2004 Jeep TJ Wrangler Service Manual – PDF DOWNLOAD
FILE DETAILS:
2004 Jeep TJ Wrangler Service Manual – PDF DOWNLOAD
Language : English
Pages : 2436
Downloadable : Yes
File Type : PDF
Size: 57.4 MB
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TABLE OF CONTENTS:
2004 Jeep TJ Wrangler Service Manual – PDF DOWNLOAD
TJ Powertrain 0
TJ Body 0
TJ Chassis 0
TJ Transmission 0
2004-TJ-SM pdf 0
MAIN WELCOME PAGE 0
INSTRUCTIONS 0
TJ Powertrain 0
TJ Body 0
TJ Chassis 0
TJ Transmission 0
TJ Service Manual 6
FOREWORD 0
GROUP TAB LOCATOR 6
in-INTRODUCTION 7
VEHICLE IDENTIFICATION NUMBER 7
DESCRIPTION 7
VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL 8
DESCRIPTION 8
VEHICLE CERTIFICATION LABEL 8
DESCRIPTION 8
BODY CODE PLATE 9
DESCRIPTION 9
BODY CODE PLATE 9
BODY CODE PLATE—LINE 3 10
BODY CODE PLATE—LINE 2 10
BODY CODE PLATE—LINE 1 10
INTERNATIONAL SYMBOLS 11
DESCRIPTION 11
FASTENER IDENTIFICATION 12
DESCRIPTION 12
FASTENER USAGE 15
DESCRIPTION 15
DESCRIPTION – FASTENER USAGE 15
DESCRIPTION – THREADED HOLE REPAIR 15
METRIC SYSTEM 16
DESCRIPTION 16
TORQUE REFERENCES 18
DESCRIPTION 18
0-LUBRICATION & MAINTENANCE 19
INTERNATIONAL SYMBOLS 19
DESCRIPTION 19
PARTS & LUBRICANT RECOMMENDATION 19
DESCRIPTION – LUBRICANT RECOMMENDATIONS 19
Chassis 19
Body 20
FLUID TYPES 20
DESCRIPTION 20
DESCRIPTION – FUEL REQUIREMENTS 20
REFORMULATED GASOLINE 20
GASOLINE/OXYGENATE BLENDS 20
MMT IN GASOLINE 20
SULFUR IN GASOLINE 20
MATERIALS ADDED TO FUEL 21
FUEL SYSTEM CAUTIONS 21
DESCRIPTION – ENGINE OIL AND LUBRICANTS 21
API SERVICE GRADE CERTIFIED 21
SAE VISCOSITY 21
ENERGY CONSERVING OIL 22
CONTAINER IDENTIFICATION 22
GEAR LUBRICANTS 22
LUBRICANTS AND GREASES 22
SPECIALIZED LUBRICANTS AND OILS 22
DESCRIPTION – HOAT COOLANT 22
COOLANT PERFORMANCE 23
COOLANT SELECTION AND ADDITIVES 23
DESCRIPTION – TRANSFER CASE – NV231 23
DESCRIPTION – TRANSFER CASE – NV241 23
DESCRIPTION – AXLE LUBRICATION 23
DESCRIPTION – MANUAL TRANSMISSION 23
DESCRIPTION – AUTOMATIC TRANSMISSION FLUID 24
FLUID ADDITIVES 24
DESCRIPTION – POWER STEERING FLUID 24
OPERATION – AUTOMATIC TRANSMISSION FLUID 24
FLUID CAPACITIES 24
SPECIFICATIONS – FLUID CAPACITIES 24
MAINTENANCE SCHEDULES 25
DESCRIPTION 25
DESCRIPTION – DOMESTIC SCHEDULES 25
Schedule “B” 26
Schedule “A” 29
DESCRIPTION – GASOLINE ENGINES – EXPORT SCHEDULES 31
Schedule “A” 32
Schedule “B” 33
DESCRIPTION – DIESEL ENGINES – EXPORT SCHEDULES 36
Schedule “A” 36
Schedule “B” 37
HOISTING 39
STANDARD PROCEDURE – HOISTING RECOMMENDATIONS 39
HOIST 39
TOWING 40
STANDARD PROCEDURE – TOWING RECOMMENDATIONS 40
SAFETY PRECAUTIONS 40
GROUND CLEARANCE 40
