Chrysler PT Cruiser Service & Repair Manual – PDF DOWNLOAD
DESCRIPTION:
Chrysler PT Cruiser Service & Repair Manual – PDF DOWNLOAD
INTRODUCTION
BODY CODE PLATE
DESCRIPTION
The Body Code Plate (Fig. 1) is located in the engine compartment on the plenum behind the right side strut tower
(Fig. 2). There are seven lines of information on the body code plate. Lines 4, 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 3 in the center of the plate to line 1 at the bottom of the plate.
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus
2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts (Fig. 3) and (Fig. 4).
TABLE OF CONTENTS:
Chrysler PT Cruiser Service & Repair Manual – PDF DOWNLOAD
PT Service Manual......................................................................................................................................................................................... 1
FOREWORD.............................................................................................................................................................................................. 0
GROUP TAB LOCATOR..................................................................................................................................................................................... 1
intro-INTRODUCTION.................................................................................................................................................................................... 3
BODY CODE PLATE................................................................................................................................................................................... 3
DESCRIPTION................................................................................................................................................................................... 3
BODY CODE PLATE LINE 2.................................................................................................................................................................... 3
BODY CODE PLATE LINE 1.................................................................................................................................................................... 4
IF TWO BODY CODE PLATES ARE REQUIRED...................................................................................................................................................... 4
FASTENER IDENTIFICATION........................................................................................................................................................................... 4
DESCRIPTION................................................................................................................................................................................... 4
FASTENER USAGE.................................................................................................................................................................................... 7
DESCRIPTION................................................................................................................................................................................... 7
DESCRIPTION - FASTENER USAGE.............................................................................................................................................................. 7
DESCRIPTION - THREADED HOLE REPAIR........................................................................................................................................................ 7
INTERNATIONAL SYMBOLS............................................................................................................................................................................. 7
DESCRIPTION................................................................................................................................................................................... 7
METRIC SYSTEM..................................................................................................................................................................................... 8
DESCRIPTION................................................................................................................................................................................... 8
TORQUE REFERENCES................................................................................................................................................................................. 10
DESCRIPTION................................................................................................................................................................................... 10
VEHICLE IDENTIFICATION NUMBER..................................................................................................................................................................... 11
DESCRIPTION - VEHICLE IDENTIFICATION NUMBER................................................................................................................................................... 11
VEHICLE SAFETY CERTIFICATION LABEL................................................................................................................................................................ 12
DESCRIPTION................................................................................................................................................................................... 12
E-MARK LABEL...................................................................................................................................................................................... 12
DESCRIPTION................................................................................................................................................................................... 12
VECI LABEL........................................................................................................................................................................................ 12
DESCRIPTION................................................................................................................................................................................... 12
MANUFACTURER PLATE................................................................................................................................................................................ 12
DESCRIPTION................................................................................................................................................................................... 12
0-LUBRICATION & MAINTENANCE........................................................................................................................................................................... 13
INTERNATIONAL SYMBOLS............................................................................................................................................................................. 13
DESCRIPTION................................................................................................................................................................................... 13
FLUID TYPES....................................................................................................................................................................................... 13
DESCRIPTION................................................................................................................................................................................... 13
DESCRIPTION - ENGINE OIL AND LUBRICANTS................................................................................................................................................... 13
API SERVICE GRADE CERTIFIED........................................................................................................................................................... 13
SAE VISCOSITY......................................................................................................................................................................... 14
ENERGY CONSERVING OIL................................................................................................................................................................. 14
CONTAINER IDENTIFICATION.............................................................................................................................................................. 14
SYNTHETIC ENGINE OILS................................................................................................................................................................. 14
MATERIALS ADDED TO ENGINE OIL......................................................................................................................................................... 14
GEAR LUBRICANTS....................................................................................................................................................................... 14
LUBRICANTS AND GREASES................................................................................................................................................................ 14
SPECIALIZED LUBRICANTS AND OILS....................................................................................................................................................... 14
DESCRIPTION - ENGINE COOLANT.............................................................................................................................................................. 15
DESCRIPTION - TRANSMISSION FLUID.......................................................................................................................................................... 15
TRANSMISSION FLUID.................................................................................................................................................................... 15
DESCRIPTION - FUEL REQUIREMENTS........................................................................................................................................................... 15
REFORMULATED GASOLINE................................................................................................................................................................. 16
GASOLINE/OXYGENATE BLENDS............................................................................................................................................................. 16
MMT IN GASOLINE....................................................................................................................................................................... 16
SULFUR IN GASOLINE.................................................................................................................................................................... 16
MATERIALS ADDED TO FUEL............................................................................................................................................................... 16
FUEL SYSTEM CAUTIONS.................................................................................................................................................................. 16
FLUID CAPACITIES.................................................................................................................................................................................. 17
SPECIFICATIONS - FLUID CAPACITIES............................................................................................................................................................. 17
FLUID FILL/CHECK LOCATIONS........................................................................................................................................................................ 17
DESCRIPTION................................................................................................................................................................................... 17
LUBRICATION POINTS................................................................................................................................................................................ 17
DESCRIPTION................................................................................................................................................................................... 17
MAINTENANCE SCHEDULES............................................................................................................................................................................. 17
DESCRIPTION................................................................................................................................................................................... 17
SCHEDULE “B”—ALL ENGINES.................................................................................................................................................................. 18
SCHEDULE “A”—NON TURBO CHARGED ENGINES.................................................................................................................................................... 22
SCHEDULE “A”—2.4L TURBO CHARGED ENGINES................................................................................................................................................... 24
HOISTING.......................................................................................................................................................................................... 26
STANDARD PROCEDURE - HOISTING................................................................................................................................................................. 26
JUMP STARTING..................................................................................................................................................................................... 26
STANDARD PROCEDURE - JUMP STARTING............................................................................................................................................................ 26
TO JUMP START A DISABLED VEHICLE:......................................................................................................................................................... 26
TOWING............................................................................................................................................................................................ 27
STANDARD PROCEDURE - TOWING................................................................................................................................................................... 27
2-SUSPENSION.......................................................................................................................................................................................... 29
FRONT SUSPENSION.................................................................................................................................................................................. 29
FRONT SUSPENSION.............................................................................................................................................................................. 30
DESCRIPTION - FRONT SUSPENSION............................................................................................................................................................ 30
OPERATION - FRONT SUSPENSION.............................................................................................................................................................. 30
WARNING................................................................................................................................................................................... 30
WARNINGS AND CAUTIONS................................................................................................................................................................. 30
STANDARD PROCEDURE - LUBRICATION.......................................................................................................................................................... 30
SPECIFICATIONS............................................................................................................................................................................ 32
FRONT SUSPENSION FASTENER TORQUE...................................................................................................................................................... 32
SPECIAL TOOLS............................................................................................................................................................................. 32
FRONT SUSPENSION...................................................................................................................................................................... 32
HUB / BEARING................................................................................................................................................................................. 34
DESCRIPTION............................................................................................................................................................................... 34
OPERATION................................................................................................................................................................................. 34
DIAGNOSIS AND TESTING - WHEEL BEARING AND HUB............................................................................................................................................. 34
REMOVAL................................................................................................................................................................................... 34
INSTALLATION.............................................................................................................................................................................. 34
KNUCKLE....................................................................................................................................................................................... 34
DESCRIPTION - STEERING KNUCKLE............................................................................................................................................................ 34
OPERATION - STEERING KNUCKLE.............................................................................................................................................................. 34
DIAGNOSIS AND TESTING - STEERING KNUCKLE.................................................................................................................................................. 34
REMOVAL - STEERING KNUCKLE................................................................................................................................................................ 34
DISASSEMBLY - STEERING KNUCKLE (WHEEL BEARING AND HUB).................................................................................................................................... 36
ASSEMBLY - STEERING KNUCKLE (WHEEL BEARING AND HUB)....................................................................................................................................... 38
INSTALLATION - STEERING KNUCKLE........................................................................................................................................................... 39
LOWER BALL JOINT.............................................................................................................................................................................. 40
DIAGNOSIS AND TESTING - BALL JOINT........................................................................................................................................................ 40
LOWER BALL JOINT SEAL BOOT.................................................................................................................................................................... 40
REMOVAL................................................................................................................................................................................... 40
INSTALLATION.............................................................................................................................................................................. 40
LOWER CONTROL ARM............................................................................................................................................................................. 41
DESCRIPTION............................................................................................................................................................................... 41
OPERATION................................................................................................................................................................................. 41
DIAGNOSIS AND TESTING - LOWER CONTROL ARM................................................................................................................................................. 41
REMOVAL - LOWER CONTROL ARM............................................................................................................................................................... 41
DISASSEMBLY............................................................................................................................................................................... 43
DISASSEMBLY - LOWER CONTROL ARM (BALL JOINT).......................................................................................................................................... 43
DISASSEMBLY - LOWER CONTROL ARM (REAR ISOLATOR BUSHING)............................................................................................................................... 43
ASSEMBLY.................................................................................................................................................................................. 44
ASSEMBLY - LOWER CONTROL ARM (BALL JOINT)............................................................................................................................................. 44
ASSEMBLY - LOWER CONTROL ARM (REAR ISOLATOR BUSHING).................................................................................................................................. 45
INSTALLATION - LOWER CONTROL ARM.......................................................................................................................................................... 45
STABILIZER BAR................................................................................................................................................................................ 47
DESCRIPTION............................................................................................................................................................................... 47
OPERATION................................................................................................................................................................................. 47
REMOVAL................................................................................................................................................................................... 47
INSPECTION................................................................................................................................................................................ 47
INSTALLATION.............................................................................................................................................................................. 47
STRUT ASSEMBLY................................................................................................................................................................................ 48
DESCRIPTION............................................................................................................................................................................... 48
OPERATION................................................................................................................................................................................. 48
DIAGNOSIS AND TESTING - STRUT ASSEMBLY (FRONT)............................................................................................................................................ 48
REMOVAL................................................................................................................................................................................... 48
DISASSEMBLY............................................................................................................................................................................... 49
ASSEMBLY.................................................................................................................................................................................. 52
INSTALLATION.............................................................................................................................................................................. 52
REAR SUSPENSION................................................................................................................................................................................... 54
REAR SUSPENSION............................................................................................................................................................................... 54
DESCRIPTION - REAR SUSPENSION............................................................................................................................................................. 54
OPERATION - REAR SUSPENSION............................................................................................................................................................... 54
WARNING................................................................................................................................................................................... 55
WARNINGS AND CAUTIONS................................................................................................................................................................. 55
SPECIFICATIONS............................................................................................................................................................................ 56
REAR SUSPENSION FASTENER TORQUE....................................................................................................................................................... 56
SPECIAL TOOLS............................................................................................................................................................................. 56
REAR SUSPENSION....................................................................................................................................................................... 56
AXLE - FRONT WHEEL DRIVE REAR................................................................................................................................................................. 57
DESCRIPTION............................................................................................................................................................................... 57
OPERATION................................................................................................................................................................................. 57
REMOVAL................................................................................................................................................................................... 57
INSPECTION................................................................................................................................................................................ 61
INSTALLATION.............................................................................................................................................................................. 61
AXLE PIVOT BUSHING............................................................................................................................................................................ 65
REMOVAL................................................................................................................................................................................... 65
INSTALLATION.............................................................................................................................................................................. 66
HUB / BEARING................................................................................................................................................................................. 67
DESCRIPTION............................................................................................................................................................................... 67
OPERATION................................................................................................................................................................................. 67
DIAGNOSIS AND TESTING - HUB AND BEARING (REAR)............................................................................................................................................ 67
REMOVAL................................................................................................................................................................................... 68
INSTALLATION.............................................................................................................................................................................. 69
JOUNCE BUMPER................................................................................................................................................................................. 69
REMOVAL................................................................................................................................................................................... 69
INSTALLATION.............................................................................................................................................................................. 69
SHOCK ABSORBER................................................................................................................................................................................ 69
DESCRIPTION............................................................................................................................................................................... 69
DIAGNOSIS AND TESTING - SHOCK ABSORBER.................................................................................................................................................... 69
REMOVAL................................................................................................................................................................................... 69
INSTALLATION.............................................................................................................................................................................. 69
SPINDLE....................................................................................................................................................................................... 70
REMOVAL................................................................................................................................................................................... 70
INSTALLATION.............................................................................................................................................................................. 71
SPRING........................................................................................................................................................................................ 72
DESCRIPTION............................................................................................................................................................................... 72
REMOVAL................................................................................................................................................................................... 72
INSTALLATION.............................................................................................................................................................................. 73
STABILIZER BAR................................................................................................................................................................................ 75
DESCRIPTION............................................................................................................................................................................... 75
OPERATION................................................................................................................................................................................. 75
REMOVAL................................................................................................................................................................................... 75
INSTALLATION.............................................................................................................................................................................. 75
STABILIZER BAR CUSHIONS....................................................................................................................................................................... 75
REMOVAL................................................................................................................................................................................... 75
INSTALLATION.............................................................................................................................................................................. 76
STABILIZER BAR LINK........................................................................................................................................................................... 76
REMOVAL................................................................................................................................................................................... 76
INSTALLATION.............................................................................................................................................................................. 76
WATTS LINK ASSEMBLY........................................................................................................................................................................... 76
DESCRIPTION............................................................................................................................................................................... 76
OPERATION................................................................................................................................................................................. 77
DIAGNOSIS AND TESTING - WATTS LINK ASSEMBLY............................................................................................................................................... 77
WATTS BELL CRANK.............................................................................................................................................................................. 77
REMOVAL................................................................................................................................................................................... 77
INSTALLATION.............................................................................................................................................................................. 77
WATTS LINK.................................................................................................................................................................................... 79
REMOVAL................................................................................................................................................................................... 79
INSTALLATION.............................................................................................................................................................................. 79
WHEEL ALIGNMENT................................................................................................................................................................................... 80
DESCRIPTION - WHEEL ALIGNMENT................................................................................................................................................................. 80
CAMBER.................................................................................................................................................................................... 80
CROSS CAMBER.............................................................................................................................................................................. 81
CASTER.................................................................................................................................................................................... 81
CROSS CASTER.............................................................................................................................................................................. 81
TOE....................................................................................................................................................................................... 81
TOE-OUT ON TURNS.......................................................................................................................................................................... 82
DYNAMIC TOE PATTERN....................................................................................................................................................................... 82
STEERING AXIS INCLINATION (S.A.I.)........................................................................................................................................................ 82
INCLUDED ANGLE (I.A.)..................................................................................................................................................................... 82
THRUST ANGLE.............................................................................................................................................................................. 83
DIAGNOSIS AND TESTING - SUSPENSION AND STEERING............................................................................................................................................... 83
STANDARD PROCEDURE............................................................................................................................................................................ 85
STANDARD PROCEDURE - CURB HEIGHT MEASUREMENT.............................................................................................................................................. 85
STANDARD PROCEDURE - WHEEL ALIGNMENT...................................................................................................................................................... 86
PRE-WHEEL ALIGNMENT INSPECTION........................................................................................................................................................ 86
WHEEL ALIGNMENT SETUP................................................................................................................................................................. 86
REAR CAMBER AND TOE................................................................................................................................................................... 86
FRONT CAMBER AND CASTER............................................................................................................................................................... 87
FRONT TOE............................................................................................................................................................................. 88
SPECIFICATIONS................................................................................................................................................................................ 88
WHEEL ALIGNMENT........................................................................................................................................................................... 88
3-DIFFERENTIAL & DRIVELINE............................................................................................................................................................................ 89
HALF SHAFT........................................................................................................................................................................................ 89
HALF SHAFT.................................................................................................................................................................................... 89
DESCRIPTION............................................................................................................................................................................... 89
All Models Except Diesel and Turbo.................................................................................................................................................... 89
Diesel and Turbo Models............................................................................................................................................................... 90
OPERATION................................................................................................................................................................................. 90
DIAGNOSIS AND TESTING - HALFSHAFT DIAGNOSIS............................................................................................................................................... 91
VEHICLE INSPECTION.................................................................................................................................................................... 91
NOISE AND/OR VIBRATION IN TURNS....................................................................................................................................................... 91
CLUNKING NOISE DURING ACCELERATION.................................................................................................................................................... 91
SHUDDER OR VIBRATION DURING ACCELERATION.............................................................................................................................................. 92
VIBRATION AT HIGHWAY SPEEDS........................................................................................................................................................... 92
REMOVAL................................................................................................................................................................................... 92
REMOVAL—EXCEPT DIESEL AND TURBO MODELS................................................................................................................................................ 92
REMOVAL—DIESEL AND TURBO MODELS....................................................................................................................................................... 94
INSTALLATION.............................................................................................................................................................................. 96
INSTALLATION—EXCEPT DIESEL AND TURBO MODELS........................................................................................................................................... 96
INSTALLATION—DIESEL AND TURBO MODELS.................................................................................................................................................. 98
SPECIFICATIONS - TORQUE................................................................................................................................................................... 100
SPECIAL TOOLS............................................................................................................................................................................. 100
HALFSHAFT............................................................................................................................................................................. 100
CV BOOT - INNER............................................................................................................................................................................... 101
REMOVAL................................................................................................................................................................................... 101
INSTALLATION.............................................................................................................................................................................. 102
CV BOOT - OUTER............................................................................................................................................................................... 106
REMOVAL................................................................................................................................................................................... 106
INSTALLATION.............................................................................................................................................................................. 107
5-BRAKES.............................................................................................................................................................................................. 109
BRAKES - BASE..................................................................................................................................................................................... 109
BRAKES - BASE................................................................................................................................................................................. 110
DESCRIPTION - BASE BRAKE SYSTEM........................................................................................................................................................... 110
OPERATION - BASE BRAKE SYSTEM............................................................................................................................................................. 111
WARNING................................................................................................................................................................................... 111
CAUTION................................................................................................................................................................................... 111
CAUTIONS.............................................................................................................................................................................. 111
DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM DIAGNOSIS CHARTS................................................................................................................................ 111
RED BRAKE WARNING INDICATOR........................................................................................................................................................... 112
BRAKE NOISE........................................................................................................................................................................... 112
OTHER BRAKE CONDITIONS................................................................................................................................................................ 113
STANDARD PROCEDURE - BASE BRAKE BLEEDING.................................................................................................................................................. 114
MANUAL BLEEDING....................................................................................................................................................................... 115
PRESSURE BLEEDING..................................................................................................................................................................... 115
SPECIFICATIONS............................................................................................................................................................................ 116
BRAKE ACTUATION SYSTEM................................................................................................................................................................ 116
BRAKE FASTENER TORQUE................................................................................................................................................................. 116
SPECIAL TOOLS............................................................................................................................................................................. 117
BASE BRAKE SYSTEM..................................................................................................................................................................... 117
BRAKE FLUID LEVEL SWITCH...................................................................................................................................................................... 118
REMOVAL................................................................................................................................................................................... 118
INSTALLATION.............................................................................................................................................................................. 118
HYDRAULIC/MECHANICAL.......................................................................................................................................................................... 118
DESCRIPTION............................................................................................................................................................................... 118
DESCRIPTION - DISC BRAKES (FRONT)..................................................................................................................................................... 118
DESCRIPTION - DISC BRAKES (REAR)...................................................................................................................................................... 121
DESCRIPTION - DRUM BRAKES (REAR)...................................................................................................................................................... 121
DIAGNOSIS AND TESTING - DRUM BRAKE AUTOMATIC ADJUSTER..................................................................................................................................... 122
BRAKE LINES................................................................................................................................................................................... 123
DESCRIPTION - BRAKE TUBES AND HOSES....................................................................................................................................................... 123
OPERATION - BRAKE TUBES AND HOSES......................................................................................................................................................... 123
INSPECTION - BRAKE TUBES AND HOSES........................................................................................................................................................ 123
BRAKE PADS/SHOES - FRONT...................................................................................................................................................................... 123
REMOVAL................................................................................................................................................................................... 123
CLEANING - DISC BRAKE SHOES............................................................................................................................................................... 124
INSPECTION - DISC BRAKE SHOES............................................................................................................................................................. 124
INSTALLATION.............................................................................................................................................................................. 124
BRAKE PADS/SHOES - REAR DISC.................................................................................................................................................................. 125
REMOVAL................................................................................................................................................................................... 125
CLEANING - DISC BRAKE SHOES............................................................................................................................................................... 126
INSPECTION - DISC BRAKE SHOES............................................................................................................................................................. 127
INSTALLATION.............................................................................................................................................................................. 127
BRAKE PADS/SHOES - REAR DRUM.................................................................................................................................................................. 127
REMOVAL................................................................................................................................................................................... 127
CLEANING - DRUM BRAKE SHOES............................................................................................................................................................... 129
INSPECTION - DRUM BRAKE SHOES............................................................................................................................................................. 129
INSTALLATION.............................................................................................................................................................................. 130
ADJUSTMENTS............................................................................................................................................................................... 131
ADJUSTMENT - DRUM BRAKE SHOES......................................................................................................................................................... 131
DISC BRAKE CALIPER - FRONT.................................................................................................................................................................... 132
REMOVAL................................................................................................................................................................................... 132
DISASSEMBLY............................................................................................................................................................................... 132
CLEANING - DISC BRAKE CALIPER............................................................................................................................................................. 133
INSPECTION - DISC BRAKE CALIPER........................................................................................................................................................... 133
ASSEMBLY.................................................................................................................................................................................. 133
INSTALLATION.............................................................................................................................................................................. 134
DISC BRAKE CALIPER - REAR..................................................................................................................................................................... 135
REMOVAL................................................................................................................................................................................... 135
DISASSEMBLY............................................................................................................................................................................... 136
DISASSEMBLY - DISC BRAKE CALIPER (GUIDE PIN BUSHINGS)................................................................................................................................. 136
DISASSEMBLY - DISC BRAKE CALIPER (PISTON AND SEAL).................................................................................................................................... 136
CLEANING - DISC BRAKE CALIPER............................................................................................................................................................. 138
INSPECTION - DISC BRAKE CALIPER........................................................................................................................................................... 138
ASSEMBLY.................................................................................................................................................................................. 138
ASSEMBLY - DISC BRAKE CALIPER (GUIDE PIN BUSHINGS).................................................................................................................................... 138
ASSEMBLY - DISC BRAKE CALIPER (PISTON AND SEAL)....................................................................................................................................... 140
INSTALLATION.............................................................................................................................................................................. 141
DISC BRAKE CALIPER ADAPTER - FRONT............................................................................................................................................................ 141
REMOVAL................................................................................................................................................................................... 141
INSTALLATION.............................................................................................................................................................................. 142
DISC BRAKE CALIPER GUIDE PINS................................................................................................................................................................. 142
REMOVAL................................................................................................................................................................................... 142
INSTALLATION.............................................................................................................................................................................. 143
DRUM.......................................................................................................................................................................................... 143
DIAGNOSIS AND TESTING - BRAKE DRUM........................................................................................................................................................ 143
STANDARD PROCEDURE - BRAKE DRUM MACHINING................................................................................................................................................. 143
REMOVAL................................................................................................................................................................................... 144
INSTALLATION.............................................................................................................................................................................. 144
FLUID......................................................................................................................................................................................... 145
DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION......................................................................................................................................... 145
STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING........................................................................................................................................... 145
SPECIFICATIONS............................................................................................................................................................................ 145
BRAKE FLUID........................................................................................................................................................................... 145
FLUID RESERVOIR............................................................................................................................................................................... 145
REMOVAL................................................................................................................................................................................... 145
INSTALLATION.............................................................................................................................................................................. 146
MASTER CYLINDER............................................................................................................................................................................... 146
DESCRIPTION............................................................................................................................................................................... 146
OPERATION................................................................................................................................................................................. 146
STANDARD PROCEDURE - MASTER CYLINDER BLEEDING............................................................................................................................................. 146
REMOVAL................................................................................................................................................................................... 147
REMOVAL - LHD WITH ABS................................................................................................................................................................ 147
REMOVAL - LHD WITHOUT ABS............................................................................................................................................................. 148
REMOVAL - RHD......................................................................................................................................................................... 149
INSTALLATION.............................................................................................................................................................................. 149
INSTALLATION - LHD WITH ABS........................................................................................................................................................... 149
INSTALLATION - LHD WITHOUT ABS........................................................................................................................................................ 149
INSTALLATION - RHD.................................................................................................................................................................... 150
PEDAL - WITH AUTOMATIC TRANSAXLE.............................................................................................................................................................. 150
REMOVAL................................................................................................................................................................................... 150
INSTALLATION.............................................................................................................................................................................. 151
PEDAL - WITH MANUAL TRANSAXLE................................................................................................................................................................. 152
REMOVAL................................................................................................................................................................................... 152
INSTALLATION.............................................................................................................................................................................. 152
POWER BRAKE BOOSTER........................................................................................................................................................................... 153
DESCRIPTION............................................................................................................................................................................... 153
OPERATION................................................................................................................................................................................. 154
DIAGNOSIS AND TESTING - POWER BRAKE BOOSTER............................................................................................................................................... 154
BASIC TEST............................................................................................................................................................................ 154
VACUUM LEAK TEST...................................................................................................................................................................... 154
REMOVAL................................................................................................................................................................................... 155
REMOVAL - LHD......................................................................................................................................................................... 155
REMOVAL - RHD......................................................................................................................................................................... 156
INSTALLATION.............................................................................................................................................................................. 156
INSTALLATION - LHD.................................................................................................................................................................... 156
INSTALLATION - RHD.................................................................................................................................................................... 157
PROPORTIONING VALVE........................................................................................................................................................................... 157
DESCRIPTION............................................................................................................................................................................... 157
OPERATION................................................................................................................................................................................. 158
DIAGNOSIS AND TESTING - PROPORTIONING VALVE............................................................................................................................................... 158
PROPORTIONING VALVE TEST.............................................................................................................................................................. 158
REMOVAL................................................................................................................................................................................... 160
INSTALLATION.............................................................................................................................................................................. 160
ROTOR......................................................................................................................................................................................... 160
DESCRIPTION............................................................................................................................................................................... 160
DIAGNOSIS AND TESTING - BRAKE ROTOR....................................................................................................................................................... 160
BRAKING SURFACE INSPECTION............................................................................................................................................................ 161
ROTOR MINIMUM THICKNESS............................................................................................................................................................... 161
ROTOR THICKNESS VARIATION............................................................................................................................................................. 161
ROTOR RUNOUT.......................................................................................................................................................................... 162
STANDARD PROCEDURE - BRAKE ROTOR MACHINING................................................................................................................................................ 163
REMOVAL................................................................................................................................................................................... 164
REMOVAL - FRONT BRAKE ROTOR........................................................................................................................................................... 164
REMOVAL - REAR BRAKE ROTOR............................................................................................................................................................ 164
INSTALLATION.............................................................................................................................................................................. 165
INSTALLATION - FRONT BRAKE ROTOR...................................................................................................................................................... 165
INSTALLATION - REAR BRAKE ROTOR....................................................................................................................................................... 165
SPECIFICATIONS............................................................................................................................................................................ 165
BRAKE ROTOR LIMITS/SPECIFICATIONS..................................................................................................................................................... 165
SUPPORT PLATE - DRUM BRAKES................................................................................................................................................................... 166
REMOVAL................................................................................................................................................................................... 166
INSTALLATION.............................................................................................................................................................................. 167
WHEEL CYLINDER - DRUM BRAKE................................................................................................................................................................... 168
REMOVAL................................................................................................................................................................................... 168
INSPECTION................................................................................................................................................................................ 169
INSTALLATION.............................................................................................................................................................................. 169
PARKING BRAKE................................................................................................................................................................................. 169
DESCRIPTION............................................................................................................................................................................... 169
OPERATION................................................................................................................................................................................. 170
STANDARD PROCEDURE - PARKING BRAKE AUTOMATIC ADJUSTER LOCKOUT............................................................................................................................. 170
LOCKING AUTOMATIC ADJUSTER OUT........................................................................................................................................................ 170
UNLOCKING AUTOMATIC ADJUSTER (UNLOADING).............................................................................................................................................. 171
CABLE - PARKING BRAKE......................................................................................................................................................................... 171
REMOVAL................................................................................................................................................................................... 171
INSTALLATION.............................................................................................................................................................................. 175
LEVER - PARKING BRAKE......................................................................................................................................................................... 176
REMOVAL................................................................................................................................................................................... 176
INSTALLATION.............................................................................................................................................................................. 177
SHOES - PARKING BRAKE......................................................................................................................................................................... 177
REMOVAL................................................................................................................................................................................... 177
INSTALLATION.............................................................................................................................................................................. 178
ADJUSTMENTS............................................................................................................................................................................... 179
ADJUSTMENT............................................................................................................................................................................ 179
BRAKES - ABS...................................................................................................................................................................................... 181
BRAKES - ABS.................................................................................................................................................................................. 181
DESCRIPTION............................................................................................................................................................................... 181
DESCRIPTION - ANTILOCK BRAKE SYSTEM................................................................................................................................................... 181
DESCRIPTION - ELECTRONIC VARIABLE BRAKE PROPORTIONING................................................................................................................................. 182
DESCRIPTION - TRACTION CONTROL SYSTEM................................................................................................................................................. 182
OPERATION................................................................................................................................................................................. 182
OPERATION - ANTILOCK BRAKE SYSTEM..................................................................................................................................................... 182
NORMAL BRAKING.................................................................................................................................................................... 182
ABS BRAKING....................................................................................................................................................................... 182
NOISE AND BRAKE PEDAL FEEL........................................................................................................................................................ 182
TIRE NOISE AND MARKS.............................................................................................................................................................. 183
START-UP CYCLE.................................................................................................................................................................... 183
DRIVE-OFF CYCLE................................................................................................................................................................... 183
PREMATURE ABS CYCLING............................................................................................................................................................. 183
OPERATION - ELECTRONIC VARIABLE BRAKE PROPORTIONING................................................................................................................................... 183
OPERATION - TRACTION CONTROL SYSTEM................................................................................................................................................... 183
CAUTION................................................................................................................................................................................... 184
CAUTIONS.............................................................................................................................................................................. 184
DIAGNOSIS AND TESTING - INSPECTION AND ROAD TEST.......................................................................................................................................... 184
STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING....................................................................................................................................... 185
SPECIFICATIONS............................................................................................................................................................................ 186
SPECIFICATIONS - ABS FASTENER TORQUE.................................................................................................................................................. 186
TONE WHEEL RUNOUT..................................................................................................................................................................... 186
WHEEL SPEED SENSOR AIR GAP............................................................................................................................................................ 186
FRONT WHEEL SPEED SENSOR...................................................................................................................................................................... 186
DESCRIPTION............................................................................................................................................................................... 186
OPERATION................................................................................................................................................................................. 186
REMOVAL................................................................................................................................................................................... 187
INSTALLATION.............................................................................................................................................................................. 188
REAR WHEEL SPEED SENSOR....................................................................................................................................................................... 188
DESCRIPTION............................................................................................................................................................................... 188
OPERATION................................................................................................................................................................................. 189
REMOVAL................................................................................................................................................................................... 189
INSTALLATION.............................................................................................................................................................................. 190
TONE WHEEL.................................................................................................................................................................................... 190
DESCRIPTION............................................................................................................................................................................... 190
OPERATION................................................................................................................................................................................. 190
INSPECTION................................................................................................................................................................................ 190
TRACTION CONTROL SWITCH....................................................................................................................................................................... 191
REMOVAL................................................................................................................................................................................... 191
INSTALLATION.............................................................................................................................................................................. 191
HCU - HYDRAULIC CONTROL UNIT.................................................................................................................................................................. 191
DESCRIPTION - HYDRAULIC CONTROL UNIT (HCU)................................................................................................................................................ 191
VALVES AND SOLENOIDS.................................................................................................................................................................. 191
BRAKE FLUID ACCUMULATORS.............................................................................................................................................................. 192
PUMP/MOTOR............................................................................................................................................................................ 192
OPERATION - HYDRAULIC CIRCUITS AND VALVES................................................................................................................................................. 192
NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL)........................................................................................... 192
ABS HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL)...................................................................................................... 194
NORMAL BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL).............................................................................. 195
ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL)................................................................................. 196
ABS TRACTION CONTROL HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL)........................................................................ 197
ICU - INTEGRATED CONTROL UNIT................................................................................................................................................................. 198
DESCRIPTION............................................................................................................................................................................... 198
OPERATION................................................................................................................................................................................. 198
REMOVAL................................................................................................................................................................................... 198
DISASSEMBLY - ICU......................................................................................................................................................................... 200
ASSEMBLY - ICU............................................................................................................................................................................ 200
INSTALLATION.............................................................................................................................................................................. 200
6-CLUTCH.............................................................................................................................................................................................. 203
CLUTCH............................................................................................................................................................................................ 204
DESCRIPTION................................................................................................................................................................................... 204
FLUID..................................................................................................................................................................................... 204
OPERATION..................................................................................................................................................................................... 204
T350-Equipped Models...................................................................................................................................................................... 204
G288-Equipped Models...................................................................................................................................................................... 205
DIAGNOSIS AND TESTING......................................................................................................................................................................... 205
DIAGNOSIS AND TESTING—CLUTCH SYSTEM DIAGNOSIS............................................................................................................................................. 205
DIAGNOSIS AND TESTING - CLUTCH CHATTER COMPLAINTS......................................................................................................................................... 208
DIAGNOSIS AND TESTING - DRIVE PLATE MISALIGNMENT.......................................................................................................................................... 208
DIAGNOSIS AND TESTING - CLASH-INTO-REVERSE COMPLAINTS..................................................................................................................................... 208
STANDARD PROCEDURE—BLEEDING CLUTCH HYDRAULIC CIRCUIT.......................................................................................................................................... 208
1.6/2.0/2.4L MODELS (Except Turbo)........................................................................................................................................................ 209
DIESEL AND TURBO MODELS................................................................................................................................................................... 209
SPECIFICATIONS................................................................................................................................................................................ 211
CLUTCH/HYDRAULICS/PEDALS.................................................................................................................................................................. 211
CLUTCH DISC AND PRESSURE PLATE.................................................................................................................................................................... 212
REMOVAL....................................................................................................................................................................................... 212
REMOVAL—1.6L.............................................................................................................................................................................. 212
REMOVAL—2.2L TD........................................................................................................................................................................... 213
INSTALLATION.................................................................................................................................................................................. 213
INSTALLATION—1.6L......................................................................................................................................................................... 213
INSTALLATION—2.2L TD...................................................................................................................................................................... 214
CLUTCH INTERLOCK/UPSTOP SWITCH.................................................................................................................................................................... 214
DESCRIPTION................................................................................................................................................................................... 214
OPERATION..................................................................................................................................................................................... 215
CLUTCH INTERLOCK SWITCH................................................................................................................................................................... 215
CLUTCH PEDAL UPSTOP SWITCH................................................................................................................................................................ 215
DIAGNOSIS AND TESTING—CLUTCH INTERLOCK/UPSTOP SWITCH.......................................................................................................................................... 215
LHD....................................................................................................................................................................................... 215
RHD....................................................................................................................................................................................... 215
CLUTCH INTERLOCK SWITCH................................................................................................................................................................... 216
UPSTOP SWITCH............................................................................................................................................................................. 217
REMOVAL....................................................................................................................................................................................... 218
REMOVAL - LHD............................................................................................................................................................................. 218
REMOVAL - RHD............................................................................................................................................................................. 219
INSTALLATION.................................................................................................................................................................................. 219
INSTALLATION - LHD........................................................................................................................................................................ 219
INSTALLATION - RHD........................................................................................................................................................................ 220
CLUTCH RELEASE BEARING............................................................................................................................................................................ 220
DESCRIPTION................................................................................................................................................................................... 220
OPERATION..................................................................................................................................................................................... 221
REMOVAL....................................................................................................................................................................................... 221
