. 347 TRANSMISSION CONTROL MODULE................................................................... 348 DESCRIPTION............................................................................... 348 OPERATION................................................................................. 348 CLUTCH VOLUME INDEX (CVI)............................................................. 349 SHIFT SCHEDULES....................................................................... 350 STANDARD PROCEDURE - TCM QUICK LEARN...................................................... 351 8f-ENGINE SYSTEMS..................................................................................... 353 BATTERY SYSTEM.................................................................................... 353 BATTERY SYSTEM................................................................................ 353 DESCRIPTION............................................................................... 353 OPERATION................................................................................. 354 DIAGNOSIS AND TESTING - BATTERY SYSTEM.................................................... 354 MICRO 420 BATTERY TESTER.............................................................. 354 ABNORMAL BATTERY DISCHARGING.......................................................... 356 CLEANING.................................................................................. 356 INSPECTION................................................................................ 358 SPECIFICATIONS............................................................................ 358 BATTERY SYSTEM SPECIFICATIONS......................................................... 358 SPECIAL TOOLS............................................................................. 359 BATTERY SYSTEM SPECIAL TOOLS.......................................................... 359 BATTERY....................................................................................... 359 DESCRIPTION............................................................................... 359 OPERATION................................................................................. 360 DIAGNOSIS AND TESTING - BATTERY........................................................... 360 MICRO 420 BATTERY TESTER.............................................................. 360 STANDARD PROCEDURE........................................................................ 360 STANDARD PROCEDURE - BATTERY CHARGING................................................. 360 CHARGING A COMPLETELY DISCHARGED BATTERY.......................................... 361 CHARGING TIME REQUIRED............................................................ 362 STANDARD PROCEDURE - BUILT-IN INDICATOR TEST.......................................... 362 STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST........................................ 363 STANDARD PROCEDURE - IGNITION-OFF DRAW TEST........................................... 363 STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER................................... 364 BATTERY TESTING................................................................... 364 REMOVAL................................................................................... 365 INSTALLATION.............................................................................. 366 BATTERY HOLDDOWN.............................................................................. 366 DESCRIPTION............................................................................... 366 OPERATION................................................................................. 367 REMOVAL................................................................................... 367 INSTALLATION.............................................................................. 367 BATTERY CABLES................................................................................ 368 DESCRIPTION............................................................................... 368 OPERATION................................................................................. 368 DIAGNOSIS AND TESTING - BATTERY CABLES.................................................... 368 VOLTAGE DROP TEST..................................................................... 368 REMOVAL................................................................................... 370 INSTALLATION.............................................................................. 370 BATTERY TRAY.................................................................................. 371 DESCRIPTION............................................................................... 371 OPERATION................................................................................. 371 REMOVAL................................................................................... 372 INSTALLATION.............................................................................. 372 CHARGING.......................................................................................... 373 CHARGING...................................................................................... 373 DESCRIPTION............................................................................... 373 OPERATION................................................................................. 373 DIAGNOSIS AND TESTING - CHARGING SYSTEM................................................... 374 SPECIFICATIONS............................................................................ 374 GENERATOR RATINGS..................................................................... 374 TORQUE................................................................................ 375 SPECIAL TOOLS............................................................................. 375 BATTERY TEMPERATURE SENSOR.................................................................... 375 DESCRIPTION............................................................................... 375 OPERATION................................................................................. 375 REMOVAL................................................................................... 375 INSTALLATION.............................................................................. 376 GENERATOR..................................................................................... 376 DESCRIPTION............................................................................... 376 OPERATION................................................................................. 376 REMOVAL................................................................................... 376 INSTALLATION.............................................................................. 376 GENERATOR DECOUPLER PULLEY.................................................................... 378 DESCRIPTION............................................................................... 378 OPERATION................................................................................. 378 DIAGNOSIS AND TESTING - GENERATOR DECOUPLER............................................... 378 REMOVAL................................................................................... 378 INSTALLATION.............................................................................. 381 VOLTAGE REGULATOR............................................................................. 382 DESCRIPTION............................................................................... 382 OPERATION................................................................................. 382 STARTING.......................................................................................... 383 STARTING...................................................................................... 383 DESCRIPTION............................................................................... 383 OPERATION................................................................................. 383 DIAGNOSIS AND TESTING - STARTING SYSTEM................................................... 384 TESTING............................................................................... 385 INSPECTION - STARTING SYSTEM.............................................................. 388 SPECIFICATIONS............................................................................ 389 STARTER............................................................................... 389 TORQUE................................................................................ 389 STARTER MOTOR................................................................................. 389 DIAGNOSIS AND TESTING - STARTER MOTOR/SOLENOID............................................ 389 STARTER MOTOR TESTING................................................................. 390 STARTER SOLENOID TESTING.............................................................. 390 REMOVAL................................................................................... 390 INSTALLATION.............................................................................. 392 STARTER MOTOR RELAY........................................................................... 392 DESCRIPTION............................................................................... 392 OPERATION................................................................................. 392 DIAGNOSIS AND TESTING - STARTER RELAY..................................................... 392 RELAY TEST............................................................................ 392 RELAY CIRCUIT TEST.................................................................... 393 REMOVAL................................................................................... 393 INSTALLATION.............................................................................. 393 8g-HEATED SYSTEMS..................................................................................... 395 HEATED GLASS...................................................................................... 395 HEATED GLASS.................................................................................. 395 DESCRIPTION............................................................................... 395 OPERATION................................................................................. 395 DIAGNOSIS AND TESTING..................................................................... 396 ELECTRIC BACKLIGHT (EBL) SYSTEM....................................................... 396 REAR WINDOW DEFOGGER RELAY.................................................................... 397 DESCRIPTION............................................................................... 397 OPERATION................................................................................. 397 REMOVAL................................................................................... 397 INSTALLATION.............................................................................. 398 REAR WINDOW DEFOGGER SWITCH................................................................... 398 DESCRIPTION............................................................................... 398 OPERATION................................................................................. 398 DIAGNOSIS AND TESTING..................................................................... 399 REAR WINDOW DEFOGGER SWITCH........................................................... 399 REMOVAL................................................................................... 399 INSTALLATION.............................................................................. 399 REAR WINDOW DEFOGGER GRID..................................................................... 400 STANDARD PROCEDURE........................................................................ 400 GRID LINE AND TERMINAL REPAIR......................................................... 400 HEATED MIRRORS.................................................................................... 401 HEATED MIRRORS................................................................................ 401 DESCRIPTION............................................................................... 401 OPERATION................................................................................. 401 8h-HORN............................................................................................... 403 HORN SYSTEM....................................................................................... 403 DESCRIPTION................................................................................... 403 OPERATION..................................................................................... 403 HORN.............................................................................................. 403 DESCRIPTION................................................................................... 403 OPERATION..................................................................................... 403 DIAGNOSIS AND TESTING - HORN.................................................................. 403 REMOVAL....................................................................................... 404 INSTALLATION.................................................................................. 404 HORN SWITCH....................................................................................... 404 DESCRIPTION................................................................................... 404 OPERATION..................................................................................... 404 DIAGNOSIS AND TESTING - HORN SWITCH........................................................... 404 REMOVAL....................................................................................... 405 INSTALLATION.................................................................................. 405 8i-IGNITION CONTROL................................................................................... 407 IGNITION CONTROL.................................................................................. 407 DESCRIPTION................................................................................... 407 OPERATION..................................................................................... 407 2.4L...................................................................................... 407 4.0L...................................................................................... 408 SPECIFICATIONS................................................................................ 408 SPECIFICATIONS - IGNITION TIMING.......................................................... 408 ENGINE FIRING ORDER - 2.4L 4-CYLINDER..................................................... 408 ENGINE FIRING ORDER - 4.0L 6-CYLINDER ENGINE.............................................. 408 IGNITION COIL RESISTANCE - 2.4L........................................................... 409 IGNITION COIL RESISTANCE - 4.0L ENGINE.................................................... 409 SPARK PLUGS............................................................................... 409 SPECIFICATIONS - SPARK PLUG CABLE RESISTANCE.............................................. 409 SPECIFICATIONS - TORQUE - IGNITION SYSTEM................................................. 410 AUTO SHUT DOWN RELAY.............................................................................. 410 DESCRIPTION - PCM OUTPUT...................................................................... 410 OPERATION..................................................................................... 410 OPERATION - ASD SENSE - PCM INPUT......................................................... 410 OPERATION - PCM OUTPUT.................................................................... 410 DIAGNOSIS AND TESTING - ASD AND FUEL PUMP RELAYS.............................................. 410 REMOVAL....................................................................................... 411 INSTALLATION.................................................................................. 412 CAMSHAFT POSITION SENSOR - 2.4L................................................................... 412 DESCRIPTION - 2.4L............................................................................ 412 OPERATION - 2.4L.............................................................................. 412 REMOVAL - 2.4L................................................................................ 412 INSTALLATION - 2.4L........................................................................... 412 CAMSHAFT POSITION SENSOR - 4.0L................................................................... 414 DESCRIPTION - 4.0L............................................................................ 414 OPERATION - 4.0L.............................................................................. 414 REMOVAL - 4.0L................................................................................ 415 CMP SENSOR ONLY - 4.0L ................................................................... 415 OIL PUMP DRIVE AND CMP SENSOR - 4.0L...................................................... 416 INSTALLATION - 4.0L........................................................................... 416 SENSOR ONLY - 4.0L ....................................................................... 416 OIL PUMP DRIVE AND CMP SENSOR - 4.0L...................................................... 417 COIL RAIL - 4.0L.................................................................................. 418 DESCRIPTION - 4.0L............................................................................ 418 OPERATION - 4.0L.............................................................................. 418 REMOVAL - 4.0L................................................................................ 419 INSTALLATION - 4.0L........................................................................... 420 IGNITION COIL - 2.4L.............................................................................. 420 DESCRIPTION - 2.4L............................................................................ 420 OPERATION - 2.4L.............................................................................. 420 REMOVAL - 2.4L................................................................................ 421 INSTALLATION - 2.4L........................................................................... 421 SPARK PLUG........................................................................................ 421 DESCRIPTION................................................................................... 421 OPERATION..................................................................................... 421 DIAGNOSIS AND TESTING - SPARK PLUG CONDITIONS................................................. 421 NORMAL OPERATING.......................................................................... 421 COLD FOULING/CARBON FOULING............................................................... 422 WET FOULING OR GAS FOULING................................................................ 422 OIL OR ASH ENCRUSTED...................................................................... 422 ELECTRODE GAP BRIDGING.................................................................... 422 SCAVENGER DEPOSITS........................................................................ 423 CHIPPED ELECTRODE INSULATOR............................................................... 423 PREIGNITION DAMAGE........................................................................ 423 SPARK PLUG OVERHEATING.................................................................... 423 REMOVAL....................................................................................... 424 2.4L...................................................................................... 424 4.0L...................................................................................... 424 CLEANING SPARK PLUGS.......................................................................... 424 INSTALLATION.................................................................................. 424 2.4L...................................................................................... 424 4.0L...................................................................................... 424 SPARK PLUG CABLE.................................................................................. 425 DESCRIPTION................................................................................... 425 OPERATION..................................................................................... 425 DIAGNOSIS AND TESTING......................................................................... 425 REMOVAL - 2.4L................................................................................ 425 INSTALLATION.................................................................................. 425 8j-INSTRUMENT CLUSTER................................................................................. 427 INSTRUMENT CLUSTER................................................................................ 428 DESCRIPTION................................................................................... 428 OPERATION..................................................................................... 430 INPUT AND OUTPUT CIRCUITS................................................................. 436 DIAGNOSIS AND TESTING - INSTRUMENT CLUSTER.................................................... 436 REMOVAL....................................................................................... 442 DISASSEMBLY................................................................................... 443 ASSEMBLY...................................................................................... 444 INSTALLATION.................................................................................. 445 ABS INDICATOR..................................................................................... 446 DESCRIPTION................................................................................... 446 OPERATION..................................................................................... 446 DIAGNOSIS AND TESTING - ABS INDICATOR......................................................... 446 AIRBAG INDICATOR.................................................................................. 447 DESCRIPTION................................................................................... 447 OPERATION..................................................................................... 447 BRAKE/PARK BRAKE INDICATOR........................................................................ 448 DESCRIPTION................................................................................... 448 OPERATION..................................................................................... 448 DIAGNOSIS AND TESTING - BRAKE INDICATOR....................................................... 449 CHECK GAUGES INDICATOR............................................................................ 450 DESCRIPTION................................................................................... 450 OPERATION..................................................................................... 450 CRUISE INDICATOR.................................................................................. 451 DESCRIPTION................................................................................... 451 OPERATION..................................................................................... 451 ENGINE TEMPERATURE GAUGE.......................................................................... 451 DESCRIPTION................................................................................... 451 OPERATION..................................................................................... 452 FOG LAMP INDICATOR................................................................................ 452 DESCRIPTION................................................................................... 452 OPERATION..................................................................................... 453 DIAGNOSIS AND TESTING - FRONT/REAR FOG LAMP INDICATOR......................................... 453 FRONT LOCK INDICATOR.............................................................................. 453 DESCRIPTION................................................................................... 453 OPERATION..................................................................................... 454 FUEL GAUGE........................................................................................ 455 DESCRIPTION................................................................................... 455 OPERATION..................................................................................... 455 HIGH BEAM INDICATOR............................................................................... 456 DESCRIPTION................................................................................... 456 OPERATION..................................................................................... 456 DIAGNOSIS AND TESTING - HIGH BEAM INDICATOR................................................... 456 LOW FUEL INDICATOR................................................................................ 457 DESCRIPTION................................................................................... 457 OPERATION..................................................................................... 457 MALFUNCTION INDICATOR LAMP (MIL).................................................................. 458 DESCRIPTION................................................................................... 458 OPERATION..................................................................................... 458 ODOMETER.......................................................................................... 459 DESCRIPTION................................................................................... 459 OPERATION..................................................................................... 459 OIL PRESSURE GAUGE................................................................................ 460 DESCRIPTION................................................................................... 460 OPERATION..................................................................................... 460 REAR LOCK INDICATOR............................................................................... 461 DESCRIPTION................................................................................... 461 OPERATION..................................................................................... 461 SEATBELT INDICATOR................................................................................ 462 DESCRIPTION................................................................................... 462 OPERATION..................................................................................... 462 SHIFT INDICATOR (TRANSFER CASE)................................................................... 463 DESCRIPTION................................................................................... 463 OPERATION..................................................................................... 463 DIAGNOSIS AND TESTING - 4WD INDICATOR......................................................... 464 SKIS INDICATOR.................................................................................... 465 DESCRIPTION................................................................................... 465 OPERATION..................................................................................... 465 SPEEDOMETER....................................................................................... 466 DESCRIPTION................................................................................... 466 OPERATION..................................................................................... 466 TACHOMETER........................................................................................ 467 DESCRIPTION................................................................................... 467 OPERATION..................................................................................... 467 TURN SIGNAL INDICATOR............................................................................. 467 DESCRIPTION................................................................................... 467 OPERATION..................................................................................... 468 VOLTAGE GAUGE..................................................................................... 468 DESCRIPTION................................................................................... 468 OPERATION..................................................................................... 468 8l-LAMPS.............................................................................................. 471 LAMPS/LIGHTING - EXTERIOR......................................................................... 471 LAMPS/LIGHTING - EXTERIOR..................................................................... 472 DESCRIPTION - TURN SIGNAL & HAZARD WARNING SYSTEM......................................... 472 OPERATION - TURN SIGNAL & HAZARD WARNING SYSTEM........................................... 473 WARNING................................................................................... 473 DIAGNOSIS AND TESTING..................................................................... 473 DIAGNOSIS AND TESTING - TURN SIGNAL & HAZARD WARNING SYSTEM........................... 473 DIAGNOSIS AND TESTING - HEADLAMP SYSTEM............................................... 474 SPECIFICATIONS............................................................................ 476 EXTERIOR LAMPS........................................................................ 476 SPECIAL TOOLS............................................................................. 476 HEADLAMP ALIGNMENT.................................................................... 