FLAT-BED TOWING RAMP ANGLE 40
VEHICLE TOWING 40
TOWING-FRONT END LIFTED (WHEEL LIFT) 40
TOWING-REAR END LIFTED (WHEEL LIFT ONLY) 40
TOWING-FRONT END LIFTED (SLING-TYPE) 40
RECREATIONAL TOWING 41
EMERGENCY TOW HOOKS 41
JUMP STARTING 41
STANDARD PROCEDURE – JUMP STARTING PROCEDURE 41
TO JUMP START A DISABLED VEHICLE: 42
DISCONNECT CABLE CLAMPS AS FOLLOWS: 42
EMERGENCY TOW HOOKS 42
DESCRIPTION — EMERGENCY TOW HOOKS 42
2-SUSPENSION 43
WHEEL ALIGNMENT 43
WHEEL ALIGNMENT 43
DESCRIPTION 43
OPERATION 43
DIAGNOSIS AND TESTING – SUSPENSION AND STEERING SYSTEM 44
STANDARD PROCEDURE 46
STANDARD PROCEDURE – CAMBER 46
STANDARD PROCEDURE – CASTER 46
STANDARD PROCEDURE – TOE POSITION 46
SPECIFICATIONS 47
ALIGNMENT SPECIFICATIONS 47
FRONT 48
FRONT 48
DESCRIPTION 48
STANDARD PROCEDURE – LUBRICATION 48
SPECIFICATIONS 49
TORQUE CHART 49
SPECIAL TOOLS 49
FRONT SUSPENSION 49
BUSHINGS 50
REMOVAL 50
INSTALLATION 50
HUB / BEARING 50
DESCRIPTION 50
OPERATION 51
REMOVAL 51
INSTALLATION 51
JOUNCE BUMPER 52
DESCRIPTION 52
KNUCKLE 52
REMOVAL 52
INSTALLATION 52
LOWER BALL JOINT 52
REMOVAL 52
LOWER CONTROL ARM 53
DESCRIPTION 53
OPERATION 53
REMOVAL 53
INSTALLATION 53
SHOCK 54
DESCRIPTION 54
OPERATION 54
DIAGNOSIS AND TESTING – SHOCK ABSORBER 54
REMOVAL 54
INSTALLATION 54
SPRING 55
DESCRIPTION 55
OPERATION 55
REMOVAL 55
INSTALLATION 55
STABILIZER BAR 56
DESCRIPTION 56
OPERATION 56
REMOVAL 56
INSTALLATION 56
TRACK BAR 56
DESCRIPTION 56
OPERATION 56
REMOVAL 56
INSTALLATION 56
UPPER BALL JOINT 57
REMOVAL 57
UPPER CONTROL ARM 57
DESCRIPTION 57
OPERATION 57
REMOVAL 57
INSTALLATION 57
REAR 58
REAR 58
DESCRIPTION 58
SPECIFICATIONS 58
TORQUE CHART 58
JOUNCE BUMPER 59
DESCRIPTION 59
OPERATION 59
LOWER CONTROL ARM 59
DESCRIPTION 59
OPERATION 59
REMOVAL 59
INSTALLATION 59
SHOCK 60
DESCRIPTION 60
OPERATION 60
DIAGNOSIS AND TESTING – SHOCK ABSORBER 60
REMOVAL 60
INSTALLATION 60
SPRING 60
DESCRIPTION 60
OPERATION 60
REMOVAL 60
INSTALLATION 61
STABILIZER BAR 61
DESCRIPTION 61
OPERATION 61
REMOVAL 61
INSTALLATION 61
TRACK BAR 62
DESCRIPTION 62
OPERATION 62
REMOVAL 62
INSTALLATION 62
UPPER CONTROL ARM 62
REMOVAL 62
INSTALLATION 62
3-DIFFERENTIAL & DRIVELINE 63
PROPELLER SHAFT 63
PROPELLER SHAFT 63
DIAGNOSIS AND TESTING 63
VIBRATION 63
BALANCE 65
RUNOUT 65
STANDARD PROCEDURE 66
PROPELLER SHAFT ANGLE 66
ADJUSTMENTS 68
SPECIFICATIONS 68
PROPELLER SHAFT 68
SPECIAL TOOLS 69
PROPELLER SHAFT – FRONT 69
REMOVAL 69
INSTALLATION 69
PROPELLER SHAFT – REAR 69
REMOVAL 69
INSTALLATION 70
PROPELLER SHAFT – REAR RUBICON 70
REMOVAL 70
INSTALLATION 71
SINGLE CARDAN UNIVERSAL JOINTS 71
DISASSEMBLY 71
ASSEMBLY 72