INSTALLATION.................................................................................................................................................................................. 221
FLYWHEEL.......................................................................................................................................................................................... 222
DESCRIPTION................................................................................................................................................................................... 222
1.6L Equipped Models...................................................................................................................................................................... 222
2.2L Turbo Diesel Equipped Models......................................................................................................................................................... 222
OPERATION..................................................................................................................................................................................... 223
REMOVAL....................................................................................................................................................................................... 223
INSTALLATION.................................................................................................................................................................................. 223
MASTER CYLINDER - LHD............................................................................................................................................................................. 224
DESCRIPTION................................................................................................................................................................................... 224
OPERATION..................................................................................................................................................................................... 224
REMOVAL....................................................................................................................................................................................... 224
INSTALLATION.................................................................................................................................................................................. 227
MASTER CYLINDER - RHD............................................................................................................................................................................. 228
DESCRIPTION................................................................................................................................................................................... 228
OPERATION..................................................................................................................................................................................... 228
REMOVAL....................................................................................................................................................................................... 228
INSTALLATION.................................................................................................................................................................................. 231
MODULAR CLUTCH.................................................................................................................................................................................... 232
DESCRIPTION................................................................................................................................................................................... 232
2.0/2.4L MODELS (Except Turbo)............................................................................................................................................................ 232
2.4L TURBO MODELS......................................................................................................................................................................... 232
OPERATION..................................................................................................................................................................................... 232
REMOVAL....................................................................................................................................................................................... 233
INSPECTION.................................................................................................................................................................................... 233
OIL CONTAMINATION......................................................................................................................................................................... 233
GREASE CONTAMINATION...................................................................................................................................................................... 234
ROAD SPLASH/WATER CONTAMINATION........................................................................................................................................................... 234
INSTALLATION.................................................................................................................................................................................. 234
SLAVE CYLINDER.................................................................................................................................................................................... 234
DESCRIPTION................................................................................................................................................................................... 234
1.6/2.0L/2.4L MODELS (Except Diesel & Turbo).............................................................................................................................................. 234
DIESEL AND TURBO MODELS................................................................................................................................................................... 234
REMOVAL....................................................................................................................................................................................... 235
REMOVAL—1.6/2.0/2.4L (Except Diesel and Turbo)............................................................................................................................................ 235
REMOVAL—DIESEL AND TURBO MODELS........................................................................................................................................................... 236
INSTALLATION.................................................................................................................................................................................. 236
INSTALLATION—1.6/2.0/2.4L MODELS (Except Diesel and Turbo)................................................................................................................................ 236
INSTALLATION—DIESEL AND TURBO MODELS...................................................................................................................................................... 236
7-COOLING............................................................................................................................................................................................. 237
COOLING........................................................................................................................................................................................... 237
COOLING....................................................................................................................................................................................... 237
WARNING................................................................................................................................................................................... 237
COOLING SYSTEM WARNINGS............................................................................................................................................................... 237
SPECIFICATIONS............................................................................................................................................................................ 237
TORQUE - 1.6L SOHC.................................................................................................................................................................... 237
TORQUE - 2.0/2.4L..................................................................................................................................................................... 238
SPECIAL TOOLS............................................................................................................................................................................. 238
COOLING SYSTEM........................................................................................................................................................................ 238
ACCESSORY DRIVE - 1.6L SOHC....................................................................................................................................................................... 239
ACCESSORY DRIVE - 1.6L SOHC................................................................................................................................................................... 239
DESCRIPTION............................................................................................................................................................................... 239
DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT DIAGNOSIS.................................................................................................................................... 239
ACCESSORY DRIVE BELT.......................................................................................................................................................................... 240
REMOVAL................................................................................................................................................................................... 240
CLEANING.................................................................................................................................................................................. 240
INSPECTION................................................................................................................................................................................ 240
INSTALLATION.............................................................................................................................................................................. 240
ACCESSORY DRIVE BELT TENSIONER................................................................................................................................................................ 241
REMOVAL................................................................................................................................................................................... 241
INSTALLATION.............................................................................................................................................................................. 241
IDLER PULLEY.................................................................................................................................................................................. 241
REMOVAL................................................................................................................................................................................... 241
INSTALLATION.............................................................................................................................................................................. 241
ACCESSORY DRIVE - 2.0/2.4L DOHC................................................................................................................................................................... 242
DRIVE BELTS................................................................................................................................................................................... 242
DESCRIPTION............................................................................................................................................................................... 242
DIAGNOSIS AND TESTING..................................................................................................................................................................... 243
ACCESSORY DRIVE BELTS................................................................................................................................................................. 243
REMOVAL................................................................................................................................................................................... 244
POWER STEERING PUMP/AIR CONDITIONING COMPRESSOR BELT.................................................................................................................................. 244
GENERATOR BELT........................................................................................................................................................................ 244
CLEANING.................................................................................................................................................................................. 244
INSPECTION................................................................................................................................................................................ 244
INSTALLATION.............................................................................................................................................................................. 246
GENERATOR BELT........................................................................................................................................................................ 246
POWER STEERING PUMP/AIR CONDITIONING COMPRESSOR BELT.................................................................................................................................. 246
ADJUSTMENTS............................................................................................................................................................................... 247
BELT TENSION.......................................................................................................................................................................... 247
AUTOMATIC BELT TENSIONER AND PULLEY........................................................................................................................................................... 247
DESCRIPTION............................................................................................................................................................................... 247
REMOVAL................................................................................................................................................................................... 247
INSTALLATION.............................................................................................................................................................................. 247
ENGINE - 1.6L SOHC................................................................................................................................................................................ 248
ENGINE - 1.6L SOHC............................................................................................................................................................................ 249
DESCRIPTION............................................................................................................................................................................... 249
OPERATION................................................................................................................................................................................. 249
DIAGNOSIS AND TESTING..................................................................................................................................................................... 250
DIAGNOSIS AND TESTING - COOLING SYSTEM AERATION....................................................................................................................................... 250
DIAGNOSIS AND TESTING - COOLING SYSTEM DEAERATION..................................................................................................................................... 250
DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK..................................................................................................................................... 250
DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TESTING................................................................................................................................... 250
STANDARD PROCEDURE........................................................................................................................................................................ 251
STANDARD PROCEDURE - DRAINING COOLING SYSTEM.......................................................................................................................................... 251
STANDARD PROCEDURE - FILLING COOLING SYSTEM........................................................................................................................................... 251
CLEANING.................................................................................................................................................................................. 252
INSPECTION................................................................................................................................................................................ 252
COOLANT....................................................................................................................................................................................... 253
DESCRIPTION............................................................................................................................................................................... 253
DIAGNOSIS AND TESTING - COOLANT CONCENTRATION TESTING..................................................................................................................................... 253
STANDARD PROCEDURE........................................................................................................................................................................ 253
STANDARD PROCEDURE - COOLANT SERVICE.................................................................................................................................................. 253
STANDARD PROCEDURE - ROUTINE COOLANT LEVEL CHECK...................................................................................................................................... 253
STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT........................................................................................................................................ 253
HOSE CLAMPS................................................................................................................................................................................... 254
DESCRIPTION - HOSE CLAMPS................................................................................................................................................................. 254
COOLANT RECOVERY CONTAINER.................................................................................................................................................................... 254
DESCRIPTION............................................................................................................................................................................... 254
OPERATION................................................................................................................................................................................. 254
REMOVAL................................................................................................................................................................................... 254
INSTALLATION.............................................................................................................................................................................. 254
ENGINE BLOCK HEATER........................................................................................................................................................................... 255
DESCRIPTION............................................................................................................................................................................... 255
OPERATION................................................................................................................................................................................. 255
DIAGNOSIS AND TESTING - ENGINE BLOCK HEATER TESTING....................................................................................................................................... 255
REMOVAL................................................................................................................................................................................... 255
INSTALLATION.............................................................................................................................................................................. 255
ENGINE COOLANT TEMP SENSOR.................................................................................................................................................................... 256
DESCRIPTION............................................................................................................................................................................... 256
OPERATION................................................................................................................................................................................. 256
REMOVAL................................................................................................................................................................................... 256
INSTALLATION.............................................................................................................................................................................. 256
ENGINE COOLANT THERMOSTAT AND HOUSING......................................................................................................................................................... 256
REMOVAL................................................................................................................................................................................... 256
INSTALLATION.............................................................................................................................................................................. 256
RADIATOR PRESSURE CAP......................................................................................................................................................................... 257
DESCRIPTION............................................................................................................................................................................... 257
OPERATION................................................................................................................................................................................. 257
DIAGNOSIS AND TESTING..................................................................................................................................................................... 257
DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP TESTING........................................................................................................................... 257
DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE RELIEF TESTING........................................................................................................................ 258
CLEANING.................................................................................................................................................................................. 258
INSPECTION................................................................................................................................................................................ 258
RADIATOR DRAINCOCK............................................................................................................................................................................ 258
REMOVAL................................................................................................................................................................................... 258
INSTALLATION.............................................................................................................................................................................. 259
RADIATOR FAN.................................................................................................................................................................................. 259
DESCRIPTION............................................................................................................................................................................... 259
OPERATION................................................................................................................................................................................. 259
DIAGNOSIS AND TESTING - RADIATOR FAN...................................................................................................................................................... 260
REMOVAL................................................................................................................................................................................... 260
INSTALLATION.............................................................................................................................................................................. 261
RADIATOR...................................................................................................................................................................................... 261
REMOVAL................................................................................................................................................................................... 261
CLEANING.................................................................................................................................................................................. 262
INSPECTION................................................................................................................................................................................ 262
INSTALLATION.............................................................................................................................................................................. 262
HEATER RETURN TUBE............................................................................................................................................................................ 263
REMOVAL................................................................................................................................................................................... 263
INSTALLATION.............................................................................................................................................................................. 263
WATER PUMP/POWER STEERING PUMP ASSEMBLY....................................................................................................................................................... 263
DESCRIPTION............................................................................................................................................................................... 263
REMOVAL................................................................................................................................................................................... 264
DISASSEMBLY............................................................................................................................................................................... 264
ASSEMBLY.................................................................................................................................................................................. 265
INSTALLATION.............................................................................................................................................................................. 266
ENGINE - 2.0/2.4L DOHC............................................................................................................................................................................ 267
ENGINE - 2.0/2.4L DOHC........................................................................................................................................................................ 268
DESCRIPTION............................................................................................................................................................................... 268
Non-Turbo............................................................................................................................................................................. 268
Turbo................................................................................................................................................................................. 268
OPERATION................................................................................................................................................................................. 268
DIAGNOSIS AND TESTING..................................................................................................................................................................... 269
COOLING SYSTEM........................................................................................................................................................................ 269
DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TESTING................................................................................................................................... 275
DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK..................................................................................................................................... 276
PREFERRED METHOD.................................................................................................................................................................. 276
ALTERNATIVE METHOD................................................................................................................................................................ 276
COOLING SYSTEM AERATION............................................................................................................................................................... 276
DIAGNOSIS AND TESTING - COOLING SYSTEM DEAERATION..................................................................................................................................... 276
STANDARD PROCEDURE........................................................................................................................................................................ 276
STANDARD PROCEDURE - DRAINING COOLING SYSTEM.......................................................................................................................................... 276
STANDARD PROCEDURE - FILLING COOLING SYSTEM........................................................................................................................................... 277
CLEANING.................................................................................................................................................................................. 278
INSPECTION................................................................................................................................................................................ 278
COOLANT....................................................................................................................................................................................... 278
DESCRIPTION............................................................................................................................................................................... 278
DIAGNOSIS AND TESTING - COOLANT CONCENTRATION TESTING..................................................................................................................................... 278
STANDARD PROCEDURE........................................................................................................................................................................ 279
STANDARD PROCEDURE - ROUTINE COOLANT LEVEL CHECK0 - 2 PT (Continued).............................................................................................................. 279
STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT........................................................................................................................................ 279
STANDARD PROCEDURE - COOLANT LEVEL SERVICING.......................................................................................................................................... 279
COOLANT RECOVERY CONTAINER.................................................................................................................................................................... 281
DESCRIPTION............................................................................................................................................................................... 281
OPERATION................................................................................................................................................................................. 281
REMOVAL................................................................................................................................................................................... 281
Non - Turbo........................................................................................................................................................................... 281
Turbo................................................................................................................................................................................. 281
INSTALLATION.............................................................................................................................................................................. 281
Non - Turbo........................................................................................................................................................................... 281
Turbo................................................................................................................................................................................. 282
COOLING SYSTEM PRESSURE CAP................................................................................................................................................................... 282
DESCRIPTION............................................................................................................................................................................... 282
OPERATION................................................................................................................................................................................. 283
DIAGNOSIS AND TESTING..................................................................................................................................................................... 283
DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP TESTING........................................................................................................................... 283
DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE RELIEF TESTING........................................................................................................................ 283
CLEANING.................................................................................................................................................................................. 284
INSPECTION................................................................................................................................................................................ 284
ENGINE BLOCK HEATER........................................................................................................................................................................... 284
DESCRIPTION............................................................................................................................................................................... 284
OPERATION................................................................................................................................................................................. 284
DIAGNOSIS AND TESTING..................................................................................................................................................................... 285
ENGINE BLOCK HEATER................................................................................................................................................................... 285
REMOVAL................................................................................................................................................................................... 285
INSTALLATION.............................................................................................................................................................................. 285
ENGINE COOLANT TEMPERATURE SENSOR............................................................................................................................................................. 285
DESCRIPTION............................................................................................................................................................................... 285
OPERATION................................................................................................................................................................................. 285
REMOVAL................................................................................................................................................................................... 286
Non-Turbo............................................................................................................................................................................. 286
Turbo................................................................................................................................................................................. 286
INSTALLATION.............................................................................................................................................................................. 286
Non-Turbo............................................................................................................................................................................. 286
Turbo................................................................................................................................................................................. 286
ENGINE COOLANT THERMOSTAT..................................................................................................................................................................... 286
DESCRIPTION............................................................................................................................................................................... 286
OPERATION................................................................................................................................................................................. 287
DIAGNOSIS AND TESTING - ENGINE COOLANT THERMOSTAT......................................................................................................................................... 287
REMOVAL................................................................................................................................................................................... 287
INSTALLATION.............................................................................................................................................................................. 287
HOSE CLAMPS................................................................................................................................................................................... 288
DESCRIPTION - HOSE CLAMPS................................................................................................................................................................. 288
OPERATION................................................................................................................................................................................. 288
RADIATOR FAN.................................................................................................................................................................................. 288
DESCRIPTION............................................................................................................................................................................... 288
Non-Turbo............................................................................................................................................................................. 288
Turbo................................................................................................................................................................................. 288
OPERATION................................................................................................................................................................................. 289
Non-Turbo............................................................................................................................................................................. 289
Turbo................................................................................................................................................................................. 289
DIAGNOSIS AND TESTING..................................................................................................................................................................... 290
RADIATOR FAN MOTOR TEST............................................................................................................................................................... 290
REMOVAL................................................................................................................................................................................... 290
INSTALLATION.............................................................................................................................................................................. 291
RADIATOR...................................................................................................................................................................................... 291
REMOVAL................................................................................................................................................................................... 291
CLEANING.................................................................................................................................................................................. 293
INSPECTION................................................................................................................................................................................ 293
INSTALLATION.............................................................................................................................................................................. 293
RADIATOR DRAINCOCK............................................................................................................................................................................ 293
REMOVAL................................................................................................................................................................................... 293
INSTALLATION.............................................................................................................................................................................. 294
THERMOSTAT HOUSING............................................................................................................................................................................ 294
REMOVAL................................................................................................................................................................................... 294
INSTALLATION.............................................................................................................................................................................. 294
WATER PUMP.................................................................................................................................................................................... 295
DIAGNOSIS AND TESTING..................................................................................................................................................................... 295
WATER PUMP............................................................................................................................................................................ 295
REMOVAL................................................................................................................................................................................... 295
INSPECTION................................................................................................................................................................................ 295
INSTALLATION.............................................................................................................................................................................. 295
WATER PUMP INLET TUBE......................................................................................................................................................................... 296
REMOVAL................................................................................................................................................................................... 296
INSTALLATION.............................................................................................................................................................................. 296
TRANSMISSION...................................................................................................................................................................................... 297
TRANSMISSION COOLER HOSES..................................................................................................................................................................... 297
DESCRIPTION............................................................................................................................................................................... 297
AUTOMATIC TRANSMISSION OIL COOLER............................................................................................................................................................. 297
DESCRIPTION............................................................................................................................................................................... 297
Non - Turbo........................................................................................................................................................................... 297
Turbo................................................................................................................................................................................. 297
REMOVAL................................................................................................................................................................................... 297
Non - Turbo........................................................................................................................................................................... 297
Turbo................................................................................................................................................................................. 298
CLEANING.................................................................................................................................................................................. 298
INSPECTION................................................................................................................................................................................ 299
INSTALLATION.............................................................................................................................................................................. 299
Non - Turbo........................................................................................................................................................................... 299
Turbo................................................................................................................................................................................. 299
8a-AUDIO.............................................................................................................................................................................................. 301
AUDIO............................................................................................................................................................................................. 301
DESCRIPTION................................................................................................................................................................................... 301
OPERATION..................................................................................................................................................................................... 301
DIAGNOSIS AND TESTING - AUDIO................................................................................................................................................................. 302
ANTENNA BODY & CABLE.............................................................................................................................................................................. 303
DESCRIPTION................................................................................................................................................................................... 303
OPERATION..................................................................................................................................................................................... 303
DIAGNOSIS AND TESTING - ANTENNA BODY AND CABLE................................................................................................................................................ 304
TEST 1.................................................................................................................................................................................... 304
TEST 2.................................................................................................................................................................................... 304
TEST 3.................................................................................................................................................................................... 305
TEST 4.................................................................................................................................................................................... 305
REMOVAL....................................................................................................................................................................................... 305
INSTALLATION.................................................................................................................................................................................. 305
ANTENNA - SATELLITE RADIO......................................................................................................................................................................... 306
DESCRIPTION................................................................................................................................................................................... 306
OPERATION..................................................................................................................................................................................... 306
REMOVAL....................................................................................................................................................................................... 306
INSTALLATION.................................................................................................................................................................................. 306
ANTENNA CABLE - SATELLITE RADIO................................................................................................................................................................... 307
DESCRIPTION................................................................................................................................................................................... 307
REMOVAL....................................................................................................................................................................................... 307
INSTALLATION.................................................................................................................................................................................. 307
RADIO............................................................................................................................................................................................. 307
DESCRIPTION................................................................................................................................................................................... 307
OPERATION..................................................................................................................................................................................... 307
REMOVAL....................................................................................................................................................................................... 308
INSTALLATION.................................................................................................................................................................................. 308
RADIO NOISE SUPPRESSION COMPONENTS................................................................................................................................................................ 308
DESCRIPTION................................................................................................................................................................................... 308
OPERATION..................................................................................................................................................................................... 308
REMOVAL....................................................................................................................................................................................... 309
ENGINE GROUND STRAP....................................................................................................................................................................... 309
HOOD HINGE GROUND STRAP................................................................................................................................................................... 310
MUFFLER GROUND STRAP...................................................................................................................................................................... 310
RADIO NOISE SUPPRESSION CAPACITOR......................................................................................................................................................... 310
STRUT BRACKET TO BODY GROUND STRAP........................................................................................................................................................ 310
INSTALLATION.................................................................................................................................................................................. 311
ENGINE GROUND STRAP....................................................................................................................................................................... 311
HOOD HINGE GROUND STRAP................................................................................................................................................................... 311
MUFFLER GROUND STRAP...................................................................................................................................................................... 311
RADIO NOISE SUPPRESSION CAPACITOR......................................................................................................................................................... 311
STRUT BRACKET TO BODY GROUND STRAP........................................................................................................................................................ 311
SATELLITE RECEIVER MODULE......................................................................................................................................................................... 311
DESCRIPTION................................................................................................................................................................................... 311
OPERATION..................................................................................................................................................................................... 311
REMOVAL....................................................................................................................................................................................... 311
INSTALLATION.................................................................................................................................................................................. 311
SPEAKER........................................................................................................................................................................................... 311
REMOVAL....................................................................................................................................................................................... 311
FRONT DOOR SPEAKER........................................................................................................................................................................ 311
INSTRUMENT PANEL SPEAKER.................................................................................................................................................................. 312
REAR SPEAKER.............................................................................................................................................................................. 312
INSTALLATION.................................................................................................................................................................................. 312
FRONT DOOR SPEAKER........................................................................................................................................................................ 312
INSTRUMENT PANEL SPEAKER.................................................................................................................................................................. 312
REAR SPEAKER.............................................................................................................................................................................. 312
8b-CHIME/BUZZER....................................................................................................................................................................................... 313
CHIME/BUZZER...................................................................................................................................................................................... 313
DESCRIPTION................................................................................................................................................................................... 313
OPERATION..................................................................................................................................................................................... 313
FASTEN SEAT BELT.......................................................................................................................................................................... 313
HEADLAMPS REMINDER........................................................................................................................................................................ 313
KEY IN IGNITION REMINDER.................................................................................................................................................................. 313
DOOR AJAR CHIME........................................................................................................................................................................... 313
TURN SIGNAL ON............................................................................................................................................................................ 313
PARK BRAKE REMINDER....................................................................................................................................................................... 313
LOW FUEL REMINDER......................................................................................................................................................................... 313
REVERSE CHIME (DIESEL and TURBO ONLY EQUIPPED WITH THE GETRAG MANUAL TRANSMISSION)........................................................................................................ 313
DIAGNOSIS AND TESTING......................................................................................................................................................................... 314
DIAGNOSIS AND TESTING - BRAKE/PARK BRAKE INDICATOR........................................................................................................................................ 314
To test the system:................................................................................................................................................................... 314
If lamp fails to light inspect for:................................................................................................................................................... 314
DIAGNOSIS AND TESTING - CHIME CONDITIONS.................................................................................................................................................. 314
NO TONE WHEN IGNITION SWITCH IS TURNED ON AND DRIVERS SEAT BELT IS UNBUCKLED.......................................................................................................... 314
NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS ON................................................................................................................................... 314
NO TONE WHEN HEADLAMPS ARE ON AND DRIVERS DOOR IS OPEN................................................................................................................................ 314
NO TONE WHEN KEY IS LEFT IN IGNITION AND DRIVERS DOOR IS OPEN......................................................................................................................... 314
DIAGNOSIS AND TESTING - FASTEN SEAT BELTS................................................................................................................................................. 314
DIAGNOSIS AND TESTING - KEY IN IGNITION................................................................................................................................................... 314
8e-ELECTRONIC CONTROL MODULES......................................................................................................................................................................... 315
CONTROLLER ANTILOCK BRAKE......................................................................................................................................................................... 315
DESCRIPTION................................................................................................................................................................................... 315
OPERATION..................................................................................................................................................................................... 315
CONTROLLER ANTILOCK BRAKE INPUTS.......................................................................................................................................................... 316
CONTROLLER ANTILOCK BRAKE OUTPUTS......................................................................................................................................................... 316
REMOVAL....................................................................................................................................................................................... 316
INSTALLATION.................................................................................................................................................................................. 317
DATA LINK CONNECTOR............................................................................................................................................................................... 317
DESCRIPTION................................................................................................................................................................................... 317
OPERATION..................................................................................................................................................................................... 317
HEATED SEAT MODULE................................................................................................................................................................................ 317
DESCRIPTION................................................................................................................................................................................... 317
OPERATION..................................................................................................................................................................................... 318
DIAGNOSIS AND TESTING - HEATED SEAT MODULE.................................................................................................................................................... 318
REMOVAL....................................................................................................................................................................................... 319
INSTALLATION.................................................................................................................................................................................. 319
POWERTRAIN CONTROL MODULE......................................................................................................................................................................... 319
DESCRIPTION................................................................................................................................................................................... 319
OPERATION - SENSOR RETURN - PCM INPUT..................................................................................................................................................... 319
OPERATION - DATA BUS COMMUNICATION RECEIVE - PCM INPUT.................................................................................................................................... 319
OPERATION - IGNITION SENSE - PCM INPUT.................................................................................................................................................... 319
OPERATION - PCM GROUND.................................................................................................................................................................... 319
OPERATION..................................................................................................................................................................................... 320
OPERATION................................................................................................................................................................................. 320
Powertrain Control Module Connectors.................................................................................................................................................. 321
TRANSMISSION CONTROL.................................................................................................................................................................. 321
OPERATION - 5 VOLT SUPPLY - PCM OUTPUT.................................................................................................................................................... 324
STANDARD PROCEDURE............................................................................................................................................................................ 324
STANDARD PROCEDURE - OBTAINING DIAGNOSTIC TROUBLE CODES................................................................................................................................... 324
BULB CHECK............................................................................................................................................................................ 324
OBTAINING DTC'S USING DRB SCAN TOOL................................................................................................................................................... 324
STANDARD PROCEDURE - PINION FACTOR SETTING................................................................................................................................................ 324
STANDARD PROCEDURE - QUICK LEARN PROCEDURE................................................................................................................................................ 324
REMOVAL....................................................................................................................................................................................... 325
REMOVAL - 1.6L............................................................................................................................................................................ 325
REMOVAL - 2.0, 2.4, and 2.4L Turbo........................................................................................................................................................ 326
INSTALLATION.................................................................................................................................................................................. 328
INSTALLATION - 1.6L....................................................................................................................................................................... 328
INSTALLATION - 2.0, 2.4, and 2.4L TURBO................................................................................................................................................... 329
SENTRY KEY IMMOBILIZER MODULE..................................................................................................................................................................... 329
DESCRIPTION................................................................................................................................................................................... 329
OPERATION..................................................................................................................................................................................... 330
STANDARD PROCEDURE - SENTRY KEY IMMOBILIZER SYSTEM INITIALIZATION............................................................................................................................. 330
REMOVAL....................................................................................................................................................................................... 330
INSTALLATION.................................................................................................................................................................................. 331
TRANSMISSION CONTROL MODULE....................................................................................................................................................................... 331
DESCRIPTION................................................................................................................................................................................... 331
OPERATION..................................................................................................................................................................................... 331
CLUTCH VOLUME INDEX (CVI)................................................................................................................................................................. 332
SHIFT SCHEDULES........................................................................................................................................................................... 333
REMOVAL....................................................................................................................................................................................... 334
INSTALLATION.................................................................................................................................................................................. 334
8f-ENGINE SYSTEMS..................................................................................................................................................................................... 337
BATTERY SYSTEM.................................................................................................................................................................................... 337
BATTERY SYSTEM................................................................................................................................................................................ 338
DESCRIPTION............................................................................................................................................................................... 338
OPERATION................................................................................................................................................................................. 338
DIAGNOSIS AND TESTING - BATTERY SYSTEM.................................................................................................................................................... 338
MICRO 420 BATTERY TESTER.............................................................................................................................................................. 338
ABNORMAL BATTERY DISCHARGING.......................................................................................................................................................... 340
CLEANING.................................................................................................................................................................................. 340
INSPECTION................................................................................................................................................................................ 342
SPECIFICATIONS............................................................................................................................................................................ 342
SPECIFICATIONS........................................................................................................................................................................ 342
TORQUE SPECIFICATIONS................................................................................................................................................................. 343
SPECIAL TOOLS............................................................................................................................................................................. 343
BATTERY SYSTEM SPECIAL TOOLS.......................................................................................................................................................... 343
BATTERY....................................................................................................................................................................................... 343
DESCRIPTION............................................................................................................................................................................... 343
SPIRAL PLATE BATTERY - DIESEL ENGINE.................................................................................................................................................. 343
CONVENTIONAL BATTERY - GASOLINE ENGINE................................................................................................................................................ 343
OPERATION................................................................................................................................................................................. 343
DIAGNOSIS AND TESTING - BATTERY........................................................................................................................................................... 344
MICRO 420 BATTERY TESTER.............................................................................................................................................................. 344
STANDARD PROCEDURE........................................................................................................................................................................ 344
STANDARD PROCEDURE - SPIRAL PLATE BATTERY CHARGING.................................................................................................................................... 344
CHARGING A COMPLETELY DISCHARGED BATTERY – SPIRAL PLATE BATTERY................................................................................................................... 345
CHARGING TIME REQUIRED............................................................................................................................................................ 345
STANDARD PROCEDURE - CONVENTIONAL BATTERY CHARGING.................................................................................................................................... 346
CHARGING A COMPLETELY DISCHARGED CONVENTIONAL BATTERY............................................................................................................................. 346
CHARGING TIME REQUIRED............................................................................................................................................................ 347
STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER................................................................................................................................... 347
BATTERY TESTING................................................................................................................................................................... 348
STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST........................................................................................................................................ 348
STANDARD PROCEDURE - IGNITION-OFF DRAW TEST........................................................................................................................................... 349
REMOVAL................................................................................................................................................................................... 350
REMOVAL - GASOLINE ENGINE............................................................................................................................................................. 350
REMOVAL - DIESEL ENGINE............................................................................................................................................................... 350
INSTALLATION.............................................................................................................................................................................. 352
INSTALLATION - GASOLINE ENGINE........................................................................................................................................................ 352
INSTALLATION - DIESEL ENGINE.......................................................................................................................................................... 352
BATTERY HOLDDOWN.............................................................................................................................................................................. 353
DESCRIPTION............................................................................................................................................................................... 353
OPERATION................................................................................................................................................................................. 353
REMOVAL................................................................................................................................................................................... 353
INSTALLATION.............................................................................................................................................................................. 353
BATTERY CABLES................................................................................................................................................................................ 354
DESCRIPTION............................................................................................................................................................................... 354
OPERATION................................................................................................................................................................................. 354
DIAGNOSIS AND TESTING - BATTERY CABLES.................................................................................................................................................... 354
VOLTAGE DROP TEST..................................................................................................................................................................... 354
REMOVAL................................................................................................................................................................................... 355
INSTALLATION.............................................................................................................................................................................. 356
BATTERY TRAY.................................................................................................................................................................................. 356
DESCRIPTION............................................................................................................................................................................... 356
OPERATION................................................................................................................................................................................. 356
REMOVAL................................................................................................................................................................................... 356
REMOVAL - GASOLINE ENGINE............................................................................................................................................................. 356
REMOVAL - DIESEL ENGINE............................................................................................................................................................... 356
INSTALLATION.............................................................................................................................................................................. 356
INSTALLATION - GASOLINE ENGINE........................................................................................................................................................ 356
INSTALLATION - DIESEL ENGINE.......................................................................................................................................................... 356
THERMAL GUARD................................................................................................................................................................................. 357
DESCRIPTION............................................................................................................................................................................... 357
OPERATION................................................................................................................................................................................. 357
REMOVAL................................................................................................................................................................................... 357
INSTALLATION.............................................................................................................................................................................. 357
BATTERY TRAY SUPPORT BRACKET.................................................................................................................................................................. 358
REMOVAL................................................................................................................................................................................... 358
INSTALLATION.............................................................................................................................................................................. 358
CHARGING.......................................................................................................................................................................................... 359
CHARGING...................................................................................................................................................................................... 359
DESCRIPTION - CHARGING SYSTEM............................................................................................................................................................. 359
OPERATION - CHARGING SYSTEM............................................................................................................................................................... 359
DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTIC SYSTEM........................................................................................................................................ 360
BATTERY TEMPERATURE SENSOR.................................................................................................................................................................... 361
OPERATION................................................................................................................................................................................. 361
REMOVAL - 2.0, 2.4, and 2.4L TURBO........................................................................................................................................................ 361
INSTALLATION - 2.0, 2.4, and 2.4L TURBO................................................................................................................................................... 362
GENERATOR..................................................................................................................................................................................... 362
DESCRIPTION............................................................................................................................................................................... 362
OPERATION................................................................................................................................................................................. 362
REMOVAL................................................................................................................................................................................... 363
REMOVAL - 2.0/2.4L.................................................................................................................................................................... 363
REMOVAL - 2.4L TURBO.................................................................................................................................................................. 364
REMOVAL - 2.2 DIESEL.................................................................................................................................................................. 367
INSTALLATION.............................................................................................................................................................................. 367
INSTALLATION - 2.0/2.4L............................................................................................................................................................... 367
INSTALLATION - 2.4L TURBO............................................................................................................................................................. 368
INSTALLATION - 2.2 DIESEL............................................................................................................................................................. 368
VOLTAGE REGULATOR............................................................................................................................................................................. 369
DESCRIPTION............................................................................................................................................................................... 369
OPERATION................................................................................................................................................................................. 369
STARTING.......................................................................................................................................................................................... 370
STARTING...................................................................................................................................................................................... 370
DESCRIPTION............................................................................................................................................................................... 370
OPERATION................................................................................................................................................................................. 370
DIAGNOSIS AND TESTING..................................................................................................................................................................... 370
DIAGNOSIS AND TESTING - STARTING SYSTEM TEST.......................................................................................................................................... 370
INSPECTION........................................................................................................................................................................ 370
DIAGNOSIS AND TESTING - CONTROL CIRCUIT TEST.......................................................................................................................................... 372
STARTER SOLENOID.................................................................................................................................................................. 372
STARTER RELAY..................................................................................................................................................................... 373
RELAY TEST........................................................................................................................................................................ 373
RELAY CIRCUIT TEST................................................................................................................................................................ 374
SAFETY SWITCHES................................................................................................................................................................... 374
IGNITION SWITCH................................................................................................................................................................... 374
BATTERY........................................................................................................................................................................... 374
ALL RELATED WIRING AND CONNECTORS................................................................................................................................................. 374
DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST.................................................................................................................................. 374