476 BRAKE LAMP SWITCH............................................................................. 476 DESCRIPTION............................................................................... 476 OPERATION................................................................................. 477 DIAGNOSIS AND TESTING - BRAKE LAMP SWITCH................................................. 477 SWITCH CIRCUIT IDENTIFICATION......................................................... 477 SWITCH CONTINUITY TEST................................................................ 477 REMOVAL................................................................................... 477 INSTALLATION.............................................................................. 477 ADJUSTMENTS............................................................................... 478 ADJUSTMENT............................................................................ 478 CENTER HIGH MOUNTED STOP LAMP UNIT............................................................ 478 REMOVAL................................................................................... 478 INSTALLATION.............................................................................. 478 CENTER HIGH MOUNTED STOP LAMP................................................................. 478 REMOVAL................................................................................... 478 INSTALLATION.............................................................................. 478 COMBINATION FLASHER........................................................................... 479 DESCRIPTION............................................................................... 479 OPERATION................................................................................. 479 REMOVAL................................................................................... 479 INSTALLATION.............................................................................. 480 DAYTIME RUNNING LAMP MODULE................................................................... 480 DESCRIPTION............................................................................... 480 OPERATION................................................................................. 481 DIAGNOSIS AND TESTING - DAYTIME RUNNING LAMP SYSTEM....................................... 481 REMOVAL................................................................................... 481 INSTALLATION.............................................................................. 481 FOG LAMP UNIT................................................................................. 482 DIAGNOSIS AND TESTING - FRONT FOG LAMP SYSTEM............................................. 482 REMOVAL................................................................................... 483 INSTALLATION.............................................................................. 483 ADJUSTMENTS............................................................................... 483 FOG LAMP...................................................................................... 484 REMOVAL................................................................................... 484 INSTALLATION.............................................................................. 484 FOG LAMP RELAY................................................................................ 485 DESCRIPTION............................................................................... 485 OPERATION................................................................................. 485 REMOVAL................................................................................... 485 INSTALLATION.............................................................................. 485 FOG LAMP UNIT - REAR.......................................................................... 485 DESCRIPTION............................................................................... 485 OPERATION................................................................................. 485 DIAGNOSIS AND TESTING - REAR FOG LAMP..................................................... 486 REMOVAL................................................................................... 486 INSTALLATION.............................................................................. 487 FOG LAMP - REAR............................................................................... 487 REMOVAL................................................................................... 487 INSTALLATION.............................................................................. 487 FRONT PARK/TURN SIGNAL LAMP UNIT.............................................................. 487 DESCRIPTION............................................................................... 487 OPERATION................................................................................. 488 REMOVAL................................................................................... 488 INSTALLATION.............................................................................. 488 FRONT PARK/TURN SIGNAL LAMP................................................................... 488 REMOVAL................................................................................... 488 INSTALLATION.............................................................................. 488 HEADLAMP...................................................................................... 488 DESCRIPTION............................................................................... 488 OPERATION................................................................................. 488 REMOVAL................................................................................... 488 INSTALLATION.............................................................................. 489 ADJUSTMENTS............................................................................... 489 HEADLAMP ALIGNMENT PREPARATION........................................................ 489 ALIGNMENT SCREEN PREPARATION.......................................................... 489 HEADLAMP ADJUSTMENT................................................................... 489 HEADLAMP LEVELING SWITCH...................................................................... 491 REMOVAL................................................................................... 491 HEADLAMP LEVELING SWITCH.............................................................. 491 INSTALLATION.............................................................................. 491 HEADLAMP LEVELING MOTOR....................................................................... 491 DIAGNOSIS AND TESTING - HEADLAMP LEVELING SYSTEM.......................................... 491 LEFT MULTI-FUNCTION SWITCH.................................................................... 493 DESCRIPTION............................................................................... 493 OPERATION................................................................................. 493 DIAGNOSIS AND TESTING - LEFT MULTI-FUNCTION SWITCH........................................ 495 REMOVAL................................................................................... 496 INSTALLATION.............................................................................. 497 SIDE MARKER LAMP UNIT......................................................................... 498 REMOVAL................................................................................... 498 INSTALLATION.............................................................................. 498 SIDE MARKER LAMP.............................................................................. 498 REMOVAL................................................................................... 498 INSTALLATION.............................................................................. 498 REPEATER LAMP................................................................................. 498 DESCRIPTION............................................................................... 498 OPERATION................................................................................. 498 DIAGNOSIS AND TESTING - SIDE REPEATER LAMP................................................ 498 TAIL LAMP UNIT................................................................................ 499 DESCRIPTION............................................................................... 499 OPERATION................................................................................. 499 REMOVAL................................................................................... 499 INSTALLATION.............................................................................. 499 TAIL LAMP..................................................................................... 500 REMOVAL................................................................................... 500 INSTALLATION.............................................................................. 500 TURN SIGNAL CANCEL CAM........................................................................ 500 DESCRIPTION............................................................................... 500 OPERATION................................................................................. 500 UNDERHOOD LAMP UNIT........................................................................... 501 REMOVAL................................................................................... 501 INSTALLATION.............................................................................. 501 UNDERHOOD LAMP................................................................................ 501 REMOVAL................................................................................... 501 INSTALLATION.............................................................................. 501 LAMPS/LIGHTING - INTERIOR......................................................................... 502 LAMPS/LIGHTING - INTERIOR..................................................................... 502 SPECIFICATIONS............................................................................ 502 INTERIOR LAMPS........................................................................ 502 DOME LAMP UNIT................................................................................ 502 REMOVAL................................................................................... 502 INSTALLATION.............................................................................. 502 DOME LAMP..................................................................................... 503 REMOVAL................................................................................... 503 INSTALLATION.............................................................................. 503 DOOR AJAR SWITCH.............................................................................. 503 DESCRIPTION............................................................................... 503 OPERATION................................................................................. 504 DIAGNOSIS AND TESTING - DOOR AJAR SWITCH.................................................. 504 REMOVAL................................................................................... 504 INSTALLATION.............................................................................. 504 REAR WIPER/WASHER SWITCH ILLUMINATION LAMP.................................................... 505 REMOVAL................................................................................... 505 INSTALLATION.............................................................................. 505 8n-POWER SYSTEMS...................................................................................... 507 AUTOMATIC DAY / NIGHT MIRROR...................................................................... 507 DESCRIPTION................................................................................... 507 OPERATION..................................................................................... 507 DIAGNOSIS AND TESTING - AUTOMATIC DAY/NIGHT MIRROR............................................ 508 STANDARD PROCEDURE............................................................................ 508 STANDARD PROCEDURE - COMPASS CALIBRATION.................................................. 508 AUTOMATIC CALIBRATION................................................................. 508 MANUAL CALIBRATION.................................................................... 508 STANDARD PROCEDURE - COMPASS VARIATION ADJUSTMENT......................................... 509 8o-RESTRAINTS......................................................................................... 511 RESTRAINTS........................................................................................ 511 DESCRIPTION................................................................................... 511 ACTIVE RESTRAINTS......................................................................... 511 PASSIVE RESTRAINTS........................................................................ 513 OPERATION..................................................................................... 514 ACTIVE RESTRAINTS......................................................................... 514 PASSIVE RESTRAINTS........................................................................ 514 WARNING....................................................................................... 515 WARNINGS - RESTRAINT SYSTEM............................................................... 515 DIAGNOSIS AND TESTING - SUPPLEMENTAL RESTRAINT SYSTEM......................................... 516 STANDARD PROCEDURE............................................................................ 516 STANDARD PROCEDURE - HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS........................ 516 SUPPLEMENTAL RESTRAINT STORAGE........................................................ 516 STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT.................... 516 CLEANUP PROCEDURE..................................................................... 516 STANDARD PROCEDURE - VERIFICATION TEST.................................................... 517 AIRBAG CONTROL MODULE............................................................................. 518 DESCRIPTION0 - 4 TJ (Continued)........................................................... 518 OPERATION..................................................................................... 518 REMOVAL....................................................................................... 520 INSTALLATION.................................................................................. 521 CHILD RESTRAINT ANCHOR............................................................................ 522 DESCRIPTION................................................................................... 522 OPERATION..................................................................................... 523 REMOVAL....................................................................................... 523 INSTALLATION.................................................................................. 524 CLOCKSPRING....................................................................................... 524 DESCRIPTION................................................................................... 524 OPERATION..................................................................................... 525 STANDARD PROCEDURE - CLOCKSPRING CENTERING.................................................... 526 REMOVAL....................................................................................... 526 INSTALLATION.................................................................................. 528 DRIVER AIRBAG..................................................................................... 529 DESCRIPTION................................................................................... 529 OPERATION..................................................................................... 529 REMOVAL....................................................................................... 530 DISASSEMBLY................................................................................... 531 ASSEMBLY...................................................................................... 532 INSTALLATION.................................................................................. 533 FRONT SEAT BELT & RETRACTOR....................................................................... 534 REMOVAL....................................................................................... 534 INSTALLATION.................................................................................. 535 FRONT SEAT BELT BUCKLE............................................................................ 536 REMOVAL....................................................................................... 536 INSTALLATION.................................................................................. 536 PASSENGER AIRBAG.................................................................................. 537 DESCRIPTION................................................................................... 537 OPERATION..................................................................................... 537 REMOVAL....................................................................................... 538 INSTALLATION.................................................................................. 538 PASSENGER AIRBAG DOOR............................................................................. 539 REMOVAL....................................................................................... 539 INSTALLATION.................................................................................. 540 PASSENGER AIRBAG ON/OFF SWITCH.................................................................... 541 DESCRIPTION................................................................................... 541 OPERATION..................................................................................... 541 REMOVAL....................................................................................... 542 INSTALLATION.................................................................................. 542 REAR SEAT BELT & RETRACTOR........................................................................ 543 REMOVAL....................................................................................... 543 INSTALLATION.................................................................................. 544 REAR SEAT BELT BUCKLE............................................................................. 544 REMOVAL....................................................................................... 544 INSTALLATION.................................................................................. 545 SEAT BELT SWITCH.................................................................................. 545 DESCRIPTION................................................................................... 545 OPERATION..................................................................................... 545 DIAGNOSIS AND TESTING - SEAT BELT SWITCH...................................................... 546 SEAT BELT TURNING LOOP ADJUSTER................................................................... 546 REMOVAL....................................................................................... 546 INSTALLATION.................................................................................. 547 8p-SPEED CONTROL...................................................................................... 549 SPEED CONTROL..................................................................................... 549 DESCRIPTION................................................................................... 549 OPERATION..................................................................................... 549 DIAGNOSIS AND TESTING - ROAD TEST............................................................. 550 SPECIFICATIONS................................................................................ 550 TORQUE - SPEED CONTROL.................................................................... 550 CABLE............................................................................................. 551 DESCRIPTION................................................................................... 551 OPERATION..................................................................................... 551 REMOVAL....................................................................................... 551 INSTALLATION.................................................................................. 551 SERVO............................................................................................. 552 DESCRIPTION................................................................................... 552 OPERATION..................................................................................... 552 REMOVAL....................................................................................... 552 INSTALLATION.................................................................................. 553 SWITCH............................................................................................ 553 DESCRIPTION................................................................................... 553 OPERATION..................................................................................... 553 Multiplexing.............................................................................. 554 REMOVAL....................................................................................... 554 INSTALLATION.................................................................................. 554 VACUUM RESERVOIR.................................................................................. 555 DESCRIPTION................................................................................... 555 OPERATION..................................................................................... 555 DIAGNOSIS AND TESTING - VACUUM RESERVOIR...................................................... 555 REMOVAL....................................................................................... 555 INSTALLATION.................................................................................. 555 8q-VEHICLE THEFT SECURITY............................................................................. 557 VEHICLE THEFT SECURITY............................................................................ 557 DESCRIPTION................................................................................... 557 OPERATION..................................................................................... 557 DIAGNOSIS AND TESTING - SENTRY KEY IMMOBILIZER SYSTEM......................................... 558 STANDARD PROCEDURE............................................................................ 560 STANDARD PROCEDURE - SKIS INITIALIZATION.................................................. 560 STANDARD PROCEDURE - SENTRY KEY TRANSPONDER PROGRAMMING................................... 560 SKIS INDICATOR.................................................................................... 561 DESCRIPTION................................................................................... 561 OPERATION..................................................................................... 561 TRANSPONDER KEY................................................................................... 562 DESCRIPTION................................................................................... 562 OPERATION..................................................................................... 562 8r-WIPERS/WASHERS..................................................................................... 563 FRONT WIPERS/WASHERS.............................................................................. 563 FRONT WIPERS/WASHERS.......................................................................... 563 DESCRIPTION............................................................................... 563 OPERATING MODES....................................................................... 565 OPERATION................................................................................. 565 OPERATING MODES....................................................................... 566 DIAGNOSIS AND TESTING - FRONT WIPER & WASHER SYSTEM....................................... 567 WIPER SYSTEM.......................................................................... 567 WASHER SYSTEM......................................................................... 568 CLEANING - FRONT WIPER & WASHER SYSTEM.................................................... 569 WIPER SYSTEM.......................................................................... 569 WASHER SYSTEM......................................................................... 569 INSPECTION - FRONT WIPER & WASHER SYSTEM.................................................. 569 WIPER SYSTEM.......................................................................... 569 WASHER SYSTEM......................................................................... 570 FRONT CHECK VALVE............................................................................. 570 DESCRIPTION............................................................................... 570 OPERATION................................................................................. 571 REMOVAL................................................................................... 571 INSTALLATION.............................................................................. 572 FRONT WASHER HOSES/TUBES...................................................................... 572 DESCRIPTION............................................................................... 572 OPERATION................................................................................. 572 FRONT WASHER NOZZLE........................................................................... 572 DESCRIPTION............................................................................... 572 OPERATION................................................................................. 573 REMOVAL................................................................................... 573 INSTALLATION.............................................................................. 573 FRONT WASHER PUMP MOTOR....................................................................... 573 DESCRIPTION............................................................................... 573 OPERATION................................................................................. 574 REMOVAL................................................................................... 574 INSTALLATION.............................................................................. 575 FRONT WIPER ARM............................................................................... 575 DESCRIPTION............................................................................... 575 OPERATION................................................................................. 575 REMOVAL................................................................................... 575 INSTALLATION.............................................................................. 576 FRONT WIPER BLADE............................................................................. 576 DESCRIPTION............................................................................... 576 OPERATION................................................................................. 577 REMOVAL................................................................................... 577 INSTALLATION.............................................................................. 577 FRONT WIPER MODULE............................................................................ 577 DESCRIPTION............................................................................... 577 OPERATION................................................................................. 578 REMOVAL................................................................................... 578 DISASSEMBLY............................................................................... 579 ASSEMBLY.................................................................................. 579 INSTALLATION.............................................................................. 579 RIGHT MULTI-FUNCTION SWITCH................................................................... 580 DESCRIPTION............................................................................... 580 OPERATION................................................................................. 581 DIAGNOSIS AND TESTING - RIGHT MULTI-FUNCTION SWITCH....................................... 581 REMOVAL................................................................................... 582 INSTALLATION.............................................................................. 583 WASHER RESERVOIR.............................................................................. 584 DESCRIPTION............................................................................... 584 OPERATION................................................................................. 584 REMOVAL................................................................................... 584 INSTALLATION.............................................................................. 585 REAR WIPERS/WASHERS............................................................................... 586 REAR WIPERS/WASHERS........................................................................... 586 DESCRIPTION............................................................................... 586 OPERATING MODES....................................................................... 588 OPERATION................................................................................. 