DOUBLE CARDAN UNIVERSAL JOINTS 73
DISASSEMBLY 73
ASSEMBLY 74
FRONT AXLE – 181FBI 77
FRONT AXLE – 181FBI 77
DIAGNOSIS AND TESTING 77
GEAR NOISE 77
BEARING NOISE 77
LOW SPEED KNOCK 78
VIBRATION 78
DRIVELINE SNAP 78
REMOVAL 81
INSTALLATION 81
ADJUSTMENTS 83
PINION DEPTH MEASUREMENT AND ADJUSTMENT 84
DIFFERENTIAL SIDE BEARING PRELOAD AND GEAR BACKLASH 85
PRELOAD SHIM SELECTION 86
GEAR CONTACT PATTERN 89
DIFFERENTIAL BEARING PRELOAD CHECK 90
SPECIFICATIONS 91
FRONT AXLE 91
SPECIAL TOOLS 91
AXLE SHAFTS 94
REMOVAL 94
INSTALLATION 95
AXLE SHAFT SEALS 95
REMOVAL 95
INSTALLATION 95
SINGLE CARDAN UNIVERSAL JOINT 96
REMOVAL 96
INSTALLATION 97
PINION SEAL 97
REMOVAL 97
INSTALLATION 97
COLLAPSIBLE SPACER 99
REMOVAL 99
INSTALLATION 99
DIFFERENTIAL COVER 100
REMOVAL 100
INSTALLATION 100
DIFFERENTIAL 101
REMOVAL 101
DISASSEMBLY 102
ASSEMBLY 103
INSTALLATION 103
DIFFERENTIAL CASE BEARINGS 105
REMOVAL 105
INSTALLATION 105
PINION GEAR/RING GEAR 106
REMOVAL 106
INSTALLATION 108
FRONT AXLE – 216FBI 111
FRONT AXLE – 216FBI 111
DIAGNOSIS AND TESTING 111
GEAR NOISE 111
BEARING NOISE 111
LOW SPEED KNOCK 112
VIBRATION 112
DRIVELINE SNAP 112
REMOVAL 115
INSTALLATION 115
ADJUSTMENTS 117
PINION DEPTH MEASUREMENT AND ADJUSTMENT 118
PRELOAD SHIM SELECTION 119
GEAR CONTACT PATTERN 123
DIFFERENTIAL BEARING PRELOAD CHECK 123
SPECIFICATIONS 125
FRONT AXLE 125
SPECIAL TOOLS 125
AXLE SHAFTS 128
REMOVAL 128
INSTALLATION 129
AXLE SHAFT SEALS 129
REMOVAL 129
INSTALLATION 129
SINGLE CARDAN UNIVERSAL JOINT 130
REMOVAL 130
INSTALLATION 130
PINION SEAL 131
REMOVAL 131
INSTALLATION 131
DIFFERENTIAL COVER 132
REMOVAL 132
INSTALLATION 132
DIFFERENTIAL – TRU-LOK 133
DESCRIPTION 133
OPERATION 133
DIAGNOSIS AND TESTING 133
UNLOCKED 133
LOCKED 134
TRU-LOK INDICATOR SWITCH 134
TRU-LOK PUMPS 134
REMOVAL 134
DISASSEMBLY 137
ASSEMBLY 138
INSTALLATION 138
DIFFERENTIAL – TRU-LOK PUMP 139
REMOVAL 139
INSTALLATION 140
PINION GEAR/RING GEAR 141
REMOVAL 141
INSTALLATION 143
REAR AXLE – 194RBI 146
REAR AXLE – 194RBI 146
DIAGNOSIS AND TESTING 146
GEAR NOISE 146
BEARING NOISE 146
LOW SPEED KNOCK 147
VIBRATION 147
DRIVELINE SNAP 147
REMOVAL 150
INSTALLATION 150
ADJUSTMENTS 151
RING AND PINION GEAR 151
PINION DEPTH MEASUREMENT 152
DIFFERENTIAL BEARING PRELOAD 153
PRELOAD SHIM SELECTION 154
GEAR CONTACT PATTERN 156
DIFFERENTIAL BEARING PRELOAD CHECK 157
SPECIFICATIONS 158
REAR AXLE 158
SPECIAL TOOLS 159
AXLE SHAFTS 162
REMOVAL 162
INSTALLATION 162
AXLE SHAFT SEALS 162
REMOVAL 162
INSTALLATION 162
AXLE BEARINGS 163
REMOVAL 163
INSTALLATION 163
PINION SEAL 163
REMOVAL 163
INSTALLATION 164
COLLAPSIBLE SPACER 165