DIAGNOSIS AND TESTING - FEED CIRCUIT TEST............................................................................................................................................. 375
SPECIFICATIONS............................................................................................................................................................................ 375
STARTER MOTOR......................................................................................................................................................................... 375
TORQUE................................................................................................................................................................................ 376
STARTER MOTOR................................................................................................................................................................................. 376
REMOVAL................................................................................................................................................................................... 376
REMOVAL - 1.6L........................................................................................................................................................................ 376
REMOVAL - 2.2 DIESEL.................................................................................................................................................................. 377
REMOVAL - 2.0/2.4L.................................................................................................................................................................... 378
REMOVAL - STARTER 2.4L TURBO.......................................................................................................................................................... 378
INSTALLATION.............................................................................................................................................................................. 380
INSTALLATION - 1.6L................................................................................................................................................................... 380
INSTALLATION - 2.2L DIESEL............................................................................................................................................................ 380
INSTALLATION - 2.0/2.4L............................................................................................................................................................... 381
INSTALLATION - STARTER 2.4L TURBO..................................................................................................................................................... 381
8g-HEATED SYSTEMS..................................................................................................................................................................................... 383
HEATED SEAT SYSTEM................................................................................................................................................................................ 383
HEATED SEAT SYSTEM............................................................................................................................................................................ 383
DESCRIPTION............................................................................................................................................................................... 383
OPERATION................................................................................................................................................................................. 384
DIAGNOSIS AND TESTING - HEATED SEAT SYSTEM................................................................................................................................................ 384
SELF-DIAGNOSTICS - HEATED SEAT SYSTEM................................................................................................................................................. 385
DRIVER HEATED SEAT SWITCH..................................................................................................................................................................... 386
DESCRIPTION............................................................................................................................................................................... 386
OPERATION................................................................................................................................................................................. 386
DIAGNOSIS AND TESTING - DRIVER HEATED SEAT SWITCH......................................................................................................................................... 386
REMOVAL................................................................................................................................................................................... 387
INSTALLATION.............................................................................................................................................................................. 387
HEATED SEAT ELEMENT........................................................................................................................................................................... 387
DESCRIPTION............................................................................................................................................................................... 387
OPERATION................................................................................................................................................................................. 388
DIAGNOSIS AND TESTING - HEATED SEAT ELEMENT............................................................................................................................................... 388
REMOVAL................................................................................................................................................................................... 388
INSTALLATION.............................................................................................................................................................................. 388
HEATED SEAT RELAY............................................................................................................................................................................. 389
DESCRIPTION............................................................................................................................................................................... 389
OPERATION................................................................................................................................................................................. 389
DIAGNOSIS AND TESTING - MICRO-RELAY....................................................................................................................................................... 389
REMOVAL................................................................................................................................................................................... 389
INSTALLATION.............................................................................................................................................................................. 390
HEATED SEAT SENSOR............................................................................................................................................................................ 390
DESCRIPTION............................................................................................................................................................................... 390
OPERATION................................................................................................................................................................................. 390
DIAGNOSIS AND TESTING - HEATED SEAT SENSOR................................................................................................................................................ 390
REMOVAL................................................................................................................................................................................... 390
PASSENGER HEATED SEAT SWITCH.................................................................................................................................................................. 390
DESCRIPTION............................................................................................................................................................................... 390
OPERATION................................................................................................................................................................................. 390
DIAGNOSIS AND TESTING - PASSENGER HEATED SEAT SWITCH...................................................................................................................................... 391
REMOVAL................................................................................................................................................................................... 391
INSTALLATION.............................................................................................................................................................................. 391
HEATED WINDOW DEFOGGER............................................................................................................................................................................ 392
HEATED WINDOW DEFOGGER........................................................................................................................................................................ 392
DESCRIPTION............................................................................................................................................................................... 392
OPERATION................................................................................................................................................................................. 392
DIAGNOSIS AND TESTING..................................................................................................................................................................... 392
REAR WINDOW DEFOGGER SYSTEM........................................................................................................................................................... 392
DEFOGGER SWITCH............................................................................................................................................................................... 393
DESCRIPTION............................................................................................................................................................................... 393
OPERATION................................................................................................................................................................................. 393
DIAGNOSIS AND TESTING..................................................................................................................................................................... 393
REAR WINDOW DEFOGGER SWITCH........................................................................................................................................................... 393
IN-VEHICLE TESTING................................................................................................................................................................ 393
BENCH TESTING..................................................................................................................................................................... 394
REAR WINDOW DEFOGGER GRID..................................................................................................................................................................... 394
DIAGNOSIS AND TESTING..................................................................................................................................................................... 394
GRID LINES............................................................................................................................................................................ 394
STANDARD PROCEDURE........................................................................................................................................................................ 395
GRID LINE AND TERMINAL REPAIR......................................................................................................................................................... 395
REAR WINDOW DEFOGGER GRID LINES....................................................................................................................................................... 395
8h-HORN............................................................................................................................................................................................... 397
HORN SYSTEM....................................................................................................................................................................................... 397
DESCRIPTION................................................................................................................................................................................... 397
OPERATION..................................................................................................................................................................................... 397
DIAGNOSIS AND TESTING - HORN SYSTEM........................................................................................................................................................... 397
HORN.............................................................................................................................................................................................. 399
DIAGNOSIS AND TESTING - HORN.................................................................................................................................................................. 399
REMOVAL....................................................................................................................................................................................... 399
INSTALLATION.................................................................................................................................................................................. 399
HORN RELAY........................................................................................................................................................................................ 399
DIAGNOSIS AND TESTING - HORN RELAY............................................................................................................................................................ 399
REMOVAL....................................................................................................................................................................................... 400
INSTALLATION.................................................................................................................................................................................. 400
HORN SWITCH....................................................................................................................................................................................... 400
DESCRIPTION................................................................................................................................................................................... 400
OPERATION..................................................................................................................................................................................... 400
REMOVAL....................................................................................................................................................................................... 400
8i-IGNITION CONTROL................................................................................................................................................................................... 401
IGNITION CONTROL.................................................................................................................................................................................. 401
DESCRIPTION - IGNITION SYSTEM................................................................................................................................................................. 401
OPERATION - IGNITION SYSTEM................................................................................................................................................................... 401
SPECIFICATIONS................................................................................................................................................................................ 402
FIRING ORDER—1.6/2.0L..................................................................................................................................................................... 402
TORQUE.................................................................................................................................................................................... 402
IGNITION COILS............................................................................................................................................................................ 403
SPARK PLUGS............................................................................................................................................................................... 403
SPARK PLUG CABLE RESISTANCE............................................................................................................................................................... 403
SPECIAL TOOLS - EXPORT........................................................................................................................................................................ 403
AUTO SHUT DOWN RELAY.............................................................................................................................................................................. 403
DESCRIPTION................................................................................................................................................................................... 403
OPERATION..................................................................................................................................................................................... 403
CAMSHAFT POSITION SENSOR.......................................................................................................................................................................... 404
DESCRIPTION................................................................................................................................................................................... 404
OPERATION..................................................................................................................................................................................... 404
REMOVAL....................................................................................................................................................................................... 405
REMOVAL - 2.0/2.4L........................................................................................................................................................................ 405
REMOVAL - 1.6L............................................................................................................................................................................ 406
INSTALLATION.................................................................................................................................................................................. 406
INSTALLATION - 2.0/2.4L................................................................................................................................................................... 406
INSTALLATION - 1.6L....................................................................................................................................................................... 406
IGNITION COIL..................................................................................................................................................................................... 406
DESCRIPTION................................................................................................................................................................................... 406
OPERATION..................................................................................................................................................................................... 406
REMOVAL....................................................................................................................................................................................... 407
REMOVAL - 1.6L............................................................................................................................................................................ 407
REMOVAL - 2.0/2.4L........................................................................................................................................................................ 408
REMOVAL - 2.4L TURBO...................................................................................................................................................................... 409
INSTALLATION.................................................................................................................................................................................. 410
INSTALLATION - 1.6L....................................................................................................................................................................... 410
INSTALLATION- 2.0/2.4L.................................................................................................................................................................... 410
INSTALLATION - 2.4L TURBO................................................................................................................................................................. 411
IGNITION COIL CAPACITOR........................................................................................................................................................................... 411
REMOVAL - 2.4L TURBO.......................................................................................................................................................................... 411
INSTALLATION - 2.4L TURBO..................................................................................................................................................................... 411
KNOCK SENSOR...................................................................................................................................................................................... 411
DESCRIPTION................................................................................................................................................................................... 411
OPERATION..................................................................................................................................................................................... 411
REMOVAL....................................................................................................................................................................................... 412
REMOVAL - 1.6L............................................................................................................................................................................ 412
REMOVAL - 2.0/2.4L........................................................................................................................................................................ 412
INSTALLATION.................................................................................................................................................................................. 412
INSTALLATION - 1.6L....................................................................................................................................................................... 412
INSTALLATION - 2.0/2.4L................................................................................................................................................................... 412
SPARK PLUG........................................................................................................................................................................................ 413
REMOVAL....................................................................................................................................................................................... 413
REMOVAL - 1.6L............................................................................................................................................................................ 413
REMOVAL - 2.0/2.4L........................................................................................................................................................................ 413
REMOVAL - 2.4L TURBO...................................................................................................................................................................... 413
INSTALLATION.................................................................................................................................................................................. 413
INSTALLATION - 1.6L....................................................................................................................................................................... 413
INSTALLATION - 2.0/2.4L................................................................................................................................................................... 414
INSTALLATION - 2.4L TURBO................................................................................................................................................................. 414
SPARK PLUG CABLE.................................................................................................................................................................................. 414
DESCRIPTION................................................................................................................................................................................... 414
REMOVAL....................................................................................................................................................................................... 415
REMOVAL - 1.6L............................................................................................................................................................................ 415
REMOVAL - 2.0/2.4L........................................................................................................................................................................ 415
INSTALLATION.................................................................................................................................................................................. 415
INSTALLATION - 1.6L....................................................................................................................................................................... 415
INSTALLATION - 2.0/2.4L................................................................................................................................................................... 415
8j-INSTRUMENT CLUSTER................................................................................................................................................................................. 417
INSTRUMENT CLUSTER................................................................................................................................................................................ 417
DESCRIPTION................................................................................................................................................................................... 417
CHIME..................................................................................................................................................................................... 417
KEY IN IGNITION SWITCH.................................................................................................................................................................... 417
INSTRUMENT CLUSTER - EXPORT............................................................................................................................................................... 418
OPERATION..................................................................................................................................................................................... 418
INSTRUMENT CLUSTER - EXPORT............................................................................................................................................................... 418
DIAGNOSIS AND TESTING......................................................................................................................................................................... 419
DIAGNOSIS AND TESTING - INSTRUMENT CLUSTER WARNING/INDICATOR LAMPS........................................................................................................................ 419
DIAGNOSIS AND TESTING - MULTIPLE/INDIVIDUAL GAUGES INOPERATIVE............................................................................................................................ 419
STANDARD PROCEDURE - SELF-DIAGNOSTICS......................................................................................................................................................... 420
REMOVAL....................................................................................................................................................................................... 420
INSTALLATION.................................................................................................................................................................................. 421
CLUSTER MASK/LENS................................................................................................................................................................................. 421
REMOVAL....................................................................................................................................................................................... 421
INSTALLATION.................................................................................................................................................................................. 421
8l-LAMPS.............................................................................................................................................................................................. 423
LAMPS/LIGHTTING - EXTERIOR........................................................................................................................................................................ 423
LAMPS/LIGHTING - EXTERIOR..................................................................................................................................................................... 424
SPECIFICATIONS............................................................................................................................................................................ 424
EXTERIOR LAMPS........................................................................................................................................................................ 424
BACK-UP LAMP.................................................................................................................................................................................. 424
REMOVAL................................................................................................................................................................................... 424
INSTALLATION.............................................................................................................................................................................. 424
BACK-UP LAMP UNIT............................................................................................................................................................................. 425
REMOVAL................................................................................................................................................................................... 425
INSTALLATION.............................................................................................................................................................................. 425
BRAKE LAMP SWITCH............................................................................................................................................................................. 425
DESCRIPTION............................................................................................................................................................................... 425
OPERATION................................................................................................................................................................................. 426
DIAGNOSIS AND TESTING - BRAKE LAMP SWITCH................................................................................................................................................. 426
REMOVAL................................................................................................................................................................................... 426
INSTALLATION.............................................................................................................................................................................. 427
CENTER HIGH MOUNTED STOP LAMP................................................................................................................................................................. 427
REMOVAL................................................................................................................................................................................... 427
INSTALLATION.............................................................................................................................................................................. 427
CENTER HIGH MOUNTED STOP LAMP UNIT............................................................................................................................................................ 427
REMOVAL................................................................................................................................................................................... 427
INSTALLATION.............................................................................................................................................................................. 428
COMBINATION FLASHER........................................................................................................................................................................... 428
DESCRIPTION............................................................................................................................................................................... 428
OPERATION................................................................................................................................................................................. 428
REMOVAL................................................................................................................................................................................... 428
INSTALLATION.............................................................................................................................................................................. 428
DAYTIME RUNNING LAMP MODULE................................................................................................................................................................... 429
DESCRIPTION............................................................................................................................................................................... 429
OPERATION................................................................................................................................................................................. 429
FOG LAMP...................................................................................................................................................................................... 429
DIAGNOSIS AND TESTING - FOG LAMP.......................................................................................................................................................... 429
REMOVAL................................................................................................................................................................................... 430
INSTALLATION.............................................................................................................................................................................. 430
FOG LAMP UNIT................................................................................................................................................................................. 430
STANDARD PROCEDURE - FOG LAMP UNIT ALIGNMENT.............................................................................................................................................. 430
REMOVAL................................................................................................................................................................................... 430
INSTALLATION.............................................................................................................................................................................. 430
FRONT POSITION LAMP - EXPORT.................................................................................................................................................................. 431
DESCRIPTION............................................................................................................................................................................... 431
OPERATION................................................................................................................................................................................. 431
DIAGNOSIS AND TESTING - FRONT POSITION LAMP - EXPORT...................................................................................................................................... 431
REMOVAL................................................................................................................................................................................... 432
INSTALLATION.............................................................................................................................................................................. 432
HEADLAMP...................................................................................................................................................................................... 432
DIAGNOSIS AND TESTING - HEADLAMPS......................................................................................................................................................... 432
REMOVAL................................................................................................................................................................................... 433
INSTALLATION.............................................................................................................................................................................. 433
HEADLAMP UNIT................................................................................................................................................................................. 434
STANDARD PROCEDURE........................................................................................................................................................................ 434
STANDARD PROCEDURE - HEADLAMP UNIT ALIGNMENT.......................................................................................................................................... 434
ALIGNMENT SCREEN PREPARATION...................................................................................................................................................... 434
HEADLAMP UNIT ALIGNMENT........................................................................................................................................................... 435
STANDARD PROCEDURE - HEADLAMP UNIT ALIGNMENT - EXPORT................................................................................................................................. 435
VEHICLE PREPARATION FOR HEADLAMP UNIT ALIGNMENT................................................................................................................................... 435
ALIGNMENT SCREEN PREPARATION...................................................................................................................................................... 435
HEADLAMP UNIT ALIGNMENT........................................................................................................................................................... 435
REMOVAL................................................................................................................................................................................... 435
INSTALLATION.............................................................................................................................................................................. 437
HEADLAMP LEVELING MOTOR - EXPORT.............................................................................................................................................................. 437
DESCRIPTION............................................................................................................................................................................... 437
OPERATION................................................................................................................................................................................. 438
DIAGNOSIS AND TESTING - HEADLAMP LEVELING MOTOR - EXPORT.................................................................................................................................. 438
REMOVAL................................................................................................................................................................................... 438
INSTALLATION.............................................................................................................................................................................. 439
HEADLAMP LEVELING SWITCH - EXPORT............................................................................................................................................................. 439
DESCRIPTION............................................................................................................................................................................... 439
OPERATION................................................................................................................................................................................. 439
DIAGNOSIS AND TESTING - HEADLAMP LEVELING SWITCH - EXPORT................................................................................................................................. 439
REMOVAL................................................................................................................................................................................... 439
INSTALLATION.............................................................................................................................................................................. 440
HEADLAMP SWITCH............................................................................................................................................................................... 440
DESCRIPTION............................................................................................................................................................................... 440
OPERATION................................................................................................................................................................................. 440
LICENSE PLATE LAMP............................................................................................................................................................................ 440
REMOVAL................................................................................................................................................................................... 440
INSTALLATION.............................................................................................................................................................................. 440
LICENSE PLATE LAMP UNIT....................................................................................................................................................................... 441
REMOVAL................................................................................................................................................................................... 441
INSTALLATION.............................................................................................................................................................................. 441
MULTI-FUNCTION SWITCH......................................................................................................................................................................... 441
DESCRIPTION............................................................................................................................................................................... 441
MULTI-FUNCTION SWITCH................................................................................................................................................................. 441
HAZARD WARNING SYSTEM................................................................................................................................................................. 442
OPERATION................................................................................................................................................................................. 442
MULTI-FUNCTION SWITCH................................................................................................................................................................. 442
HAZARD WARNING SYSTEM................................................................................................................................................................. 442
DIAGNOSIS AND TESTING - MULTI-FUNCTION SWITCH............................................................................................................................................. 442
FLASHER DIAGNOSIS..................................................................................................................................................................... 442
SWITCH DIAGNOSIS...................................................................................................................................................................... 444
REMOVAL................................................................................................................................................................................... 446
INSTALLATION.............................................................................................................................................................................. 446
PARK/TURN SIGNAL LAMP......................................................................................................................................................................... 447
REMOVAL................................................................................................................................................................................... 447
INSTALLATION.............................................................................................................................................................................. 447
REAR FOG LAMP SWITCH - EXPORT................................................................................................................................................................. 447
DESCRIPTION............................................................................................................................................................................... 447
OPERATION................................................................................................................................................................................. 447
SIDE REPEATER LAMP - EXPORT................................................................................................................................................................... 448
DIAGNOSIS AND TESTING - SIDE REPEATER LAMP................................................................................................................................................ 448
REMOVAL................................................................................................................................................................................... 448
INSTALLATION.............................................................................................................................................................................. 448
SIDE REPEATER LAMP UNIT - EXPORT.............................................................................................................................................................. 448
REMOVAL................................................................................................................................................................................... 448
INSTALLATION.............................................................................................................................................................................. 448
TAIL LAMP..................................................................................................................................................................................... 448
REMOVAL................................................................................................................................................................................... 448
INSTALLATION.............................................................................................................................................................................. 448
TAIL LAMP UNIT................................................................................................................................................................................ 449
REMOVAL................................................................................................................................................................................... 449
INSTALLATION.............................................................................................................................................................................. 449
LAMPS/LIGHTING - INTERIOR......................................................................................................................................................................... 450
LAMPS/LIGHTING - INTERIOR..................................................................................................................................................................... 450
SPECIFICATIONS............................................................................................................................................................................ 450
INTERIOR LAMPS........................................................................................................................................................................ 450
CENTER CONSOLE FLOOD LAMP..................................................................................................................................................................... 451
REMOVAL................................................................................................................................................................................... 451
INSTALLATION.............................................................................................................................................................................. 451
CENTER CONSOLE FLOOD LAMP HOUSING............................................................................................................................................................. 451
REMOVAL................................................................................................................................................................................... 451
INSTALLATION.............................................................................................................................................................................. 451
COURTESY/READING LAMP......................................................................................................................................................................... 452
REMOVAL................................................................................................................................................................................... 452
INSTALLATION.............................................................................................................................................................................. 452
DOME LAMP..................................................................................................................................................................................... 452
REMOVAL................................................................................................................................................................................... 452
INSTALLATION.............................................................................................................................................................................. 452
DOME LAMP UNIT................................................................................................................................................................................ 452
REMOVAL................................................................................................................................................................................... 452
INSTALLATION.............................................................................................................................................................................. 452
DOME LAMP WITH INTRUSION SENSOR - EXPORT...................................................................................................................................................... 452
REMOVAL................................................................................................................................................................................... 452
INSTALLATION.............................................................................................................................................................................. 452
DOME LAMP UNIT WITH INTRUSION SENSOR - EXPORT................................................................................................................................................. 452
REMOVAL................................................................................................................................................................................... 452
INSTALLATION.............................................................................................................................................................................. 453
CLUSTER ILLUMINATION LAMPS.................................................................................................................................................................... 453
REMOVAL................................................................................................................................................................................... 453
INSTALLATION.............................................................................................................................................................................. 454
REAR CARGO LAMP............................................................................................................................................................................... 454
REMOVAL................................................................................................................................................................................... 454
INSTALLATION.............................................................................................................................................................................. 454
REAR CARGO LAMP UNIT.......................................................................................................................................................................... 454
REMOVAL................................................................................................................................................................................... 454
INSTALLATION.............................................................................................................................................................................. 454
TRANS RANGE INDICATOR ILLUMINATION............................................................................................................................................................ 455
REMOVAL................................................................................................................................................................................... 455
INSTALLATION.............................................................................................................................................................................. 455
VANITY LAMP................................................................................................................................................................................... 455
REMOVAL................................................................................................................................................................................... 455
INSTALLATION.............................................................................................................................................................................. 455
8m-MESSAGE SYSTEMS.................................................................................................................................................................................... 457
OVERHEAD CONSOLE.................................................................................................................................................................................. 457
DESCRIPTION................................................................................................................................................................................... 457
OPERATION..................................................................................................................................................................................... 457
AUTOMATIC COMPASS CALIBRATION............................................................................................................................................................. 458
MANUAL COMPASS CALIBRATION................................................................................................................................................................ 458
ZONE VARIANCE............................................................................................................................................................................. 458
OUTSIDE TEMPERATURE....................................................................................................................................................................... 458
STANDARD PROCEDURE............................................................................................................................................................................ 458
STANDARD PROCEDURE - COMPASS CALIBRATION.................................................................................................................................................. 458
STANDARD PROCEDURE - COMPASS VARIATION ADJUSTMENT......................................................................................................................................... 459
PROGRAMMING ZONE VARIATION............................................................................................................................................................ 459
STANDARD PROCEDURE - COMPASS DEMAGNETIZING................................................................................................................................................ 460
REMOVAL....................................................................................................................................................................................... 460
INSTALLATION.................................................................................................................................................................................. 461
SPECIAL TOOLS................................................................................................................................................................................. 461
OVERHEAD CONSOLE.......................................................................................................................................................................... 461
AMBIENT TEMP SENSOR............................................................................................................................................................................... 461
DESCRIPTION................................................................................................................................................................................... 461
OPERATION..................................................................................................................................................................................... 461
DIAGNOSIS AND TESTING - AMBIENT TEMPERATURE SENSOR............................................................................................................................................ 461
SENSOR TESTING............................................................................................................................................................................ 461
SENSOR CIRCUIT TESTING.................................................................................................................................................................... 462
REMOVAL....................................................................................................................................................................................... 462
INSTALLATION.................................................................................................................................................................................. 462
8n-POWER SYSTEMS...................................................................................................................................................................................... 463
POWER LOCKS....................................................................................................................................................................................... 463
POWER LOCKS................................................................................................................................................................................... 463
DESCRIPTION............................................................................................................................................................................... 463
POWER LOCKS........................................................................................................................................................................... 463
CHILD PROTECTION LOCKS................................................................................................................................................................ 464
DOOR LOCK INHIBIT..................................................................................................................................................................... 464
REMOTE KEYLESS ENTRY.................................................................................................................................................................. 464
OPERATION................................................................................................................................................................................. 464
POWER LOCKS........................................................................................................................................................................... 464
CENTRAL LOCKING/UNLOCKING (IF EQUIPPED)0 - 4 PT (Continued)....................................................................................................................... 464
REMOTE KEYLESS ENTRY.................................................................................................................................................................. 464
ROLLING DOOR LOCKS.................................................................................................................................................................... 464
DIAGNOSIS AND TESTING - POWER LOCKS....................................................................................................................................................... 465
STANDARD PROCEDURE........................................................................................................................................................................ 465
STANDARD PROCEDURE - DOUBLE ACTIVATION UNLOCK......................................................................................................................................... 465
DRB lll PROGRAMMING............................................................................................................................................................... 465
CUSTOMER PROGRAMMING.............................................................................................................................................................. 465
STANDARD PROCEDURE - ROLLING DOOR LOCKS............................................................................................................................................... 465
DRB lll PROGRAMMING............................................................................................................................................................... 465
CUSTOMER PROGRAMMING.............................................................................................................................................................. 465
DOOR LOCK SWITCH.............................................................................................................................................................................. 465
DIAGNOSIS AND TESTING - DOOR LOCK SWITCH.................................................................................................................................................. 465
REMOVAL................................................................................................................................................................................... 466
INSTALLATION.............................................................................................................................................................................. 466
DOOR LOCK MOTOR............................................................................................................................................................................... 466
DESCRIPTION............................................................................................................................................................................... 466
OPERATION................................................................................................................................................................................. 466
DIAGNOSIS AND TESTING - DOOR LOCK MOTOR................................................................................................................................................... 466
LIFTGATE LOCK MOTOR........................................................................................................................................................................... 467
REMOVAL................................................................................................................................................................................... 467
INSTALLATION.............................................................................................................................................................................. 467
REMOTE KEYLESS ENTRY MODULE................................................................................................................................................................... 467
DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY MODULE....................................................................................................................................... 467
REMOVAL................................................................................................................................................................................... 467
INSTALLATION.............................................................................................................................................................................. 467
REMOTE KEYLESS ENTRY TRANSMITTER.............................................................................................................................................................. 468
DESCRIPTION............................................................................................................................................................................... 468
OPERATION................................................................................................................................................................................. 468
DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY TRANSMITTER.................................................................................................................................. 468
STANDARD PROCEDURE........................................................................................................................................................................ 468
STANDARD PROCEDURE - HORN CHIRP TOGGLE................................................................................................................................................ 468
DRB lll PROGRAMMING............................................................................................................................................................... 468
CUSTOMER PROGRAMMING.............................................................................................................................................................. 468
STANDARD PROCEDURE - TRANSMITTER PROGRAMING........................................................................................................................................... 469
DRB lll PROGRAMMING............................................................................................................................................................... 469
CUSTOMER PROGRAMMING.............................................................................................................................................................. 469
STANDARD PROCEDURE - RKE TRANSMITTER BATTERIES........................................................................................................................................ 469
SPECIFICATIONS - TRANSMITTER RANGE........................................................................................................................................................ 469
POWER MIRRORS..................................................................................................................................................................................... 470
POWER MIRRORS................................................................................................................................................................................. 470
DESCRIPTION............................................................................................................................................................................... 470
OPERATION................................................................................................................................................................................. 470
DIAGNOSIS AND TESTING - POWER MIRRORS..................................................................................................................................................... 470
WIRING VOLTAGE TEST (LHD)............................................................................................................................................................. 470
POWER MIRROR MOTOR TEST (LHD)......................................................................................................................................................... 470
POWER MIRROR SWITCH - LHD..................................................................................................................................................................... 471
DIAGNOSIS AND TESTING - POWER MIRROR SWITCH - LHD......................................................................................................................................... 471
REMOVAL................................................................................................................................................................................... 471
INSTALLATION.............................................................................................................................................................................. 471
POWER FOLDAWAY MIRROR SWITCH - RHD............................................................................................................................................................ 472
DIAGNOSIS AND TESTING - POWER FOLDAWAY MIRROR SWITCH - RHD................................................................................................................................ 472
EXTENDED MIRROR SWITCH CIRCUIT TEST................................................................................................................................................... 472
RETRACTED MIRROR SWITCH CIRCUIT TEST.................................................................................................................................................. 473
REMOVAL................................................................................................................................................................................... 473
INSTALLATION.............................................................................................................................................................................. 473
POWER SEAT SYSTEM................................................................................................................................................................................. 474
POWER SEAT SYSTEM............................................................................................................................................................................. 474
DESCRIPTION............................................................................................................................................................................... 474
OPERATION................................................................................................................................................................................. 474
DIAGNOSIS AND TESTING - POWER SEAT SYSTEM................................................................................................................................................. 475
DRIVER SEAT SWITCH............................................................................................................................................................................ 475
DESCRIPTION............................................................................................................................................................................... 475
OPERATION................................................................................................................................................................................. 475
DIAGNOSIS AND TESTING - DRIVER SEAT SWITCH................................................................................................................................................ 475
REMOVAL................................................................................................................................................................................... 476
INSTALLATION.............................................................................................................................................................................. 476
POWER SEAT TRACK.............................................................................................................................................................................. 476
DESCRIPTION............................................................................................................................................................................... 476
OPERATION................................................................................................................................................................................. 476
DIAGNOSIS AND TESTING - POWER SEAT TRACK.................................................................................................................................................. 476
REMOVAL................................................................................................................................................................................... 477
INSTALLATION.............................................................................................................................................................................. 477
LUMBAR........................................................................................................................................................................................ 478
DESCRIPTION............................................................................................................................................................................... 478
OPERATION................................................................................................................................................................................. 478
REMOVAL................................................................................................................................................................................... 478
INSTALLATION.............................................................................................................................................................................. 478
POWER WINDOWS..................................................................................................................................................................................... 479
POWER WINDOWS................................................................................................................................................................................. 479
DESCRIPTION............................................................................................................................................................................... 479
OPERATION................................................................................................................................................................................. 479
DIAGNOSIS AND TESTING - POWER WINDOWS..................................................................................................................................................... 479
WIRING VOLTAGE TEST................................................................................................................................................................... 479
POWER WINDOW MOTOR TEST............................................................................................................................................................... 479
POWER WINDOW SWITCH........................................................................................................................................................................... 480
DIAGNOSIS AND TESTING - POWER WINDOW SWITCH............................................................................................................................................... 480
REMOVAL................................................................................................................................................................................... 481
FRONT................................................................................................................................................................................. 481
REAR.................................................................................................................................................................................. 481
INSTALLATION.............................................................................................................................................................................. 481
FRONT................................................................................................................................................................................. 481
REAR.................................................................................................................................................................................. 481
WINDOW MOTOR.................................................................................................................................................................................. 481
REMOVAL................................................................................................................................................................................... 481
INSTALLATION.............................................................................................................................................................................. 481
8o-RESTRAINTS......................................................................................................................................................................................... 483
RESTRAINTS........................................................................................................................................................................................ 483
DESCRIPTION................................................................................................................................................................................... 483
FRONT AIRBAG SYSTEM....................................................................................................................................................................... 483
SIDE IMPACT AIRBAG SYSTEM................................................................................................................................................................. 484
BELT TENSIONER SYSTEM..................................................................................................................................................................... 484
OPERATION..................................................................................................................................................................................... 484
FRONT AIRBAG SYSTEM....................................................................................................................................................................... 484
SIDE IMPACT AIRBAG SYSTEM................................................................................................................................................................. 484
BELT TENSIONER SYSTEM..................................................................................................................................................................... 485
WARNING....................................................................................................................................................................................... 485
FRONT AIRBAG SYSTEM....................................................................................................................................................................... 485
SIDE IMPACT AIRBAG SYSTEM................................................................................................................................................................. 486
DIAGNOSIS AND TESTING - AIRBAG SYSTEM......................................................................................................................................................... 486
STANDARD PROCEDURE............................................................................................................................................................................ 486
STANDARD PROCEDURE - HANDLING AIRBAGS..................................................................................................................................................... 486
DEPLOYED AIRBAG....................................................................................................................................................................... 486
UNDEPLOYED AIRBAG..................................................................................................................................................................... 486
STANDARD PROCEDURE - SERVICE AFTER AN AIRBAG DEPLOYMENT................................................................................................................................... 487
DRIVER AIRBAG......................................................................................................................................................................... 487
PASSENGER AIRBAG...................................................................................................................................................................... 487
SEAT AIRBAG........................................................................................................................................................................... 487
SEAT BELT TENSIONERS.................................................................................................................................................................. 487
CLEAN UP PROCEDURE.................................................................................................................................................................... 487
CLOCK SPRING...................................................................................................................................................................................... 487
DESCRIPTION................................................................................................................................................................................... 487
OPERATION..................................................................................................................................................................................... 488
STANDARD PROCEDURE - CLOCK SPRING CENTERING................................................................................................................................................... 488
REMOVAL....................................................................................................................................................................................... 488
INSTALLATION.................................................................................................................................................................................. 489
DRIVER AIRBAG..................................................................................................................................................................................... 489
DESCRIPTION................................................................................................................................................................................... 489
OPERATION..................................................................................................................................................................................... 490
REMOVAL....................................................................................................................................................................................... 490
INSTALLATION.................................................................................................................................................................................. 491
DRIVER AIRBAG COVER............................................................................................................................................................................... 491
REMOVAL....................................................................................................................................................................................... 491
INSTALLATION.................................................................................................................................................................................. 492
FRONT SEAT BELT & RETRACTOR....................................................................................................................................................................... 493
REMOVAL....................................................................................................................................................................................... 493
INSTALLATION.................................................................................................................................................................................. 493
FRONT SEAT BELT BUCKLE............................................................................................................................................................................ 493
REMOVAL....................................................................................................................................................................................... 493
INSTALLATION.................................................................................................................................................................................. 493
FRONT SEAT BELT HEIGHT ADJUSTER................................................................................................................................................................... 494
REMOVAL....................................................................................................................................................................................... 494
INSTALLATION.................................................................................................................................................................................. 494
OCCUPANT RESTRAINT CONTROLLER..................................................................................................................................................................... 494
DESCRIPTION................................................................................................................................................................................... 494
OPERATION..................................................................................................................................................................................... 494
REMOVAL....................................................................................................................................................................................... 495
INSTALLATION.................................................................................................................................................................................. 495
PASSENGER AIRBAG.................................................................................................................................................................................. 495
DESCRIPTION................................................................................................................................................................................... 495
OPERATION..................................................................................................................................................................................... 496
REMOVAL....................................................................................................................................................................................... 496
NON-DEPLOYED AIRBAG....................................................................................................................................................................... 496
DEPLOYED AIRBAG........................................................................................................................................................................... 496
INSTALLATION.................................................................................................................................................................................. 497
PASSENGER AIRBAG COVER............................................................................................................................................................................ 497
REMOVAL....................................................................................................................................................................................... 497