588 OPERATING MODES....................................................................... 588 DIAGNOSIS AND TESTING - REAR WIPER & WASHER SYSTEM........................................ 589 WIPER SYSTEM.......................................................................... 589 WASHER SYSTEM......................................................................... 590 CLEANING - REAR WIPER & WASHER SYSTEM..................................................... 590 WIPER SYSTEM.......................................................................... 590 WASHER SYSTEM......................................................................... 591 INSPECTION - REAR WIPER & WASHER SYSTEM................................................... 591 WIPER SYSTEM.......................................................................... 591 WASHER SYSTEM......................................................................... 591 REAR CHECK VALVE.............................................................................. 592 DESCRIPTION............................................................................... 592 OPERATION................................................................................. 592 REMOVAL................................................................................... 593 INSTALLATION.............................................................................. 593 REAR WASHER HOSES/TUBES....................................................................... 593 DESCRIPTION............................................................................... 593 OPERATION................................................................................. 594 REAR WASHER NOZZLE............................................................................ 594 DESCRIPTION............................................................................... 594 OPERATION................................................................................. 594 REMOVAL................................................................................... 595 INSTALLATION.............................................................................. 595 REAR WASHER PUMP MOTOR........................................................................ 595 DESCRIPTION............................................................................... 595 OPERATION................................................................................. 596 REMOVAL................................................................................... 596 INSTALLATION.............................................................................. 596 REAR WIPER ARM................................................................................ 596 DESCRIPTION............................................................................... 596 OPERATION................................................................................. 597 REMOVAL................................................................................... 597 INSTALLATION.............................................................................. 597 REAR WIPER BLADE.............................................................................. 598 DESCRIPTION............................................................................... 598 OPERATION................................................................................. 599 REMOVAL................................................................................... 599 INSTALLATION.............................................................................. 599 REAR WIPER MOTOR.............................................................................. 599 DESCRIPTION............................................................................... 599 OPERATION................................................................................. 600 REMOVAL................................................................................... 600 INSTALLATION.............................................................................. 601 REAR WIPER MOTOR TRIM COVER................................................................... 601 REMOVAL................................................................................... 601 INSTALLATION.............................................................................. 602 REAR WIPER/WASHER SWITCH...................................................................... 602 DESCRIPTION............................................................................... 602 OPERATION................................................................................. 602 DIAGNOSIS AND TESTING - REAR WIPER & WASHER SWITCH........................................ 603 REMOVAL................................................................................... 603 INSTALLATION.............................................................................. 604 8w-WIRING............................................................................................. 605 8W-01 WIRING DIAGRAM INFORMATION.................................................................. 607 WIRING DIAGRAM INFORMATION.................................................................... 607 DESCRIPTION............................................................................... 607 DESCRIPTION - HOW TO USE WIRING DIAGRAMS.............................................. 607 SYMBOLS........................................................................... 607 TERMINOLOGY....................................................................... 611 DESCRIPTION - CIRCUIT INFORMATION..................................................... 611 DESCRIPTION - CIRCUIT FUNCTIONS....................................................... 612 DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION.................................. 612 DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION................................ 613 IDENTIFICATION.................................................................... 613 LOCATIONS......................................................................... 613 WARNINGS - GENERAL........................................................................ 613 DIAGNOSIS AND TESTING - WIRING HARNESS.................................................... 613 TROUBLESHOOTING TOOLS................................................................. 613 INTERMITTENT AND POOR CONNECTIONS..................................................... 614 TROUBLESHOOTING WIRING PROBLEMS....................................................... 614 STANDARD PROCEDURE........................................................................ 614 STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES.................. 614 STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL..................................... 615 STANDARD PROCEDURE - TESTING FOR CONTINUITY........................................... 615 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND.................................... 615 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS.... 616 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP....................................... 616 SPECIAL TOOLS............................................................................. 616 WIRING/TERMINAL....................................................................... 616 CONNECTOR..................................................................................... 617 REMOVAL................................................................................... 617 INSTALLATION.............................................................................. 617 DIODE......................................................................................... 620 REMOVAL................................................................................... 620 INSTALLATION.............................................................................. 620 TERMINAL...................................................................................... 620 REMOVAL................................................................................... 620 INSTALLATION.............................................................................. 620 WIRE.......................................................................................... 621 STANDARD PROCEDURE - WIRE SPLICING........................................................ 621 8W-02 COMPONENT INDEX............................................................................. 623 8W-10 POWER DISTRIBUTION.......................................................................... 625 8W-11 FUSE BLOCK.................................................................................. 645 8W-15 GROUND DISTRIBUTION......................................................................... 657 8W-18 BUS COMMUNICATIONS.......................................................................... 669 8W-20 CHARGING SYSTEM............................................................................. 673 8W-21 STARTING SYSTEM............................................................................. 675 8W-30 FUEL/IGNITION SYSTEM........................................................................ 679 8W-31 TRANSMISSION CONTROL SYSTEM................................................................. 701 8W-33 VEHICLE SPEED CONTROL....................................................................... 715 8W-35 ANTILOCK BRAKES............................................................................. 719 8W-39 VEHICLE THEFT SECURITY SYSTEM............................................................... 723 8W-40 INSTRUMENT CLUSTER.......................................................................... 725 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET............................................................. 735 8W-42 AIR CONDITIONING-HEATER..................................................................... 739 8W-43 AIRBAG SYSTEM............................................................................... 749 8W-44 INTERIOR LIGHTING........................................................................... 751 8W-47 AUDIO SYSTEM................................................................................ 757 8W-48 REAR WINDOW DEFOGGER........................................................................ 763 8W-50 FRONT LIGHTING.............................................................................. 767 8W-51 REAR LIGHTING............................................................................... 777 8W-52 TURN SIGNALS................................................................................ 785 8W-53 WIPERS...................................................................................... 789 8W-70 SPLICE INFORMATION.......................................................................... 793 8W-80 CONNECTOR PIN-OUTS.......................................................................... 801 8W-91 CONNECTOR/GROUND/SPLICE LOCATION............................................................ 857 CONNECTOR/GROUND/SPLICE LOCATION.............................................................. 857 DESCRIPTION............................................................................... 857 8W-97 POWER DISTRIBUTION.......................................................................... 905 POWER DISTRIBUTION............................................................................ 905 DESCRIPTION............................................................................... 905 OPERATION................................................................................. 905 SPECIAL TOOLS............................................................................. 906 POWER DISTRIBUTION SYSTEMS............................................................ 906 CIGAR LIGHTER OUTLET.......................................................................... 906 DESCRIPTION............................................................................... 906 OPERATION................................................................................. 906 DIAGNOSIS AND TESTING - CIGAR LIGHTER OUTLET.............................................. 906 FUSE BLOCK.................................................................................... 907 DESCRIPTION............................................................................... 907 OPERATION................................................................................. 908 REMOVAL................................................................................... 908 INSTALLATION.............................................................................. 908 IOD FUSE...................................................................................... 909 DESCRIPTION............................................................................... 909 OPERATION................................................................................. 909 REMOVAL................................................................................... 909 INSTALLATION.............................................................................. 909 MICRO-RELAY................................................................................... 910 DESCRIPTION............................................................................... 910 OPERATION................................................................................. 910 DIAGNOSIS AND TESTING - MICRO-RELAY....................................................... 910 REMOVAL................................................................................... 910 INSTALLATION.............................................................................. 910 POWER DISTRIBUTION CENTER..................................................................... 911 DESCRIPTION............................................................................... 911 OPERATION................................................................................. 911 REMOVAL................................................................................... 911 DISASSEMBLY............................................................................... 912 POWER DISTRIBUTION CENTER DISASSEMBLY................................................. 912 PDC HOUSING LOWER COVER REMOVAL................................................... 912 PDC B(+) TERMINAL MODULE REMOVAL.................................................. 913 PDC RELAY WEDGE REMOVAL........................................................... 913 PDC RELAY CASSETTE REMOVAL........................................................ 913 ASSEMBLY.................................................................................. 914 POWER DISTRIBUTION CENTER ASSEMBLY.................................................... 914 PDC HOUSING LOWER COVER INSTALLATION.............................................. 914 PDC B+ TERMINAL MODULE INSTALLATION............................................... 914 PDC RELAY WEDGE INSTALLATION...................................................... 914 PDC RELAY CASSETTE INSTALLATION................................................... 915 INSTALLATION.............................................................................. 915 POWER DISTRIBUTION CENTER SUPPORT BRACKET..................................................... 916 REMOVAL................................................................................... 916 INSTALLATION.............................................................................. 916 POWER OUTLET.................................................................................. 916 DESCRIPTION............................................................................... 916 OPERATION................................................................................. 916 DIAGNOSIS AND TESTING - POWER OUTLET...................................................... 917 REMOVAL................................................................................... 917 INSTALLATION.............................................................................. 917 RELAY......................................................................................... 918 DESCRIPTION............................................................................... 918 OPERATION................................................................................. 918 DIAGNOSIS AND TESTING - RELAY............................................................. 918 DIAGNOSIS & TESTING - RELAY CIRCUIT TEST.............................................. 918 REMOVAL................................................................................... 919 INSTALLATION.............................................................................. 919 9-ENGINE.............................................................................................. 921 ENGINE 2.4L....................................................................................... 921 ENGINE 2.4L................................................................................... 923 DESCRIPTION............................................................................... 923 DIAGNOSIS AND TESTING..................................................................... 923 CYLINDER COMPRESSION PRESSURE TEST.................................................... 923 ENGINE DIAGNOSIS - PERFORMANCE........................................................ 924 CYLINDER COMBUSTION PRESSURE LEAKAGE TEST............................................. 925 ENGINE OIL LEAK INSPECTION............................................................ 926 INSPECTION FOR REAR SEAL AREA LEAKS............................................... 926 ENGINE DIAGNOSIS...................................................................... 927 ENGINE MECHANICAL..................................................................... 927 STANDARD PROCEDURE........................................................................ 929 REPAIR OF DAMAGED OR WORN THREADS..................................................... 929 HYDROSTATIC LOCKED ENGINE............................................................. 929 ENGINE CORE AND OIL GALLERY PLUGS..................................................... 930 ENGINE GASKET SURFACE PREPARATION..................................................... 930 MEASURING BEARING CLEARANCE USING PLASTIGAGE.......................................... 931 FORM-IN-PLACE GASKETS AND SEALERS..................................................... 931 SEALER APPLICATION................................................................ 932 REMOVAL - ENGINE ASSEMBLY................................................................. 932 INSTALLATION - ENGINE ASSEMBLY............................................................ 933 SPECIFICATIONS............................................................................ 934 SPECIFICATIONS - 2.4L ENGINE.......................................................... 934 SPECIFICATIONS - TORQUE............................................................... 938 SPECIAL TOOLS............................................................................. 939 2.4L ENGINE........................................................................... 939 AIR CLEANER ELEMENT - 2.4L.................................................................... 941 REMOVAL - 2.4L............................................................................ 941 INSTALLATION - 2.4L....................................................................... 941 AIR CLEANER HOUSING........................................................................... 941 REMOVAL................................................................................... 941 INSTALLATION.............................................................................. 942 CYLINDER HEAD................................................................................. 942 DESCRIPTION............................................................................... 942 OPERATION................................................................................. 942 DIAGNOSIS AND TESTING..................................................................... 942 CYLINDER HEAD GASKET.................................................................. 942 CYLINDER-TO-CYLINDER LEAKAGE TEST................................................. 942 CYLINDER-TO-WATER JACKET LEAKAGE TEST............................................. 942 REMOVAL - CYLINDER HEAD................................................................... 943 CLEANING.................................................................................. 943 INSPECTION................................................................................ 943 INSTALLATION - CYLINDER HEAD.............................................................. 944 CAMSHAFT OIL SEAL(S).......................................................................... 945 REMOVAL................................................................................... 945 INSTALLATION.............................................................................. 946 CAMSHAFT(S)................................................................................... 946 DESCRIPTION............................................................................... 946 OPERATION................................................................................. 946 STANDARD PROCEDURE - CAMSHAFT END-PLAY.................................................... 947 REMOVAL................................................................................... 947 CLEANING.................................................................................. 947 INSPECTION................................................................................ 947 INSTALLATION.............................................................................. 948 CYLINDER HEAD COVER........................................................................... 948 REMOVAL................................................................................... 948 CLEANING.................................................................................. 948 INSPECTION................................................................................ 948 INSTALLATION.............................................................................. 949 INTAKE/EXHAUST VALVES & SEATS................................................................. 950 DESCRIPTION............................................................................... 950 CLEANING.................................................................................. 950 VALVE SPRINGS................................................................................. 950 REMOVAL................................................................................... 950 REMOVAL - CYLINDER HEAD ON............................................................ 950 REMOVAL - CYLINDER HEAD OFF........................................................... 950 INSPECTION................................................................................ 951 INSTALLATION.............................................................................. 951 INSTALLATION - CYLINDER HEAD ON....................................................... 951 INSTALLATION - CYLINDER HEAD OFF...................................................... 951 HYDRAULIC LIFTERS............................................................................. 952 DIAGNOSIS AND TESTING..................................................................... 952 LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS................................................ 952 REMOVAL................................................................................... 952 INSTALLATION.............................................................................. 952 ROCKER ARMS................................................................................... 952 REMOVAL................................................................................... 952 INSPECTION................................................................................ 953 INSTALLATION.............................................................................. 953 ENGINE BLOCK.................................................................................. 953 DESCRIPTION............................................................................... 953 STANDARD PROCEDURE........................................................................ 953 PISTON TO CYLINDER BORE FITTING....................................................... 953 CYLINDER BORE HONING.................................................................. 954 CLEANING.................................................................................. 954 INSPECTION................................................................................ 954 ENGINE BLOCK.......................................................................... 954 CYLINDER BORE......................................................................... 955 CONNECTING ROD BEARINGS....................................................................... 955 STANDARD PROCEDURE........................................................................ 955 CONNECTING ROD - FITTING.............................................................. 955 CRANKSHAFT.................................................................................... 956 DESCRIPTION............................................................................... 956 OPERATION................................................................................. 956 STANDARD PROCEDURE - CRANKSHAFT END PLAY.................................................. 956 REMOVAL................................................................................... 956 INSPECTION................................................................................ 957 INSTALLATION.............................................................................. 957 CRANKSHAFT MAIN BEARINGS...................................................................... 959 STANDARD PROCEDURE - MAIN BEARING - FITTING............................................... 959 CRANKSHAFT MAIN BEARINGS.............................................................. 959 MAIN BEARING INSTALLATION ............................................................ 959 CRANKSHAFT OIL SEAL - FRONT................................................................... 960 REMOVAL................................................................................... 960 INSTALLATION.............................................................................. 961 CRANKSHAFT OIL SEAL - REAR.................................................................... 962 REMOVAL................................................................................... 962 INSTALLATION.............................................................................. 962 PISTON & CONNECTING ROD....................................................................... 963 DESCRIPTION............................................................................... 963 OPERATION................................................................................. 963 REMOVAL................................................................................... 963 INSTALLATION.............................................................................. 964 PISTON RINGS.................................................................................. 965 STANDARD PROCEDURE........................................................................ 965 PISTON RING - FITTING................................................................. 965 PISTON RINGS - INSTALLATION ...................................................... 966 VIBRATION DAMPER.............................................................................. 967 REMOVAL................................................................................... 967 INSTALLATION.............................................................................. 967 STRUCTURAL COLLAR............................................................................. 967 REMOVAL................................................................................... 967 INSTALLATION.............................................................................. 967 ENGINE MOUNTING............................................................................... 967 DESCRIPTION............................................................................... 967 FRONT MOUNT................................................................................... 968 REMOVAL................................................................................... 968 INSTALLATION.............................................................................. 968 REAR MOUNT.................................................................................... 969 REMOVAL................................................................................... 969 INSTALLATION.............................................................................. 969 LUBRICATION................................................................................... 969 DESCRIPTION............................................................................... 969 OPERATION................................................................................. 969 DIAGNOSIS AND TESTING..................................................................... 970 ENGINE OIL PRESSURE CHECKING.......................................................... 970 OIL........................................................................................... 970 STANDARD PROCEDURE........................................................................ 970 ENGINE OIL LEVEL CHECK................................................................ 970 ENGINE OIL AND FILTER CHANGE.......................................................... 970 OIL FILTER.................................................................................... 971 DESCRIPTION............................................................................... 971 REMOVAL................................................................................... 