REMOVAL 165
INSTALLATION 165
DIFFERENTIAL COVER 167
REMOVAL 167
INSTALLATION 167
DIFFERENTIAL 167
REMOVAL 167
DISASSEMBLY 168
ASSEMBLY 168
INSTALLATION 169
DIFFERENTIAL – TRAC-LOK 170
DESCRIPTION 170
OPERATION 170
DIAGNOSIS AND TESTING 170
DIFFERENTIAL TEST 170
DISASSEMBLY 171
ASSEMBLY 172
DIFFERENTIAL CASE BEARINGS 174
REMOVAL 174
INSTALLATION 175
PINION GEAR/RING GEAR 175
REMOVAL 175
INSTALLATION 177
REAR AXLE – 216RBI 180
REAR AXLE – 216RBI 180
DIAGNOSIS AND TESTING 180
GEAR NOISE 180
BEARING NOISE 180
LOW SPEED KNOCK 181
VIBRATION 181
DRIVELINE SNAP 181
REMOVAL 184
INSTALLATION 184
ADJUSTMENTS 185
RING AND PINION GEAR 185
PINION DEPTH MEASUREMENT AND ADJUSTMENT 186
PRELOAD SHIM SELECTION 187
GEAR CONTACT PATTERN 190
DIFFERENTIAL BEARING PRELOAD CHECK 191
SPECIFICATIONS 193
REAR AXLE 193
SPECIAL TOOLS 193
AXLE SHAFTS 196
REMOVAL 196
INSTALLATION 196
AXLE BEARINGS 197
REMOVAL 197
INSTALLATION 198
PINION SEAL 198
REMOVAL 198
INSTALLATION 199
DIFFERENTIAL COVER 200
REMOVAL 200
INSTALLATION 200
DIFFERENTIAL 201
REMOVAL 201
DISASSEMBLY 202
ASSEMBLY 202
INSTALLATION 203
DIFFERENTIAL -TRAC-LOK 203
DESCRIPTION 203
OPERATION 203
DIAGNOSIS AND TESTING 204
DIFFERENTIAL TEST 204
DISASSEMBLY 204
ASSEMBLY 206
DIFFERENTIAL – TRU-LOK 208
DESCRIPTION 208
OPERATION 208
DIAGNOSIS AND TESTING 208
UNLOCKED 208
LOCKED 208
TRU-LOK INDICATOR SWITCH 208
TRU-LOK PUMPS 209
REMOVAL 209
DISASSEMBLY 210
ASSEMBLY 213
INSTALLATION 213
DIFFERENTIAL – TRU-LOK PUMP 214
REMOVAL 214
INSTALLATION 215
DIFFERENTIAL CASE BEARINGS 216
REMOVAL 216
INSTALLATION 216
PINION GEAR/RING GEAR/TONE RING 217
REMOVAL 217
INSTALLATION 219
5-BRAKES 223
BRAKES – BASE 223
BRAKES – BASE 224
DESCRIPTION 224
DESCRIPTION – BRAKE SYSTEM 224
DESCRIPTION – SERVICE WARNINGS & CAUTIONS 225
DIAGNOSIS AND TESTING – BASE BRAKE SYSTEM 225
PRELIMINARY BRAKE CHECK 225
ROAD TESTING 225
STANDARD PROCEDURE 227
STANDARD PROCEDURE – MANUAL BLEEDING 227
STANDARD PROCEDURE – PRESSURE BLEEDING 227
SPECIFICATIONS 228
BRAKE COMPONENTS 228
TORQUE CHART 229
SPECIAL TOOLS 230
BASE BRAKES 230
BRAKE LINES 230
DESCRIPTION 230
OPERATION 230
DIAGNOSIS AND TESTING – BRAKE LINE AND HOSES 230
STANDARD PROCEDURE 230
STANDARD PROCEDURE – BRAKE TUBE FLARING 230
STANDARD PROCEDURE – DOUBLE INVERTED FLARING 230
STANDARD PROCEDURE – ISO FLARING 231
DISC BRAKE CALIPERS 232
DESCRIPTION 232
OPERATION 232
REMOVAL 232
REMOVAL – FRONT 232
REMOVAL – REAR 233
DISASSEMBLY 234
CLEANING 235
INSPECTION 235
ASSEMBLY 235
INSTALLATION 237
INSTALLATION – FRONT 237
INSTALLATION – REAR 238
BRAKE PADS/SHOES 238
REMOVAL 238
REMOVAL – FRONT PADS 238