INSTALLATION.................................................................................................................................................................................. 497
REAR CENTER SEAT BELT & RETRACTOR................................................................................................................................................................. 498
REMOVAL....................................................................................................................................................................................... 498
INSTALLATION.................................................................................................................................................................................. 498
REAR SEAT BELT & RETRACTOR........................................................................................................................................................................ 498
REMOVAL....................................................................................................................................................................................... 498
INSTALLATION.................................................................................................................................................................................. 498
REAR SEAT BELT BUCKLE............................................................................................................................................................................. 498
REMOVAL....................................................................................................................................................................................... 498
SEAT AIRBAG....................................................................................................................................................................................... 498
DESCRIPTION................................................................................................................................................................................... 498
OPERATION..................................................................................................................................................................................... 499
REMOVAL....................................................................................................................................................................................... 499
DEPLOYED SEAT AIRBAG...................................................................................................................................................................... 499
NONDEPLOYED SEAT AIRBAG................................................................................................................................................................... 499
INSTALLATION.................................................................................................................................................................................. 500
DEPLOYED SEAT AIRBAG...................................................................................................................................................................... 500
NONDEPLOYED SEAT AIRBAG................................................................................................................................................................... 500
SIDE IMPACT AIRBAG CONTROL MODULE................................................................................................................................................................. 501
DESCRIPTION................................................................................................................................................................................... 501
OPERATION..................................................................................................................................................................................... 501
REMOVAL....................................................................................................................................................................................... 501
INSTALLATION.................................................................................................................................................................................. 502
8p-SPEED CONTROL...................................................................................................................................................................................... 503
SPEED CONTROL..................................................................................................................................................................................... 503
DESCRIPTION................................................................................................................................................................................... 503
OPERATION..................................................................................................................................................................................... 504
OPERATION................................................................................................................................................................................. 504
OPERATION - INTERACTIVE SPEED CONTROL (4 Speed EATX Only)................................................................................................................................. 504
CLIMBING A GRADE...................................................................................................................................................................... 504
GRADE HUNTING......................................................................................................................................................................... 505
AUTOMATIC SPEED CONTROL OVERSPEED REDUCTION........................................................................................................................................... 505
OPERATION - CHECKING FOR DIAGNOSTIC CODES................................................................................................................................................. 505
DIAGNOSIS AND TESTING - ROAD TEST............................................................................................................................................................. 505
CABLE............................................................................................................................................................................................. 506
DESCRIPTION................................................................................................................................................................................... 506
OPERATION..................................................................................................................................................................................... 506
REMOVAL....................................................................................................................................................................................... 506
REMOVAL................................................................................................................................................................................... 506
REMOVAL - 2.4L TURBO...................................................................................................................................................................... 507
INSTALLATION.................................................................................................................................................................................. 507
INSTALLATION.............................................................................................................................................................................. 507
INSTALLATION - 2.4L TURBO................................................................................................................................................................. 508
SERVO............................................................................................................................................................................................. 508
DESCRIPTION................................................................................................................................................................................... 508
OPERATION..................................................................................................................................................................................... 509
REMOVAL....................................................................................................................................................................................... 509
REMOVAL................................................................................................................................................................................... 509
REMOVAL - 2.4L TURBO...................................................................................................................................................................... 509
INSTALLATION.................................................................................................................................................................................. 510
INSTALLATION.............................................................................................................................................................................. 510
INSTALLATION - 2.4L TURBO................................................................................................................................................................. 510
SWITCH............................................................................................................................................................................................ 510
REMOVAL....................................................................................................................................................................................... 510
INSTALLATION.................................................................................................................................................................................. 510
VACUUM RESERVOIR.................................................................................................................................................................................. 511
DESCRIPTION................................................................................................................................................................................... 511
OPERATION..................................................................................................................................................................................... 511
REMOVAL....................................................................................................................................................................................... 511
INSTALLATION.................................................................................................................................................................................. 512
8q-VEHICLE THEFT SECURITY............................................................................................................................................................................. 513
VEHICLE THEFT SECURITY............................................................................................................................................................................ 513
DESCRIPTION................................................................................................................................................................................... 513
VEHICLE THEFT SECURITY SYSTEM............................................................................................................................................................. 513
VEHICLE THEFT SECURITY SYSTEM - EXPORT.................................................................................................................................................... 513
SENTRY KEY IMMOBILIZER SYSTEM............................................................................................................................................................. 513
OPERATION..................................................................................................................................................................................... 514
VEHICLE THEFT SECURITY SYSTEM............................................................................................................................................................. 514
TRIGGERING THE VTSS....................................................................................................................................................................... 514
VEHICLE THEFT SECURITY SYSTEM - EXPORT.................................................................................................................................................... 514
SENTRY KEY IMMOBILIZER SYSTEM............................................................................................................................................................. 514
DIAGNOSIS AND TESTING - SENTRY KEY IMMOBILIZER SYSTEM......................................................................................................................................... 514
GENERAL TROUBLESHOOTING TIPS.............................................................................................................................................................. 515
STANDARD PROCEDURE............................................................................................................................................................................ 515
STANDARD PROCEDURE - RKE/VTSS CONFIGURING A NEW MODULE.................................................................................................................................... 515
STANDARD PROCEDURE - SENTRY KEY IMMOBILIZER SYSTEM INITIALIZATION......................................................................................................................... 515
DOOR CYLINDER LOCK SWITCH......................................................................................................................................................................... 516
REMOVAL....................................................................................................................................................................................... 516
INSTALLATION.................................................................................................................................................................................. 516
HOOD AJAR SWITCH - EXPORT......................................................................................................................................................................... 517
REMOVAL....................................................................................................................................................................................... 517
INSTALLATION.................................................................................................................................................................................. 517
INTRUSION SENSOR - EXPORT......................................................................................................................................................................... 517
DESCRIPTION................................................................................................................................................................................... 517
OPERATION..................................................................................................................................................................................... 517
DISARMING THE INTRUSION SENSOR............................................................................................................................................................ 517
REMOVAL....................................................................................................................................................................................... 517
INSTALLATION.................................................................................................................................................................................. 518
LIFTGATE CYLINDER LOCK SWITCH..................................................................................................................................................................... 518
REMOVAL....................................................................................................................................................................................... 518
INSTALLATION.................................................................................................................................................................................. 518
SKIS INDICATOR LAMP............................................................................................................................................................................... 519
DESCRIPTION................................................................................................................................................................................... 519
OPERATION..................................................................................................................................................................................... 519
SIREN - EXPORT.................................................................................................................................................................................... 519
DESCRIPTION................................................................................................................................................................................... 519
OPERATION..................................................................................................................................................................................... 519
REMOVAL....................................................................................................................................................................................... 519
INSTALLATION.................................................................................................................................................................................. 520
TRANSPONDER KEY................................................................................................................................................................................... 520
DESCRIPTION................................................................................................................................................................................... 520
OPERATION..................................................................................................................................................................................... 520
STANDARD PROCEDURE - TRANSPONDER PROGRAMMING.................................................................................................................................................. 520
USING A DRB III SCAN TOOL................................................................................................................................................................. 520
“CUSTOMER LEARN” MODE..................................................................................................................................................................... 521
8r-WIPERS/WASHERS..................................................................................................................................................................................... 523
WIPERS/WASHERS.................................................................................................................................................................................... 523
DESCRIPTION................................................................................................................................................................................... 523
FRONT WINDSHIELD WIPER SYSTEM............................................................................................................................................................. 523
FRONT WINDSHIELD WASHER SYSTEM............................................................................................................................................................ 524
REAR WINDSHIELD WIPER SYSTEM.............................................................................................................................................................. 524
REAR WINDSHIELD WASHER SYSTEM............................................................................................................................................................. 524
OPERATION..................................................................................................................................................................................... 525
FRONT WINDSHIELD WIPER SYSTEM............................................................................................................................................................. 525
FRONT WINDSHIELD WASHER SYSTEM............................................................................................................................................................ 525
REAR WINDSHIELD WIPER SYSTEM.............................................................................................................................................................. 525
REAR WINDSHIELD WASHER SYSTEM............................................................................................................................................................. 525
DIAGNOSIS AND TESTING......................................................................................................................................................................... 525
DIAGNOSIS AND TESTING - FRONT WIPER CONDITIONS............................................................................................................................................ 525
MOTOR WILL NOT OPERATE ALL SWITCH POSITIONS........................................................................................................................................... 525
MOTOR OPERATES SLOWLY AT ALL SPEEDS................................................................................................................................................... 526
WIPERS RUN AT HIGH SPEED WITH SWITCH IN LOW SPEED POSITION OR WIPERS RUN AT LOW SPEED WITH SWITCH IN HIGH SPEED POSITION.............................................................. 526
WIPERS WILL OPERATE CONTINUOUSLY WITH THE SWITCH IN THE INTERMITTENT POSITION - WHEN WIPER SWITCH IS TURNED OFF, WIPERS STOP WHEREVER THEY ARE WITHOUT RETURNING TO PARK POSITION..... 527
WIPERS DO NOT OPERATE WHEN WASHER MOTOR IS ENGAGED (PULSE WIPE) OR WIPERS DO OPERATE IN INTERMITTENT POSITION......................................................................... 527
DIAGNOSIS AND TESTING - REAR WIPER SYSTEM................................................................................................................................................. 527
DIAGNOSIS AND TESTING - WASHER SYSTEM..................................................................................................................................................... 527
FRONT WASHER NOZZLE............................................................................................................................................................................... 528
REMOVAL....................................................................................................................................................................................... 528
INSTALLATION.................................................................................................................................................................................. 528
FRONT WIPER ARMS.................................................................................................................................................................................. 528
REMOVAL....................................................................................................................................................................................... 528
INSTALLATION.................................................................................................................................................................................. 529
ADJUSTMENTS................................................................................................................................................................................... 529
ADJUSTMENT - FRONT WIPER ARMS............................................................................................................................................................. 529
ADJUSTMENT - FRONT WIPER ARMS - RHD....................................................................................................................................................... 529
FRONT WIPER BLADES................................................................................................................................................................................ 529
REMOVAL....................................................................................................................................................................................... 529
CLEANING - FRONT WIPER BLADES................................................................................................................................................................. 530
INSTALLATION.................................................................................................................................................................................. 530
FRONT WIPER BLADE ELEMENTS........................................................................................................................................................................ 530
REMOVAL....................................................................................................................................................................................... 530
INSTALLATION.................................................................................................................................................................................. 530
FRONT WIPER MODULE................................................................................................................................................................................ 531
REMOVAL....................................................................................................................................................................................... 531
INSTALLATION.................................................................................................................................................................................. 531
FRONT WIPER MODULE - RHD.......................................................................................................................................................................... 532
REMOVAL....................................................................................................................................................................................... 532
INSTALLATION.................................................................................................................................................................................. 532
FRONT WIPER MOTOR................................................................................................................................................................................. 532
DIAGNOSIS AND TESTING - WIPER MOTOR........................................................................................................................................................... 532
REMOVAL....................................................................................................................................................................................... 534
INSTALLATION.................................................................................................................................................................................. 534
FRONT WIPER MOTOR - RHD........................................................................................................................................................................... 534
REMOVAL....................................................................................................................................................................................... 534
INSTALLATION.................................................................................................................................................................................. 535
FRONT WIPER SWITCH................................................................................................................................................................................ 535
DIAGNOSIS AND TESTING - FRONT WIPER/WASHER SWITCH............................................................................................................................................. 535
REMOVAL....................................................................................................................................................................................... 535
INSTALLATION.................................................................................................................................................................................. 535
REAR WASHER NOZZLE................................................................................................................................................................................ 536
REMOVAL....................................................................................................................................................................................... 536
INSTALLATION.................................................................................................................................................................................. 536
REAR WIPER ARMS................................................................................................................................................................................... 536
REMOVAL....................................................................................................................................................................................... 536
INSTALLATION.................................................................................................................................................................................. 537
REAR WIPER BLADE.................................................................................................................................................................................. 537
REMOVAL....................................................................................................................................................................................... 537
INSTALLATION.................................................................................................................................................................................. 537
REAR WIPER MOTOR.................................................................................................................................................................................. 537
REMOVAL....................................................................................................................................................................................... 537
INSTALLATION.................................................................................................................................................................................. 538
REAR WIPER SWITCH................................................................................................................................................................................. 538
DIAGNOSIS AND TESTING - REAR WIPER SWITCH..................................................................................................................................................... 538
IN-VEHICLE TESTING........................................................................................................................................................................ 538
BENCH TESTING............................................................................................................................................................................. 538
REMOVAL....................................................................................................................................................................................... 539
WASHER HOSES...................................................................................................................................................................................... 539
REMOVAL....................................................................................................................................................................................... 539
INSTALLATION.................................................................................................................................................................................. 539
WASHER PUMP MOTOR................................................................................................................................................................................. 539
REMOVAL....................................................................................................................................................................................... 539
INSTALLATION.................................................................................................................................................................................. 540
WASHER PUMP MOTOR - RHD........................................................................................................................................................................... 540
REMOVAL....................................................................................................................................................................................... 540
INSTALLATION.................................................................................................................................................................................. 540
WASHER RESERVOIR.................................................................................................................................................................................. 541
REMOVAL....................................................................................................................................................................................... 541
INSTALLATION.................................................................................................................................................................................. 541
8w-WIRING............................................................................................................................................................................................. 543
8W-01 WIRING DIAGRAM INFORMATION.................................................................................................................................................................. 545
WIRING DIAGRAM INFORMATION.................................................................................................................................................................... 545
DESCRIPTION............................................................................................................................................................................... 545
DESCRIPTION - HOW TO USE WIRING DIAGRAMS.............................................................................................................................................. 545
SYMBOLS........................................................................................................................................................................... 545
TERMINOLOGY....................................................................................................................................................................... 549
DESCRIPTION - CIRCUIT INFORMATION..................................................................................................................................................... 549
DESCRIPTION - CIRCUIT FUNCTIONS....................................................................................................................................................... 550
DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION.................................................................................................................................. 550
DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION................................................................................................................................ 551
IDENTIFICATION.................................................................................................................................................................... 551
LOCATIONS......................................................................................................................................................................... 551
WARNING................................................................................................................................................................................... 551
WARNINGS - GENERAL.................................................................................................................................................................... 551
DIAGNOSIS AND TESTING - WIRING HARNESS.................................................................................................................................................... 551
TROUBLESHOOTING TOOLS................................................................................................................................................................. 551
INTERMITTENT AND POOR CONNECTIONS..................................................................................................................................................... 552
TROUBLESHOOTING WIRING PROBLEMS....................................................................................................................................................... 552
STANDARD PROCEDURE........................................................................................................................................................................ 552
STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES.................................................................................................................. 552
STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL..................................................................................................................................... 553
STANDARD PROCEDURE - TESTING FOR CONTINUITY........................................................................................................................................... 553
STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND.................................................................................................................................... 553
STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS.................................................................................................... 553
STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP....................................................................................................................................... 554
SPECIAL TOOLS............................................................................................................................................................................. 554
WIRING/TERMINAL....................................................................................................................................................................... 554
CONNECTOR..................................................................................................................................................................................... 555
REMOVAL................................................................................................................................................................................... 555
INSTALLATION.............................................................................................................................................................................. 555
DIODE......................................................................................................................................................................................... 558
REMOVAL................................................................................................................................................................................... 558
INSTALLATION.............................................................................................................................................................................. 558
TERMINAL...................................................................................................................................................................................... 558
REMOVAL................................................................................................................................................................................... 558
INSTALLATION.............................................................................................................................................................................. 558
WIRE.......................................................................................................................................................................................... 559
STANDARD PROCEDURE - WIRE SPLICING........................................................................................................................................................ 559
8W-02 COMPONENT INDEX............................................................................................................................................................................. 561
8W-10 POWER DISTRIBUTION.......................................................................................................................................................................... 563
8W-11 FUSE BLOCK.................................................................................................................................................................................. 595
8W-15 GROUND DISTRIBUTION......................................................................................................................................................................... 615
8W-18 BUS COMMUNICATIONS.......................................................................................................................................................................... 643
8W-20 CHARGING SYSTEM............................................................................................................................................................................. 649
8W-21 STARTING SYSTEM............................................................................................................................................................................. 657
8W-30 FUEL/IGNITION SYSTEM........................................................................................................................................................................ 661
8W-31 TRANSMISSION CONTROL SYSTEM................................................................................................................................................................. 711
8W-33 VEHICLE SPEED CONTROL....................................................................................................................................................................... 719
8W-35 ANTILOCK BRAKES............................................................................................................................................................................. 727
8W-39 VEHICLE THEFT SECURITY SYSTEM............................................................................................................................................................... 731
8W-40 INSTRUMENT CLUSTER.......................................................................................................................................................................... 745
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET............................................................................................................................................................. 763
8W-42 AIR CONDITIONING-HEATER..................................................................................................................................................................... 767
8W-43 OCCUPANT RESTRAINT SYSTEM................................................................................................................................................................... 777
8W-44 INTERIOR LIGHTING........................................................................................................................................................................... 783
8W-47 AUDIO SYSTEM................................................................................................................................................................................ 789
8W-48 REAR WINDOW DEFOGGER........................................................................................................................................................................ 793
8W-49 OVERHEAD CONSOLE............................................................................................................................................................................ 795
8W-50 FRONT LIGHTING.............................................................................................................................................................................. 799
8W-51 REAR LIGHTING............................................................................................................................................................................... 809
8W-52 TURN SIGNALS................................................................................................................................................................................ 819
8W-53 WIPERS...................................................................................................................................................................................... 825
8W-60 POWER WINDOWS............................................................................................................................................................................... 829
8W-61 POWER DOOR LOCKS............................................................................................................................................................................ 835
8W-62 POWER MIRRORS............................................................................................................................................................................... 845
8W-63 POWER SEAT.................................................................................................................................................................................. 853
8W-64 POWER SUNROOF............................................................................................................................................................................... 859
8W-70 SPLICE INFORMATION.......................................................................................................................................................................... 861
8W-80 CONNECTOR PIN-OUTS.......................................................................................................................................................................... 865
8W-91 CONNECTOR/GROUND/SPLICE LOCATION............................................................................................................................................................ 957
CONNECTOR/GROUND/SPLICE LOCATION.............................................................................................................................................................. 957
DESCRIPTION............................................................................................................................................................................... 957
8W-97 POWER DISTRIBUTION..........................................................................................................................................................................1015
POWER DISTRIBUTION............................................................................................................................................................................1015
DESCRIPTION...............................................................................................................................................................................1015
OPERATION.................................................................................................................................................................................1015
CIGAR LIGHTER/POWER OUTLET....................................................................................................................................................................1015
DESCRIPTION...............................................................................................................................................................................1015
INSTRUMENT PANEL MOUNTED..............................................................................................................................................................1015
FRONT CONSOLE AND REAR CARGO MOUNTED..................................................................................................................................................1016
OPERATION.................................................................................................................................................................................1016
CIGAR LIGHTER/POWER OUTLET (INSTRUMENT PANEL AND CONSOLE MOUNTED).....................................................................................................................1016
POWER OUTLET (REAR CARGO AREA MOUNTED)................................................................................................................................................1017
REMOVAL...................................................................................................................................................................................1017
INSTALLATION..............................................................................................................................................................................1017
FUSE BLOCK....................................................................................................................................................................................1018
DESCRIPTION...............................................................................................................................................................................1018
OPERATION.................................................................................................................................................................................1018
REMOVAL...................................................................................................................................................................................1018
INSTALLATION..............................................................................................................................................................................1018
IOD FUSE......................................................................................................................................................................................1018
DESCRIPTION...............................................................................................................................................................................1018
OPERATION.................................................................................................................................................................................1018
REMOVAL...................................................................................................................................................................................1019
INSTALLATION..............................................................................................................................................................................1019
POWER DISTRIBUTION CENTER.....................................................................................................................................................................1019
DESCRIPTION...............................................................................................................................................................................1019
OPERATION.................................................................................................................................................................................1019
REMOVAL...................................................................................................................................................................................1020
INSTALLATION..............................................................................................................................................................................1020
RELAY.........................................................................................................................................................................................1020
REMOVAL...................................................................................................................................................................................1020
INSTALLATION..............................................................................................................................................................................1020
9-ENGINE..............................................................................................................................................................................................1021
ENGINE 1.6L SOHC..................................................................................................................................................................................1021
ENGINE 1.6L SOHC..............................................................................................................................................................................1023
DESCRIPTION...............................................................................................................................................................................1023
DIAGNOSIS AND TESTING.....................................................................................................................................................................1023
DIAGNOSIS AND TESTING - INTRODUCTION..................................................................................................................................................1023
DIAGNOSIS AND TESTING - ENGINE PERFORMANCE............................................................................................................................................1024
DIAGNOSIS AND TESTING - ENGINE MECHANICAL.............................................................................................................................................1026
DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST............................................................................................................................1028
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST.....................................................................................................................1029
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET............................................................................................................................................1029
CYLINDER-TO-CYLINDER LEAKAGE TEST.................................................................................................................................................1029
CYLINDER-TO-WATER JACKET LEAKAGE TEST.............................................................................................................................................1029
DIAGNOSIS AND TESTING - LASH ADJUSTER NOISE DIAGNOSIS.................................................................................................................................1029
DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION....................................................................................................................................1030
INSPECTION FOR REAR SEAL AREA LEAKS...............................................................................................................................................1030
STANDARD PROCEDURE........................................................................................................................................................................1031
STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS................................................................................................................................1031
STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE........................................................................................................................................1031
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS................................................................................................................................1031
SEALER APPLICATION................................................................................................................................................................1032
STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION................................................................................................................................1032
STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE.....................................................................................................................1033
STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS................................................................................................................................1033
REMOVAL - ENGINE ASSEMBLY.................................................................................................................................................................1033
INSTALLATION - ENGINE ASSEMBLY............................................................................................................................................................1035
SPECIFICATIONS............................................................................................................................................................................1037
1.6L SOHC ENGINE......................................................................................................................................................................1037
TORQUE................................................................................................................................................................................1041
SPECIAL TOOLS.............................................................................................................................................................................1041
1.6L SOHC ENGINE......................................................................................................................................................................1041
AIR CLEANER ELEMENT...........................................................................................................................................................................1045
REMOVAL...................................................................................................................................................................................1045
INSTALLATION..............................................................................................................................................................................1045
AIR CLEANER HOUSING...........................................................................................................................................................................1045
REMOVAL...................................................................................................................................................................................1045
INSTALLATION..............................................................................................................................................................................1046
CYLINDER HEAD.................................................................................................................................................................................1046
REMOVAL - CYLINDER HEAD...................................................................................................................................................................1046
CLEANING..................................................................................................................................................................................1047
INSPECTION................................................................................................................................................................................1047
INSTALLATION - CYLINDER HEAD..............................................................................................................................................................1048
CYLINDER HEAD COVER...........................................................................................................................................................................1051
REMOVAL...................................................................................................................................................................................1051
CLEANING..................................................................................................................................................................................1051
INSPECTION................................................................................................................................................................................1051
INSTALLATION..............................................................................................................................................................................1051
SPARK PLUG TUBE SEAL..........................................................................................................................................................................1052
DESCRIPTION...............................................................................................................................................................................1052
REMOVAL...................................................................................................................................................................................1052
INSTALLATION..............................................................................................................................................................................1052
SPARK PLUG TUBE...............................................................................................................................................................................1053
REMOVAL...................................................................................................................................................................................1053
INSTALLATION..............................................................................................................................................................................1053
ROCKER ARM SHAFT / ROCKER ARM / LASH ADJUSTER.................................................................................................................................................1054
DESCRIPTION...............................................................................................................................................................................1054
REMOVAL...................................................................................................................................................................................1054
INSTALLATION..............................................................................................................................................................................1055
CAMSHAFT......................................................................................................................................................................................1055
REMOVAL...................................................................................................................................................................................1055
INSPECTION................................................................................................................................................................................1056
INSTALLATION..............................................................................................................................................................................1056
VALVE SPRINGS AND SEALS (ON VEHICLE SERVICE)..................................................................................................................................................1057
STANDARD PROCEDURE - VALVE SPRINGS AND SEALS (ON VEHICLE SERVICE).........................................................................................................................1057
VALVE SPRINGS AND SEALS (CYLINDER HEAD REMOVED)...............................................................................................................................................1059
STANDARD PROCEDURE - VALVE SPRINGS AND SEALS (CYLINDER HEAD REMOVED)......................................................................................................................1059
INSPECTION................................................................................................................................................................................1059
INTAKE/EXHAUST VALVES & SEATS.................................................................................................................................................................1060
STANDARD PROCEDURE - VALVE AND VALVE SEAT REFACING........................................................................................................................................1060
ENGINE BLOCK..................................................................................................................................................................................1061
DESCRIPTION...............................................................................................................................................................................1061
STANDARD PROCEDURE - CYLINDER BORE HONING.................................................................................................................................................1061
CLEANING..................................................................................................................................................................................1063
INSPECTION................................................................................................................................................................................1063
ENGINE BLOCK..........................................................................................................................................................................1063
CYLINDER BORE.........................................................................................................................................................................1063
CRANKSHAFT MAIN BEARINGS......................................................................................................................................................................1064
DESCRIPTION...............................................................................................................................................................................1064
CRANKSHAFT....................................................................................................................................................................................1064
DESCRIPTION...............................................................................................................................................................................1064
STANDARD PROCEDURE - CRANKSHAFT END PLAY..................................................................................................................................................1064
REMOVAL...................................................................................................................................................................................1064
INSPECTION................................................................................................................................................................................1065
INSTALLATION..............................................................................................................................................................................1065
CRANKSHAFT OIL SEAL - FRONT...................................................................................................................................................................1067
REMOVAL...................................................................................................................................................................................1067
INSTALLATION..............................................................................................................................................................................1067
CRANKSHAFT OIL SEAL - REAR....................................................................................................................................................................1067
REMOVAL...................................................................................................................................................................................1067
INSTALLATION..............................................................................................................................................................................1067
PISTON & CONNECTING ROD.......................................................................................................................................................................1068
DESCRIPTION...............................................................................................................................................................................1068
STANDARD PROCEDURE........................................................................................................................................................................1068
STANDARD PROCEDURE - CONNECTING ROD AND BEARING - FITTING.............................................................................................................................1068
STANDARD PROCEDURE - CYLINDER BORE AND PISTON - FITTING...............................................................................................................................1068
REMOVAL...................................................................................................................................................................................1069
INSTALLATION..............................................................................................................................................................................1070
PISTON RINGS..................................................................................................................................................................................1070
STANDARD PROCEDURE - PISTON RING - FITTING................................................................................................................................................1070
REMOVAL...................................................................................................................................................................................1071
INSTALLATION..............................................................................................................................................................................1071
VIBRATION DAMPER..............................................................................................................................................................................1072
REMOVAL...................................................................................................................................................................................1072
INSTALLATION..............................................................................................................................................................................1072
ENGINE MOUNTING...............................................................................................................................................................................1072
DESCRIPTION...............................................................................................................................................................................1072
TORQUE STRUTS.................................................................................................................................................................................1073
REMOVAL...................................................................................................................................................................................1073
UPPER TORQUE STRUT....................................................................................................................................................................1073
LOWER TORQUE STRUT....................................................................................................................................................................1073
INSTALLATION..............................................................................................................................................................................1074
UPPER TORQUE STRUT....................................................................................................................................................................1074
LOWER TORQUE STRUT....................................................................................................................................................................1074
ADJUSTMENTS...............................................................................................................................................................................1074
ADJUSTMENT............................................................................................................................................................................1074
RIGHT ENGINE MOUNT BRACKET....................................................................................................................................................................1074
REMOVAL...................................................................................................................................................................................1074
INSTALLATION..............................................................................................................................................................................1075
RIGHT MOUNT...................................................................................................................................................................................1075
REMOVAL...................................................................................................................................................................................1075
INSTALLATION..............................................................................................................................................................................1075
LEFT MOUNT....................................................................................................................................................................................1076
REMOVAL...................................................................................................................................................................................1076
INSTALLATION..............................................................................................................................................................................1076
LUBRICATION...................................................................................................................................................................................1077
DESCRIPTION...............................................................................................................................................................................1077
OPERATION.................................................................................................................................................................................1077
DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE......................................................................................................................................1077
OIL FILTER CARTRIDGE..........................................................................................................................................................................1079
REMOVAL...................................................................................................................................................................................1079
INSTALLATION..............................................................................................................................................................................1079
OIL FILTER CARTRIDGE HOUSING..................................................................................................................................................................1080
DESCRIPTION...............................................................................................................................................................................1080
REMOVAL...................................................................................................................................................................................1080
INSTALLATION..............................................................................................................................................................................1080
OIL PAN.......................................................................................................................................................................................1080
REMOVAL...................................................................................................................................................................................1080
INSTALLATION..............................................................................................................................................................................1081
OIL PUMP......................................................................................................................................................................................1082
REMOVAL...................................................................................................................................................................................1082
INSTALLATION..............................................................................................................................................................................1082
OIL PUMP PICK-UP..............................................................................................................................................................................1082
REMOVAL...................................................................................................................................................................................1082
INSTALLATION..............................................................................................................................................................................1082
INTAKE MANIFOLD...............................................................................................................................................................................1083
REMOVAL...................................................................................................................................................................................1083
REMOVAL - UPPER INTAKE MANIFOLD.......................................................................................................................................................1083
REMOVAL - LOWER INTAKE MANIFOLD.......................................................................................................................................................1083
INSTALLATION..............................................................................................................................................................................1083
INSTALLATION - UPPER INTAKE MANIFOLD..................................................................................................................................................1083
INSTALLATION - LOWER INTAKE MANIFOLD..................................................................................................................................................1083
EXHAUST MANIFOLD..............................................................................................................................................................................1084
REMOVAL...................................................................................................................................................................................1084
CLEANING..................................................................................................................................................................................1084
INSPECTION................................................................................................................................................................................1084
INSTALLATION..............................................................................................................................................................................1084
VALVE TIMING..................................................................................................................................................................................1085
DESCRIPTION...............................................................................................................................................................................1085
STANDARD PROCEDURE - VALVE TIMING VERIFICATION............................................................................................................................................1085
TIMING CHAIN COVER............................................................................................................................................................................1085
REMOVAL...................................................................................................................................................................................1085
INSTALLATION..............................................................................................................................................................................1086
TIMING CHAIN/GUIDES/SPROCKETS.................................................................................................................................................................1087
REMOVAL...................................................................................................................................................................................1087
REMOVAL - TIMING CHAIN AND GUIDES.....................................................................................................................................................1087
REMOVAL - CAMSHAFT SPROCKET...........................................................................................................................................................1088
REMOVAL - CRANKSHAFT SPROCKET.........................................................................................................................................................1089
INSTALLATION..............................................................................................................................................................................1089
INSTALLATION - CRANKSHAFT SPROCKET....................................................................................................................................................1089
INSTALLATION - CAMSHAFT SPROCKET......................................................................................................................................................1089
INSTALLATION - TIMING CHAIN AND GUIDES................................................................................................................................................1090
ENGINE 2.0L DOHC..................................................................................................................................................................................1093
ENGINE 2.0L DOHC..............................................................................................................................................................................1095
DESCRIPTION...............................................................................................................................................................................1095
DIAGNOSIS AND TESTING.....................................................................................................................................................................1096
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION...............................................................................................................................1096
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE................................................................................................................................1096
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL.................................................................................................................................1098
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST.....................................................................................................................1100
DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST............................................................................................................................1100
DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION....................................................................................................................................1101
INSPECTION FOR REAR SEAL AREA LEAKS...............................................................................................................................................1101
STANDARD PROCEDURE........................................................................................................................................................................1102
STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS................................................................................................................................1102
STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE........................................................................................................................................1102
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS................................................................................................................................1102
SEALER APPLICATION................................................................................................................................................................1103
STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION................................................................................................................................1103
STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS................................................................................................................................1104
STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE.....................................................................................................................1104
REMOVAL - ENGINE ASSEMBLY.................................................................................................................................................................1104
INSTALLATION - ENGINE ASSEMBLY............................................................................................................................................................1107
SPECIFICATIONS............................................................................................................................................................................1109
2.0L DOHC ENGINE......................................................................................................................................................................1109
TORQUE................................................................................................................................................................................1112
SPECIAL TOOLS.............................................................................................................................................................................1112
2.0L DOHC ENGINE......................................................................................................................................................................1112
AIR CLEANER ELEMENT...........................................................................................................................................................................1116
REMOVAL...................................................................................................................................................................................1116
INSTALLATION..............................................................................................................................................................................1116
AIR CLEANER HOUSING...........................................................................................................................................................................1116
REMOVAL...................................................................................................................................................................................1116
INSTALLATION..............................................................................................................................................................................1116
CYLINDER HEAD.................................................................................................................................................................................1116
DESCRIPTION...............................................................................................................................................................................1116
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET................................................................................................................................................1116
CYLINDER-TO-CYLINDER LEAKAGE TEST.....................................................................................................................................................1117
CYLINDER-TO-WATER JACKET LEAKAGE TEST.................................................................................................................................................1117
REMOVAL...................................................................................................................................................................................1117
CLEANING..................................................................................................................................................................................1118
INSPECTION................................................................................................................................................................................1118
INSTALLATION..............................................................................................................................................................................1119
CAMSHAFT OIL SEAL(S)..........................................................................................................................................................................1120
REMOVAL...................................................................................................................................................................................1120
INSTALLATION..............................................................................................................................................................................1121
CAMSHAFT(S)...................................................................................................................................................................................1121
DESCRIPTION...............................................................................................................................................................................1121