971 INSTALLATION.............................................................................. 971 OIL PAN....................................................................................... 971 REMOVAL................................................................................... 971 INSTALLATION.............................................................................. 972 OIL PRESSURE SENSOR/SWITCH.................................................................... 972 DESCRIPTION............................................................................... 972 OPERATION................................................................................. 972 OIL PUMP...................................................................................... 972 REMOVAL................................................................................... 972 DISASSEMBLY............................................................................... 973 CLEANING.................................................................................. 973 INSPECTION................................................................................ 973 ASSEMBLY.................................................................................. 974 INSTALLATION.............................................................................. 974 INTAKE MANIFOLD............................................................................... 975 DESCRIPTION............................................................................... 975 OPERATION................................................................................. 975 DIAGNOSIS AND TESTING..................................................................... 975 INTAKE MANIFOLD LEAKS................................................................. 975 REMOVAL................................................................................... 975 INSPECTION................................................................................ 976 INSTALLATION.............................................................................. 976 EXHAUST MANIFOLD.............................................................................. 976 DESCRIPTION............................................................................... 976 OPERATION................................................................................. 976 REMOVAL................................................................................... 976 CLEANING.................................................................................. 977 INSPECTION................................................................................ 977 INSTALLATION.............................................................................. 977 TIMING BELT COVER(S).......................................................................... 977 REMOVAL................................................................................... 977 FRONT COVER........................................................................... 977 REAR COVER............................................................................ 977 INSTALLATION.............................................................................. 977 REAR COVER............................................................................ 977 FRONT COVER........................................................................... 977 TIMING BELT AND SPROCKET(S)................................................................... 978 REMOVAL................................................................................... 978 TIMING BELT........................................................................... 978 CRANKSHAFT SPROCKET................................................................... 979 CLEANING.................................................................................. 979 INSTALLATION.............................................................................. 979 CRANKSHAFT SPROCKET................................................................... 979 TIMING BELT........................................................................... 980 TIMING BELT TENSIONER & PULLEY................................................................ 982 REMOVAL................................................................................... 982 INSTALLATION.............................................................................. 982 BALANCE SHAFTS AND CARRIER ASSEMBLY........................................................... 983 DESCRIPTION............................................................................... 983 OPERATION................................................................................. 983 REMOVAL................................................................................... 983 BALANCE SHAFTS/CHAIN/SPROCKETS........................................................ 983 BALANCE SHAFT CARRIER................................................................. 983 INSTALLATION.............................................................................. 985 BALANCE SHAFT INSTALLATION/TIMING..................................................... 985 BALANCE SHAFT CARRIER......................................................................... 987 DESCRIPTION............................................................................... 987 OPERATION................................................................................. 987 REMOVAL................................................................................... 987 INSTALLATION.............................................................................. 987 BALANCE SHAFT CHAIN........................................................................... 987 REMOVAL................................................................................... 987 INSTALLATION.............................................................................. 987 ENGINE 4.0L....................................................................................... 988 ENGINE 4.0L................................................................................... 990 DESCRIPTION............................................................................... 990 DESCRIPTION - ENGINE BLOCK............................................................ 990 DESCRIPTION - ENGINE.................................................................. 990 DIAGNOSIS AND TESTING..................................................................... 991 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION............................... 991 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE................................ 991 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL................................. 994 DIAGNOSIS AND TESTING—CYLINDER COMPRESSION PRESSURE................................... 996 DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE.......................... 996 STANDARD PROCEDURE........................................................................ 997 STANDARD PROCEDURE - FORM-IN-PLACE GASKETS............................................ 997 MOPAR SILICONE RUBBER ADHESIVE SEALANT............................................ 997 MOPAR GASKET MAKER................................................................ 997 SURFACE PREPARATION............................................................... 997 GASKET APPLICATION................................................................ 997 STANDARD PROCEDURE - HYDROSTATIC LOCK................................................. 998 STANDARD PROCEDURE - SERVICE ENGINE ASSEMBLY (SHORT BLOCK)............................ 998 STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS................................... 998 STANDARD PROCEDURE - ENGINE PERFORMANCE............................................... 998 REMOVAL................................................................................... 998 INSTALLATION..............................................................................1000 SPECIFICATIONS............................................................................1001 ENGINE - 4.0L.........................................................................1001 TORQUE - 4.0L ENGINE..................................................................1005 AIR CLEANER ELEMENT...........................................................................1006 REMOVAL...................................................................................1006 INSTALLATION..............................................................................1006 AIR CLEANER HOUSING...........................................................................1006 REMOVAL...................................................................................1006 INSTALLATION..............................................................................1006 CYLINDER HEAD.................................................................................1006 DESCRIPTION...............................................................................1006 DIAGNOSIS AND TESTING - ENGINE CYLINDER HEAD GASKET FAILURE...............................1007 CYLINDER-TO-CYLINDER LEAKAGE TEST.....................................................1007 CYLINDER-TO-WATER JACKET LEAKAGE TEST.................................................1007 REMOVAL...................................................................................1007 CLEANING..................................................................................1008 INSPECTION................................................................................1008 INSTALLATION..............................................................................1008 CYLINDER HEAD COVER(S)........................................................................1010 DESCRIPTION...............................................................................1010 REMOVAL...................................................................................1010 CLEANING..................................................................................1010 INSPECTION................................................................................1010 INSTALLATION..............................................................................1010 INTAKE/EXHAUST VALVES & SEATS.................................................................1011 DESCRIPTION...............................................................................1011 STANDARD PROCEDURE - VALVE SERVICE........................................................1011 VALVE REFACING........................................................................1011 VALVE SEAT REFACING...................................................................1011 VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT.............................................1012 REMOVAL...................................................................................1013 INSTALLATION..............................................................................1013 ROCKER ARM / ADJUSTER ASSEMBLY................................................................1014 DESCRIPTION...............................................................................1014 OPERATION.................................................................................1014 REMOVAL...................................................................................1014 CLEANING..................................................................................1014 INSPECTION................................................................................1014 INSTALLATION..............................................................................1015 VALVE STEM SEALS..............................................................................1015 DESCRIPTION...............................................................................1015 VALVE SPRINGS.................................................................................1016 DESCRIPTION...............................................................................1016 STANDARD PROCEDURE - VALVE SPRING TENSION TEST............................................1016 REMOVAL...................................................................................1016 INSTALLATION..............................................................................1017 ENGINE BLOCK..................................................................................1017 CLEANING..................................................................................1017 INSPECTION................................................................................1018 CAMSHAFT & BEARINGS (IN BLOCK)................................................................1018 DESCRIPTION...............................................................................1018 REMOVAL...................................................................................1018 REMOVAL - CAMSHAFT BEARINGS...........................................................1018 REMOVAL - CAMSHAFT....................................................................1019 INSTALLATION..............................................................................1020 INSTALLATION - CAMSHAFT BEARINGS......................................................1020 INSTALLATION - CAMSHAFT...............................................................1020 CONNECTING ROD BEARINGS.......................................................................1021 STANDARD PROCEDURE - FITTING CONNECTING ROD BEARINGS......................................1021 BEARING-TO-JOURNAL CLEARANCE..........................................................1021 SIDE CLEARANCE MEASUREMENT............................................................1023 CRANKSHAFT....................................................................................1023 DESCRIPTION...............................................................................1023 CRANKSHAFT MAIN BEARINGS......................................................................1023 STANDARD PROCEDURE - FITTING CRANKSHAFT MAIN BEARINGS.....................................1023 FITTING BEARINGS (CRANKSHAFT INSTALLED)...............................................1023 BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT INSTALLED)...................................1024 JOURNAL DIAMETER (CRANKSHAFT REMOVED).................................................1025 REMOVAL...................................................................................1026 INSPECTION................................................................................1027 INSTALLATION..............................................................................1027 CRANKSHAFT OIL SEAL - FRONT...................................................................1028 REMOVAL...................................................................................1028 INSTALLATION..............................................................................1029 CRANKSHAFT OIL SEAL - REAR....................................................................1029 REMOVAL...................................................................................1029 INSTALLATION..............................................................................1029 HYDRAULIC LIFTERS.............................................................................1030 DESCRIPTION...............................................................................1030 REMOVAL...................................................................................1030 CLEANING..................................................................................1030 INSPECTION................................................................................1030 INSTALLATION..............................................................................1031 PISTON & CONNECTING ROD.......................................................................1031 DESCRIPTION...............................................................................1031 STANDARD PROCEDURE - PISTON FITTING.......................................................1031 REMOVAL...................................................................................1032 INSTALLATION..............................................................................1033 PISTON RINGS..................................................................................1034 STANDARD PROCEDURE - PISTON RING FITTING..................................................1034 VIBRATION DAMPER..............................................................................1037 REMOVAL...................................................................................1037 INSTALLATION..............................................................................1037 STRUCTURAL SUPPORT............................................................................1037 REMOVAL...................................................................................1037 INSTALLATION..............................................................................1037 FRONT MOUNT...................................................................................1038 REMOVAL...................................................................................1038 INSTALLATION..............................................................................1039 REAR MOUNT....................................................................................1039 REMOVAL...................................................................................1039 ALL TRANSMISSIONS.....................................................................1039 MANUAL TRANSMISSIONS..................................................................1039 AUTOMATIC TRANSMISSIONS...............................................................1039 INSTALLATION..............................................................................1039 MANUAL TRANSMISSION...................................................................1039 AUTOMATIC TRANSMISSION................................................................1040 ALL TRANSMISSIONS0 - 6 TJ (Continued).............................................1040 LUBRICATION...................................................................................1040 DESCRIPTION...............................................................................1040 OPERATION.................................................................................1040 DIAGNOSIS AND TESTING.....................................................................1042 DIAGNOSIS AND TESTING - ENGINE OIL PRESSURE...........................................1042 DIAGNOSIS AND TESTING - ENGINE OIL LEAK...............................................1042 Air Leak Detection Test Method....................................................1042 INSPECTION FOR REAR SEAL AREA LEAKS...............................................1042 OIL...........................................................................................1043 STANDARD PROCEDURE - ENGINE OIL SERVICE...................................................1043 ENGINE OIL CHANGE.....................................................................1043 CRANKCASE OIL LEVEL INSPECTION........................................................1043 USED ENGINE OIL DISPOSAL..............................................................1044 OIL FILTER....................................................................................1044 REMOVAL...................................................................................1044 INSTALLATION..............................................................................1044 OIL PAN.......................................................................................1044 DESCRIPTION...............................................................................1044 REMOVAL...................................................................................1044 INSTALLATION..............................................................................1045 ENGINE OIL PRESSURE SENSOR....................................................................1046 DESCRIPTION...............................................................................1046 OPERATION.................................................................................1046 OIL PUMP......................................................................................1046 REMOVAL...................................................................................1046 INSTALLATION..............................................................................1046 VALVE TIMING..................................................................................1047 STANDARD PROCEDURE - VALVE TIMING.........................................................1047 TIMING BELT / CHAIN COVER(S)..................................................................1047 REMOVAL...................................................................................1047 INSTALLATION..............................................................................1047 TIMING BELT/CHAIN AND SPROCKETS...............................................................1048 REMOVAL...................................................................................1048 INSTALLATION..............................................................................1049 INTAKE MANIFOLD...............................................................................1049 DESCRIPTION...............................................................................1049 DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKAGE...........................................1049 REMOVAL...................................................................................1049 INSTALLATION..............................................................................1050 EXHAUST MANIFOLD..............................................................................1051 DESCRIPTION...............................................................................1051 REMOVAL...................................................................................1051 11-EXHAUST SYSTEM.....................................................................................1053 EXHAUST SYSTEM....................................................................................1053 DESCRIPTION...................................................................................1053 DIAGNOSIS AND TESTING - EXHAUST SYSTEM........................................................1056 SPECIFICATIONS................................................................................1056 TORQUE....................................................................................1056 CATALYTIC CONVERTER...............................................................................1056 DESCRIPTION...................................................................................1056 REMOVAL.......................................................................................1057 REMOVAL - 2.4L............................................................................1057 REMOVAL - 4.0L............................................................................1057 INSTALLATION..................................................................................1058 INSTALLATION - 2.4L.......................................................................1058 INSTALLATION - 4.0L.......................................................................1058 EXHAUST PIPE......................................................................................1058 REMOVAL.......................................................................................1058 REMOVAL - 2.4L............................................................................1058 REMOVAL - 4.0L............................................................................1059 INSTALLATION..................................................................................1059 INSTALLATION - 2.4L.......................................................................1059 INSTALLATION - 4.0L.......................................................................1060 HEAT SHIELDS......................................................................................1060 DESCRIPTION...................................................................................1060 REMOVAL.......................................................................................1060 INSTALLATION..................................................................................1060 MUFFLER...........................................................................................1061 DESCRIPTION...................................................................................1061 REMOVAL.......................................................................................1061 INSTALLATION..................................................................................1062 TAILPIPE..........................................................................................1063 DESCRIPTION...................................................................................1063 TAILPIPE..................................................................................1063 DESCRIPTION...........................................................................1063 OPERATION.....................................................................................1063 13-FRAME & BUMPERS....................................................................................1065 FRAME & BUMPERS...................................................................................1065 SPECIFICATIONS................................................................................1065 TORQUE SPECIFICATIONS.....................................................................1065 FRONT EXTENSION...................................................................................1066 REMOVAL.......................................................................................1066 INSTALLATION..................................................................................1066 FRONT BUMPER......................................................................................1066 REMOVAL.......................................................................................1066 INSTALLATION..................................................................................1066 REAR EXTENSION....................................................................................1066 REMOVAL.......................................................................................1066 INSTALLATION..................................................................................1066 REAR BUMPER.......................................................................................1066 REMOVAL.......................................................................................1066 INSTALLATION..................................................................................1067 FRAME.............................................................................................1067 STANDARD PROCEDURE - FRAME SERVICE............................................................1067 SAFETY PRECAUTIONS AND WARNINGS...........................................................1067 FRAME STRAIGHTENING.......................................................................1067 FRAME REPAIRS.............................................................................1067 FRAME FASTENERS...........................................................................1068 SPECIFICATIONS................................................................................1068 FRAME DIMENSIONS..........................................................................1068 VEHICLE PREPARATION...................................................................1068 TRANSFER CASE SKID PLATE..........................................................................1073 REMOVAL.......................................................................................1073 INSTALLATION..................................................................................1073 FUEL TANK SKID PLATE..............................................................................1074 REMOVAL.......................................................................................1074 INSTALLATION..................................................................................1074 FRONT TOW HOOK....................................................................................1074 REMOVAL.......................................................................................1074 INSTALLATION..................................................................................1074 REAR TOW HOOK.....................................................................................1075 REMOVAL.......................................................................................1075 INSTALLATION..................................................................................1075 TRANSMISSION SKID PLATE...........................................................................1075 REMOVAL.......................................................................................1075 INSTALLATION..................................................................................1075 14-FUEL SYSTEM........................................................................................1077 FUEL DELIVERY.....................................................................................1077 FUEL DELIVERY.................................................................................1077 DESCRIPTION...............................................................................1077 OPERATION.................................................................................1077 STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE.........................................1078 SPECIFICATIONS............................................................................1078 FUEL SYSTEM PRESSURE..................................................................1078 TORQUE - FUEL DELIVERY................................................................1078 