REMOVAL – DRUM BRAKE SHOES 239
REMOVAL – REAR DISC BRAKE PADS 239
INSTALLATION 239
INSTALLATION – FRONT PADS 239
INSTALLATION – DRUM BRAKE SHOES 239
INSTALLATION – REAR DISC BRAKE PADS 241
DRUM 241
DESCRIPTION 241
OPERATION 241
DIAGNOSIS AND TESTING – BRAKE DRUM RUNOUT 241
BRAKE DRUM RUNOUT 241
STANDARD PROCEDURE – BRAKE DRUM MACHINING 241
CLEANING 241
INSPECTION 241
ADJUSTMENTS – REAR DRUM BRAKE 242
ADJUSTMENT WITH BRAKE GAUGE 242
ADJUSTMENT WITH ADJUSTING TOOL 243
FLUID 243
DIAGNOSIS AND TESTING – BRAKE FLUID CONTAMINATION 243
STANDARD PROCEDURE – BRAKE FLUID LEVEL 243
SPECIFICATIONS 243
BRAKE FLUID 243
FLUID RESERVOIR 244
REMOVAL 244
INSTALLATION 245
MASTER CYLINDER 245
DESCRIPTION 245
OPERATION 245
DIAGNOSIS AND TESTING – MASTER CYLINDER/POWER BOOSTER 245
POWER BOOSTER VACUUM TEST 245
POWER BOOSTER CHECK VALVE TEST 245
STANDARD PROCEDURE – MASTER CYLINDER BLEEDING 246
REMOVAL 246
INSTALLATION 247
PEDAL 247
DESCRIPTION 247
OPERATION 247
REMOVAL 247
INSTALLATION 247
POWER BRAKE BOOSTER 248
DESCRIPTION 248
OPERATION 248
REMOVAL 249
INSTALLATION 249
COMBINATION VALVE 249
DESCRIPTION 249
OPERATION 249
PRESSURE DIFFERENTIAL VALVE 249
PROPORTIONING VALVE 250
DIAGNOSIS AND TESTING – COMBINATION VALVE 250
Pressure Differential Switch 250
REMOVAL 250
INSTALLATION 250
ROTORS 250
DIAGNOSIS AND TESTING 250
DIAGNOSIS AND TESTING – DISC BRAKE ROTOR 250
ROTOR MINIMUM THICKNESS 251
ROTOR RUNOUT 251
ROTOR THICKNESS VARIATION 251
DIAGNOSIS AND TESTING – BRAKE DRUM IN HAT ROTOR 251
BRAKE DRUM RUNOUT 251
STANDARD PROCEDURE 251
STANDARD PROCEDURE – DISC ROTOR MACHINING 251
STANDARD PROCEDURE – BRAKE DRUM IN HAT ROTOR MACHINING 252
REMOVAL 252
REMOVAL – FRONT 252
REMOVAL – REAR 252
INSTALLATION 253
INSTALLATION – FRONT 253
INSTALLATION – REAR 253
WHEEL CYLINDERS 253
REMOVAL 253
DISASSEMBLY 253
CLEANING 253
INSPECTION 253
ASSEMBLY 253
INSTALLATION 254
SUPPORT PLATE 254
REMOVAL 254
INSTALLATION 254
PARKING BRAKE 255
DESCRIPTION 255
OPERATION 255
DIAGNOSIS AND TESTING – PARKING BRAKE 255
SHOES 256
DESCRIPTION 256
OPERATION 256
REMOVAL 256
CLEANING – REAR DRUM IN HAT BRAKE 256
INSPECTION – REAR DRUM IN HAT BRAKE 256
INSTALLATION 257
ADJUSTMENTS 257
ADJUSTMENT – REAR DRUM IN HAT PARK BRAKE (ROTOR REMOVED) 257
ADJUSTMENT – WITH ADJUSTING TOOL 259
CABLES 259
REMOVAL 259
REMOVAL – DRUM BRAKES 259
REMOVAL – DISC BRAKES 260
INSTALLATION 260
INSTALLATION – DRUM BRAKES 260
INSTALLATION – DISC BRAKES 260
BRAKES – ABS 261
BRAKES – ABS 261
DESCRIPTION 261
OPERATION 261
DIAGNOSIS AND TESTING – ANTILOCK BRAKES 261
STANDARD PROCEDURE – BLEEDING ABS BRAKE SYSTEM 262
SPECIFICATIONS 262