OPERATION.................................................................................................................................................................................1121
STANDARD PROCEDURE - MEASURING CAMSHAFT END PLAY..........................................................................................................................................1121
REMOVAL...................................................................................................................................................................................1121
CLEANING..................................................................................................................................................................................1122
INSPECTION................................................................................................................................................................................1122
INSTALLATION..............................................................................................................................................................................1122
CYLINDER HEAD COVER...........................................................................................................................................................................1123
REMOVAL...................................................................................................................................................................................1123
INSTALLATION..............................................................................................................................................................................1123
HYDRAULIC LASH ADJUSTERS......................................................................................................................................................................1125
DIAGNOSIS AND TESTING.....................................................................................................................................................................1125
HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS...............................................................................................................................................1125
REMOVAL...................................................................................................................................................................................1125
INSTALLATION..............................................................................................................................................................................1125
INTAKE/EXHAUST VALVES & SEATS.................................................................................................................................................................1126
DESCRIPTION...............................................................................................................................................................................1126
OPERATION.................................................................................................................................................................................1126
CLEANING..................................................................................................................................................................................1126
ROCKER ARMS...................................................................................................................................................................................1126
REMOVAL...................................................................................................................................................................................1126
INSPECTION................................................................................................................................................................................1126
INSTALLATION..............................................................................................................................................................................1126
VALVE SPRINGS AND SEALS.......................................................................................................................................................................1127
REMOVAL...................................................................................................................................................................................1127
REMOVAL - CYLINDER HEAD ON............................................................................................................................................................1127
REMOVAL - CYLINDER HEAD OFF...........................................................................................................................................................1127
INSPECTION................................................................................................................................................................................1127
INSTALLATION..............................................................................................................................................................................1127
INSTALLATION - CYLINDER HEAD ON.......................................................................................................................................................1127
INSTALLATION - CYLINDER HEAD OFF......................................................................................................................................................1127
ENGINE BLOCK..................................................................................................................................................................................1128
DESCRIPTION...............................................................................................................................................................................1128
STANDARD PROCEDURE - CYLINDER BORE HONING.................................................................................................................................................1128
CLEANING..................................................................................................................................................................................1129
INSPECTION................................................................................................................................................................................1129
ENGINE BLOCK..........................................................................................................................................................................1129
CYLINDER BORE.........................................................................................................................................................................1129
CRANKSHAFT....................................................................................................................................................................................1130
STANDARD PROCEDURE - CRANKSHAFT END PLAY..................................................................................................................................................1130
REMOVAL - CRANKSHAFT......................................................................................................................................................................1130
INSPECTION................................................................................................................................................................................1132
INSTALLATION - CRANKSHAFT.................................................................................................................................................................1132
CRANKSHAFT MAIN BEARING LOCATION......................................................................................................................................................1132
CRANKSHAFT OIL SEAL - FRONT...................................................................................................................................................................1134
REMOVAL...................................................................................................................................................................................1134
INSTALLATION..............................................................................................................................................................................1134
CRANKSHAFT OIL SEAL - REAR....................................................................................................................................................................1135
REMOVAL...................................................................................................................................................................................1135
INSTALLATION0 - 6 PT (Continued)......................................................................................................................................................1135
PISTON & CONNECTING ROD.......................................................................................................................................................................1137
DESCRIPTION...............................................................................................................................................................................1137
STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING......................................................................................................................................1137
REMOVAL...................................................................................................................................................................................1138
INSTALLATION..............................................................................................................................................................................1138
CONNECTING ROD BEARINGS.......................................................................................................................................................................1139
STANDARD PROCEDURE........................................................................................................................................................................1139
CONNECTING ROD - FITTING..............................................................................................................................................................1139
PISTON RINGS..................................................................................................................................................................................1140
STANDARD PROCEDURE - PISTON RING - FITTING................................................................................................................................................1140
REMOVAL...................................................................................................................................................................................1140
INSTALLATION..............................................................................................................................................................................1140
STRUCTURAL COLLAR.............................................................................................................................................................................1141
REMOVAL...................................................................................................................................................................................1141
INSTALLATION..............................................................................................................................................................................1141
VIBRATION DAMPER..............................................................................................................................................................................1142
REMOVAL...................................................................................................................................................................................1142
INSTALLATION..............................................................................................................................................................................1142
ENGINE MOUNTING...............................................................................................................................................................................1142
DESCRIPTION...............................................................................................................................................................................1142
OPERATION.................................................................................................................................................................................1142
LEFT MOUNT....................................................................................................................................................................................1143
REMOVAL...................................................................................................................................................................................1143
INSTALLATION..............................................................................................................................................................................1143
RIGHT MOUNT...................................................................................................................................................................................1143
REMOVAL...................................................................................................................................................................................1143
INSTALLATION..............................................................................................................................................................................1143
TORQUE STRUT..................................................................................................................................................................................1144
REMOVAL...................................................................................................................................................................................1144
REMOVAL - UPPER.......................................................................................................................................................................1144
REMOVAL - LOWER.......................................................................................................................................................................1145
INSTALLATION..............................................................................................................................................................................1145
INSTALLATION - UPPER..................................................................................................................................................................1145
INSTALLATION - LOWER..................................................................................................................................................................1145
ADJUSTMENTS...............................................................................................................................................................................1145
ENGINE TORQUE STRUT ADJUSTMENT........................................................................................................................................................1145
LUBRICATION...................................................................................................................................................................................1146
DESCRIPTION...............................................................................................................................................................................1146
OPERATION.................................................................................................................................................................................1146
DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE......................................................................................................................................1146
OIL...........................................................................................................................................................................................1148
STANDARD PROCEDURE........................................................................................................................................................................1148
ENGINE OIL LEVEL CHECK................................................................................................................................................................1148
STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE.....................................................................................................................................1149
OIL FILTER SPECIFICATION..........................................................................................................................................................1149
USED ENGINE OIL DISPOSAL..........................................................................................................................................................1149
OIL FILTER....................................................................................................................................................................................1149
REMOVAL...................................................................................................................................................................................1149
INSTALLATION..............................................................................................................................................................................1149
OIL FILTER ADAPTER............................................................................................................................................................................1150
REMOVAL...................................................................................................................................................................................1150
INSTALLATION..............................................................................................................................................................................1150
OIL PAN.......................................................................................................................................................................................1150
REMOVAL...................................................................................................................................................................................1150
INSTALLATION..............................................................................................................................................................................1150
OIL PRESSURE SENSOR/SWITCH....................................................................................................................................................................1151
REMOVAL...................................................................................................................................................................................1151
INSTALLATION..............................................................................................................................................................................1151
OIL PUMP......................................................................................................................................................................................1151
REMOVAL...................................................................................................................................................................................1151
DISASSEMBLY...............................................................................................................................................................................1152
INSPECTION................................................................................................................................................................................1152
ASSEMBLY..................................................................................................................................................................................1154
INSTALLATION..............................................................................................................................................................................1154
INTAKE MANIFOLD...............................................................................................................................................................................1155
DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS.............................................................................................................................................1155
REMOVAL...................................................................................................................................................................................1155
REMOVAL - UPPER INTAKE MANIFOLD.......................................................................................................................................................1155
REMOVAL - LOWER INTAKE MANIFOLD.......................................................................................................................................................1158
CLEANING..................................................................................................................................................................................1158
INSPECTION................................................................................................................................................................................1158
INSTALLATION..............................................................................................................................................................................1158
INSTALLATION - UPPER INTAKE MANIFOLD..................................................................................................................................................1158
INSTALLATION - LOWER INTAKE MANIFOLD..................................................................................................................................................1159
EXHAUST MANIFOLD..............................................................................................................................................................................1160
REMOVAL...................................................................................................................................................................................1160
CLEANING..................................................................................................................................................................................1160
INSPECTION................................................................................................................................................................................1160
INSTALLATION..............................................................................................................................................................................1161
VALVE TIMING..................................................................................................................................................................................1162
STANDARD PROCEDURE - VALVE TIMING VERIFICATION............................................................................................................................................1162
TIMING BELT COVER(S)..........................................................................................................................................................................1162
REMOVAL...................................................................................................................................................................................1162
FRONT COVER...........................................................................................................................................................................1162
REAR COVER............................................................................................................................................................................1162
INSTALLATION..............................................................................................................................................................................1163
REAR COVER............................................................................................................................................................................1163
FRONT COVER...........................................................................................................................................................................1163
TIMING BELT AND SPROCKETS.....................................................................................................................................................................1163
REMOVAL...................................................................................................................................................................................1163
REMOVAL - TIMING BELT.................................................................................................................................................................1163
REMOVAL - CAMSHAFT SPROCKET(S)........................................................................................................................................................1165
REMOVAL - CRANKSHAFT SPROCKET.........................................................................................................................................................1165
CLEANING..................................................................................................................................................................................1166
INSTALLATION..............................................................................................................................................................................1166
INSTALLATION - CRANKSHAFT SPROCKET....................................................................................................................................................1166
INSTALLATION - CAMSHAFT SPROCKETS.....................................................................................................................................................1166
INSTALLATION - TIMING BELT............................................................................................................................................................1166
TIMING BELT TENSIONER & PULLEY................................................................................................................................................................1168
REMOVAL...................................................................................................................................................................................1168
INSTALLATION..............................................................................................................................................................................1168
ENGINE 2.4L DOHC..................................................................................................................................................................................1169
ENGINE 2.4L DOHC..............................................................................................................................................................................1171
DESCRIPTION...............................................................................................................................................................................1171
DIAGNOSIS AND TESTING.....................................................................................................................................................................1171
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION...............................................................................................................................1171
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE................................................................................................................................1172
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL.................................................................................................................................1174
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST.....................................................................................................................1176
DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST............................................................................................................................1176
DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION....................................................................................................................................1177
INSPECTION FOR REAR SEAL AREA LEAKS...............................................................................................................................................1177
STANDARD PROCEDURE........................................................................................................................................................................1178
STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS................................................................................................................................1178
STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE........................................................................................................................................1178
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS................................................................................................................................1178
SEALER APPLICATION................................................................................................................................................................1179
STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION................................................................................................................................1179
STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS................................................................................................................................1180
STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE.....................................................................................................................1180
REMOVAL - ENGINE ASSEMBLY.................................................................................................................................................................1180
INSTALLATION - ENGINE ASSEMBLY............................................................................................................................................................1184
SPECIFICATIONS............................................................................................................................................................................1186
2.4L ENGINE...........................................................................................................................................................................1186
TORQUE................................................................................................................................................................................1189
SPECIAL TOOLS.............................................................................................................................................................................1190
2.4L ENGINE...........................................................................................................................................................................1190
AIR CLEANER ELEMENT...........................................................................................................................................................................1193
REMOVAL...................................................................................................................................................................................1193
INSTALLATION..............................................................................................................................................................................1193
AIR CLEANER HOUSING...........................................................................................................................................................................1193
REMOVAL...................................................................................................................................................................................1193
INSTALLATION..............................................................................................................................................................................1193
CYLINDER HEAD.................................................................................................................................................................................1194
DESCRIPTION...............................................................................................................................................................................1194
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET................................................................................................................................................1194
CYLINDER-TO-CYLINDER LEAKAGE TEST.....................................................................................................................................................1195
CYLINDER-TO-WATER JACKET LEAKAGE TEST.................................................................................................................................................1195
REMOVAL - CYLINDER HEAD...................................................................................................................................................................1195
CLEANING..................................................................................................................................................................................1197
INSPECTION................................................................................................................................................................................1197
INSTALLATION - CYLINDER HEAD..............................................................................................................................................................1197
CAMSHAFT OIL SEAL(S)..........................................................................................................................................................................1199
REMOVAL...................................................................................................................................................................................1199
INSTALLATION..............................................................................................................................................................................1199
CAMSHAFT(S)...................................................................................................................................................................................1200
DESCRIPTION...............................................................................................................................................................................1200
OPERATION.................................................................................................................................................................................1200
STANDARD PROCEDURE - MEASURING CAMSHAFT END PLAY..........................................................................................................................................1200
REMOVAL...................................................................................................................................................................................1200
CLEANING..................................................................................................................................................................................1201
INSPECTION................................................................................................................................................................................1201
INSTALLATION..............................................................................................................................................................................1201
CYLINDER HEAD COVER...........................................................................................................................................................................1202
REMOVAL...................................................................................................................................................................................1202
INSTALLATION..............................................................................................................................................................................1202
HYDRAULIC LASH ADJUSTERS......................................................................................................................................................................1204
DIAGNOSIS AND TESTING.....................................................................................................................................................................1204
HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS...............................................................................................................................................1204
REMOVAL...................................................................................................................................................................................1204
INSTALLATION..............................................................................................................................................................................1204
INTAKE/EXHAUST VALVES & SEATS.................................................................................................................................................................1205
DESCRIPTION...............................................................................................................................................................................1205
OPERATION.................................................................................................................................................................................1205
CLEANING..................................................................................................................................................................................1205
ROCKER ARMS...................................................................................................................................................................................1205
REMOVAL...................................................................................................................................................................................1205
INSPECTION................................................................................................................................................................................1205
INSTALLATION..............................................................................................................................................................................1205
VALVE SPRINGS & SEALS.........................................................................................................................................................................1206
REMOVAL...................................................................................................................................................................................1206
REMOVAL - CYLINDER HEAD ON............................................................................................................................................................1206
REMOVAL - CYLINDER HEAD OFF...........................................................................................................................................................1206
INSPECTION................................................................................................................................................................................1206
INSTALLATION..............................................................................................................................................................................1206
INSTALLATION - CYLINDER HEAD ON.......................................................................................................................................................1206
INSTALLATION - CYLINDER HEAD OFF......................................................................................................................................................1207
ENGINE BLOCK..................................................................................................................................................................................1207
DESCRIPTION...............................................................................................................................................................................1207
STANDARD PROCEDURE - CYLINDER BORE HONING.................................................................................................................................................1207
CLEANING..................................................................................................................................................................................1208
INSPECTION................................................................................................................................................................................1208
ENGINE BLOCK..........................................................................................................................................................................1208
CYLINDER BORE.........................................................................................................................................................................1208
CRANKSHAFT....................................................................................................................................................................................1209
STANDARD PROCEDURE - MEASURING CRANKSHAFT END PLAY........................................................................................................................................1209
REMOVAL - CRANKSHAFT......................................................................................................................................................................1209
INSPECTION................................................................................................................................................................................1210
INSTALLATION - CRANKSHAFT.................................................................................................................................................................1210
CRANKSHAFT MAIN BEARING LOCATION......................................................................................................................................................1210
CRANKSHAFT OIL SEAL - FRONT...................................................................................................................................................................1212
REMOVAL...................................................................................................................................................................................1212
INSTALLATION..............................................................................................................................................................................1212
CRANKSHAFT OIL SEAL - REAR....................................................................................................................................................................1213
REMOVAL...................................................................................................................................................................................1213
INSTALLATION..............................................................................................................................................................................1213
PISTON & CONNECTING ROD.......................................................................................................................................................................1215
DESCRIPTION...............................................................................................................................................................................1215
Non-Turbo.............................................................................................................................................................................1215
Turbo.................................................................................................................................................................................1215
STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING......................................................................................................................................1215
REMOVAL...................................................................................................................................................................................1215
INSTALLATION..............................................................................................................................................................................1217
CONNECTING ROD BEARINGS.......................................................................................................................................................................1218
STANDARD PROCEDURE........................................................................................................................................................................1218
CONNECTING ROD - FITTING..............................................................................................................................................................1218
PISTON RINGS..................................................................................................................................................................................1218
STANDARD PROCEDURE........................................................................................................................................................................1218
PISTON RING - FITTING.................................................................................................................................................................1218
REMOVAL...................................................................................................................................................................................1219
INSTALLATION..............................................................................................................................................................................1219
STRUCTURAL COLLAR.............................................................................................................................................................................1220
REMOVAL...................................................................................................................................................................................1220
STRUCTURAL COLLAR—AUTOMATIC TRANSAXLE EQUIPPED........................................................................................................................................1220
STRUCTURAL COLLAR—MANUAL TRANSAXLE EQUIPPED...........................................................................................................................................1220
INSTALLATION..............................................................................................................................................................................1220
STRUCTURAL COLLAR—AUTOMATIC TRANSAXLE EQUIPPED........................................................................................................................................1220
STRUCTURAL COLLAR—MANUAL TRANSAXLE EQUIPPED...........................................................................................................................................1221
VIBRATION DAMPER..............................................................................................................................................................................1221
REMOVAL...................................................................................................................................................................................1221
INSTALLATION..............................................................................................................................................................................1221
ENGINE MOUNTING...............................................................................................................................................................................1222
DESCRIPTION...............................................................................................................................................................................1222
OPERATION.................................................................................................................................................................................1222
LEFT MOUNT....................................................................................................................................................................................1222
REMOVAL...................................................................................................................................................................................1222
INSTALLATION..............................................................................................................................................................................1222
RIGHT MOUNT...................................................................................................................................................................................1223
REMOVAL...................................................................................................................................................................................1223
INSTALLATION..............................................................................................................................................................................1223
TORQUE STRUT..................................................................................................................................................................................1224
REMOVAL...................................................................................................................................................................................1224
REMOVAL - UPPER.......................................................................................................................................................................1224
REMOVAL - LOWER.......................................................................................................................................................................1224
INSTALLATION..............................................................................................................................................................................1224
INSTALLATION - UPPER..................................................................................................................................................................1224
INSTALLATION - LOWER..................................................................................................................................................................1225
ADJUSTMENTS...............................................................................................................................................................................1225
ENGINE TORQUE STRUT ADJUSTMENT........................................................................................................................................................1225
LUBRICATION...................................................................................................................................................................................1226
DESCRIPTION...............................................................................................................................................................................1226
OPERATION.................................................................................................................................................................................1226
DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE......................................................................................................................................1226
OIL...........................................................................................................................................................................................1227
STANDARD PROCEDURE........................................................................................................................................................................1227
ENGINE OIL LEVEL CHECK................................................................................................................................................................1227
STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE.....................................................................................................................................1227
OIL FILTER SPECIFICATION..........................................................................................................................................................1229
USED ENGINE OIL DISPOSAL..........................................................................................................................................................1229
OIL FILTER....................................................................................................................................................................................1229
REMOVAL...................................................................................................................................................................................1229
INSTALLATION..............................................................................................................................................................................1229
OIL FILTER ADAPTER............................................................................................................................................................................1229
REMOVAL...................................................................................................................................................................................1229
INSTALLATION..............................................................................................................................................................................1229
OIL PAN.......................................................................................................................................................................................1230
REMOVAL...................................................................................................................................................................................1230
INSTALLATION..............................................................................................................................................................................1230
OIL PRESSURE SENSOR/SWITCH....................................................................................................................................................................1230
DESCRIPTION...............................................................................................................................................................................1230
OPERATION.................................................................................................................................................................................1231
REMOVAL...................................................................................................................................................................................1231
INSTALLATION..............................................................................................................................................................................1231
OIL PUMP......................................................................................................................................................................................1231
REMOVAL...................................................................................................................................................................................1231
DISASSEMBLY...............................................................................................................................................................................1231
CLEANING..................................................................................................................................................................................1231
INSPECTION................................................................................................................................................................................1232
ASSEMBLY..................................................................................................................................................................................1232
INSTALLATION..............................................................................................................................................................................1233
OIL JET - 2.4L TURBO..........................................................................................................................................................................1234
DESCRIPTION...............................................................................................................................................................................1234
REMOVAL...................................................................................................................................................................................1234
INSTALLATION..............................................................................................................................................................................1234
OIL COOLER & LINES - 2.4L TURBO...............................................................................................................................................................1235
DESCRIPTION...............................................................................................................................................................................1235
REMOVAL...................................................................................................................................................................................1235
INSTALLATION..............................................................................................................................................................................1235
INTAKE MANIFOLD...............................................................................................................................................................................1236
DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS.............................................................................................................................................1236
REMOVAL...................................................................................................................................................................................1236
REMOVAL - UPPER INTAKE MANIFOLD.......................................................................................................................................................1236
Non-Turbo.........................................................................................................................................................................1236
Turbo.............................................................................................................................................................................1238
REMOVAL - LOWER INTAKE MANIFOLD.......................................................................................................................................................1240
CLEANING..................................................................................................................................................................................1241
INSPECTION................................................................................................................................................................................1241
INSTALLATION..............................................................................................................................................................................1241
INSTALLATION - UPPER INTAKE MANIFOLD..................................................................................................................................................1241
Non-Turbo.........................................................................................................................................................................1241
Turbo.............................................................................................................................................................................1241
INSTALLATION - LOWER INTAKE MANIFOLD..................................................................................................................................................1242
EXHAUST MANIFOLD..............................................................................................................................................................................1243
REMOVAL...................................................................................................................................................................................1243
CLEANING..................................................................................................................................................................................1244
INSPECTION................................................................................................................................................................................1244
INSTALLATION..............................................................................................................................................................................1244
TIMING BELT COVER(S)..........................................................................................................................................................................1245
REMOVAL...................................................................................................................................................................................1245
FRONT COVER—UPPER.....................................................................................................................................................................1245
FRONT COVER—LOWER.....................................................................................................................................................................1245
REAR COVER............................................................................................................................................................................1245
INSTALLATION..............................................................................................................................................................................1245
FRONT COVER—UPPER.....................................................................................................................................................................1245
FRONT COVER—LOWER.....................................................................................................................................................................1247
REAR COVER............................................................................................................................................................................1247
TIMING BELT AND SPROCKETS.....................................................................................................................................................................1247
REMOVAL...................................................................................................................................................................................1247
REMOVAL - TIMING BELT.................................................................................................................................................................1247
REMOVAL - CAMSHAFT SPROCKET(S)........................................................................................................................................................1247
REMOVAL - CRANKSHAFT SPROCKET.........................................................................................................................................................1248
INSTALLATION..............................................................................................................................................................................1248
INSTALLATION - CRANKSHAFT SPROCKET....................................................................................................................................................1248
INSTALLATION - CAMSHAFT SPROCKET(S)...................................................................................................................................................1249
INSTALLATION - TIMING BELT............................................................................................................................................................1249
TIMING BELT TENSIONER & PULLEY................................................................................................................................................................1251
REMOVAL...................................................................................................................................................................................1251
INSTALLATION..............................................................................................................................................................................1251
BALANCE SHAFTS AND CARRIER ASSEMBLY...........................................................................................................................................................1252
DESCRIPTION...............................................................................................................................................................................1252
OPERATION.................................................................................................................................................................................1252
REMOVAL...................................................................................................................................................................................1252
BALANCE SHAFTS/CHAIN/SPROCKETS........................................................................................................................................................1252
BALANCE SHAFT CARRIER.................................................................................................................................................................1253
INSTALLATION..............................................................................................................................................................................1253
BALANCE SHAFT INSTALLATION/TIMING.....................................................................................................................................................1253
11-EXHAUST SYSTEM AND TURBOCHARGER....................................................................................................................................................................1257
EXHAUST SYSTEM AND TURBOCHARGER...................................................................................................................................................................1258
DESCRIPTION - EXHAUST SYSTEM..................................................................................................................................................................1258
DIAGNOSIS AND TESTING.........................................................................................................................................................................1258
EXHAUST SYSTEM DIAGNOSIS..................................................................................................................................................................1258
DIAGNOSIS AND TESTING - EXHAUST SYSTEM RESTRICTION CHECK..................................................................................................................................1259
INSPECTION....................................................................................................................................................................................1259
ADJUSTMENTS...................................................................................................................................................................................1259
EXHAUST SYSTEM ALIGNMENT..................................................................................................................................................................1259
SPECIFICATIONS................................................................................................................................................................................1260
EXHAUST SYSTEM CLEARANCE..................................................................................................................................................................1260
TORQUE - EXHAUST SYSTEM COMPONENTS........................................................................................................................................................1261
TORQUE - TURBOCHARGER COMPONENTS..........................................................................................................................................................1261
SPECIAL TOOLS.................................................................................................................................................................................1261
EXHAUST SYSTEM............................................................................................................................................................................1261
MUFFLER...........................................................................................................................................................................................1262
REMOVAL.......................................................................................................................................................................................1262
INSTALLATION..................................................................................................................................................................................1262
INTERMEDIATE PIPE.................................................................................................................................................................................1263
REMOVAL.......................................................................................................................................................................................1263
INSTALLATION..................................................................................................................................................................................1264
CATALYTIC CONVERTER...............................................................................................................................................................................1265
DESCRIPTION...................................................................................................................................................................................1265
OPERATION.....................................................................................................................................................................................1265
REMOVAL.......................................................................................................................................................................................1265
INSPECTION....................................................................................................................................................................................1266
INSTALLATION..................................................................................................................................................................................1266
SUPPORT BRACKETS AND ISOLATORS....................................................................................................................................................................1267
REMOVAL.......................................................................................................................................................................................1267
INSTALLATION..................................................................................................................................................................................1267
HEAT SHIELDS......................................................................................................................................................................................1268
DESCRIPTION...................................................................................................................................................................................1268
REMOVAL.......................................................................................................................................................................................1268
INSTALLATION..................................................................................................................................................................................1268
TURBOCHARGER SYSTEM...............................................................................................................................................................................1269
DIAGNOSIS AND TESTING - TURBOCHARGER..........................................................................................................................................................1269
TURBOCHARGER......................................................................................................................................................................................1270
DESCRIPTION...................................................................................................................................................................................1270
OPERATION.....................................................................................................................................................................................1270
REMOVAL - TURBOCHARGER........................................................................................................................................................................1271
INSTALLATION - TURBOCHARGER...................................................................................................................................................................1274
CHARGE AIR COOLER AND HOSES.......................................................................................................................................................................1275
REMOVAL.......................................................................................................................................................................................1275
REMOVAL - CHARGE AIR COOLER HOSES.........................................................................................................................................................1275
HOSE - CHARGE AIR COOLER TO THROTTLE BODY.............................................................................................................................................1275
HOSE - TURBOCHARGER TO CHARGE AIR COOLER..............................................................................................................................................1276
REMOVAL - CHARGE AIR COOLER...............................................................................................................................................................1276
INSTALLATION..................................................................................................................................................................................1277
INSTALLATION - CHARGE AIR COOLER HOSES....................................................................................................................................................1277
HOSE - CHARGE AIR COOLER TO THROTTLE BODY.............................................................................................................................................1277
HOSE - TURBOCHARGER TO CHARGE AIR COOLER..............................................................................................................................................1277
INSTALLATION - CHARGE AIR COOLER..........................................................................................................................................................1277
LINES AND HOSES...................................................................................................................................................................................1278
REMOVAL - LINES AND HOSES.....................................................................................................................................................................1278
COOLANT SUPPLY LINE.......................................................................................................................................................................1278
COOLANT RETURN LINE.......................................................................................................................................................................1278
OIL SUPPLY LINE...........................................................................................................................................................................1279
OIL RETURN LINE...........................................................................................................................................................................1279
INSTALLATION - LINES AND HOSES................................................................................................................................................................1280
COOLANT SUPPLY LINE.......................................................................................................................................................................1280
COOLANT RETURN LINE.......................................................................................................................................................................1280
OIL SUPPLY LINE...........................................................................................................................................................................1280
OIL RETURN LINE...........................................................................................................................................................................1280
SOLENOIDS AND VACUUM HARNESS......................................................................................................................................................................1281
DESCRIPTION...................................................................................................................................................................................1281
REMOVAL.......................................................................................................................................................................................1281
INSTALLATION..................................................................................................................................................................................1282
13-FRAMES & BUMPERS...................................................................................................................................................................................1283
FRONT BUMPER REINFORCEMENT........................................................................................................................................................................1283
REMOVAL.......................................................................................................................................................................................1283
INSTALLATION..................................................................................................................................................................................1283
FRONT BUMPER FASCIA...............................................................................................................................................................................1284
REMOVAL.......................................................................................................................................................................................1284
INSTALLATION..................................................................................................................................................................................1284
REAR BUMPER FASCIA................................................................................................................................................................................1285
REMOVAL.......................................................................................................................................................................................1285
INSTALLATION..................................................................................................................................................................................1285
REAR BUMPER REINFORCEMENT.........................................................................................................................................................................1285
REMOVAL.......................................................................................................................................................................................1285
INSTALLATION..................................................................................................................................................................................1285
FRAME.............................................................................................................................................................................................1286
SPECIFICATIONS................................................................................................................................................................................1286
SPECIFICATIONS - FRAME DIMENSIONS.........................................................................................................................................................1286
VEHICLE PREPARATION...................................................................................................................................................................1286
SPECIFICATIONS - TORQUE...................................................................................................................................................................1290
FRONT CROSSMEMBER.................................................................................................................................................................................1291
REMOVAL.......................................................................................................................................................................................1291
INSTALLATION..................................................................................................................................................................................1293
FRONT EMERGENCY TOW EYE...........................................................................................................................................................................1295
REMOVAL.......................................................................................................................................................................................1295
INSTALLATION..................................................................................................................................................................................1295
REAR EMERGENCY TOW EYE............................................................................................................................................................................1295
REMOVAL.......................................................................................................................................................................................1295
INSTALLATION..................................................................................................................................................................................1295
14-FUEL SYSTEM........................................................................................................................................................................................1297
FUEL DELIVERY.....................................................................................................................................................................................1297
FUEL DELIVERY.................................................................................................................................................................................1298
DESCRIPTION...............................................................................................................................................................................1298
OPERATION.................................................................................................................................................................................1298
DIAGNOSIS AND TESTING - FUEL DELIVERY SYSTEM..............................................................................................................................................1298
STANDARD PROCEDURE........................................................................................................................................................................1298
STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE...........................................................................................................................1298
STANDARD PROCEDURE - DRAINING FUEL TANK...............................................................................................................................................1298
SPECIFICATIONS............................................................................................................................................................................1299
TORQUE................................................................................................................................................................................1299
FUEL SYSTEM PRESSURE..................................................................................................................................................................1299
SPECIAL TOOLS.............................................................................................................................................................................1299
FUEL..................................................................................................................................................................................1299
FUEL FILTER...................................................................................................................................................................................1300
DESCRIPTION...............................................................................................................................................................................1300
FUEL LEVEL SENDING UNIT / SENSOR..............................................................................................................................................................1300
DESCRIPTION...............................................................................................................................................................................1300
OPERATION.................................................................................................................................................................................1300
REMOVAL...................................................................................................................................................................................1300
INSTALLATION..............................................................................................................................................................................1301
FUEL LINES....................................................................................................................................................................................1301
DESCRIPTION - FUEL LINES/HOSES AND CLAMPS.................................................................................................................................................1301
STANDARD PROCEDURE - HOSES AND CLAMP......................................................................................................................................................1302
FUEL PRESSURE REGULATOR.......................................................................................................................................................................1302
DESCRIPTION...............................................................................................................................................................................1302
OPERATION.................................................................................................................................................................................1302
REMOVAL...................................................................................................................................................................................1302
INSTALLATION..............................................................................................................................................................................1303
FUEL PUMP.....................................................................................................................................................................................1303
DESCRIPTION...............................................................................................................................................................................1303
OPERATION.................................................................................................................................................................................1303
FUEL PUMP MODULE..............................................................................................................................................................................1303
DESCRIPTION...............................................................................................................................................................................1303
OPERATION.................................................................................................................................................................................1303
FUEL PUMP ELECTRICAL CONTROL..........................................................................................................................................................1304
ELECTRICAL PUMP REPLACEMENT...........................................................................................................................................................1304
REMOVAL...................................................................................................................................................................................1304
INSTALLATION..............................................................................................................................................................................1304
FUEL RAIL.....................................................................................................................................................................................1305
DESCRIPTION...............................................................................................................................................................................1305
OPERATION.................................................................................................................................................................................1305
REMOVAL...................................................................................................................................................................................1305
REMOVAL...............................................................................................................................................................................1305