SPECIAL TOOLS.............................................................................1079 FUEL SYSTEM...........................................................................1079 FUEL PRESSURE REGULATOR.......................................................................1079 DESCRIPTION...............................................................................1079 FUEL LEVEL SENDING UNIT / SENSOR..............................................................1079 DESCRIPTION...............................................................................1079 FUEL LINES....................................................................................1079 DESCRIPTION...............................................................................1079 FUEL PUMP.....................................................................................1079 DESCRIPTION...............................................................................1079 FUEL PUMP MODULE..............................................................................1080 DESCRIPTION...............................................................................1080 Electric Fuel Pump....................................................................1080 Fuel Filters..........................................................................1080 Fuel Pressure Regulator...............................................................1080 Fuel Gauge Sending Unit (Fuel level sensor)...........................................1080 REMOVAL...................................................................................1081 INSTALLATION..............................................................................1081 FUEL RAIL/FUEL DAMPER - 2.4L..................................................................1082 DESCRIPTION - 2.4L........................................................................1082 OPERATION - 2.4L..........................................................................1082 REMOVAL - 2.4L............................................................................1082 INSTALLATION - 2.4L.......................................................................1083 FUEL RAIL - 4.0L ENGINE.......................................................................1084 DESCRIPTION - 4.0L........................................................................1084 OPERATION - 4.0L..........................................................................1084 REMOVAL - 4.0L............................................................................1084 INSTALLATION - 4.0L.......................................................................1084 FUEL TANK.....................................................................................1085 DESCRIPTION...............................................................................1085 OPERATION.................................................................................1085 REMOVAL...................................................................................1086 INSTALLATION..............................................................................1088 INLET FILTER..................................................................................1091 REMOVAL...................................................................................1091 INSTALLATION..............................................................................1091 QUICK CONNECT FITTING.........................................................................1092 DESCRIPTION...............................................................................1092 STANDARD PROCEDURE - QUICK-CONNECT FITTINGS...............................................1092 DISCONNECTING.........................................................................1092 CONNECTING............................................................................1096 FUEL INJECTION....................................................................................1097 FUEL INJECTION................................................................................1098 DESCRIPTION...............................................................................1098 SPECIFICATIONS............................................................................1098 TORQUE - FUEL INJECTION...............................................................1098 ACCELERATOR PEDAL.............................................................................1099 REMOVAL...................................................................................1099 INSTALLATION..............................................................................1099 CRANKSHAFT POSITION SENSOR....................................................................1099 DESCRIPTION...............................................................................1099 OPERATION.................................................................................1099 REMOVAL...................................................................................1100 INSTALLATION..............................................................................1101 FUEL INJECTOR.................................................................................1103 DESCRIPTION...............................................................................1103 OPERATION.................................................................................1103 OPERATION - PCM OUTPUT................................................................1103 OPERATION - FUEL INJECTOR.............................................................1103 REMOVAL...................................................................................1103 INSTALLATION..............................................................................1104 FUEL PUMP RELAY...............................................................................1104 DESCRIPTION...............................................................................1104 OPERATION.................................................................................1104 REMOVAL...................................................................................1104 INSTALLATION..............................................................................1104 IDLE AIR CONTROL MOTOR........................................................................1104 DESCRIPTION...............................................................................1104 OPERATION.................................................................................1104 REMOVAL...................................................................................1105 INSTALLATION..............................................................................1106 INTAKE AIR TEMPERATURE SENSOR.................................................................1106 DESCRIPTION...............................................................................1106 OPERATION.................................................................................1106 REMOVAL...................................................................................1106 INSTALLATION..............................................................................1107 MAP SENSOR....................................................................................1107 DESCRIPTION...............................................................................1107 OPERATION.................................................................................1107 REMOVAL...................................................................................1108 INSTALLATION..............................................................................1109 O2 HEATER RELAY...............................................................................1110 DESCRIPTION...............................................................................1110 OPERATION.................................................................................1110 REMOVAL...................................................................................1110 INSTALLATION..............................................................................1110 O2 SENSOR.....................................................................................1110 DESCRIPTION...............................................................................1110 OPERATION.................................................................................1110 REMOVAL...................................................................................1111 INSTALLATION..............................................................................1112 THROTTLE BODY.................................................................................1112 DESCRIPTION...............................................................................1112 OPERATION.................................................................................1112 REMOVAL...................................................................................1113 INSTALLATION..............................................................................1113 THROTTLE CONTROL CABLE........................................................................1114 REMOVAL...................................................................................1114 INSTALLATION..............................................................................1116 THROTTLE POSITION SENSOR......................................................................1116 DESCRIPTION...............................................................................1116 OPERATION.................................................................................1116 REMOVAL...................................................................................1116 INSTALLATION..............................................................................1117 19-STEERING...........................................................................................1119 STEERING..........................................................................................1119 DESCRIPTION...................................................................................1119 OPERATION.....................................................................................1120 DIAGNOSIS AND TESTING.........................................................................1120 DIAGNOSIS AND TESTING - POWER STEERING SYSTEM DIAGNOSIS CHARTS............................1120 DIAGNOSIS AND TESTING - POWER STEERING FLOW AND PRESSURE..................................1122 FLOW AND PRESSURE TEST................................................................1122 COLUMN............................................................................................1124 COLUMN........................................................................................1124 DESCRIPTION...............................................................................1124 OPERATION - SERVICE PRECAUTIONS...........................................................1124 REMOVAL...................................................................................1124 INSTALLATION..............................................................................1126 SPECIFICATIONS............................................................................1127 TORQUE CHART..........................................................................1127 IGNITION SWITCH...............................................................................1127 DESCRIPTION...............................................................................1127 DIAGNOSIS AND TESTING - IGNITION SWITCH...................................................1127 ELECTRICAL DIAGNOSIS..................................................................1127 MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE)........................................1127 REMOVAL...................................................................................1127 INSTALLATION..............................................................................1128 KEY-IN IGNITION SWITCH........................................................................1128 DESCRIPTION...............................................................................1128 DIAGNOSIS AND TESTING - KEY-IN IGNITION SWITCH............................................1128 KEY CYLINDER..................................................................................1129 REMOVAL...................................................................................1129 INSTALLATION..............................................................................1129 STEERING WHEEL................................................................................1129 REMOVAL...................................................................................1129 INSTALLATION..............................................................................1130 GEAR..............................................................................................1131 GEAR..........................................................................................1131 DESCRIPTION...............................................................................1131 OPERATION.................................................................................1131 DIAGNOSIS AND TESTING - POWER STEERING GEAR LEAKAGE AREAS.................................1131 REMOVAL...................................................................................1131 INSTALLATION..............................................................................1132 ADJUSTMENTS...............................................................................1133 WORM THRUST BEARING PRELOAD...........................................................1133 OVER-CENTER ROTATING TORQUE...........................................................1133 SPECIFICATIONS............................................................................1134 POWER STEERING GEAR...................................................................1134 TORQUE CHART..........................................................................1134 SPECIAL TOOLS.............................................................................1134 POWER STEERING GEAR...................................................................1134 LINKAGE...........................................................................................1135 LINKAGE.......................................................................................1135 DESCRIPTION...............................................................................1135 STANDARD PROCEDURE........................................................................1135 STANDARD PROCEDURE - LUBRICATION......................................................1135 STANDARD PROCEDURE - STEERING LINKAGE.................................................1135 SPECIFICATIONS............................................................................1136 TORQUE CHART..........................................................................1136 SPECIAL TOOLS.............................................................................1136 STEERING LINKAGE......................................................................1136 DAMPER........................................................................................1136 REMOVAL...................................................................................1136 INSTALLATION..............................................................................1136 DRAG LINK.....................................................................................1137 REMOVAL...................................................................................1137 INSTALLATION..............................................................................1137 PITMAN ARM....................................................................................1137 REMOVAL...................................................................................1137 INSTALLATION..............................................................................1137 TIE ROD END...................................................................................1137 REMOVAL...................................................................................1137 INSTALLATION..............................................................................1137 PUMP..............................................................................................1138 PUMP..........................................................................................1138 DESCRIPTION...............................................................................1138 OPERATION.................................................................................1138 DIAGNOSIS AND TESTING - PUMP LEAKAGE......................................................1138 STANDARD PROCEDURE - POWER STEERING PUMP - INITIAL OPERATION..............................1138 REMOVAL...................................................................................1139 REMOVAL - 4.0L........................................................................1139 REMOVAL - 2.4L........................................................................1139 INSTALLATION..............................................................................1139 INSTALLATION - 4.0L...................................................................1139 INSTALLATION - 2.4L...................................................................1140 SPECIFICATIONS............................................................................1141 TORQUE CHART..........................................................................1141 SPECIAL TOOLS.............................................................................1141 POWER STEERING PUMP...................................................................1141 HOSES.........................................................................................1142 DESCRIPTION...............................................................................1142 DESCRIPTION - PRESSURE LINE...........................................................1142 DESCRIPTION - RETURN LINE.............................................................1142 OPERATION.................................................................................1142 OPERATION - PRESSURE LINE.............................................................1142 OPERATION - RETURN LINE...............................................................1142 FLUID.........................................................................................1142 DESCRIPTION...............................................................................1142 STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING..................................1142 POWER STEERING PRESSURE SWITCH................................................................1142 DESCRIPTION...............................................................................1142 OPERATION.................................................................................1142 REMOVAL...................................................................................1143 INSTALLATION..............................................................................1143 PULLEY........................................................................................1143 REMOVAL...................................................................................1143 INSTALLATION..............................................................................1143 RESERVOIR.....................................................................................1144 REMOVAL...................................................................................1144 REMOVAL - 4.0L........................................................................1144 REMOVAL - 2.4L........................................................................1144 INSTALLATION..............................................................................1144 INSTALLATION - 4.0L...................................................................1144 INSTALLATION - 2.4L...................................................................1144 21-TRANSMISSION AND TRANSFER CASE.....................................................................1145 MANUAL TRANSMISSION - NSG370......................................................................1145 MANUAL TRANSMISSION - NSG370..................................................................1145 DIAGNOSIS AND TESTING.....................................................................1145 MANUAL TRANSMISSION - NSG370..........................................................1145 LOW LUBRICANT LEVEL...............................................................1145 HARD SHIFTING.....................................................................1145 TRANSMISSION NOISE................................................................1145 STANDARD PROCEDURE - DRAIN AND FILL.......................................................1146 REMOVAL...................................................................................1146 DISASSEMBLY...............................................................................1147 MAINSHAFT ............................................................................1150 COUNTERSHAFT .........................................................................1154 FRONT HOUSING ........................................................................1155 INPUT SHAFT ..........................................................................1156 REAR HOUSING .........................................................................1156 CLEANING..................................................................................1158 INSPECTION................................................................................1159 ASSEMBLY..................................................................................1160 MAINSHAFT ............................................................................1160 REAR HOUSING .........................................................................1167 INPUT SHAFT ..........................................................................1169 FRONT HOUSING ........................................................................1170 FINAL ASSEMBLY .......................................................................1171 INSTALLATION..............................................................................1176 SPECIFICATIONS - NSG370...................................................................1179 SPECIAL TOOLS.............................................................................1179 AUTOMATIC TRANSMISSION - 42RLE....................................................................1182 AUTOMATIC TRANSMISSION - 42RLE................................................................1183 DESCRIPTION...............................................................................1183 TRANSMISSION IDENTIFICATION ..........................................................1185 OPERATION.................................................................................1185 FIRST GEAR POWERFLOW .................................................................1186 SECOND GEAR POWERFLOW ................................................................1187 THIRD GEAR POWERFLOW .................................................................1188 FOURTH GEAR POWERFLOW ................................................................1189 REVERSE GEAR POWERFLOW ...............................................................1190 DIAGNOSIS AND TESTING.....................................................................1191 DIAGNOSIS AND TESTING - AUTOMATIC TRANSMISSION........................................1191 DIAGNOSIS AND TESTING - ROAD TEST.....................................................1191 DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TESTS......................................1192 TEST ONE - SELECTOR IN MANUAL 1 (1st Gear)........................................1193 TEST TWO - SELECTOR IN MANUAL 2 (Second Gear).....................................1193 TEST TWO A - SELECTOR IN DRIVE (OD ON - Fourth Gear)..............................1193 TEST THREE - SELECTOR IN DRIVE (OD OFF - Third and Second Gear)...................1193 TEST FOUR - SELECTOR IN DRIVE (OD ON - Fourth Gear)...............................1193 TEST FIVE-SELECTOR IN DRIVE (OD ON - Fourth Gear, CC on)..........................1193 TEST SIX-SELECTOR IN REVERSE......................................................1193 TEST RESULT INDICATIONS...........................................................1194 DIAGNOSIS AND TESTING - CLUTCH AIR PRESSURE TESTS.....................................1195 2/4 CLUTCH........................................................................1195 OVERDRIVE CLUTCH..................................................................1195 REVERSE CLUTCH....................................................................1195 LOW/REVERSE CLUTCH................................................................1195 UNDERDRIVE CLUTCH ................................................................1195 DIAGNOSIS AND TESTING - FLUID LEAKAGE.................................................1195 FLUID LEAKAGE - TORQUE CONVERTER HOUSING AREA ....................................1195 TORQUE CONVERTER LEAKAGE .........................................................1196 STANDARD PROCEDURE - ALUMINUM THREAD REPAIR...............................................1196 REMOVAL...................................................................................1196 DISASSEMBLY...............................................................................1198 ASSEMBLY..................................................................................1214 INSTALLATION..............................................................................1230 SCHEMATICS AND DIAGRAMS - 42RLE TRANSMISSION..............................................1233 SPECIFICATIONS............................................................................1246 42RLE AUTOMATIC TRANSMISSION..........................................................1246 SPECIAL TOOLS.............................................................................1248 42RLE AUTOMATIC TRANSMISSION..........................................................1248 ACCUMULATOR...................................................................................1251 DESCRIPTION...............................................................................1251 OPERATION.................................................................................1251 ADAPTER HOUSING SEAL..........................................................................1251 REMOVAL...................................................................................1251 INSTALLATION..............................................................................1251 BEARINGS......................................................................................1251 ADJUSTMENTS...............................................................................1251 BEARING ADJUSTMENT PROCEDURES.........................................................1251 BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM..................................................1252 DESCRIPTION...............................................................................1252 OPERATION.................................................................................1253 REMOVAL...................................................................................1253 INSTALLATION..............................................................................1253 ADJUSTMENTS...............................................................................1253 ADJUSTMENT - BRAKE TRANSMISSION SHIFT INTERLOCK CABLE.................................1253 DRIVING CLUTCHES..............................................................................1254 DESCRIPTION...............................................................................1254 OPERATION.................................................................................1254 UNDERDRIVE CLUTCH.....................................................................1255 OVERDRIVE CLUTCH......................................................................1255 REVERSE CLUTCH........................................................................1255 FLUID AND FILTER..............................................................................1255 DIAGNOSIS AND TESTING.....................................................................1255 DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID.........................................1255 EFFECTS OF INCORRECT FLUID LEVEL......................................................1255 FLUID CONTAMINATION...................................................................1255 STANDARD PROCEDURE........................................................................1256 STANDARD PROCEDURE - FLUID LEVEL CHECK................................................1256 FLUID LEVEL CHECK.................................................................1256 FLUID LEVEL CHECK USING DRB ......................................................1256 STANDARD PROCEDURE - FLUID/FILTER SERVICE.............................................1256 STANDARD PROCEDURE - TRANSMISSION FILL................................................1257 GEARSHIFT CABLE...............................................................................1258 REMOVAL...................................................................................1258 INSTALLATION..............................................................................1258 HOLDING CLUTCHES..............................................................................1259 DESCRIPTION...............................................................................1259 OPERATION.................................................................................1259 2/4 CLUTCH............................................................................1259 LOW/REVERSE CLUTCH....................................................................1259 INPUT CLUTCH ASSEMBLY.........................................................................1259 DISASSEMBLY...............................................................................1259 ASSEMBLY..................................................................................1266 INPUT SPEED SENSOR............................................................................1276 DESCRIPTION...............................................................................1276 OPERATION.................................................................................1276 REMOVAL...................................................................................1276 INSTALLATION..............................................................................1277 OIL PUMP......................................................................................1277 DESCRIPTION...............................................................................1277 OPERATION.................................................................................1277 DISASSEMBLY...............................................................................1277 ASSEMBLY..................................................................................1278 OUTPUT SPEED SENSOR...........................................................................1279 DESCRIPTION...............................................................................1279 OPERATION.................................................................................1279 REMOVAL...................................................................................1279 INSTALLATION..............................................................................1279 OVERDRIVE SWITCH..............................................................................1280 DESCRIPTION...............................................................................1280 OPERATION.................................................................................1280 REMOVAL...................................................................................1280 INSTALLATION..............................................................................1280 PLANETARY GEARTRAIN...........................................................................1281 DESCRIPTION...............................................................................1281 OPERATION.................................................................................1281 OIL PUMP SEAL.................................................................................1281 REMOVAL...................................................................................1281 INSTALLATION..............................................................................1281 SHIFT MECHANISM...............................................................................1281 DESCRIPTION...............................................................................1281 OPERATION.................................................................................1281 DIAGNOSIS AND TESTING - SHIFT MECHANISM...................................................1281 ADJUSTMENTS - SHIFT MECHANISM.............................................................1282 Gearshift Adjustment Procedure........................................................1282 SOLENOID......................................................................................1282 DESCRIPTION...............................................................................1282 OPERATION.................................................................................1283 SOLENOID/PRESSURE SWITCH ASSY.................................................................1283 DESCRIPTION...............................................................................1283 OPERATION.................................................................................1284 SOLENOIDS.............................................................................1284 PRESSURE SWITCHES.....................................................................1284 REMOVAL...................................................................................1284 INSTALLATION..............................................................................1285 TORQUE CONVERTER..............................................................................1286 DESCRIPTION...............................................................................1286 IMPELLER .............................................................................1287 TURBINE ..............................................................................1288 STATOR ...............................................................................1289 TORQUE CONVERTER CLUTCH (TCC) ........................................................1289 OPERATION.................................................................................1290 TURBINE...............................................................................1290 STATOR................................................................................1290 TORQUE CONVERTER CLUTCH (TCC).........................................................1290 REMOVAL...................................................................................1291 INSTALLATION..............................................................................1291 TRANSMISSION CONTROL RELAY....................................................................1291 DESCRIPTION...............................................................................1291 OPERATION.................................................................................1292 TRANSMISSION RANGE SENSOR.....................................................................1292 DESCRIPTION...............................................................................1292 OPERATION.................................................................................1292 REMOVAL...................................................................................1293 INSTALLATION..............................................................................1293 TRANSMISSION TEMPERATURE SENSOR...............................................................1294 DESCRIPTION...............................................................................1294 OPERATION.................................................................................1294 CALCULATED TEMPERATURE................................................................1294 VALVE BODY....................................................................................1294 DESCRIPTION...............................................................................1294 OPERATION.................................................................................1295 THERMAL VALVE ........................................................................1295 REGULATOR VALVE ......................................................................1296 SOLENOID SWITCH VALVE ................................................................1296 MANUAL VALVE .........................................................................1297 CONVERTER CLUTCH SWITCH VALVE ........................................................1297 CONVERTER CLUTCH CONTROL VALVE .......................................................1297 T/C REGULATOR VALVE...................................................................1298 LOW/REVERSE SWITCH VALVE..............................................................1298 REMOVAL...................................................................................1298 DISASSEMBLY...............................................................................1299 ASSEMBLY..................................................................................1304 INSTALLATION..............................................................................1309 TRANSFER CASE - NV231.............................................................................1310 TRANSFER CASE - NV231.........................................................................1310 DESCRIPTION...............................................................................1310 OPERATING RANGES......................................................................1310 SHIFT MECHANISM.......................................................................1310 IDENTIFICATION........................................................................1311 OPERATION.................................................................................1311 DIAGNOSIS AND TESTING - TRANSFER CASE - NV231.............................................1311 REMOVAL...................................................................................1312 DISASSEMBLY...............................................................................1312 REAR RETAINER AND OIL PUMP............................................................1312 YOKE AND RANGE LEVER..................................................................1314 FRONT OUTPUT SHAFT AND DRIVE CHAIN....................................................1315 SHIFT FORKS AND MAINSHAFT.............................................................1316 MAINSHAFT.............................................................................1317 INPUT GEAR AND LOW RANGE GEAR.........................................................1318 INPUT AND LOW RANGE GEAR..............................................................1319 CLEANING..................................................................................1320 INSPECTION................................................................................1320 MAINSHAFT/SPROCKET/HUB................................................................1320 INPUT GEAR AND PLANETARY CARRIER......................................................1320 SHIFT FORKS/HUBS/SLEEVES..............................................................1321 REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT..............................................1322 REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN....................................................1323 LOW RANGE ANNULUS GEAR................................................................1323 FRONT/REAR CASES AND FRONT RETAINER...................................................1323 OIL PUMP/OIL PICKUP...................................................................1323 ASSEMBLY..................................................................................1324 BEARINGS AND SEALS....................................................................1324 INPUT AND LOW RANGE GEAR..............................................................1328 INPUT GEAR AND LOW RANGE GEAR.........................................................1328 MAINSHAFT.............................................................................1329 SHIFT FORKS AND MAINSHAFT.............................................................1329 FRONT OUTPUT SHAFT AND DRIVE CHAIN....................................................1331 OIL PUMP AND REAR CASE................................................................1332 YOKE AND RANGE LEVER..................................................................1332 REAR RETAINER.........................................................................1333 INSTALLATION..............................................................................1335 SPECIFICATIONS............................................................................1335 TRANSFER CASE - NV231.................................................................1335 SPECIAL TOOLS.............................................................................1336 NV231.................................................................................1336 FLUID.........................................................................................1338 STANDARD PROCEDURE - FLUID DRAIN AND FILL.................................................1338 FRONT OUTPUT SHAFT SEAL.......................................................................1338 REMOVAL...................................................................................1338 INSTALLATION..............................................................................1338 REAR OUTPUT SHAFT SEAL........................................................................1339 REMOVAL...................................................................................1339 INSTALLATION..............................................................................1340 SHIFT LEVER...................................................................................1341 REMOVAL...................................................................................1341 INSTALLATION..............................................................................1341 ADJUSTMENTS - SHIFT LINKAGE...............................................................1343 SPEEDOMETER DRIVE ADAPTER.....................................................................1343 REMOVAL...................................................................................1343 INSTALLATION..............................................................................1343 VEHICLE SPEED SENSOR..........................................................................1344 DESCRIPTION...............................................................................1344 OPERATION.................................................................................1344 REMOVAL...................................................................................1345 INSTALLATION..............................................................................1345 TRANSFER CASE - NV241.............................................................................1346 TRANSFER CASE - NV241.........................................................................1346 DESCRIPTION...............................................................................1346 IDENTIFICATION........................................................................1346 OPERATION.................................................................................1346 OPERATING RANGES......................................................................1346 SHIFT MECHANISM.......................................................................1347 SHIFTING..............................................................................1347 DIAGNOSIS AND TESTING - TRANSFER CASE.....................................................1347 REMOVAL...................................................................................1348 DISASSEMBLY...............................................................................1348 REAR EXTENSION, RETAINER, AND REAR CASE...............................................1349 YOKE AND SHIFT LEVER..................................................................1350 MAINSHAFT, FRONT OUTPUT SHAFT, AND DRIVE CHAIN........................................1352 SHIFT FORKS...........................................................................1354 MAINSHAFT.............................................................................1355 INPUT AND PLANETARY GEAR..............................................................1357 CLEANING..................................................................................1359 INSPECTION................................................................................1359 MAINSHAFT/SPROCKET/HUB................................................................1359 INPUT GEAR AND PLANETARY CARRIER......................................................1359 SHIFT FORKS/HUBS/SLEEVES..............................................................1359 DRIVE CHAIN...........................................................................1359 LOW RANGE ANNULUS GEAR................................................................1359 FRONT-REAR CASES......................................................................1359 OIL PUMP/OIL PICKUP...................................................................1360 ASSEMBLY..................................................................................1360 BEARINGS AND SEALS....................................................................1360 INPUT AND PLANETARY GEAR..............................................................1362 SHIFT FORKS AND MAINSHAFT.............................................................1363 FRONT OUTPUT SHAFT AND DRIVE CHAIN....................................................1366 OIL PUMP AND REAR CASE................................................................1367 YOKE..................................................................................1369 REAR EXTENSION........................................................................1370 INSTALLATION..............................................................................1371 SPECIFICATIONS............................................................................1372 TRANSFER CASE - NV241.................................................................1372 SPECIAL TOOLS.............................................................................1372 TRANSFER CASE - NV241.................................................................1372 REAR EXTENSION SEAL...........................................................................1374 REMOVAL...................................................................................1374 INSTALLATION..............................................................................1374 FLUID.........................................................................................1374 STANDARD PROCEDURE - FLUID DRAIN AND FILL.................................................1374 FRONT OUTPUT SHAFT SEAL.......................................................................1374 REMOVAL...................................................................................1374 INSTALLATION..............................................................................1375 POSITION SENSOR...............................................................................1376 DESCRIPTION...............................................................................1376 OPERATION.................................................................................1376 REMOVAL...................................................................................1376 INSTALLATION..............................................................................1376 SHIFT LEVER...................................................................................1377 REMOVAL...................................................................................1377 INSTALLATION..............................................................................1378 ADJUSTMENTS - SHIFT LINKAGE...............................................................1378 VEHICLE SPEED SENSOR..........................................................................1378 DESCRIPTION...............................................................................1378 OPERATION.................................................................................1378 REMOVAL...................................................................................1379 INSTALLATION..............................................................................1379 22-TIRES/WHEELS.......................................................................................1380 TIRES/WHEELS......................................................................................1380 DIAGNOSIS AND TESTING - TIRE AND WHEEL RUNOUT.................................................1380 METHOD 1 (RELOCATE WHEEL ON HUB)..........................................................1380 METHOD 2 (RELOCATE TIRE ON WHEEL).........................................................1380 STANDARD PROCEDURE............................................................................1381 STANDARD PROCEDURE - ROTATION.............................................................1381 STANDARD PROCEDURE - MATCH MOUNTING.......................................................1382 STANDARD PROCEDURE - TIRE AND WHEEL BALANCE...............................................1383 TIRES.............................................................................................1384 DESCRIPTION...................................................................................1384 DESCRIPTION - TIRES.......................................................................1384 TIRE IDENTIFICATION...................................................................1384 TIRE CHAINS...........................................................................1384 DESCRIPTION - RADIAL-PLY TIRES............................................................1385 DESCRIPTION - TIRE INFLATION PRESSURES....................................................1385 DESCRIPTION - TIRE PRESSURE FOR HIGH SPEED................................................1386 DESCRIPTION - REPLACEMENT TIRES...........................................................1386 DIAGNOSIS AND TESTING.........................................................................1386 DIAGNOSIS AND TESTING - PRESSURE GAUGES...................................................1386 DIAGNOSIS AND TESTING - TREAD WEAR INDICATORS.............................................1386 DIAGNOSIS AND TESTING - TIRE WEAR PATTERNS................................................1386 DIAGNOSIS AND TESTING - TIRE NOISE OR VIBRATION0 - 8 TJ (Continued)...................1387 DIAGNOSIS AND TESTING - TIRE/VEHICLE LEAD.................................................1387 STANDARD PROCEDURE - REPAIRING LEAKS..........................................................1389 CLEANING - TIRES..............................................................................1389 SPECIFICATIONS................................................................................1389 TIRE SIZE.................................................................................1389 SPARE TIRE........................................................................................1389 DESCRIPTION...................................................................................1389 DESCRIPTION - SPARE/TEMPORARY.............................................................1389 DESCRIPTION - FULL SIZE, SPARE WHEEL WITH MATCHING TIRE...................................1389 SPARE TIRE CARRIER................................................................................1390 REMOVAL.......................................................................................1390 INSTALLATION..................................................................................1390 WHEELS............................................................................................1390 DESCRIPTION...................................................................................1390 DIAGNOSIS AND TESTING - WHEEL INSPECTION......................................................1391 STANDARD PROCEDURE............................................................................1391 STANDARD PROCEDURE - WHEEL INSTALLATION...................................................1391 WHEEL REPLACEMENT.....................................................................1391 STANDARD PROCEDURE - WHEEL REPLACEMENT....................................................1391 SPECIFICATIONS................................................................................1392 TORQUE CHART..............................................................................1392 STUDS.............................................................................................1392 REMOVAL.......................................................................................1392 INSTALLATION..................................................................................1392 23-BODY...............................................................................................1394 BODY..............................................................................................1394 WARNING.......................................................................................1394 SAFETY PRECAUTIONS AND WARNINGS...........................................................1394 STANDARD PROCEDURE............................................................................1394 STANDARD PROCEDURE - BODY LUBRICATION.....................................................1394 STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR............................................1395 Rigid Plastics:.......................................................................1395 Semi-Rigid Plastics:..................................................................1395 Flexible Plastics:....................................................................1395 Repair Procedure:.....................................................................1395 Adhesion Promoter/Surface Modifier:...................................................1395 SAFETY PRECAUTION AND WARNINGS........................................................1395 RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES...................................1396 PANEL SECTIONING......................................................................1398 PANEL REINFORCEMENT...................................................................1398 VISUAL INSPECTION.....................................................................1399 PANEL SURFACE PREPARATION.............................................................1399 PATCHING PANELS.......................................................................1399 PANEL PATCH FABRICATIONS..............................................................1400 PANEL PATCH INSTALLATION..............................................................1400 PATCHED PANEL SURFACING...............................................................1402 BUZZ, SQUEAK & RATTLE.....................................................................1402 SPECIFICATIONS - TORQUE.......................................................................1404 SPECIAL TOOLS.................................................................................1405 BODY......................................................................................1405 TAILGATE..........................................................................................1406 TAILGATE OUTSIDE HANDLE.......................................................................1406 REMOVAL...................................................................................1406 INSTALLATION..............................................................................1406 TAILGATE HINGE................................................................................1407 REMOVAL...................................................................................1407 INSTALLATION..............................................................................1407 TAILGATE LATCH................................................................................1407 REMOVAL...................................................................................1407 INSTALLATION..............................................................................1407 TAILGATE LATCH STRIKER........................................................................1408 REMOVAL...................................................................................1408 INSTALLATION..............................................................................1408 LIFTGATE GLASS HINGE..........................................................................1408 REMOVAL...................................................................................1408 INSTALLATION..............................................................................1408 LIFTGATE GLASS................................................................................1408 REMOVAL...................................................................................1408 INSTALLATION..............................................................................1409 LIFTGATE GLASS WEATHERSTRIP...................................................................1409 DESCRIPTION...............................................................................1409 TAILGATE LOCK CYLINDER........................................................................1409 REMOVAL...................................................................................1409 INSTALLATION..............................................................................1409 LIFTGATE GLASS SUPPORT CYLINDER...............................................................1409 REMOVAL...................................................................................1409 INSTALLATION..............................................................................1409 TAILGATE......................................................................................1410 REMOVAL...................................................................................1410 INSTALLATION..............................................................................1410 ADJUSTMENTS...............................................................................1410 ADJUSTMENT............................................................................1410 FULL DOOR.........................................................................................1411 DOOR..........................................................................................1411 REMOVAL...................................................................................1411 INSTALLATION..............................................................................1411 ADJUSTMENTS...............................................................................1411 ADJUSTMENT............................................................................1411 DOOR GLASS....................................................................................1412 REMOVAL...................................................................................1412 INSTALLATION..............................................................................1412 WINDOW REGULATOR..............................................................................1412 