REMOVAL - 2.4L TURBO..................................................................................................................................................................1306
REMOVAL - 1.6L........................................................................................................................................................................1309
INSTALLATION..............................................................................................................................................................................1310
INSTALLATION..........................................................................................................................................................................1310
INSTALLATION - 2.4L TURBO.............................................................................................................................................................1310
INSTALLATION - 1.6L...................................................................................................................................................................1310
FUEL TANK.....................................................................................................................................................................................1310
DESCRIPTION...............................................................................................................................................................................1310
OPERATION.................................................................................................................................................................................1310
REMOVAL...................................................................................................................................................................................1311
INSTALLATION..............................................................................................................................................................................1312
FUEL TANK FILLER TUBE.........................................................................................................................................................................1312
REMOVAL...................................................................................................................................................................................1312
INSTALLATION..............................................................................................................................................................................1313
INLET FILTER..................................................................................................................................................................................1313
DESCRIPTION...............................................................................................................................................................................1313
QUICK CONNECT FITTING.........................................................................................................................................................................1313
STANDARD PROCEDURE - QUICK-CONNECT FITTINGS...............................................................................................................................................1313
REMOVAL...............................................................................................................................................................................1313
INSTALLATION..........................................................................................................................................................................1313
TWO-TAB TYPE FITTING..................................................................................................................................................................1314
PLASTIC RETAINER RING TYPE FITTING....................................................................................................................................................1315
FUEL INJECTION....................................................................................................................................................................................1316
FUEL INJECTION................................................................................................................................................................................1317
OPERATION.................................................................................................................................................................................1317
OPERATION - INJECTION SYSTEM..........................................................................................................................................................1317
OPERATION - MODES OF OPERATION........................................................................................................................................................1317
IGNITION SWITCH ON (ZERO RPM) MODE................................................................................................................................................1317
ENGINE START-UP MODE..............................................................................................................................................................1318
ENGINE WARM-UP MODE...............................................................................................................................................................1318
CRUISE OR IDLE MODE...............................................................................................................................................................1318
ACCELERATION MODE.................................................................................................................................................................1319
DECELERATION MODE.................................................................................................................................................................1319
WIDE-OPEN-THROTTLE MODE...........................................................................................................................................................1319
IGNITION SWITCH OFF MODE..........................................................................................................................................................1319
FUEL CORRECTION or ADAPTIVE MEMORIES..................................................................................................................................................1319
DESCRIPTION.......................................................................................................................................................................1319
OPERATION.........................................................................................................................................................................1319
PROGRAMMABLE COMMUNICATIONS INTERFACE (PCI) BUS.......................................................................................................................................1320
DESCRIPTION.......................................................................................................................................................................1320
OPERATION.........................................................................................................................................................................1320
SYSTEM DIAGNOSIS......................................................................................................................................................................1321
OPERATION.........................................................................................................................................................................1321
SPECIFICATIONS............................................................................................................................................................................1321
TORQUE................................................................................................................................................................................1321
SPECIAL TOOLS.............................................................................................................................................................................1322
FUEL..................................................................................................................................................................................1322
ACCELERATOR PEDAL.............................................................................................................................................................................1322
REMOVAL...................................................................................................................................................................................1322
INSTALLATION..............................................................................................................................................................................1323
ACCELERATOR PEDAL POSITION SENSOR - 1.6L......................................................................................................................................................1323
DESCRIPTION...............................................................................................................................................................................1323
REMOVAL - LHD.............................................................................................................................................................................1323
INSTALLATION - LHD........................................................................................................................................................................1323
CRANKSHAFT POSITION SENSOR....................................................................................................................................................................1324
DESCRIPTION...............................................................................................................................................................................1324
OPERATION.................................................................................................................................................................................1324
REMOVAL...................................................................................................................................................................................1325
REMOVAL - 1.6L........................................................................................................................................................................1325
REMOVAL - 2.0, 2.4, 2.4L TURBO........................................................................................................................................................1325
INSTALLATION..............................................................................................................................................................................1326
INSTALLATION - 1.6L...................................................................................................................................................................1326
INSTALLATION - 2.0, 2.4, 2.4L Turbo...................................................................................................................................................1326
FUEL INJECTOR.................................................................................................................................................................................1326
DESCRIPTION...............................................................................................................................................................................1326
OPERATION.................................................................................................................................................................................1326
STANDARD PROCEDURE........................................................................................................................................................................1327
REMOVAL - INJECTOR CONNECTOR..........................................................................................................................................................1327
REMOVAL...................................................................................................................................................................................1327
REMOVAL - 2.0, 2.4L...................................................................................................................................................................1327
REMOVAL - 1.6L........................................................................................................................................................................1328
REMOVAL - 2.4L TURBO..................................................................................................................................................................1328
INSTALLATION..............................................................................................................................................................................1331
INSTALLATION - 2.0, 2.4L..............................................................................................................................................................1331
INSTALLATION - 1.6L...................................................................................................................................................................1332
INSTALLATION - 2.4L TURBO.............................................................................................................................................................1332
FUEL PUMP RELAY...............................................................................................................................................................................1332
DESCRIPTION...............................................................................................................................................................................1332
OPERATION.................................................................................................................................................................................1332
IDLE AIR CONTROL MOTOR........................................................................................................................................................................1333
DESCRIPTION...............................................................................................................................................................................1333
OPERATION.................................................................................................................................................................................1333
Target Idle...........................................................................................................................................................................1333
REMOVAL...................................................................................................................................................................................1333
INSTALLATION..............................................................................................................................................................................1333
INLET AIR TEMPERATURE SENSOR..................................................................................................................................................................1334
DESCRIPTION...............................................................................................................................................................................1334
OPERATION.................................................................................................................................................................................1334
Inlet/Intake Air Temperature (NGC)....................................................................................................................................................1334
Battery Temperature (SBEC Vehicles without Battery Temperature sensor)................................................................................................................1334
REMOVAL...................................................................................................................................................................................1334
INSTALLATION..............................................................................................................................................................................1334
MAP SENSOR....................................................................................................................................................................................1335
DESCRIPTION...............................................................................................................................................................................1335
OPERATION.................................................................................................................................................................................1335
REMOVAL...................................................................................................................................................................................1336
REMOVAL - 2.0, 2.4, 2.4L TURBO........................................................................................................................................................1336
REMOVAL - 1.6L........................................................................................................................................................................1336
INSTALLATION..............................................................................................................................................................................1336
INSTALLATION - 2.0, 2.4, 2.4L Turbo...................................................................................................................................................1336
INSTALLATION - 1.6L...................................................................................................................................................................1336
O2 SENSOR.....................................................................................................................................................................................1336
DESCRIPTION...............................................................................................................................................................................1336
OPERATION.................................................................................................................................................................................1336
UPSTREAM OXYGEN SENSOR................................................................................................................................................................1337
DOWNSTREAM OXYGEN SENSOR..............................................................................................................................................................1338
REMOVAL...................................................................................................................................................................................1338
REMOVAL - 1/1 UPSTREAM................................................................................................................................................................1338
REMOVAL - 1/2 DOWNSTREAM..............................................................................................................................................................1338
REMOVAL - 2.4L TURBO..................................................................................................................................................................1338
INSTALLATION..............................................................................................................................................................................1339
INSTALLATION - 1/1 UPSTREAM...........................................................................................................................................................1339
INSTALLATION - 1/2 DOWNSTREAM.........................................................................................................................................................1339
INSTALLATION - 2.4L TURBO.............................................................................................................................................................1339
THROTTLE BODY.................................................................................................................................................................................1340
DESCRIPTION...............................................................................................................................................................................1340
OPERATION.................................................................................................................................................................................1340
REMOVAL...................................................................................................................................................................................1340
REMOVAL - 2.0, 2.4L...................................................................................................................................................................1340
REMOVAL - 1.6L........................................................................................................................................................................1341
REMOVAL - 2.4L TURBO..................................................................................................................................................................1342
INSTALLATION..............................................................................................................................................................................1343
INSTALLATION - 2.0, 2.4L..............................................................................................................................................................1343
INSTALLATION - 1.6L...................................................................................................................................................................1343
INSTALLATION - 2.4L TURBO.............................................................................................................................................................1344
THROTTLE CONTROL CABLE........................................................................................................................................................................1344
REMOVAL...................................................................................................................................................................................1344
INSTALLATION..............................................................................................................................................................................1344
THROTTLE POSITION SENSOR......................................................................................................................................................................1345
DESCRIPTION...............................................................................................................................................................................1345
OPERATION.................................................................................................................................................................................1345
REMOVAL...................................................................................................................................................................................1345
INSTALLATION..............................................................................................................................................................................1346
19-STEERING...........................................................................................................................................................................................1347
STEERING..........................................................................................................................................................................................1347
STEERING......................................................................................................................................................................................1347
DESCRIPTION - POWER STEERING SYSTEM.......................................................................................................................................................1347
OPERATION - POWER STEERING SYSTEM.........................................................................................................................................................1347
WARNING...................................................................................................................................................................................1347
WARNINGS AND CAUTIONS.................................................................................................................................................................1347
DIAGNOSIS AND TESTING.....................................................................................................................................................................1347
DIAGNOSIS AND TESTING - POWER STEERING FLOW AND PRESSURE TEST.........................................................................................................................1347
TEST PROCEDURE....................................................................................................................................................................1348
DIAGNOSIS AND TESTING - STEERING DIAGNOSIS CHARTS.....................................................................................................................................1349
POWER STEERING NOISE..............................................................................................................................................................1349
STEERING WHEEL FEEL...............................................................................................................................................................1351
POWER STEERING FLUID..............................................................................................................................................................1354
SPECIFICATIONS - POWER STEERING FASTENER TORQUE...........................................................................................................................................1354
SPECIAL TOOLS.............................................................................................................................................................................1355
POWER STEERING........................................................................................................................................................................1355
COLUMN............................................................................................................................................................................................1356
COLUMN........................................................................................................................................................................................1356
DESCRIPTION...............................................................................................................................................................................1356
OPERATION.................................................................................................................................................................................1356
WARNING...................................................................................................................................................................................1357
WARNINGS AND CAUTIONS.................................................................................................................................................................1357
DIAGNOSIS AND TESTING - STEERING COLUMN...................................................................................................................................................1357
REMOVAL...................................................................................................................................................................................1357
REMOVAL...............................................................................................................................................................................1357
REMOVAL - RHD.........................................................................................................................................................................1362
INSTALLATION..............................................................................................................................................................................1362
INSTALLATION..........................................................................................................................................................................1362
INSTALLATION - RHD....................................................................................................................................................................1364
SPECIFICATIONS - STEERING COLUMN FASTENER TORQUE..........................................................................................................................................1364
IGNITION SWITCH...............................................................................................................................................................................1364
REMOVAL...................................................................................................................................................................................1364
INSTALLATION..............................................................................................................................................................................1365
KEY/LOCK CYLINDER.............................................................................................................................................................................1366
REMOVAL...................................................................................................................................................................................1366
INSTALLATION..............................................................................................................................................................................1366
SHROUD - UPPER/LOWER..........................................................................................................................................................................1367
REMOVAL...................................................................................................................................................................................1367
INSTALLATION..............................................................................................................................................................................1367
STEERING COUPLING - LOWER.....................................................................................................................................................................1367
DESCRIPTION...............................................................................................................................................................................1367
OPERATION.................................................................................................................................................................................1367
DIAGNOSIS AND TESTING - STEERING COLUMN LOWER COUPLING....................................................................................................................................1368
REMOVAL...................................................................................................................................................................................1368
INSTALLATION..............................................................................................................................................................................1371
STEERING WHEEL................................................................................................................................................................................1372
REMOVAL...................................................................................................................................................................................1372
INSTALLATION..............................................................................................................................................................................1372
GEAR..............................................................................................................................................................................................1374
GEAR..........................................................................................................................................................................................1374
DESCRIPTION...............................................................................................................................................................................1374
OPERATION.................................................................................................................................................................................1374
REMOVAL...................................................................................................................................................................................1375
REMOVAL...............................................................................................................................................................................1375
REMOVAL - RHD.........................................................................................................................................................................1378
INSTALLATION..............................................................................................................................................................................1378
INSTALLATION..........................................................................................................................................................................1378
INSTALLATION - RHD....................................................................................................................................................................1380
POWER STEERING PRESSURE SWITCH................................................................................................................................................................1380
DESCRIPTION...............................................................................................................................................................................1380
OPERATION.................................................................................................................................................................................1380
REMOVAL...................................................................................................................................................................................1380
INSTALLATION..............................................................................................................................................................................1381
TIE ROD - OUTER...............................................................................................................................................................................1381
REMOVAL...................................................................................................................................................................................1381
INSTALLATION..............................................................................................................................................................................1382
PUMP..............................................................................................................................................................................................1383
PUMP..........................................................................................................................................................................................1383
DESCRIPTION...............................................................................................................................................................................1383
DESCRIPTION - 1.6L ENGINE.............................................................................................................................................................1383
DESCRIPTION - 2.0L/2.4L/2.4L TURBO ENGINE.............................................................................................................................................1384
DESCRIPTION - 2.2L DIESEL.............................................................................................................................................................1384
STANDARD PROCEDURE - POWER STEERING PUMP INITIAL OPERATION................................................................................................................................1384
REMOVAL...................................................................................................................................................................................1385
REMOVAL - 1.6L ENGINE.................................................................................................................................................................1385
REMOVAL - 2.0L/2.4L ENGINE............................................................................................................................................................1385
REMOVAL - 2.4L TURBO..................................................................................................................................................................1388
REMOVAL - 2.2L DIESEL.................................................................................................................................................................1390
DISASSEMBLY...............................................................................................................................................................................1390
ASSEMBLY..................................................................................................................................................................................1390
INSTALLATION..............................................................................................................................................................................1391
INSTALLATION - 1.6L ENGINE............................................................................................................................................................1391
INSTALLATION - 2.0L/2.4L ENGINE.......................................................................................................................................................1391
INSTALLATION - 2.4L TURBO.............................................................................................................................................................1391
INSTALLATION - 2.2L DIESEL............................................................................................................................................................1392
FLUID.........................................................................................................................................................................................1392
STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING0 - 8 PT (Continued)..........................................................................................................1392
1.6L GAS/2.2L DIESEL ENGINE...........................................................................................................................................................1392
2.0L/2.4L ENGINE......................................................................................................................................................................1392
2.4L TURBO ENGINE.....................................................................................................................................................................1392
FLUID COOLER..................................................................................................................................................................................1393
DESCRIPTION...............................................................................................................................................................................1393
REMOVAL - NON-TURBO ENGINES...............................................................................................................................................................1393
INSTALLATION - NON-TURBO ENGINES..........................................................................................................................................................1393
HOSE - POWER STEERING PRESSURE................................................................................................................................................................1394
REMOVAL...................................................................................................................................................................................1394
REMOVAL - 2.0L ENGINE.................................................................................................................................................................1394
REMOVAL - 2.4L ENGINE.................................................................................................................................................................1395
REMOVAL - 2.2L DIESEL.................................................................................................................................................................1396
INSTALLATION..............................................................................................................................................................................1397
INSTALLATION - 2.0L ENGINE............................................................................................................................................................1397
INSTALLATION - 2.4L ENGINE............................................................................................................................................................1398
INSTALLATION - 2.2L DIESEL............................................................................................................................................................1399
HOSE - POWER STEERING PRESSURE/RETURN.........................................................................................................................................................1399
REMOVAL - 2.4L TURBO......................................................................................................................................................................1399
INSTALLATION - 2.4L TURBO.................................................................................................................................................................1402
HOSE - POWER STEERING RETURN..................................................................................................................................................................1403
REMOVAL...................................................................................................................................................................................1403
REMOVAL - 2.0L/2.4L ENGINE............................................................................................................................................................1403
REMOVAL - 2.4L TURBO..................................................................................................................................................................1404
REMOVAL - 2.2L DIESEL.................................................................................................................................................................1404
INSTALLATION..............................................................................................................................................................................1404
INSTALLATION - 2.0L/2.4L ENGINE.......................................................................................................................................................1404
INSTALLATION - 2.4L TURBO.............................................................................................................................................................1405
INSTALLATION - 2.2L DIESEL............................................................................................................................................................1405
HOSE - POWER STEERING SUPPLY..................................................................................................................................................................1405
REMOVAL...................................................................................................................................................................................1405
REMOVAL - 2.0L/2.4L ENGINE............................................................................................................................................................1405
REMOVAL - 2.2L DIESEL.................................................................................................................................................................1406
INSTALLATION..............................................................................................................................................................................1407
INSTALLATION - 2.0L/2.4L ENGINE.......................................................................................................................................................1407
INSTALLATION - 2.2L DIESEL............................................................................................................................................................1407
PULLEY........................................................................................................................................................................................1408
REMOVAL - 2.2L DIESEL.....................................................................................................................................................................1408
INSTALLATION - 2.2L DIESEL................................................................................................................................................................1408
RESERVOIR.....................................................................................................................................................................................1408
DESCRIPTION...............................................................................................................................................................................1408
REMOVAL...................................................................................................................................................................................1408
REMOVAL - 1.6L ENGINE.................................................................................................................................................................1408
REMOVAL - 2.0L/2.4L ENGINE............................................................................................................................................................1409
REMOVAL - 2.2L DIESEL.................................................................................................................................................................1409
INSTALLATION..............................................................................................................................................................................1410
INSTALLATION - 1.6L ENGINE............................................................................................................................................................1410
INSTALLATION - 2.0L/2.4L ENGINE.......................................................................................................................................................1410
INSTALLATION - 2.2L DIESEL............................................................................................................................................................1411
21-TRANSAXLE..........................................................................................................................................................................................1413
G288 MANUAL TRANSAXLE.............................................................................................................................................................................1413
G288 MANUAL TRANSAXLE.........................................................................................................................................................................1414
DESCRIPTION...............................................................................................................................................................................1414
TRANSAXLE IDENTIFICATION..............................................................................................................................................................1416
OPERATION.................................................................................................................................................................................1417
NEUTRAL...............................................................................................................................................................................1417
FIRST GEAR............................................................................................................................................................................1418
SECOND GEAR...........................................................................................................................................................................1419
THIRD GEAR............................................................................................................................................................................1420
FOURTH GEAR...........................................................................................................................................................................1421
FIFTH GEAR............................................................................................................................................................................1422
REVERSE GEAR..........................................................................................................................................................................1423
SHIFT SYSTEM..........................................................................................................................................................................1424
REMOVAL...................................................................................................................................................................................1425
REMOVAL—2.2L TURBO DIESEL.............................................................................................................................................................1425
REMOVAL—2.4L TURBO....................................................................................................................................................................1429
DISASSEMBLY...............................................................................................................................................................................1434
ASSEMBLY..................................................................................................................................................................................1439
INSTALLATION..............................................................................................................................................................................1446
INSTALLATION—2.2L TURBO DIESEL........................................................................................................................................................1446
INSTALLATION—2.4L TURBO...............................................................................................................................................................1450
SPECIFICATIONS............................................................................................................................................................................1455
SPECIAL TOOLS.............................................................................................................................................................................1456
AXLE SEAL.....................................................................................................................................................................................1460
REMOVAL...................................................................................................................................................................................1460
INSTALLATION..............................................................................................................................................................................1460
BACKUP LAMP SWITCH............................................................................................................................................................................1460
REMOVAL...................................................................................................................................................................................1460
INSTALLATION..............................................................................................................................................................................1461
CLUTCH BELLHOUSING............................................................................................................................................................................1461
DISASSEMBLY...............................................................................................................................................................................1461
ASSEMBLY..................................................................................................................................................................................1463
DETENT PLUG...................................................................................................................................................................................1465
DESCRIPTION...............................................................................................................................................................................1465
REMOVAL...................................................................................................................................................................................1467
INSTALLATION..............................................................................................................................................................................1467
DIFFERENTIAL..................................................................................................................................................................................1468
DESCRIPTION...............................................................................................................................................................................1468
OPERATION.................................................................................................................................................................................1468
REMOVAL...................................................................................................................................................................................1468
DISASSEMBLY...............................................................................................................................................................................1468
ASSEMBLY..................................................................................................................................................................................1469
INSTALLATION..............................................................................................................................................................................1469
FLUID.........................................................................................................................................................................................1470
STANDARD PROCEDURE........................................................................................................................................................................1470
STANDARD PROCEDURE - FLUID LEVEL CHECKING.............................................................................................................................................1470
STANDARD PROCEDURE - FLUID DRAIN AND FILL.............................................................................................................................................1470
GEAR SHIFT BOOT...............................................................................................................................................................................1471
REMOVAL...................................................................................................................................................................................1471
INSTALLATION..............................................................................................................................................................................1471
GEAR SHIFT CABLE..............................................................................................................................................................................1471
REMOVAL...................................................................................................................................................................................1471
INSTALLATION..............................................................................................................................................................................1475
ADJUSTMENTS...............................................................................................................................................................................1478
ADJUSTMENT - GEARSHIFT CROSSOVER CABLE................................................................................................................................................1478
GEAR SHIFT KNOB...............................................................................................................................................................................1478
REMOVAL...................................................................................................................................................................................1478
INSTALLATION..............................................................................................................................................................................1478
GEAR SHIFT MECHANISM..........................................................................................................................................................................1479
REMOVAL...................................................................................................................................................................................1479
INSTALLATION..............................................................................................................................................................................1480
INPUT SHAFT...................................................................................................................................................................................1481
DESCRIPTION...............................................................................................................................................................................1481
DISASSEMBLY...............................................................................................................................................................................1482
ASSEMBLY..................................................................................................................................................................................1484
OUTPUT SHAFT..................................................................................................................................................................................1489
DESCRIPTION...............................................................................................................................................................................1489
DISASSEMBLY...............................................................................................................................................................................1490
ASSEMBLY..................................................................................................................................................................................1492
REVERSE SHAFT.................................................................................................................................................................................1497
DESCRIPTION...............................................................................................................................................................................1497
DISASSEMBLY...............................................................................................................................................................................1498
ASSEMBLY..................................................................................................................................................................................1499
SYNCHRONIZER..................................................................................................................................................................................1502
DESCRIPTION...............................................................................................................................................................................1502
REMOVAL...................................................................................................................................................................................1503
DISASSEMBLY...............................................................................................................................................................................1503
INSPECTION................................................................................................................................................................................1503
ASSEMBLY..................................................................................................................................................................................1503
INSTALLATION..............................................................................................................................................................................1503
TRANSAXLE HOUSING.............................................................................................................................................................................1504
DISASSEMBLY...............................................................................................................................................................................1504
ASSEMBLY..................................................................................................................................................................................1505
T350 MANUAL TRANSAXLE.............................................................................................................................................................................1506
T350 MANUAL TRANSAXLE.........................................................................................................................................................................1507
DESCRIPTION...............................................................................................................................................................................1507
TRANSAXLE IDENTIFICATION..............................................................................................................................................................1507
GEAR RATIOS...........................................................................................................................................................................1508
GEARSHIFT PATTERN.....................................................................................................................................................................1508
LUBRICANT/ADDITIVES...................................................................................................................................................................1508
SEALANTS..............................................................................................................................................................................1508
DIAGNOSIS AND TESTING - COMMON PROBLEM CAUSES.............................................................................................................................................1508
HARD SHIFTING.........................................................................................................................................................................1508
NOISY OPERATION.......................................................................................................................................................................1508
SLIPS OUT OF GEAR.....................................................................................................................................................................1508
LOW LUBRICANT LEVEL...................................................................................................................................................................1509
CLUTCH PROBLEMS.......................................................................................................................................................................1509
REMOVAL...................................................................................................................................................................................1509
DISASSEMBLY...............................................................................................................................................................................1513
CLEANING..................................................................................................................................................................................1520
INSPECTION................................................................................................................................................................................1520
ASSEMBLY..................................................................................................................................................................................1520
BEARING ADJUSTMENT PROCEDURE..........................................................................................................................................................1524
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT...............................................................................................................................................1524
INSTALLATION..............................................................................................................................................................................1526
SPECIFICATIONS............................................................................................................................................................................1527
SPECIAL TOOLS.............................................................................................................................................................................1528
AXLE SEAL.....................................................................................................................................................................................1530
REMOVAL...................................................................................................................................................................................1530
INSTALLATION..............................................................................................................................................................................1530
BACK-UP LAMP SWITCH...........................................................................................................................................................................1530
REMOVAL...................................................................................................................................................................................1530
INSTALLATION..............................................................................................................................................................................1530
DIFFERENTIAL..................................................................................................................................................................................1531
DISASSEMBLY...............................................................................................................................................................................1531
ASSEMBLY..................................................................................................................................................................................1533
Measure and Adjust Side Gear End-Play.................................................................................................................................................1536
ADJUSTMENTS...............................................................................................................................................................................1536
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT / SHIM SELECTION..............................................................................................................................1536
DIFFERENTIAL BEARING CUPS.....................................................................................................................................................................1537
REMOVAL...................................................................................................................................................................................1537
INSTALLATION..............................................................................................................................................................................1538
FLUID.........................................................................................................................................................................................1538
STANDARD PROCEDURE - FLUID DRAIN AND FILL.................................................................................................................................................1538
GEAR SHIFT BOOT...............................................................................................................................................................................1538
REMOVAL...................................................................................................................................................................................1538
INSTALLATION..............................................................................................................................................................................1539
GEAR SHIFT CABLE..............................................................................................................................................................................1539
REMOVAL...................................................................................................................................................................................1539
INSTALLATION..............................................................................................................................................................................1542
ADJUSTMENTS...............................................................................................................................................................................1545
ADJUSTMENT - GEARSHIFT CROSSOVER CABLE................................................................................................................................................1545
GEAR SHIFT KNOB...............................................................................................................................................................................1546
REMOVAL...................................................................................................................................................................................1546
INSTALLATION..............................................................................................................................................................................1546
GEAR SHIFT MECHANISM..........................................................................................................................................................................1546
REMOVAL...................................................................................................................................................................................1546
INSTALLATION..............................................................................................................................................................................1546
INPUT BEARING AND SLEEVE......................................................................................................................................................................1548
REMOVAL...................................................................................................................................................................................1548
INSTALLATION..............................................................................................................................................................................1548
INPUT SHAFT...................................................................................................................................................................................1549
DISASSEMBLY...............................................................................................................................................................................1549
ASSEMBLY..................................................................................................................................................................................1552
OUTPUT SHAFT..................................................................................................................................................................................1554
DISASSEMBLY...............................................................................................................................................................................1554
OUTPUT BEARING AND RACE.......................................................................................................................................................................1555
REMOVAL...................................................................................................................................................................................1555
INSTALLATION..............................................................................................................................................................................1556
REAR BEARING OIL FEED TROUGH..................................................................................................................................................................1556
REMOVAL...................................................................................................................................................................................1556
INSTALLATION..............................................................................................................................................................................1556
SHIFT CROSSOVER LEVER.........................................................................................................................................................................1556
REMOVAL...................................................................................................................................................................................1556
INSTALLATION..............................................................................................................................................................................1557
SHIFT CROSSOVER SHAFT.........................................................................................................................................................................1557
REMOVAL...................................................................................................................................................................................1557
INSTALLATION..............................................................................................................................................................................1557
SHIFT CROSSOVER SHAFT BUSHING.................................................................................................................................................................1557
REMOVAL...................................................................................................................................................................................1557
INSTALLATION..............................................................................................................................................................................1557
SHIFT RAIL AND FORK...........................................................................................................................................................................1558
DISASSEMBLY...............................................................................................................................................................................1558
SHIFT RAIL BUSHINGS...........................................................................................................................................................................1558
REMOVAL...................................................................................................................................................................................1558
INSTALLATION..............................................................................................................................................................................1558
SHIFT SELECTOR SHAFT..........................................................................................................................................................................1558
REMOVAL...................................................................................................................................................................................1558
INSTALLATION..............................................................................................................................................................................1558
SHIFT SELECTOR SHAFT BUSHING..................................................................................................................................................................1558
REMOVAL...................................................................................................................................................................................1558
INSTALLATION..............................................................................................................................................................................1559
SHIFT SHAFT SEALS.............................................................................................................................................................................1559
REMOVAL...................................................................................................................................................................................1559
INSTALLATION..............................................................................................................................................................................1559
SYNCHRONIZER..................................................................................................................................................................................1559
DISASSEMBLY...............................................................................................................................................................................1559
CLEANING..................................................................................................................................................................................1559
CLEAN.................................................................................................................................................................................1559
INSPECTION................................................................................................................................................................................1559
INSPECT...............................................................................................................................................................................1559
ASSEMBLY..................................................................................................................................................................................1559
VEHICLE SPEED SENSOR..........................................................................................................................................................................1561
DESCRIPTION...............................................................................................................................................................................1561
VEHICLE SPEED SENSOR..................................................................................................................................................................1561
REMOVAL...................................................................................................................................................................................1561
INSTALLATION..............................................................................................................................................................................1561
41TE AUTOMATIC TRANSAXLE..........................................................................................................................................................................1562
41TE AUTOMATIC TRANSAXLE......................................................................................................................................................................1563
DESCRIPTION...............................................................................................................................................................................1563
TRANSAXLE IDENTIFICATION..............................................................................................................................................................1565
OPERATION.................................................................................................................................................................................1565
DIAGNOSIS AND TESTING.....................................................................................................................................................................1565
DIAGNOSIS AND TESTING - 41TE TRANSAXLE GENERAL DIAGNOSIS..............................................................................................................................1565
DIAGNOSIS AND TESTING - ROAD TEST.....................................................................................................................................................1566
DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TESTS......................................................................................................................................1566
TEST ONE-SELECTOR IN LOW (1st GEAR)...............................................................................................................................................1567
TEST TWO-SELECTOR IN DRIVE (2nd GEAR).............................................................................................................................................1567
TEST TWO A–SELECTOR IN OD (4th Gear)..............................................................................................................................................1567
TEST THREE-OVERDRIVE CLUTCH CHECK (3rd and 2nd Gear)..............................................................................................................................1567
TEST FOUR-SELECTOR IN OVERDRIVE (4th Gear)........................................................................................................................................1567
TEST FIVE-SELECTOR IN OVERDRIVE (4th Gear-CC on)..................................................................................................................................1567
TEST SIX-SELECTOR IN REVERSE......................................................................................................................................................1567
TEST RESULT INDICATIONS...........................................................................................................................................................1568
DIAGNOSIS AND TESTING - CLUTCH AIR PRESSURE TESTS.....................................................................................................................................1569
OVERDRIVE CLUTCH..................................................................................................................................................................1569
REVERSE CLUTCH....................................................................................................................................................................1569
2/4 CLUTCH........................................................................................................................................................................1569
LOW/REVERSE CLUTCH................................................................................................................................................................1569
UNDERDRIVE CLUTCH.................................................................................................................................................................1569
DIAGNOSIS AND TESTING - TORQUE CONVERTER HOUSING FLUID LEAKAGE........................................................................................................................1570
TORQUE CONVERTER LEAKAGE..........................................................................................................................................................1570
REMOVAL...................................................................................................................................................................................1570
DISASSEMBLY...............................................................................................................................................................................1574
ASSEMBLY..................................................................................................................................................................................1592
INSTALLATION..............................................................................................................................................................................1614
SCHEMATICS AND DIAGRAMS...................................................................................................................................................................1615
41TE TRANSAXLE HYDRAULIC SCHEMATICS...................................................................................................................................................1615
SPECIFICATIONS............................................................................................................................................................................1627
SPECIAL TOOLS.............................................................................................................................................................................1629
ACCUMULATOR...................................................................................................................................................................................1635
DESCRIPTION...............................................................................................................................................................................1635
OPERATION.................................................................................................................................................................................1635
DRIVING CLUTCHES..............................................................................................................................................................................1635
DESCRIPTION...............................................................................................................................................................................1635
OPERATION.................................................................................................................................................................................1636
UNDERDRIVE CLUTCH.....................................................................................................................................................................1636
OVERDRIVE CLUTCH......................................................................................................................................................................1636
REVERSE CLUTCH........................................................................................................................................................................1636
FINAL DRIVE...................................................................................................................................................................................1636
DESCRIPTION...............................................................................................................................................................................1636
OPERATION.................................................................................................................................................................................1636
DISASSEMBLY...............................................................................................................................................................................1637
ASSEMBLY..................................................................................................................................................................................1640
ADJUSTMENTS...............................................................................................................................................................................1641
DIFFERENTIAL BEARING PRELOAD MEASUREMENT AND ADJUSTMENT...............................................................................................................................1641
FLUID.........................................................................................................................................................................................1643
STANDARD PROCEDURE........................................................................................................................................................................1643
FLUID LEVEL AND CONDITION CHECK.......................................................................................................................................................1643
FLUID LEVEL CHECK.................................................................................................................................................................1643
FLUID LEVEL CHECK USING DRB.......................................................................................................................................................1644
FLUID CONDITION...................................................................................................................................................................1644
STANDARD PROCEDURE - FLUID AND FILTER SERVICE.........................................................................................................................................1645
FLUID/FILTER SERVICE (RECOMMENDED)................................................................................................................................................1645
DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE)..................................................................................................................................1645
GEAR SHIFT CABLE..............................................................................................................................................................................1646
REMOVAL...................................................................................................................................................................................1646
INSTALLATION..............................................................................................................................................................................1648
ADJUSTMENTS...............................................................................................................................................................................1649
GEARSHIFT CABLE.......................................................................................................................................................................1649
ADJUSTMENT........................................................................................................................................................................1649
HOLDING CLUTCHES..............................................................................................................................................................................1650
DESCRIPTION...............................................................................................................................................................................1650
OPERATION.................................................................................................................................................................................1650
2/4 CLUTCH............................................................................................................................................................................1650
LOW/REVERSE CLUTCH....................................................................................................................................................................1650
INPUT CLUTCH ASSEMBLY.........................................................................................................................................................................1651
DISASSEMBLY...............................................................................................................................................................................1651
ASSEMBLY..................................................................................................................................................................................1660
OIL PUMP......................................................................................................................................................................................1675
DESCRIPTION...............................................................................................................................................................................1675
OPERATION.................................................................................................................................................................................1675
DISASSEMBLY...............................................................................................................................................................................1675
ASSEMBLY..................................................................................................................................................................................1676
PLANETARY GEARTRAIN...........................................................................................................................................................................1676
DESCRIPTION...............................................................................................................................................................................1676
OPERATION.................................................................................................................................................................................1676
SEAL - OIL PUMP...............................................................................................................................................................................1677
REMOVAL...................................................................................................................................................................................1677
INSTALLATION..............................................................................................................................................................................1677
SHIFT INTERLOCK CABLE.........................................................................................................................................................................1677
REMOVAL...................................................................................................................................................................................1677
INSTALLATION..............................................................................................................................................................................1679
SHIFT INTERLOCK MECHANISM.....................................................................................................................................................................1680
REMOVAL...................................................................................................................................................................................1680
INSTALLATION..............................................................................................................................................................................1681
SHIFT INTERLOCK SYSTEM........................................................................................................................................................................1682
ADJUSTMENTS...............................................................................................................................................................................1682
BRAKE/TRANSMISSION SHIFT INTERLOCK SYSTEM.............................................................................................................................................1682
VERIFICATION......................................................................................................................................................................1682
ADJUSTMENT........................................................................................................................................................................1682
SOLENOID/PRESSURE SWITCH ASSY.................................................................................................................................................................1683
DESCRIPTION...............................................................................................................................................................................1683
OPERATION.................................................................................................................................................................................1683
SOLENOIDS.............................................................................................................................................................................1683
PRESSURE SWITCHES.....................................................................................................................................................................1684
REMOVAL...................................................................................................................................................................................1684
INSTALLATION..............................................................................................................................................................................1685
SPEED SENSOR - INPUT..........................................................................................................................................................................1686
DESCRIPTION...............................................................................................................................................................................1686
OPERATION.................................................................................................................................................................................1686
REMOVAL...................................................................................................................................................................................1687
INSTALLATION..............................................................................................................................................................................1688
SPEED SENSOR - OUTPUT.........................................................................................................................................................................1688
DESCRIPTION...............................................................................................................................................................................1688
OPERATION.................................................................................................................................................................................1689
VEHICLE SPEED SIGNAL..................................................................................................................................................................1689
REMOVAL...................................................................................................................................................................................1689
INSTALLATION..............................................................................................................................................................................1690
TORQUE CONVERTER..............................................................................................................................................................................1691
DESCRIPTION...............................................................................................................................................................................1691
IMPELLER..............................................................................................................................................................................1692
TURBINE...............................................................................................................................................................................1693
STATOR................................................................................................................................................................................1694
TORQUE CONVERTER CLUTCH (TCC).........................................................................................................................................................1694
OPERATION.................................................................................................................................................................................1695
TURBINE...............................................................................................................................................................................1695
STATOR................................................................................................................................................................................1696
TORQUE CONVERTER CLUTCH (TCC).........................................................................................................................................................1696
REMOVAL...................................................................................................................................................................................1696
INSTALLATION..............................................................................................................................................................................1696
TRANSMISSION CONTROL RELAY....................................................................................................................................................................1697
DESCRIPTION...............................................................................................................................................................................1697
OPERATION.................................................................................................................................................................................1697
TRANSMISSION RANGE SENSOR.....................................................................................................................................................................1697
DESCRIPTION...............................................................................................................................................................................1697
OPERATION.................................................................................................................................................................................1698
TRANSMISSION TEMPERATURE SENSOR.......................................................................................................................................................1698
CALCULATED TEMPERATURE................................................................................................................................................................1698
VALVE BODY....................................................................................................................................................................................1699
DESCRIPTION...............................................................................................................................................................................1699
OPERATION.................................................................................................................................................................................1699
REGULATOR VALVE.......................................................................................................................................................................1699
SOLENOID SWITCH VALVE.................................................................................................................................................................1699
MANUAL VALVE..........................................................................................................................................................................1700
CONVERTER CLUTCH SWITCH VALVE.........................................................................................................................................................1700
CONVERTER CLUTCH CONTROL VALVE........................................................................................................................................................1700
T/C REGULATOR VALVE...................................................................................................................................................................1700
LOW/REVERSE SWITCH VALVE..............................................................................................................................................................1700
REMOVAL...................................................................................................................................................................................1700
DISASSEMBLY...............................................................................................................................................................................1703
ASSEMBLY..................................................................................................................................................................................1707
INSTALLATION..............................................................................................................................................................................1712
22-TIRES/WHEELS.......................................................................................................................................................................................1713
TIRES/WHEELS......................................................................................................................................................................................1713
DIAGNOSIS AND TESTING - TIRE AND WHEEL RUNOUT.................................................................................................................................................1713
METHOD 1 (RELOCATE WHEEL ON HUB)..........................................................................................................................................................1714
METHOD 2 (RELOCATE TIRE ON WHEEL).........................................................................................................................................................1714
STANDARD PROCEDURE............................................................................................................................................................................1715
STANDARD PROCEDURE - TIRE AND WHEEL BALANCE...............................................................................................................................................1715
STANDARD PROCEDURE - TIRE AND WHEEL MATCH MOUNTING........................................................................................................................................1716
STANDARD PROCEDURE - TIRE AND WHEEL ROTATION..............................................................................................................................................1718
NON-DIRECTIONAL TREAD PATTERN TIRES...................................................................................................................................................1718
DIRECTIONAL TREAD PATTERN TIRES.......................................................................................................................................................1718
REMOVAL.......................................................................................................................................................................................1718
REMOVAL - TIRE AND WHEEL ASSEMBLY (ALUMINUM WHEEL)........................................................................................................................................1718
REMOVAL - TIRE AND WHEEL ASSEMBLY (STEEL WHEEL)...........................................................................................................................................1718
INSTALLATION..................................................................................................................................................................................1719
INSTALLATION - TIRE AND WHEEL ASSEMBLY (ALUMINUM WHEEL)...................................................................................................................................1719
INSTALLATION - TIRE AND WHEEL ASSEMBLY (STEEL WHEEL)......................................................................................................................................1719
TIRES.............................................................................................................................................................................................1719
DESCRIPTION...................................................................................................................................................................................1719
DESCRIPTION - TIRE........................................................................................................................................................................1719
TIRE IDENTIFICATION...................................................................................................................................................................1720
TIRE CHAINS...........................................................................................................................................................................1720
DESCRIPTION - RADIAL-PLY TIRES............................................................................................................................................................1720
DESCRIPTION - REPLACEMENT TIRES...........................................................................................................................................................1720
DESCRIPTION - SPARE TIRE (TEMPORARY)......................................................................................................................................................1721
DIAGNOSIS AND TESTING.........................................................................................................................................................................1721
DIAGNOSIS AND TESTING - TIRE NOISE OR VIBRATION...........................................................................................................................................1721
DIAGNOSIS AND TESTING - TIRE WEAR PATTERNS................................................................................................................................................1721
DIAGNOSIS AND TESTING - TREAD WEAR INDICATORS.............................................................................................................................................1721
DIAGNOSIS AND TESTING - VEHICLE LEAD DIAGNOSIS AND CORRECTION.............................................................................................................................1722
STANDARD PROCEDURE............................................................................................................................................................................1722
STANDARD PROCEDURE - TIRE INFLATION PRESSURES.............................................................................................................................................1722
STANDARD PROCEDURE - TIRE PRESSURE FOR HIGH SPEED OPERATION...............................................................................................................................1722
STANDARD PROCEDURE - TIRE LEAK REPAIRING..................................................................................................................................................1722
CLEANING - TIRES..............................................................................................................................................................................1722
WHEELS............................................................................................................................................................................................1724
DESCRIPTION - WHEEL...........................................................................................................................................................................1724
DIAGNOSIS AND TESTING - WHEEL INSPECTION......................................................................................................................................................1725
CLEANING......................................................................................................................................................................................1725
WHEEL AND WHEEL TRIM CARE.................................................................................................................................................................1725
SPECIFICATIONS................................................................................................................................................................................1725
WHEEL.....................................................................................................................................................................................1725
WHEEL COVER.......................................................................................................................................................................................1726
REMOVAL.......................................................................................................................................................................................1726
INSTALLATION..................................................................................................................................................................................1726
WHEEL MOUNTING STUDS - FRONT......................................................................................................................................................................1726
REMOVAL.......................................................................................................................................................................................1726
INSTALLATION..................................................................................................................................................................................1727
WHEEL MOUNTING STUDS - REAR.......................................................................................................................................................................1728
REMOVAL.......................................................................................................................................................................................1728
INSTALLATION..................................................................................................................................................................................1728
23-BODY...............................................................................................................................................................................................1729
BODY..............................................................................................................................................................................................1729
BODY..........................................................................................................................................................................................1729
DESCRIPTION - VEHICLE IDENTIFICATION......................................................................................................................................................1729
WARNING...................................................................................................................................................................................1729
SAFETY PRECAUTIONS AND WARNINGS.......................................................................................................................................................1729
DIAGNOSIS AND TESTING.....................................................................................................................................................................1730
DIAGNOSIS AND TESTING - WATER LEAKS...................................................................................................................................................1730
VISUAL INSPECTION BEFORE WATER LEAK TESTS.........................................................................................................................................1730
WATER LEAK TESTS..................................................................................................................................................................1730
WATER LEAK DETECTION..............................................................................................................................................................1730
DIAGNOSIS AND TESTING - WIND NOISE....................................................................................................................................................1731
VISUAL INSPECTION BEFORE TESTS....................................................................................................................................................1731
STANDARD PROCEDURE........................................................................................................................................................................1731
STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR........................................................................................................................................1731
Rigid Plastics:...................................................................................................................................................................1731
Semi-Rigid Plastics:..............................................................................................................................................................1731
Flexible Plastics:................................................................................................................................................................1731
Repair Procedure:.................................................................................................................................................................1731
Adhesion Promoter/Surface Modifier:...............................................................................................................................................1731
SAFETY PRECAUTION AND WARNINGS....................................................................................................................................................1731
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES...............................................................................................................................1732
PANEL SECTIONING..................................................................................................................................................................1734
PANEL REINFORCEMENT...............................................................................................................................................................1734
VISUAL INSPECTION.................................................................................................................................................................1735
PANEL SURFACE PREPARATION.........................................................................................................................................................1735
PATCHING PANELS...................................................................................................................................................................1735
PANEL PATCH FABRICATIONS..........................................................................................................................................................1736
PANEL PATCH INSTALLATION..........................................................................................................................................................1736
PATCHED PANEL SURFACING...........................................................................................................................................................1737
STANDARD PROCEDURE - HEAT STAKING.....................................................................................................................................................1738
SPECIFICATIONS............................................................................................................................................................................1738
BODY LUBRICATION......................................................................................................................................................................1738
LUBRICATION REQUIREMENTS..........................................................................................................................................................1738
LUBRICANT APPLICATION.............................................................................................................................................................1738
LUBRICANT USAGE...................................................................................................................................................................1739
SPECIFICATIONS - TORQUE...............................................................................................................................................................1739
SPECIAL TOOLS.............................................................................................................................................................................1740
BODY..................................................................................................................................................................................1740
LIFTGATE..........................................................................................................................................................................................1741
LIFTGATE CHMSL ACCESS PANEL...................................................................................................................................................................1741
REMOVAL...................................................................................................................................................................................1741
INSTALLATION..............................................................................................................................................................................1741
LIFTGATE OUTSIDE HANDLE.......................................................................................................................................................................1741
REMOVAL...................................................................................................................................................................................1741
INSTALLATION..............................................................................................................................................................................1741
LIFTGATE HINGE................................................................................................................................................................................1742
REMOVAL...................................................................................................................................................................................1742
INSTALLATION..............................................................................................................................................................................1742
LIFTGATE LATCH................................................................................................................................................................................1743
REMOVAL...................................................................................................................................................................................1743
INSTALLATION..............................................................................................................................................................................1743
LIFTGATE INNER CONTROL ASSEMBLY PANEL.........................................................................................................................................................1743
REMOVAL...................................................................................................................................................................................1743
INSTALLATION..............................................................................................................................................................................1743
LATCH STRIKER.................................................................................................................................................................................1743
REMOVAL...................................................................................................................................................................................1743
INSTALLATION..............................................................................................................................................................................1743
LIFTGATE......................................................................................................................................................................................1744
REMOVAL...................................................................................................................................................................................1744
INSTALLATION..............................................................................................................................................................................1744
LIFTGATE LOCK CYLINDER........................................................................................................................................................................1745
REMOVAL...................................................................................................................................................................................1745
INSTALLATION..............................................................................................................................................................................1745
LIFTGATE SUPPORT ROD..........................................................................................................................................................................1745
REMOVAL...................................................................................................................................................................................1745
INSTALLATION..............................................................................................................................................................................1745
LIFTGATE TRIM PANEL...........................................................................................................................................................................1746
REMOVAL...................................................................................................................................................................................1746
INSTALLATION..............................................................................................................................................................................1746
DOOR - FRONT......................................................................................................................................................................................1747
FRONT DOOR APPLIQUE...........................................................................................................................................................................1747
REMOVAL...................................................................................................................................................................................1747
INSTALLATION..............................................................................................................................................................................1747
FRONT DOOR CHECK STRAP........................................................................................................................................................................1748
REMOVAL...................................................................................................................................................................................1748
INSTALLATION..............................................................................................................................................................................1748
FRONT DOOR....................................................................................................................................................................................1748
REMOVAL...................................................................................................................................................................................1748
INSTALLATION..............................................................................................................................................................................1748
FRONT DOOR GLASS..............................................................................................................................................................................1749
REMOVAL...................................................................................................................................................................................1749
INSTALLATION..............................................................................................................................................................................1749
FRONT DOOR OUTSIDE HANDLE.....................................................................................................................................................................1749
REMOVAL...................................................................................................................................................................................1749
INSTALLATION..............................................................................................................................................................................1749
FRONT DOOR HINGE..............................................................................................................................................................................1750
REMOVAL...................................................................................................................................................................................1750
INSTALLATION..............................................................................................................................................................................1750
FRONT DOOR INSIDE HANDLE ACTUATOR.............................................................................................................................................................1750
REMOVAL...................................................................................................................................................................................1750
INSTALLATION..............................................................................................................................................................................1751
FRONT DOOR LATCH..............................................................................................................................................................................1751
REMOVAL...................................................................................................................................................................................1751
INSTALLATION..............................................................................................................................................................................1751
ADJUSTMENTS...............................................................................................................................................................................1752
FRONT DOOR LATCH ADJUSTMENT...........................................................................................................................................................1752
FRONT DOOR LATCH STRIKER......................................................................................................................................................................1752
REMOVAL...................................................................................................................................................................................1752
INSTALLATION..............................................................................................................................................................................1752
FRONT DOOR LOCK CYLINDER......................................................................................................................................................................1753
REMOVAL...................................................................................................................................................................................1753
INSTALLATION..............................................................................................................................................................................1753
FRONT DOOR VERTICAL GUIDE BAR.................................................................................................................................................................1753
REMOVAL...................................................................................................................................................................................1753
INSTALLATION..............................................................................................................................................................................1753
SIDE VIEW MIRROR TRIM BEZEL...................................................................................................................................................................1753
REMOVAL...................................................................................................................................................................................1753
INSTALLATION..............................................................................................................................................................................1753
FRONT DOOR TRIM PANEL.........................................................................................................................................................................1753
REMOVAL...................................................................................................................................................................................1753
INSTALLATION..............................................................................................................................................................................1753
FRONT DOOR WATER DAM..........................................................................................................................................................................1754
REMOVAL...................................................................................................................................................................................1754
INSTALLATION..............................................................................................................................................................................1755
FRONT DOOR WINDOW REGULATOR...................................................................................................................................................................1755
REMOVAL...................................................................................................................................................................................1755
INSTALLATION..............................................................................................................................................................................1755
DOORS-REAR........................................................................................................................................................................................1756
REAR DOOR APPLIQUE............................................................................................................................................................................1756
REMOVAL...................................................................................................................................................................................1756
INSTALLATION..............................................................................................................................................................................1757
REAR DOOR CHECK STRAP.........................................................................................................................................................................1757
REMOVAL...................................................................................................................................................................................1757
INSTALLATION..............................................................................................................................................................................1757
REAR DOOR.....................................................................................................................................................................................1758
REMOVAL...................................................................................................................................................................................1758
INSTALLATION..............................................................................................................................................................................1758
REAR DOOR GLASS...............................................................................................................................................................................1758
REMOVAL0 - 10 PT (Continued)..........................................................................................................................................................1758
INSTALLATION..............................................................................................................................................................................1758
REAR DOOR OUTSIDE HANDLE......................................................................................................................................................................1759
REMOVAL...................................................................................................................................................................................1759
INSTALLATION..............................................................................................................................................................................1759
REAR DOOR HINGE...............................................................................................................................................................................1759
REMOVAL...................................................................................................................................................................................1759
INSTALLATION..............................................................................................................................................................................1759
REAR DOOR LATCH...............................................................................................................................................................................1760
REMOVAL...................................................................................................................................................................................1760
INSTALLATION..............................................................................................................................................................................1760
ADJUSTMENTS...............................................................................................................................................................................1760
REAR DOOR LATCH ADJUSTMENT............................................................................................................................................................1760
REAR DOOR LATCH STRIKER.......................................................................................................................................................................1760
REMOVAL...................................................................................................................................................................................1760
INSTALLATION..............................................................................................................................................................................1760
REAR DOOR TRIM PANEL..........................................................................................................................................................................1760
REMOVAL...................................................................................................................................................................................1760
INSTALLATION..............................................................................................................................................................................1761
REAR DOOR WATER DAM...........................................................................................................................................................................1761
REMOVAL...................................................................................................................................................................................1761
INSTALLATION..............................................................................................................................................................................1761
REAR DOOR WINDOW REGULATOR....................................................................................................................................................................1762
REMOVAL...................................................................................................................................................................................1762
INSTALLATION..............................................................................................................................................................................1762
EXTERIOR..........................................................................................................................................................................................1763
COWL GRILLE SCREEN............................................................................................................................................................................1763
REMOVAL...................................................................................................................................................................................1763
INSTALLATION..............................................................................................................................................................................1763
EXTERIOR NAME PLATES..........................................................................................................................................................................1763
REMOVAL...................................................................................................................................................................................1763
REMOVAL - EXTERIOR BADGING............................................................................................................................................................1763
REMOVAL - BADGING/TAPE................................................................................................................................................................1764
INSTALLATION..............................................................................................................................................................................1764
INSTALLATION - EXTERIOR BADGING.......................................................................................................................................................1764
INSTALLATION - BADGING/TAPE...........................................................................................................................................................1764
FRONT WHEELHOUSE SPLASH SHIELDS...............................................................................................................................................................1764
REMOVAL...................................................................................................................................................................................1764
INSTALLATION..............................................................................................................................................................................1764
FRONT FENDER..................................................................................................................................................................................1765
REMOVAL...................................................................................................................................................................................1765
INSTALLATION..............................................................................................................................................................................1765
FUEL FILL DOOR................................................................................................................................................................................1765
REMOVAL...................................................................................................................................................................................1765
INSTALLATION..............................................................................................................................................................................1765
GRILLE........................................................................................................................................................................................1766
REMOVAL...................................................................................................................................................................................1766
INSTALLATION..............................................................................................................................................................................1766
FRONT SIDE RAIL ACCESS PULLEY SPLASH SHIELD...................................................................................................................................................1766
REMOVAL...................................................................................................................................................................................1766
INSTALLATION..............................................................................................................................................................................1766
LUGGAGE RACK CROSSBAR.........................................................................................................................................................................1767
REMOVAL...................................................................................................................................................................................1767
INSTALLATION..............................................................................................................................................................................1767
LUGGAGE RACK SIDE RAIL........................................................................................................................................................................1767
REMOVAL...................................................................................................................................................................................1767
INSTALLATION..............................................................................................................................................................................1767
RADIATOR CLOSURE PANEL........................................................................................................................................................................1767
REMOVAL...................................................................................................................................................................................1767
INSTALLATION..............................................................................................................................................................................1768
SIDE VIEW MIRROR..............................................................................................................................................................................1768
REMOVAL...................................................................................................................................................................................1768
INSTALLATION..............................................................................................................................................................................1768
SIDE VIEW MIRROR GLASS........................................................................................................................................................................1769
REMOVAL...................................................................................................................................................................................1769
INSTALLATION..............................................................................................................................................................................1769
BODY SIDE MOLDINGS............................................................................................................................................................................1769
REMOVAL...................................................................................................................................................................................1769
INSTALLATION..............................................................................................................................................................................1769
WOOD GRAIN/FLAME DECALS.......................................................................................................................................................................1769
REMOVAL...................................................................................................................................................................................1769
INSTALLATION..............................................................................................................................................................................1769
Surface Preparation...................................................................................................................................................................1769
Application...........................................................................................................................................................................1769
HOOD..............................................................................................................................................................................................1771
HOOD HINGE....................................................................................................................................................................................1771
REMOVAL...................................................................................................................................................................................1771
INSTALLATION..............................................................................................................................................................................1771
HOOD..........................................................................................................................................................................................1771
REMOVAL...................................................................................................................................................................................1771
INSTALLATION..............................................................................................................................................................................1771
HOOD LATCH....................................................................................................................................................................................1772
REMOVAL...................................................................................................................................................................................1772
INSTALLATION..............................................................................................................................................................................1772
HOOD LATCH RELEASE CABLE......................................................................................................................................................................1772
REMOVAL...................................................................................................................................................................................1772
INSTALLATION..............................................................................................................................................................................1773
HOOD LATCH STRIKER............................................................................................................................................................................1773
REMOVAL...................................................................................................................................................................................1773
INSTALLATION..............................................................................................................................................................................1773
SILENCER PAD..................................................................................................................................................................................1773
REMOVAL...................................................................................................................................................................................1773
INSTALLATION..............................................................................................................................................................................1773
INSTRUMENT PANEL..................................................................................................................................................................................1774
ACCESSORY SWITCH BEZEL........................................................................................................................................................................1774
REMOVAL...................................................................................................................................................................................1774
INSTALLATION..............................................................................................................................................................................1774
CLUSTER BEZEL.................................................................................................................................................................................1774
REMOVAL...................................................................................................................................................................................1774
INSTALLATION..............................................................................................................................................................................1776
GLOVE BOX.....................................................................................................................................................................................1776
REMOVAL...................................................................................................................................................................................1776
INSTALLATION..............................................................................................................................................................................1776
GLOVE BOX LATCH...............................................................................................................................................................................1777
REMOVAL...................................................................................................................................................................................1777
INSTALLATION..............................................................................................................................................................................1777
GLOVE BOX LOCK CYLINDER.......................................................................................................................................................................1777
REMOVAL...................................................................................................................................................................................1777
INSTALLATION..............................................................................................................................................................................1778
INSTRUMENT PANEL ASSEMBLY.....................................................................................................................................................................1778
REMOVAL...................................................................................................................................................................................1778
INSTALLATION..............................................................................................................................................................................1781
INSTRUMENT PANEL CENTER BEZEL.................................................................................................................................................................1784
REMOVAL...................................................................................................................................................................................1784
INSTALLATION..............................................................................................................................................................................1784
INSTRUMENT PANEL CENTER BEZEL CONTROL KNOBS...................................................................................................................................................1784
REMOVAL...................................................................................................................................................................................1784
INSTALLATION..............................................................................................................................................................................1785
INSTRUMENT PANEL END CAP......................................................................................................................................................................1785
REMOVAL...................................................................................................................................................................................1785
LEFT END CAP..........................................................................................................................................................................1785
RIGHT END CAP.........................................................................................................................................................................1785
INSTALLATION..............................................................................................................................................................................1785
LEFT END CAP..........................................................................................................................................................................1785
RIGHT END CAP.........................................................................................................................................................................1785
INSTRUMENT PANEL TOP COVER....................................................................................................................................................................1785
REMOVAL...................................................................................................................................................................................1785
INSTALLATION..............................................................................................................................................................................1786
STEERING COLUMN OPENING COVER.................................................................................................................................................................1787
REMOVAL...................................................................................................................................................................................1787
INSTALLATION..............................................................................................................................................................................1787
INTERIOR..........................................................................................................................................................................................1788
A-PILLAR TRIM.................................................................................................................................................................................1788
REMOVAL...................................................................................................................................................................................1788
INSTALLATION..............................................................................................................................................................................1788
B-PILLAR TRIM.................................................................................................................................................................................1788
REMOVAL...................................................................................................................................................................................1788
INSTALLATION..............................................................................................................................................................................1788
BODY VENT.....................................................................................................................................................................................1789
REMOVAL...................................................................................................................................................................................1789
INSTALLATION..............................................................................................................................................................................1789
FLOOR CARPET..................................................................................................................................................................................1789
REMOVAL...................................................................................................................................................................................1789
INSTALLATION..............................................................................................................................................................................1789
SIDE COWL TRIM PANEL..........................................................................................................................................................................1790
REMOVAL...................................................................................................................................................................................1790
INSTALLATION..............................................................................................................................................................................1790
UPPER C-PILLAR TRIM...........................................................................................................................................................................1791
REMOVAL...................................................................................................................................................................................1791
INSTALLATION..............................................................................................................................................................................1791
DOOR SILL TRIM................................................................................................................................................................................1791
REMOVAL...................................................................................................................................................................................1791
INSTALLATION..............................................................................................................................................................................1791
UPPER D-PILLAR TRIM...........................................................................................................................................................................1791
REMOVAL...................................................................................................................................................................................1791
INSTALLATION..............................................................................................................................................................................1791
HEADLINER.....................................................................................................................................................................................1791
REMOVAL...................................................................................................................................................................................1791
INSTALLATION..............................................................................................................................................................................1792
LOWER QUARTER TRIM PANEL......................................................................................................................................................................1792
REMOVAL...................................................................................................................................................................................1792
INSTALLATION..............................................................................................................................................................................1792
INSIDE REAR VIEW MIRROR.......................................................................................................................................................................1793
REMOVAL...................................................................................................................................................................................1793
INSTALLATION..............................................................................................................................................................................1793
SUN VISOR.....................................................................................................................................................................................1793
REMOVAL...................................................................................................................................................................................1793
INSTALLATION..............................................................................................................................................................................1793
PAINT.............................................................................................................................................................................................1794
PAINT.........................................................................................................................................................................................1794
SPECIFICATIONS - COLOR CODES..............................................................................................................................................................1794
BASECOAT/CLEARCOAT FINISH.....................................................................................................................................................................1794
DESCRIPTION...............................................................................................................................................................................1794
PAINT CODE....................................................................................................................................................................................1794
DESCRIPTION...............................................................................................................................................................................1794
PAINT TOUCH-UP................................................................................................................................................................................1795
DESCRIPTION...............................................................................................................................................................................1795
TOUCH UP PROCEDURE....................................................................................................................................................................1795
FINESSE SANDING/BUFFING & POLISHING...........................................................................................................................................................1795
DESCRIPTION...............................................................................................................................................................................1795
SEATS.............................................................................................................................................................................................1796
FRONT SEAT....................................................................................................................................................................................1796
REMOVAL...................................................................................................................................................................................1796
INSTALLATION..............................................................................................................................................................................1796
FRONT SEAT BACK...............................................................................................................................................................................1797
REMOVAL...................................................................................................................................................................................1797
INSTALLATION..............................................................................................................................................................................1797
FRONT SEAT BACK COVER.........................................................................................................................................................................1797
REMOVAL...................................................................................................................................................................................1797
INSTALLATION..............................................................................................................................................................................1797
FRONT SEAT CUSHION............................................................................................................................................................................1798
REMOVAL...................................................................................................................................................................................1798
INSTALLATION..............................................................................................................................................................................1798
FRONT SEAT CUSHION COVER......................................................................................................................................................................1798
REMOVAL...................................................................................................................................................................................1798
INSTALLATION..............................................................................................................................................................................1798
FRONT SEAT HEAD RESTRAINT.....................................................................................................................................................................1798
REMOVAL...................................................................................................................................................................................1798
INSTALLATION..............................................................................................................................................................................1798
REAR SEAT.....................................................................................................................................................................................1798
REMOVAL...................................................................................................................................................................................1798
INSTALLATION..............................................................................................................................................................................1798
REAR SEAT BACK................................................................................................................................................................................1799
REMOVAL...................................................................................................................................................................................1799
INSTALLATION..............................................................................................................................................................................1799
REAR SEAT BACK COVER..........................................................................................................................................................................1799
REMOVAL...................................................................................................................................................................................1799
INSTALLATION..............................................................................................................................................................................1799
REAR SEAT CUSHION.............................................................................................................................................................................1799
REMOVAL...................................................................................................................................................................................1799
INSTALLATION..............................................................................................................................................................................1799
REAR SEAT BACK CUSHION / COVER................................................................................................................................................................1799
REMOVAL...................................................................................................................................................................................1799
INSTALLATION..............................................................................................................................................................................1800
UNDER SEAT STORAGE BIN........................................................................................................................................................................1800
REMOVAL...................................................................................................................................................................................1800
INSTALLATION..............................................................................................................................................................................1800
REAR SEAT PIVOT BEZEL.........................................................................................................................................................................1800
REMOVAL...................................................................................................................................................................................1800
INSTALLATION..............................................................................................................................................................................1800
CHILD SEAT TETHER ANCHOR BEZEL................................................................................................................................................................1801
REMOVAL...................................................................................................................................................................................1801
INSTALLATION..............................................................................................................................................................................1801
STATIONARY GLASS..................................................................................................................................................................................1802
BACKLITE......................................................................................................................................................................................1802
REMOVAL...................................................................................................................................................................................1802
INSTALLATION..............................................................................................................................................................................1802
QUARTER WINDOW................................................................................................................................................................................1804
REMOVAL...................................................................................................................................................................................1804
INSTALLATION..............................................................................................................................................................................1804
WINDSHIELD....................................................................................................................................................................................1805
DESCRIPTION...............................................................................................................................................................................1805
RECOMMENDED TOOLS AND ADHESIVE........................................................................................................................................................1806
ADHESIVE, PRIMER AND CLEANER..........................................................................................................................................................1806
RECOMMENDED TOOLS AND ADHESIVE........................................................................................................................................................1806
WARNING...................................................................................................................................................................................1806
WINDSHIELD SAFETY PRECAUTIONS.........................................................................................................................................................1806
REMOVAL...................................................................................................................................................................................1806
REMOVAL - EXTERIOR METHOD.............................................................................................................................................................1806
REMOVAL - INTERIOR METHOD.............................................................................................................................................................1806
INSTALLATION..............................................................................................................................................................................1807
SUNROOF...........................................................................................................................................................................................1809
SUNROOF.......................................................................................................................................................................................1809
DESCRIPTION...............................................................................................................................................................................1809
DIAGNOSIS AND TESTING - SUNROOF...........................................................................................................................................................1809
WATER DRAINAGE AND WIND NOISE DIAGNOSIS...............................................................................................................................................1811