REMOVAL...................................................................................1412 INSTALLATION..............................................................................1413 EXTERIOR HANDLE...............................................................................1413 REMOVAL...................................................................................1413 INSTALLATION..............................................................................1413 GLASS RUN CHANNEL.............................................................................1414 REMOVAL...................................................................................1414 INSTALLATION..............................................................................1414 HINGE.........................................................................................1414 REMOVAL...................................................................................1414 INSTALLATION..............................................................................1414 INSIDE HANDLE ACTUATOR........................................................................1415 REMOVAL...................................................................................1415 INSTALLATION..............................................................................1415 LATCH.........................................................................................1415 REMOVAL...................................................................................1415 INSTALLATION..............................................................................1415 LATCH STRIKER.................................................................................1416 REMOVAL...................................................................................1416 INSTALLATION..............................................................................1416 LOCK CYLINDER.................................................................................1416 REMOVAL...................................................................................1416 INSTALLATION..............................................................................1416 TRIM PANEL....................................................................................1416 REMOVAL...................................................................................1416 INSTALLATION..............................................................................1416 HALF DOOR.........................................................................................1417 DOOR..........................................................................................1417 REMOVAL...................................................................................1417 INSTALLATION..............................................................................1417 WINDOW........................................................................................1417 REMOVAL...................................................................................1417 INSTALLATION..............................................................................1417 EXTERIOR HANDLE...............................................................................1418 REMOVAL...................................................................................1418 INSTALLATION..............................................................................1418 HINGE.........................................................................................1418 DESCRIPTION...............................................................................1418 INSIDE HANDLE ACTUATOR........................................................................1418 REMOVAL...................................................................................1418 INSTALLATION..............................................................................1418 LATCH.........................................................................................1418 REMOVAL...................................................................................1418 INSTALLATION..............................................................................1419 LATCH STRIKER.................................................................................1419 REMOVAL...................................................................................1419 INSTALLATION..............................................................................1419 LOCK CYLINDER.................................................................................1419 REMOVAL...................................................................................1419 INSTALLATION..............................................................................1419 TRIM PANEL....................................................................................1419 REMOVAL...................................................................................1419 INSTALLATION..............................................................................1419 EXTERIOR..........................................................................................1420 BODY DECALS...................................................................................1420 DESCRIPTION...............................................................................1420 REMOVAL...................................................................................1420 INSTALLATION..............................................................................1420 COWL GRILLE AND SCREEN........................................................................1421 REMOVAL...................................................................................1421 INSTALLATION..............................................................................1421 RIGHT FRONT FENDER............................................................................1421 REMOVAL...................................................................................1421 INSTALLATION..............................................................................1421 LEFT FRONT FENDER.............................................................................1422 REMOVAL...................................................................................1422 INSTALLATION..............................................................................1422 RADIATOR GRILLE PANEL.........................................................................1423 REMOVAL...................................................................................1423 INSTALLATION..............................................................................1424 WHEELHOUSE SPLASH SHIELD......................................................................1424 REMOVAL...................................................................................1424 INSTALLATION..............................................................................1424 SIDE VIEW MIRROR..............................................................................1425 REMOVAL...................................................................................1425 INSTALLATION..............................................................................1425 WHEEL OPENING FLARE MOLDING...................................................................1425 REMOVAL...................................................................................1425 INSTALLATION..............................................................................1425 EXHAUSTER.....................................................................................1426 REMOVAL...................................................................................1426 INSTALLATION..............................................................................1426 BODY SIDE GUARD...............................................................................1426 REMOVAL...................................................................................1426 INSTALLATION..............................................................................1426 SIDE STEP.....................................................................................1427 REMOVAL...................................................................................1427 INSTALLATION..............................................................................1427 LICENSE PLATE BRACKET.........................................................................1427 REMOVAL...................................................................................1427 INSTALLATION..............................................................................1427 HOOD..............................................................................................1428 HINGE.........................................................................................1428 REMOVAL...................................................................................1428 INSTALLATION..............................................................................1428 HOOD..........................................................................................1429 REMOVAL...................................................................................1429 INSTALLATION..............................................................................1429 ADJUSTMENTS...............................................................................1429 ADJUSTMENT............................................................................1429 HOOD SAFETY LATCH.............................................................................1429 REMOVAL...................................................................................1429 INSTALLATION..............................................................................1429 INSTRUMENT PANEL..................................................................................1430 ACCESSORY SWITCH BEZEL........................................................................1430 REMOVAL...................................................................................1430 INSTALLATION..............................................................................1431 AXLE LOCK SWITCH..............................................................................1431 DESCRIPTION...............................................................................1431 OPERATION.................................................................................1431 DIAGNOSIS AND TESTING - AXLE LOCK SWITCH..................................................1431 REMOVAL...................................................................................1432 INSTALLATION..............................................................................1432 BASE TRIM.....................................................................................1433 REMOVAL...................................................................................1433 INSTALLATION..............................................................................1433 CENTER BEZEL..................................................................................1434 REMOVAL...................................................................................1434 INSTALLATION..............................................................................1434 CLUSTER BEZEL.................................................................................1435 REMOVAL...................................................................................1435 INSTALLATION..............................................................................1435 GLOVE BOX.....................................................................................1436 REMOVAL...................................................................................1436 DISASSEMBLY...............................................................................1436 ASSEMBLY..................................................................................1437 INSTALLATION..............................................................................1437 GLOVE BOX CHECK STRAP.........................................................................1438 REMOVAL...................................................................................1438 INSTALLATION..............................................................................1438 GLOVE BOX LATCH STRIKER.......................................................................1438 REMOVAL...................................................................................1438 INSTALLATION..............................................................................1439 GRAB HANDLE...................................................................................1439 REMOVAL...................................................................................1439 INSTALLATION..............................................................................1439 GRAB HANDLE BEZEL.............................................................................1440 REMOVAL...................................................................................1440 INSTALLATION..............................................................................1440 INSTRUMENT PANEL ASSEMBLY.....................................................................1441 REMOVAL...................................................................................1441 INSTALLATION..............................................................................1442 STEERING COLUMN OPENING COVER.................................................................1443 REMOVAL...................................................................................1443 INSTALLATION..............................................................................1443 TOP COVER.....................................................................................1444 REMOVAL...................................................................................1444 INSTALLATION..............................................................................1444 INTERIOR..........................................................................................1445 ADD-A-TRUNK...................................................................................1445 REMOVAL...................................................................................1445 INSTALLATION..............................................................................1445 FRONT CARPET..................................................................................1446 REMOVAL...................................................................................1446 INSTALLATION..............................................................................1446 CENTER CARPET.................................................................................1447 REMOVAL...................................................................................1447 INSTALLATION..............................................................................1447 CARGO AREA CARPET.............................................................................1447 REMOVAL...................................................................................1447 INSTALLATION..............................................................................1447 WHEELHOUSE CARPET.............................................................................1448 REMOVAL...................................................................................1448 INSTALLATION..............................................................................1448 REAR VIEW MIRROR..............................................................................1448 REMOVAL...................................................................................1448 INSTALLATION..............................................................................1448 REAR VIEW MIRROR SUPPORT BRACKET..............................................................1448 INSTALLATION..............................................................................1448 SUNVISOR......................................................................................1449 REMOVAL...................................................................................1449 INSTALLATION..............................................................................1449 SHIFT BEZEL - AUTOMATIC TRANSMISSION..........................................................1449 REMOVAL...................................................................................1449 INSTALLATION..............................................................................1449 SHIFT BOOT....................................................................................1450 REMOVAL...................................................................................1450 INSTALLATION..............................................................................1450 CENTER CONSOLE................................................................................1450 REMOVAL...................................................................................1450 INSTALLATION..............................................................................1451 CENTER CONSOLE CUP HOLDER.....................................................................1451 REMOVAL...................................................................................1451 INSTALLATION..............................................................................1451 CONSOLE LOCK CYLINDER.........................................................................1452 REMOVAL...................................................................................1452 INSTALLATION..............................................................................1452 SPORT BAR.....................................................................................1452 REMOVAL...................................................................................1452 INSTALLATION..............................................................................1452 A-PILLAR TRIM.................................................................................1454 REMOVAL...................................................................................1454 INSTALLATION..............................................................................1454 REAR HEADER TRIM..............................................................................1454 REMOVAL...................................................................................1454 INSTALLATION..............................................................................1454 WINDSHIELD HEADER.............................................................................1455 REMOVAL...................................................................................1455 INSTALLATION..............................................................................1455 SPORT BAR - SPEAKER POD.......................................................................1455 REMOVAL...................................................................................1455 INSTALLATION..............................................................................1455 PAINT.............................................................................................1456 PAINT.........................................................................................1456 SPECIFICATIONS - PAINT CODES..............................................................1456 PAINT CODE....................................................................................1456 DESCRIPTION...............................................................................1456 BASECOAT/CLEARCOAT FINISH.....................................................................1457 DESCRIPTION...............................................................................1457 PAINT TOUCH-UP................................................................................1457 STANDARD PROCEDURE - PAINT TOUCH-UP.......................................................1457 FINESSE SANDING, BUFFING & POLISHING..........................................................1457 DESCRIPTION...............................................................................1457 REMOVEABLE TOP....................................................................................1458 REMOVEABLE TOP................................................................................1458 STANDARD PROCEDURE........................................................................1458 HARD TOP REPAIR.......................................................................1458 Hard Top Locators.................................................................1458 HARD TOP REPAIR.......................................................................1458 HARD TOP FRACTURE REPAIR..............................................................1459 HARD TOP SAG REPAIR...................................................................1459 HARD TOP......................................................................................1460 REMOVAL...................................................................................1460 INSTALLATION..............................................................................1460 SOFT TOP......................................................................................1461 REMOVAL...................................................................................1461 INSTALLATION..............................................................................1461 SOFT TOP FABRIC...............................................................................1462 REMOVAL...................................................................................1462 INSTALLATION..............................................................................1462 DOOR OPENING FRAME............................................................................1463 REMOVAL...................................................................................1463 INSTALLATION..............................................................................1463 HARD/SOFT TOP LATCH...........................................................................1463 REMOVAL...................................................................................1463 INSTALLATION..............................................................................1463 SEATS.............................................................................................1464 FRONT SEAT....................................................................................1464 REMOVAL...................................................................................1464 INSTALLATION..............................................................................1464 FRONT SEAT BACK...............................................................................1465 REMOVAL...................................................................................1465 INSTALLATION..............................................................................1465 FRONT SEAT BACK COVER.........................................................................1466 REMOVAL...................................................................................1466 INSTALLATION..............................................................................1466 FRONT SEAT CUSHION COVER......................................................................1466 REMOVAL...................................................................................1466 INSTALLATION..............................................................................1466 FRONT SEAT BACK RECLINER/COVER................................................................1466 REMOVAL...................................................................................1466 INSTALLATION..............................................................................1466 FRONT SEAT BACK RECLINER CABLE................................................................1467 REMOVAL...................................................................................1467 INSTALLATION..............................................................................1467 FRONT SEAT FOLDING RELEASE CABLE..............................................................1467 REMOVAL...................................................................................1467 INSTALLATION..............................................................................1468 FRONT SEAT BACK DUMP CABLE....................................................................1468 REMOVAL...................................................................................1468 INSTALLATION..............................................................................1468 FRONT SEAT TRACK ADJUSTER.....................................................................1469 REMOVAL...................................................................................1469 INSTALLATION..............................................................................1469 REAR SEAT.....................................................................................1470 REMOVAL...................................................................................1470 INSTALLATION..............................................................................1470 REAR SEAT BACK................................................................................1470 REMOVAL...................................................................................1470 INSTALLATION..............................................................................1470 REAR SEAT BACK HINGE..........................................................................1471 REMOVAL...................................................................................1471 INSTALLATION..............................................................................1471 REAR SEAT BACK COVER..........................................................................1471 REMOVAL...................................................................................1471 INSTALLATION..............................................................................1471 REAR SEAT CUSHION COVER.......................................................................1472 REMOVAL...................................................................................1472 INSTALLATION..............................................................................1472 REAR SEAT RELEASE CABLE.......................................................................1472 REMOVAL...................................................................................1472 INSTALLATION..............................................................................1472 REAR SEAT STRIKERS............................................................................1473 REMOVAL...................................................................................1473 Rear Strikers.........................................................................1473 Front Strikers........................................................................1473 INSTALLATION..............................................................................1473 Front Strikers........................................................................1473 Rear Strikers.........................................................................1473 STATIONARY GLASS..................................................................................1474 STATIONARY GLASS..............................................................................1474 DESCRIPTION...............................................................................1474 WINDSHIELD SAFETY PRECAUTIONS.........................................................1474 DESCRIPTION.......................................................................1474 QUARTER GLASS.................................................................................1475 REMOVAL...................................................................................1475 INSTALLATION..............................................................................1475 WINDSHIELD....................................................................................1476 REMOVAL...................................................................................1476 INSTALLATION..............................................................................1476 WINDSHIELD HINGE..............................................................................1477 REMOVAL...................................................................................1477 INSTALLATION..............................................................................1477 WINDSHIELD FRAME..............................................................................1478 REMOVAL...................................................................................1478 INSTALLATION..............................................................................1478 WEATHERSTRIP/SEALS................................................................................1479 HOOD TO COWL WEATHERSTRIP.....................................................................1479 REMOVAL...................................................................................1479 INSTALLATION..............................................................................1479 FULL DOOR INNER BELT WEATHERSTRIP.............................................................1479 DESCRIPTION - FULL DOOR INNER BELT WEATHERSTRIP...........................................1479 FULL DOOR OUTER BELT SEAL.....................................................................1480 REMOVAL...................................................................................1480 INSTALLATION..............................................................................1480 FULL DOOR WEATHERSTRIP........................................................................1480 REMOVAL...................................................................................1480 INSTALLATION..............................................................................1480 HALF