SUNROOF MODULE ASSEMBLY.......................................................................................................................................................................1811
REMOVAL...................................................................................................................................................................................1811
INSTALLATION..............................................................................................................................................................................1811
ELECTRONIC CONTROL MODULE.....................................................................................................................................................................1812
REMOVAL...................................................................................................................................................................................1812
INSTALLATION..............................................................................................................................................................................1812
SUNROOF DRIVE MOTOR...........................................................................................................................................................................1812
REMOVAL...................................................................................................................................................................................1812
INSTALLATION..............................................................................................................................................................................1813
SUNROOF CONTROL SWITCH........................................................................................................................................................................1813
REMOVAL...................................................................................................................................................................................1813
INSTALLATION..............................................................................................................................................................................1813
WIND DEFLECTOR................................................................................................................................................................................1813
REMOVAL...................................................................................................................................................................................1813
INSTALLATION..............................................................................................................................................................................1813
GLASS PANEL...................................................................................................................................................................................1814
REMOVAL...................................................................................................................................................................................1814
INSTALLATION..............................................................................................................................................................................1814
ADJUSTMENTS...............................................................................................................................................................................1814
SUNROOF GLASS PANEL ADJUSTMENT........................................................................................................................................................1814
SUNROOF SUNSHADE..............................................................................................................................................................................1814
REMOVAL...................................................................................................................................................................................1814
INSTALLATION..............................................................................................................................................................................1815
SUNROOF GLASS PANEL SEAL......................................................................................................................................................................1815
REMOVAL...................................................................................................................................................................................1815
INSTALLATION..............................................................................................................................................................................1815
OPENING TRIM LACE.............................................................................................................................................................................1815
REMOVAL...................................................................................................................................................................................1815
INSTALLATION..............................................................................................................................................................................1815
SUNROOF TROUGH GUIDE ASSEMBLY.................................................................................................................................................................1815
REMOVAL...................................................................................................................................................................................1815
INSTALLATION..............................................................................................................................................................................1816
DRAIN TUBE....................................................................................................................................................................................1816
REMOVAL...................................................................................................................................................................................1816
FRONT HOSES...........................................................................................................................................................................1816
REAR HOUSING HOSE.....................................................................................................................................................................1816
INSTALLATION..............................................................................................................................................................................1816
FRONT HOSES...........................................................................................................................................................................1816
REAR HOUSING HOSE.....................................................................................................................................................................1817
WEATHERSTRIP/SEALS................................................................................................................................................................................1818
FRONT AND REAR DOOR OPENING WEATHERSTRIP......................................................................................................................................................1818
REMOVAL...................................................................................................................................................................................1818
INSTALLATION..............................................................................................................................................................................1818
FRONT AND REAR DOOR UPPER SECONDARY WEATHERSTRIP..............................................................................................................................................1818
REMOVAL...................................................................................................................................................................................1818
INSTALLATION..............................................................................................................................................................................1818
FRONT DOOR GLASS RUN WEATHERSTRIP.............................................................................................................................................................1818
REMOVAL...................................................................................................................................................................................1818
INSTALLATION..............................................................................................................................................................................1818
FRONT DOOR INNER BELT WEATHERSTRIP............................................................................................................................................................1820
REMOVAL...................................................................................................................................................................................1820
INSTALLATION..............................................................................................................................................................................1820
FRONT DOOR OUTER BELT WEATHERSTRIP............................................................................................................................................................1820
REMOVAL...................................................................................................................................................................................1820
INSTALLATION..............................................................................................................................................................................1820
LIFTGATE WEATHERSTRIP.........................................................................................................................................................................1820
REMOVAL...................................................................................................................................................................................1820
INSTALLATION..............................................................................................................................................................................1820
REAR DOOR GLASS RUN WEATHERSTRIP..............................................................................................................................................................1820
REMOVAL...................................................................................................................................................................................1820
INSTALLATION..............................................................................................................................................................................1821
REAR DOOR INNER BELT WEATHERSTRIP.............................................................................................................................................................1821
REMOVAL...................................................................................................................................................................................1821
INSTALLATION..............................................................................................................................................................................1821
SILL SECONDARY WEATHERSTRIP...................................................................................................................................................................1821
REMOVAL...................................................................................................................................................................................1821
INSTALLATION..............................................................................................................................................................................1821
BODY STRUCTURE....................................................................................................................................................................................1823
GAP AND FLUSH.................................................................................................................................................................................1823
SPECIFICATIONS - BODY GAP AND FLUSH MEASUREMENTS..........................................................................................................................................1823
OPENING DIMENSIONS............................................................................................................................................................................1825
SPECIFICATIONS - BODY OPENING DIMENSION...................................................................................................................................................1825
SEALER LOCATIONS..............................................................................................................................................................................1827
SPECIFICATIONS - BODY SEALING LOCATIONS...................................................................................................................................................1827
STRUCTURAL ADHESIVE LOCATIONS.................................................................................................................................................................1842
SPECIFICATIONS - STRUCTURAL ADHESIVES.....................................................................................................................................................1842
WELD LOCATIONS................................................................................................................................................................................1847
SPECIFICATIONS - WELD LOCATIONS...........................................................................................................................................................1847
24-HEATING & AIR CONDITIONING.........................................................................................................................................................................1907
HEATING & AIR COND. - LHD.........................................................................................................................................................................1907
HEATING & AIR COND. - LHD.....................................................................................................................................................................1909
DESCRIPTION...............................................................................................................................................................................1909
ENGINE COOLING SYSTEM REQUIREMENTS....................................................................................................................................................1909
SAFETY PRECAUTIONS AND WARNINGS.......................................................................................................................................................1909
DIAGNOSIS AND TESTING.....................................................................................................................................................................1909
DIAGNOSIS AND TESTING - HEATER PERFORMANCE TEST.......................................................................................................................................1909
PRE-DIAGNOSTIC PREPARATIONS.......................................................................................................................................................1909
MAXIMUM HEATER OUTPUT: TEST AND ACTION............................................................................................................................................1909
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW............................................................................................................................1910
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT...................................................................................................................................1910
TEMPERATURE CONTROL...............................................................................................................................................................1910
DIAGNOSIS AND TESTING - A/C PERFORMANCE TEST..........................................................................................................................................1910
PERFORMANCE TEST PROCEDURE........................................................................................................................................................1910
STANDARD PROCEDURE........................................................................................................................................................................1911
STANDARD PROCEDURE - HANDLING TUBING AND FITTINGS.....................................................................................................................................1911
STANDARD PROCEDURE - SYSTEM CHARGE LEVEL TEST.........................................................................................................................................1911
STANDARD PROCEDURE - CHARGING A/C SYSTEM..............................................................................................................................................1912
PARTIAL CHARGE....................................................................................................................................................................1912
EVACUATION........................................................................................................................................................................1913
CHARGING A/C SYSTEM...............................................................................................................................................................1913
STANDARD PROCEDURE - EVACUATING REFRIGERANT SYSTEM....................................................................................................................................1914
STANDARD PROCEDURE - SYSTEM LEAK CHECKING.............................................................................................................................................1915
EMPTY REFRIGERANT SYSTEM LEAK TEST................................................................................................................................................1915
LOW REFRIGERANT LEVEL LEAK TEST...................................................................................................................................................1915
STANDARD PROCEDURE - REFRIGERANT RECOVERY0 - 12 PT (Continued)....................................................................................................................1915
SPECIFICATIONS............................................................................................................................................................................1916
A/C APPLICATION TABLE.................................................................................................................................................................1916
TORQUE................................................................................................................................................................................1917
A/C COMPRESSOR CLUTCH RELAY...................................................................................................................................................................1917
DESCRIPTION...............................................................................................................................................................................1917
OPERATION.................................................................................................................................................................................1918
REMOVAL...................................................................................................................................................................................1918
INSTALLATION..............................................................................................................................................................................1918
A/C HEATER CONTROL............................................................................................................................................................................1919
DESCRIPTION...............................................................................................................................................................................1919
DIAGNOSIS AND TESTING - VACUUM CONTROL SYSTEM.............................................................................................................................................1919
ONE-WAY CHECK VALVE...................................................................................................................................................................1920
HEATER-A/C CONTROLS...................................................................................................................................................................1920
LOCATING VACUUM LEAKS.................................................................................................................................................................1920
LOCATING PINCHED VACUUM LINES.........................................................................................................................................................1920
REMOVAL...................................................................................................................................................................................1921
INSTALLATION..............................................................................................................................................................................1921
A/C COMPRESSOR CLUTCH COIL....................................................................................................................................................................1922
REMOVAL...................................................................................................................................................................................1922
INSTALLATION..............................................................................................................................................................................1923
CLUTCH BREAK-IN.......................................................................................................................................................................1924
A/C HIGH PRESSURE SWITCH......................................................................................................................................................................1924
DESCRIPTION...............................................................................................................................................................................1924
REMOVAL...................................................................................................................................................................................1924
INSTALLATION..............................................................................................................................................................................1924
A/C LOW PRESSURE SWITCH.......................................................................................................................................................................1925
DESCRIPTION...............................................................................................................................................................................1925
OPERATION.................................................................................................................................................................................1925
DIAGNOSIS AND TESTING - A/C LOW PRESSURE CLUTCH CYCLING SWITCH............................................................................................................................1925
REMOVAL...................................................................................................................................................................................1925
INSTALLATION..............................................................................................................................................................................1925
A/C PRESSURE TRANSDUCER.......................................................................................................................................................................1926
DESCRIPTION...............................................................................................................................................................................1926
OPERATION.................................................................................................................................................................................1926
DIAGNOSIS AND TESTING - A/C PRESSURE TRANSDUCER...........................................................................................................................................1926
REMOVAL...................................................................................................................................................................................1926
INSTALLATION..............................................................................................................................................................................1926
BLOWER MOTOR RESISTOR BLOCK...................................................................................................................................................................1927
DESCRIPTION...............................................................................................................................................................................1927
REMOVAL...................................................................................................................................................................................1927
INSTALLATION..............................................................................................................................................................................1927
MODE DOOR CABLE...............................................................................................................................................................................1928
REMOVAL...................................................................................................................................................................................1928
INSTALLATION..............................................................................................................................................................................1928
ADJUSTMENT............................................................................................................................................................................1928
RECIRCULATION DOOR ACTUATOR...................................................................................................................................................................1929
DESCRIPTION...............................................................................................................................................................................1929
REMOVAL...................................................................................................................................................................................1929
INSTALLATION..............................................................................................................................................................................1930
TEMPERATURE CONTROL CABLES....................................................................................................................................................................1930
REMOVAL...................................................................................................................................................................................1930
INSTALLATION..............................................................................................................................................................................1930
ADJUSTMENTS...........................................................................................................................................................................1931
DISTRIBUTION..................................................................................................................................................................................1931
DESCRIPTION...............................................................................................................................................................................1931
DESCRIPTION - SYSTEM AIRFLOW..........................................................................................................................................................1931
DESCRIPTION - HEATER AND AIR CONDITIONING.............................................................................................................................................1931
AIR FILTER - EXPORT...........................................................................................................................................................................1932
DESCRIPTION...............................................................................................................................................................................1932
REMOVAL...................................................................................................................................................................................1932
INSTALLATION..............................................................................................................................................................................1932
AIR FLOW DISTRIBUTION.........................................................................................................................................................................1932
DESCRIPTION...............................................................................................................................................................................1932
OPERATION.................................................................................................................................................................................1933
AIR OUTLETS...................................................................................................................................................................................1933
DESCRIPTION...............................................................................................................................................................................1933
REMOVAL - CENTER AIR OUTLET DUCT..........................................................................................................................................................1933
INSTALLATION - CENTER AIR OUTLET DUCT.....................................................................................................................................................1933
BLOWER MOTOR..................................................................................................................................................................................1934
DESCRIPTION - BLOWER MOTOR WHEEL..........................................................................................................................................................1934
OPERATION.................................................................................................................................................................................1934
DIAGNOSIS AND TESTING - BLOWER MOTOR......................................................................................................................................................1934
REMOVAL...................................................................................................................................................................................1934
WITH AIR CONDITIONING.................................................................................................................................................................1936
WITHOUT AIR CONDITIONING..............................................................................................................................................................1936
INSTALLATION..............................................................................................................................................................................1936
WITH AIR CONDITIONING.................................................................................................................................................................1936
WITHOUT AIR CONDITIONING..............................................................................................................................................................1936
HVAC HOUSING..................................................................................................................................................................................1936
REMOVAL...................................................................................................................................................................................1936
DISASSEMBLY...............................................................................................................................................................................1937
ASSEMBLY..................................................................................................................................................................................1938
INSTALLATION..............................................................................................................................................................................1938
A/C COMPRESSOR................................................................................................................................................................................1939
DESCRIPTION...............................................................................................................................................................................1939
DESCRIPTION...........................................................................................................................................................................1939
DESCRIPTION - COMPRESSOR FRONT SHAFT SEAL.............................................................................................................................................1939
OPERATION.................................................................................................................................................................................1939
DIAGNOSIS AND TESTING - COMPRESSOR NOISE..................................................................................................................................................1939
REMOVAL...................................................................................................................................................................................1940
INSTALLATION..............................................................................................................................................................................1941
A/C CONDENSER.................................................................................................................................................................................1942
DESCRIPTION...............................................................................................................................................................................1942
OPERATION.................................................................................................................................................................................1942
REMOVAL...................................................................................................................................................................................1942
INSTALLATION..............................................................................................................................................................................1943
A/C DISCHARGE LINE............................................................................................................................................................................1943
DESCRIPTION - DISCHARGE LINE..............................................................................................................................................................1943
REMOVAL...................................................................................................................................................................................1943
INSTALLATION..............................................................................................................................................................................1943
A/C EVAPORATOR................................................................................................................................................................................1944
DESCRIPTION...............................................................................................................................................................................1944
OPERATION.................................................................................................................................................................................1944
REMOVAL...................................................................................................................................................................................1944
INSTALLATION..............................................................................................................................................................................1945
A/C HIGH PRESSURE RELIEF VALVE................................................................................................................................................................1946
REMOVAL - HIGH PRESSURE RELIEF VALVE......................................................................................................................................................1946
INSTALLATION - HIGH PRESSURE RELIEF VALVE.................................................................................................................................................1946
A/C VARIABLE ORIFICE TUBE.....................................................................................................................................................................1946
DESCRIPTION...............................................................................................................................................................................1946
REMOVAL - INSTALLATION....................................................................................................................................................................1946
ACCUMULATOR...................................................................................................................................................................................1947
DESCRIPTION...............................................................................................................................................................................1947
OPERATION.................................................................................................................................................................................1947
REMOVAL...................................................................................................................................................................................1947
INSTALLATION..............................................................................................................................................................................1947
CONDENSATION DRAIN TUBE.......................................................................................................................................................................1948
DESCRIPTION...............................................................................................................................................................................1948
REMOVAL...................................................................................................................................................................................1948
INSTALLATION..............................................................................................................................................................................1949
HEATER CORE...................................................................................................................................................................................1949
DESCRIPTION...............................................................................................................................................................................1949
OPERATION.................................................................................................................................................................................1949
REMOVAL...................................................................................................................................................................................1949
INSTALLATION..............................................................................................................................................................................1950
HEATER INLET HOSE.............................................................................................................................................................................1950
REMOVAL...................................................................................................................................................................................1950
INSTALLATION..............................................................................................................................................................................1950
HEATER RETURN HOSE............................................................................................................................................................................1951
REMOVAL...................................................................................................................................................................................1951
INSTALLATION..............................................................................................................................................................................1951
LIQUID LINE...................................................................................................................................................................................1952
DESCRIPTION...............................................................................................................................................................................1952
REMOVAL...................................................................................................................................................................................1952
INSTALLATION..............................................................................................................................................................................1953
REFRIGERANT...................................................................................................................................................................................1953
DESCRIPTION...............................................................................................................................................................................1953
OPERATION.................................................................................................................................................................................1953
STANDARD PROCEDURE - REFRIGERANT..........................................................................................................................................................1953
REFRIGERANT OIL...............................................................................................................................................................................1954
DESCRIPTION...............................................................................................................................................................................1954
OPERATION.................................................................................................................................................................................1954
STANDARD PROCEDURE........................................................................................................................................................................1955
STANDARD PROCEDURE - SERVICING REFRIGERANT OIL LEVEL..................................................................................................................................1955
STANDARD PROCEDURE - REFRIGERANT OIL LEVEL CHECK......................................................................................................................................1955
SUCTION LINE..................................................................................................................................................................................1956
DESCRIPTION...............................................................................................................................................................................1956
OPERATION.................................................................................................................................................................................1957
REMOVAL...................................................................................................................................................................................1957
INSTALLATION..............................................................................................................................................................................1958
SUCTION AND LIQUID LINE ASSEMBLY..............................................................................................................................................................1959
REMOVAL...................................................................................................................................................................................1959
INSTALLATION..............................................................................................................................................................................1959
SERVICE PORT VALVE CORE.......................................................................................................................................................................1960
DESCRIPTION...............................................................................................................................................................................1960
A/C SERVICE PORT VALVE CORES..........................................................................................................................................................1960
REMOVAL– SERVICE PORT VALVE CORES.........................................................................................................................................................1961
INSTALLATION - SERVICE PORT VALVE CORES...................................................................................................................................................1961
A/C VARIABLE ORIFICE TUBE.....................................................................................................................................................................1961
DESCRIPTION...............................................................................................................................................................................1961
REMOVAL - INSTALLATION....................................................................................................................................................................1961
CABIN HEATER..................................................................................................................................................................................1961
DESCRIPTION...............................................................................................................................................................................1961
OPERATION.................................................................................................................................................................................1961
DIAGNOSIS AND TESTING - DIESEL ENGINE CABIN HEATER........................................................................................................................................1962
HEATING & AIR COND. - RHD.........................................................................................................................................................................1963
HEATING & AIR COND. - RHD.....................................................................................................................................................................1965
DESCRIPTION...............................................................................................................................................................................1965
ENGINE COOLING SYSTEM REQUIREMENTS....................................................................................................................................................1965
SAFETY PRECAUTIONS AND WARNINGS.......................................................................................................................................................1965
DIAGNOSIS AND TESTING.....................................................................................................................................................................1965
DIAGNOSIS AND TESTING - HEATER PERFORMANCE TEST.......................................................................................................................................1965
PRE-DIAGNOSTIC PREPARATIONS.......................................................................................................................................................1965
MAXIMUM HEATER OUTPUT: TEST AND ACTION............................................................................................................................................1965
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW............................................................................................................................1966
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT...................................................................................................................................1966
TEMPERATURE CONTROL...............................................................................................................................................................1966
DIAGNOSIS AND TESTING - A/C PERFORMANCE TEST..........................................................................................................................................1966
PERFORMANCE TEST PROCEDURE........................................................................................................................................................1966
STANDARD PROCEDURE........................................................................................................................................................................1967
STANDARD PROCEDURE - HANDLING TUBING AND FITTINGS.....................................................................................................................................1967
STANDARD PROCEDURE - SYSTEM CHARGE LEVEL TEST.........................................................................................................................................1967
STANDARD PROCEDURE - EVACUATING REFRIGERANT SYSTEM....................................................................................................................................1968
STANDARD PROCEDURE - CHARGING A/C SYSTEM..............................................................................................................................................1969
PARTIAL CHARGE....................................................................................................................................................................1969
EVACUATION........................................................................................................................................................................1969
CHARGING A/C SYSTEM...............................................................................................................................................................1970
STANDARD PROCEDURE - SYSTEM LEAK CHECKING.............................................................................................................................................1971
EMPTY REFRIGERANT SYSTEM LEAK TEST................................................................................................................................................1971
LOW REFRIGERANT LEVEL LEAK TEST...................................................................................................................................................1971
STANDARD PROCEDURE - REFRIGERANT RECOVERY.............................................................................................................................................1971
SPECIFICATIONS............................................................................................................................................................................1972
A/C APPLICATION TABLE.................................................................................................................................................................1972
TORQUE................................................................................................................................................................................1973
A/C COMPRESSOR CLUTCH RELAY...................................................................................................................................................................1973
DESCRIPTION...............................................................................................................................................................................1973
OPERATION.................................................................................................................................................................................1974
REMOVAL...................................................................................................................................................................................1974
INSTALLATION..............................................................................................................................................................................1974
A/C HEATER CONTROL............................................................................................................................................................................1975
DESCRIPTION...............................................................................................................................................................................1975
DIAGNOSIS AND TESTING - VACUUM CONTROL SYSTEM.............................................................................................................................................1975
ONE-WAY CHECK VALVE...................................................................................................................................................................1976
HEATER-A/C CONTROLS...................................................................................................................................................................1976
LOCATING VACUUM LEAKS.................................................................................................................................................................1976
LOCATING PINCHED VACUUM LINES.........................................................................................................................................................1976
REMOVAL...................................................................................................................................................................................1977
INSTALLATION..............................................................................................................................................................................1977
A/C COMPRESSOR CLUTCH COIL....................................................................................................................................................................1978
REMOVAL...................................................................................................................................................................................1978
INSTALLATION..............................................................................................................................................................................1979
CLUTCH BREAK-IN.......................................................................................................................................................................1980
A/C HIGH PRESSURE SWITCH......................................................................................................................................................................1980
DESCRIPTION...............................................................................................................................................................................1980
REMOVAL...................................................................................................................................................................................1980
INSTALLATION..............................................................................................................................................................................1980
A/C LOW PRESSURE SWITCH.......................................................................................................................................................................1981
DESCRIPTION...............................................................................................................................................................................1981
OPERATION.................................................................................................................................................................................1981
DIAGNOSIS AND TESTING - A/C LOW PRESSURE CLUTCH CYCLING SWITCH............................................................................................................................1981
REMOVAL...................................................................................................................................................................................1981
INSTALLATION..............................................................................................................................................................................1981
A/C PRESSURE TRANSDUCER.......................................................................................................................................................................1982
DESCRIPTION...............................................................................................................................................................................1982
OPERATION.................................................................................................................................................................................1982
DIAGNOSIS AND TESTING - A/C PRESSURE TRANSDUCER...........................................................................................................................................1982
REMOVAL...................................................................................................................................................................................1982
INSTALLATION..............................................................................................................................................................................1982
BLOWER MOTOR RESISTOR BLOCK...................................................................................................................................................................1982
DESCRIPTION...............................................................................................................................................................................1982
REMOVAL...................................................................................................................................................................................1982
INSTALLATION..............................................................................................................................................................................1983
MODE DOOR CABLE...............................................................................................................................................................................1983
REMOVAL...................................................................................................................................................................................1983
INSTALLATION..............................................................................................................................................................................1984
ADJUSTMENT............................................................................................................................................................................1984
RECIRCULATION DOOR ACTUATOR...................................................................................................................................................................1984
DESCRIPTION...............................................................................................................................................................................1984
REMOVAL...................................................................................................................................................................................1985
INSTALLATION..............................................................................................................................................................................1985
TEMPERATURE CONTROL CABLES....................................................................................................................................................................1985
REMOVAL...................................................................................................................................................................................1985
INSTALLATION..............................................................................................................................................................................1986
ADJUSTMENTS...........................................................................................................................................................................1986
DISTRIBUTION..................................................................................................................................................................................1986
DESCRIPTION...............................................................................................................................................................................1986
DESCRIPTION - SYSTEM AIRFLOW..........................................................................................................................................................1986
DESCRIPTION - HEATER AND AIR CONDITIONING.............................................................................................................................................1987
AIR FILTER - EXPORT...........................................................................................................................................................................1987
DESCRIPTION...............................................................................................................................................................................1987
REMOVAL...................................................................................................................................................................................1987
INSTALLATION..............................................................................................................................................................................1988
AIR FLOW DISTRIBUTION.........................................................................................................................................................................1988
DESCRIPTION...............................................................................................................................................................................1988
OPERATION.................................................................................................................................................................................1988
AIR OUTLETS...................................................................................................................................................................................1989
DESCRIPTION...............................................................................................................................................................................1989
REMOVAL - CENTER AIR OUTLET DUCT..........................................................................................................................................................1989
INSTALLATION - CENTER AIR OUTLET DUCT.....................................................................................................................................................1989
BLOWER MOTOR..................................................................................................................................................................................1989
DESCRIPTION - BLOWER MOTOR WHEEL..........................................................................................................................................................1989
OPERATION.................................................................................................................................................................................1989
DIAGNOSIS AND TESTING - BLOWER MOTOR......................................................................................................................................................1989
REMOVAL...................................................................................................................................................................................1989
WITH AIR CONDITIONING.................................................................................................................................................................1991
WITHOUT AIR CONDITIONING..............................................................................................................................................................1991
INSTALLATION..............................................................................................................................................................................1991
WITH AIR CONDITIONING.................................................................................................................................................................1991
WITHOUT AIR CONDITIONING..............................................................................................................................................................1991
HVAC HOUSING..................................................................................................................................................................................1991
REMOVAL...................................................................................................................................................................................1991
DISASSEMBLY...............................................................................................................................................................................1992
ASSEMBLY..................................................................................................................................................................................1992
INSTALLATION..............................................................................................................................................................................1993
A/C COMPRESSOR................................................................................................................................................................................1994
DESCRIPTION...............................................................................................................................................................................1994
DESCRIPTION...........................................................................................................................................................................1994
DESCRIPTION - COMPRESSOR FRONT SHAFT SEAL.............................................................................................................................................1994
OPERATION.................................................................................................................................................................................1994
DIAGNOSIS AND TESTING - COMPRESSOR NOISE..................................................................................................................................................1994
REMOVAL...................................................................................................................................................................................1994
INSTALLATION..............................................................................................................................................................................1995
A/C CONDENSER.................................................................................................................................................................................1996
DESCRIPTION...............................................................................................................................................................................1996
OPERATION.................................................................................................................................................................................1997
REMOVAL...................................................................................................................................................................................1997
INSTALLATION..............................................................................................................................................................................1997
A/C DISCHARGE LINE............................................................................................................................................................................1998
DESCRIPTION - DISCHARGE LINE..............................................................................................................................................................1998
REMOVAL...................................................................................................................................................................................1998
INSTALLATION..............................................................................................................................................................................1999
A/C EVAPORATOR................................................................................................................................................................................1999
REMOVAL...................................................................................................................................................................................1999
INSTALLATION..............................................................................................................................................................................2000
A/C HIGH PRESSURE RELIEF VALVE................................................................................................................................................................2001
REMOVAL - HIGH PRESSURE RELIEF VALVE......................................................................................................................................................2001
INSTALLATION - HIGH PRESSURE RELIEF VALVE.................................................................................................................................................2001
ACCUMULATOR...................................................................................................................................................................................2001
DESCRIPTION...............................................................................................................................................................................2001
OPERATION.................................................................................................................................................................................2001
REMOVAL...................................................................................................................................................................................2001
INSTALLATION..............................................................................................................................................................................2002
CONDENSATION DRAIN TUBE.......................................................................................................................................................................2003
DESCRIPTION...............................................................................................................................................................................2003
REMOVAL...................................................................................................................................................................................2003
INSTALLATION..............................................................................................................................................................................2003
HEATER CORE - EXPORT..........................................................................................................................................................................2003
DESCRIPTION...............................................................................................................................................................................2003
OPERATION.................................................................................................................................................................................2004
REMOVAL...................................................................................................................................................................................2004
INSTALLATION..............................................................................................................................................................................2005
HEATER INLET HOSE.............................................................................................................................................................................2006
REMOVAL...................................................................................................................................................................................2006
INSTALLATION..............................................................................................................................................................................2006
HEATER RETURN HOSE............................................................................................................................................................................2007
REMOVAL...................................................................................................................................................................................2007
INSTALLATION..............................................................................................................................................................................2007
LIQUID LINE...................................................................................................................................................................................2008
DESCRIPTION...............................................................................................................................................................................2008
REMOVAL...................................................................................................................................................................................2008
INSTALLATION..............................................................................................................................................................................2008
REFRIGERANT...................................................................................................................................................................................2009
DESCRIPTION...............................................................................................................................................................................2009
OPERATION.................................................................................................................................................................................2009
STANDARD PROCEDURE - REFRIGERANT..........................................................................................................................................................2009
REFRIGERANT OIL...............................................................................................................................................................................2010
DESCRIPTION...............................................................................................................................................................................2010
OPERATION.................................................................................................................................................................................2010
STANDARD PROCEDURE........................................................................................................................................................................2010
STANDARD PROCEDURE - SERVICING REFRIGERANT OIL LEVEL..................................................................................................................................2010
STANDARD PROCEDURE - REFRIGERANT OIL LEVEL CHECK......................................................................................................................................2010
SUCTION LINE..................................................................................................................................................................................2011
DESCRIPTION...............................................................................................................................................................................2011
OPERATION.................................................................................................................................................................................2012
REMOVAL...................................................................................................................................................................................2013
INSTALLATION..............................................................................................................................................................................2014
SUCTION AND LIQUID LINE ASSEMBLY..............................................................................................................................................................2015
REMOVAL...................................................................................................................................................................................2015
INSTALLATION..............................................................................................................................................................................2015
SERVICE PORT VALVE CORE0 - 14 PT (Continued)..............................................................................................................................................2016
DESCRIPTION...............................................................................................................................................................................2016
A/C SERVICE PORT VALVE CORES..........................................................................................................................................................2016
REMOVAL– SERVICE PORT VALVE CORES.........................................................................................................................................................2017
INSTALLATION - SERVICE PORT VALVE CORES...................................................................................................................................................2017
A/C VARIABLE ORIFICE TUBE.....................................................................................................................................................................2017
DESCRIPTION...............................................................................................................................................................................2017
REMOVAL - INSTALLATION....................................................................................................................................................................2017
CABIN HEATER..................................................................................................................................................................................2017
DESCRIPTION...............................................................................................................................................................................2017
OPERATION.................................................................................................................................................................................2017
DIAGNOSIS AND TESTING - DIESEL ENGINE CABIN HEATER........................................................................................................................................2017
HEATER UNIT...................................................................................................................................................................................2018
REMOVAL...................................................................................................................................................................................2018
INSTALLATION..............................................................................................................................................................................2018
25-EMISSIONS CONTROL..................................................................................................................................................................................2019
EMISSIONS CONTROL.................................................................................................................................................................................2019
EMISSIONS CONTROL.............................................................................................................................................................................2019
DESCRIPTION...............................................................................................................................................................................2019
DESCRIPTION - MONITORED COMPONENT.....................................................................................................................................................2019
DESCRIPTION - VEHICLE EMISSION CONTROL INFORMATION LABEL..............................................................................................................................2023
DESCRIPTION - TRIP DEFINITION.........................................................................................................................................................2023
OPERATION - NON-MONITORED CIRCUITS....................................................................................................................................................2023
DESCRIPTION - MONITORED SYSTEMS.......................................................................................................................................................2024
DESCRIPTION - HIGH AND LOW LIMITS.....................................................................................................................................................2027
OPERATION.................................................................................................................................................................................2027
OPERATION - SYSTEM....................................................................................................................................................................2027
DRB III STATE DISPLAY TEST MODE.......................................................................................................................................................2028
OPERATION.........................................................................................................................................................................2028
EVAPORATIVE EMISSIONS.............................................................................................................................................................................2029
EVAPORATIVE EMISSIONS.........................................................................................................................................................................2029
OPERATION - EVAPORATION CONTROL SYSTEM....................................................................................................................................................2029
EVAP/PURGE SOLENOID...........................................................................................................................................................................2031
DESCRIPTION...............................................................................................................................................................................2031
OPERATION.................................................................................................................................................................................2031
REMOVAL...................................................................................................................................................................................2031
REMOVAL...............................................................................................................................................................................2031
REMOVAL - 2.4L TURBO..................................................................................................................................................................2031
INSTALLATION..............................................................................................................................................................................2032
INSTALLATION..........................................................................................................................................................................2032
INSTALLATION - 2.4L TURBO.............................................................................................................................................................2032
FUEL FILLER CAP...............................................................................................................................................................................2032
DESCRIPTION...............................................................................................................................................................................2032
OPERATION.................................................................................................................................................................................2032
NATURAL VAC LEAK DETECTION ASSY...............................................................................................................................................................2032
REMOVAL...................................................................................................................................................................................2032
INSTALLATION..............................................................................................................................................................................2033
ORVR..........................................................................................................................................................................................2033
DESCRIPTION...............................................................................................................................................................................2033
OPERATION.................................................................................................................................................................................2033
DIAGNOSIS AND TESTING - VEHICLE DOES NOT FILL.............................................................................................................................................2035
PCV VALVE.....................................................................................................................................................................................2036
DESCRIPTION...............................................................................................................................................................................2036
OPERATION.................................................................................................................................................................................2036
DIAGNOSIS AND TESTING - PCV SYSTEM........................................................................................................................................................2036
REMOVAL - 1.6L............................................................................................................................................................................2037
INSTALLATION - 1.6L.......................................................................................................................................................................2037
VAPOR CANISTER................................................................................................................................................................................2037
DESCRIPTION...............................................................................................................................................................................2037
OPERATION.................................................................................................................................................................................2037
Purge Free Cells......................................................................................................................................................................2037
REMOVAL...................................................................................................................................................................................2038
INSTALLATION..............................................................................................................................................................................2039
ON-BOARD DIAGNOSTICS..............................................................................................................................................................................2040
TASK MANAGER..................................................................................................................................................................................2040
DESCRIPTION...............................................................................................................................................................................2040
OPERATION.................................................................................................................................................................................2040
INDEX.................................................................................................................................................................................................2045
SERVICE MANUAL COMMENTS...............................................................................................................................................................................2077
CHRYSLER PT CRUISER SERVICE & REPAIR MANUAL – PDF DOWNLOAD:
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