DOOR WEATHERSTRIP........................................................................1481 REMOVAL...................................................................................1481 INSTALLATION..............................................................................1481 TAILGATE WEATHERSTRIP AND CHANNEL.............................................................1481 REMOVAL...................................................................................1481 INSTALLATION..............................................................................1481 WINDSHIELD FRAME WEATHERSTRIP.................................................................1482 REMOVAL...................................................................................1482 UPPER (Header)........................................................................1482 LOWER.................................................................................1482 INSTALLATION..............................................................................1482 UPPER (Header)........................................................................1482 LOWER.................................................................................1482 BODY STRUCTURE....................................................................................1483 GAP AND FLUSH.................................................................................1483 SPECIFICATIONS - GAP AND FLUSH............................................................1483 OPENING DIMENSIONS............................................................................1486 SPECIFICATIONS............................................................................1486 BODY OPENING DIMENSIONS...............................................................1486 SEALER LOCATIONS..............................................................................1491 SPECIFICATIONS............................................................................1491 SEALER LOCATIONS......................................................................1491 STRUCTURAL ADHESIVE LOCATIONS.................................................................1508 SPECIFICATIONS............................................................................1508 WELD LOCATIONS................................................................................1517 SPECIFICATIONS............................................................................1517 WELD LOCATIONS........................................................................1517 24-HEATING & AIR CONDITIONING.........................................................................1570 HEATING & AIR CONDITIONING........................................................................1570 DESCRIPTION...................................................................................1570 OPERATION.....................................................................................1571 DIAGNOSIS AND TESTING.........................................................................1572 A/C PERFORMANCE...........................................................................1572 A/C PERFORMANCE TEST..................................................................1572 HEATER PERFORMANCE........................................................................1576 SPECIFICATIONS................................................................................1577 HEATING-A/C SYSTEM........................................................................1577 CONTROLS..........................................................................................1579 A/C COMPRESSOR CLUTCH.........................................................................1580 DESCRIPTION...............................................................................1580 OPERATION.................................................................................1580 DIAGNOSIS AND TESTING.....................................................................1580 A/C COMPRESSOR CLUTCH COIL............................................................1580 STANDARD PROCEDURE........................................................................1581 DIODE REPLACEMENT.....................................................................1581 A/C CLUTCH INSPECTION.................................................................1581 A/C CLUTCH BREAK-IN...................................................................1581 REMOVAL...................................................................................1581 INSTALLATION..............................................................................1583 A/C CLUTCH RELAY..............................................................................1584 DESCRIPTION...............................................................................1584 OPERATION.................................................................................1584 REMOVAL...................................................................................1585 INSTALLATION..............................................................................1585 A/C HEATER CONTROL............................................................................1585 DESCRIPTION...............................................................................1585 DIAGNOSIS AND TESTING.....................................................................1586 VACUUM CONTROL SYSTEM.................................................................1586 VACUUM CHECK VALVE................................................................1586 A/C HEATER CONTROLS...............................................................1586 LOCATING VACUUM LEAKS.............................................................1586 REMOVAL...................................................................................1590 INSTALLATION..............................................................................1590 A/C HIGH PRESSURE SWITCH......................................................................1590 DESCRIPTION...............................................................................1590 OPERATION.................................................................................1591 DIAGNOSIS AND TESTING.....................................................................1591 A/C HIGH PRESSURE SWITCH..............................................................1591 REMOVAL...................................................................................1591 INSTALLATION..............................................................................1591 A/C LOW PRESSURE SWITCH.......................................................................1592 DESCRIPTION...............................................................................1592 OPERATION.................................................................................1592 DIAGNOSIS AND TESTING.....................................................................1592 A/C LOW PRESSURE SWITCH...............................................................1592 REMOVAL...................................................................................1593 INSTALLATION..............................................................................1593 A/C PRESSURE TRANSDUCER.......................................................................1593 DESCRIPTION...............................................................................1593 OPERATION.................................................................................1593 DIAGNOSIS AND TESTING.....................................................................1594 A/C PRESSURE TRANSDUCER...............................................................1594 REMOVAL...................................................................................1594 INSTALLATION..............................................................................1594 BLEND DOOR ACTUATOR...........................................................................1595 DESCRIPTION...............................................................................1595 OPERATION.................................................................................1595 REMOVAL...................................................................................1595 INSTALLATION..............................................................................1596 BLOWER MOTOR RELAY............................................................................1596 DESCRIPTION...............................................................................1596 OPERATION.................................................................................1596 REMOVAL...................................................................................1597 INSTALLATION..............................................................................1597 BLOWER MOTOR RESISTOR.........................................................................1597 DESCRIPTION...............................................................................1597 OPERATION.................................................................................1597 DIAGNOSIS AND TESTING.....................................................................1598 BLOWER MOTOR RESISTOR.................................................................1598 REMOVAL...................................................................................1598 INSTALLATION..............................................................................1599 BLOWER MOTOR SWITCH...........................................................................1599 DESCRIPTION...............................................................................1599 OPERATION.................................................................................1599 DIAGNOSIS AND TESTING.....................................................................1599 BLOWER MOTOR SWITCH...................................................................1599 REMOVAL...................................................................................1600 INSTALLATION..............................................................................1600 MODE DOOR ACTUATORS...........................................................................1600 DESCRIPTION...............................................................................1600 REMOVAL...................................................................................1601 INSTALLATION..............................................................................1601 RECIRCULATION DOOR ACTUATOR...................................................................1602 DESCRIPTION...............................................................................1602 REMOVAL...................................................................................1602 INSTALLATION..............................................................................1603 VACUUM CHECK VALVE............................................................................1603 DESCRIPTION...............................................................................1603 OPERATION.................................................................................1603 REMOVAL...................................................................................1604 INSTALLATION..............................................................................1604 VACUUM RESERVOIR..............................................................................1604 DESCRIPTION...............................................................................1604 OPERATION.................................................................................1604 REMOVAL...................................................................................1605 INSTALLATION..............................................................................1605 DISTRIBUTION......................................................................................1606 AIR OUTLETS...................................................................................1606 DESCRIPTION...............................................................................1606 REMOVAL...................................................................................1606 INSTALLATION..............................................................................1607 BLOWER MOTOR..................................................................................1607 DESCRIPTION...............................................................................1607 OPERATION.................................................................................1607 DIAGNOSIS AND TESTING.....................................................................1607 BLOWER MOTOR..........................................................................1607 REMOVAL...................................................................................1608 INSTALLATION..............................................................................1608 DEFROSTER DUCT................................................................................1609 REMOVAL...................................................................................1609 INSTALLATION..............................................................................1609 FLOOR DISTRIBUTION DUCT.......................................................................1609 REMOVAL...................................................................................1609 INSTALLATION..............................................................................1609 HVAC HOUSING..................................................................................1610 DESCRIPTION...............................................................................1610 REMOVAL...................................................................................1610 HVAC HOUSING..........................................................................1610 AIR INLET HOUSING.....................................................................1611 DISASSEMBLY...............................................................................1612 HVAC HOUSING..........................................................................1612 AIR INLET HOUSING.....................................................................1616 ASSEMBLY..................................................................................1617 HVAC HOUSING..........................................................................1617 AIR INLET HOUSING.....................................................................1620 INSTALLATION..............................................................................1621 HVAC HOUSING..........................................................................1621 AIR INLET HOUSING.....................................................................1622 INSTRUMENT PANEL DEMISTER DUCTS...............................................................1622 REMOVAL...................................................................................1622 INSTALLATION..............................................................................1623 INSTRUMENT PANEL DUCTS........................................................................1624 REMOVAL...................................................................................1624 INSTALLATION..............................................................................1625 PLUMBING..........................................................................................1626 PLUMBING......................................................................................1627 DESCRIPTION...............................................................................1627 OPERATION.................................................................................1627 WARNINGS..................................................................................1627 CAUTIONS..................................................................................1627 DIAGNOSIS AND TESTING.....................................................................1628 REFRIGERANT SYSTEM LEAKS..............................................................1628 STANDARD PROCEDURE........................................................................1629 REFRIGERANT SYSTEM SERVICE EQUIPMENT..................................................1629 REFRIGERANT SYSTEM CHARGE LEVEL.......................................................1630 REFRIGERANT SYSTEM RECOVERY...........................................................1631 REFRIGERANT SYSTEM EVACUATE...........................................................1631 REFRIGERANT SYSTEM CHARGE.............................................................1632 A/C COMPRESSOR................................................................................1633 DESCRIPTION...............................................................................1633 A/C COMPRESSOR........................................................................1633 HIGH PRESSURE RELIEF VALVE............................................................1633 OPERATION.................................................................................1633 A/C COMPRESSOR........................................................................1633 HIGH PRESSURE RELIEF VALVE............................................................1633 DIAGNOSIS AND TESTING.....................................................................1633 A/C COMPRESSOR NOISE..................................................................1633 REMOVAL...................................................................................1634 2.4L ENGINE...........................................................................1634 4.0L ENGINE...........................................................................1635 INSTALLATION..............................................................................1636 2.4L ENGINE...........................................................................1636 4.0L ENGINE...........................................................................1636 A/C CONDENSER.................................................................................1637 DESCRIPTION...............................................................................1637 OPERATION.................................................................................1637 REMOVAL...................................................................................1637 INSTALLATION..............................................................................1638 A/C DISCHARGE LINE............................................................................1639 DESCRIPTION...............................................................................1639 REMOVAL...................................................................................1639 2.4L ENGINE...........................................................................1639 4.0L ENGINE...........................................................................1640 INSTALLATION..............................................................................1640 2.4L ENGINE...........................................................................1640 4.0L ENGINE...........................................................................1641 A/C EVAPORATOR................................................................................1641 DESCRIPTION...............................................................................1641 OPERATION.................................................................................1642 REMOVAL...................................................................................1642 INSTALLATION..............................................................................1642 A/C ORIFICE TUBE..............................................................................1642 DESCRIPTION...............................................................................1642 OPERATION.................................................................................1643 DIAGNOSIS AND TESTING.....................................................................1643 A/C ORIFICE TUBE......................................................................1643 ACCUMULATOR...................................................................................1643 DESCRIPTION...............................................................................1643 OPERATION.................................................................................1643 REMOVAL...................................................................................1644 INSTALLATION..............................................................................1645 HEATER CORE...................................................................................1645 DESCRIPTION...............................................................................1645 OPERATION.................................................................................1645 REMOVAL...................................................................................1646 INSTALLATION..............................................................................1646 LIQUID LINE...................................................................................1646 DESCRIPTION...............................................................................1646 REMOVAL...................................................................................1646 INSTALLATION..............................................................................1647 REFRIGERANT...................................................................................1648 DESCRIPTION...............................................................................1648 OPERATION.................................................................................1648 REFRIGERANT LINE COUPLER......................................................................1648 DESCRIPTION...............................................................................1648 OPERATION.................................................................................1649 REMOVAL...................................................................................1649 INSTALLATION..............................................................................1650 REFRIGERANT OIL...............................................................................1650 DESCRIPTION...............................................................................1650 OPERATION.................................................................................1650 STANDARD PROCEDURE........................................................................1650 REFRIGERANT OIL LEVEL.................................................................1650 SERVICE PORT VALVE CORE.......................................................................1651 DESCRIPTION...............................................................................1651 REMOVAL...................................................................................1651 INSTALLATION..............................................................................1651 SUCTION LINE..................................................................................1652 DESCRIPTION...............................................................................1652 REMOVAL...................................................................................1652 INSTALLATION..............................................................................1653 25-EMISSIONS CONTROL..................................................................................1654 EMISSIONS CONTROL.................................................................................1654 DESCRIPTION...................................................................................1654 DESCRIPTION - EMISSION CONTROL SYSTEM.....................................................1654 DESCRIPTION - STATE DISPLAY TEST MODE.....................................................1655 DESCRIPTION - CIRCUIT ACTUATION TEST MODE.................................................1655 DESCRIPTION - DIAGNOSTIC TROUBLE CODES....................................................1655 DESCRIPTION - TASK MANAGER................................................................1655 DESCRIPTION - MONITORED SYSTEMS...........................................................1655 OXYGEN SENSOR (O2S) MONITOR...........................................................1655 OXYGEN SENSOR HEATER MONITOR..........................................................1656 LEAK DETECTION PUMP MONITOR (IF EQUIPPED).............................................1656 MISFIRE MONITOR.......................................................................1657 FUEL SYSTEM MONITOR...................................................................1657 CATALYST MONITOR......................................................................1657 DESCRIPTION - TRIP DEFINITION.............................................................1657 DESCRIPTION - COMPONENT MONITORS0 - 10 TJ (Continued).................................1658 DESCRIPTION - NON-MONITORED CIRCUITS......................................................1658 DESCRIPTION - HIGH AND LOW LIMITS.........................................................1659 DESCRIPTION - LOAD VALUE..................................................................1659 OPERATION - TASK MANAGER......................................................................1659 Test Sequence.............................................................................1659 MIL Illumination..........................................................................1660 Diagnostic Trouble Codes (DTCs)...........................................................1660 DTC Self Erasure..........................................................................1660 Trip Indicator............................................................................1660 Freeze Frame Data Storage.................................................................1661 Similar Conditions Window.................................................................1661 EVAPORATIVE EMISSIONS.............................................................................1663 EVAPORATIVE EMISSIONS.........................................................................1663 DESCRIPTION - EVAPORATION CONTROL SYSTEM..................................................1663 SPECIFICATIONS............................................................................1664 TORQUE - EMISSIONS....................................................................1664 CCV SYSTEM....................................................................................1664 DESCRIPTION - CCV SYSTEM..................................................................1664 OPERATION - CCV SYSTEM....................................................................1664 DIAGNOSIS AND TESTING - CCV SYSTEM........................................................1664 TESTING/CLEANING......................................................................1664 PCV VALVE.....................................................................................1665 DESCRIPTION...............................................................................1665 2.4L..................................................................................1665 OPERATION.................................................................................1665 2.4L..................................................................................1665 REMOVAL...................................................................................1666 EVAP/PURGE SOLENOID...........................................................................1666 DESCRIPTION...............................................................................1666 OPERATION.................................................................................1666 REMOVAL...................................................................................1666 INSTALLATION..............................................................................1667 FUEL FILLER CAP...............................................................................1667 DESCRIPTION...............................................................................1667 OPERATION.................................................................................1667 REMOVAL...................................................................................1667 ORVR..........................................................................................1667 DESCRIPTION...............................................................................1667 OPERATION.................................................................................1668 NATURAL VACUUM LEAK DETECTION ASSEMBLY........................................................1669 DESCRIPTION...............................................................................1669 OPERATION.................................................................................1669 REMOVAL...................................................................................1670 INSTALLATION..............................................................................1671 VACUUM LINES..................................................................................1672 DESCRIPTION...............................................................................1672 VAPOR CANISTER................................................................................1672 DESCRIPTION...............................................................................1672 OPERATION.................................................................................1673 REMOVAL...................................................................................1673 INSTALLATION..............................................................................1673 INDEX.................................................................................................1674 COMMENTS..............................................................................................1678
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