T0RQUE CHART 262
FRONT WHEEL SPEED SENSOR 263
DESCRIPTION 263
OPERATION 263
FRONT SENSOR AIR GAP 263
REAR SENSOR AIR GAP 263
REMOVAL 263
INSTALLATION 263
G-SWITCH 264
DESCRIPTION 264
OPERATION 264
REMOVAL 264
INSTALLATION 264
REAR WHEEL SPEED SENSOR 264
DESCRIPTION 264
OPERATION 264
REMOVAL 265
INSTALLATION 265
HCU (HYDRAULIC CONTROL UNIT) 265
DESCRIPTION 265
OPERATION 265
PRESSURE DECREASE 266
PRESSURE HOLD 266
PRESSURE INCREASE 266
REMOVAL 266
INSTALLATION 266
6-CLUTCH 267
CLUTCH 267
WARNING 267
DIAGNOSIS AND TESTING 267
CLUTCH CONTAMINATION 267
IMPROPER RELEASE OR CLUTCH ENGAGEMENT 267
CLUTCH MISALIGNMENT 268
PRESSURE PLATE AND DISC RUNOUT 268
FLYWHEEL RUNOUT 268
DIAGNOSIS CHART 268
SPECIFICATIONS 271
CLUTCH 271
CLUTCH DISC 272
REMOVAL 272
INSTALLATION 272
CLUTCH RELEASE BEARING 273
REMOVAL 273
INSTALLATION 273
FLYWHEEL 273
DESCRIPTION 273
STANDARD FLYWHEEL 273
DUAL MASS FLYWHEEL 273
OPERATION 273
DIAGNOSIS AND TESTING 273
PILOT BEARING 274
REMOVAL 274
INSTALLATION 274
LINKAGE 274
REMOVAL 274
INSTALLATION 275
MASTER CYLINDER 275
INSPECTION 275
CLUTCH PEDAL 276
REMOVAL 276
INSTALLATION 276
CLUTCH PEDAL POSITION SWITCH 276
DESCRIPTION 276
OPERATION 277
DIAGNOSIS AND TESTING 277
7-COOLING 279
COOLING 279
DESCRIPTION 279
DESCRIPTION – COOLING SYSTEM 2 4L ENGINE 279
DESCRIPTION – 4 0L ENGINE 279
DESCRIPTION – HOSE CLAMPS 280
OPERATION – HOSE CLAMPS 280
DIAGNOSIS AND TESTING 280
ON-BOARD DIAGNOSTICS – OBD 280
COOLING SYSTEM RELATED DIAGNOSTICS 280
ACCESSING DIAGNOSTIC TROUBLE CODES 280
DIAGNOSIS AND TESTING – PRELIMINARY CHECKS 280
ENGINE COOLING SYSTEM OVERHEATING 280
DIAGNOSIS AND TESTING – COOLING SYSTEM – TESTING FOR LEAKS 287
ULTRAVIOLET LIGHT METHOD 287
PRESSURE TESTER METHOD 287
INTERNAL LEAKAGE INSPECTION 288
COMBUSTION LEAKAGE TEST (WITHOUT PRESSURE TESTER) 288
DIAGNOSIS AND TESTING – RADIATOR COOLANT FLOW CHECK0 – 2 TJ (Continued) 288
STANDARD PROCEDURE 288
STANDARD PROCEDURE – DRAINING COOLING SYSTEM – 2 4L 288
STANDARD PROCEDURE – REFILLING COOLING SYSTEM – 2 4L 289
STANDARD PROCEDURE – COOLANT LEVEL CHECK 289
STANDARD PROCEDURE – COOLING SYSTEM – DRAINING 289
STANDARD PROCEDURE – COOLING SYSTEM – REFILLING 290
STANDARD PROCEDURE – COOLING SYSTEM – REVERSE FLUSHING 290
CHEMICAL CLEANING 290
REVERSE FLUSHING RADIATOR 290
REVERSE FLUSHING ENGINE 290
SPECIFICATIONS 291
TORQUE 291
SPECIAL TOOLS 291
COOLING 291
ACCESSORY DRIVE 292
ACCESSORY DRIVE 292
SPECIFICATIONS 292
BELT TENSION 292
BELT TENSIONERS 292
DESCRIPTION 292
REMOVAL 293
REMOVAL – 2 4L ENGINE 293
REMOVAL 293
INSTALLATION 293
INSTALLATION – 2 4L ENGINE 293
INSTALLATION 294
DRIVE BELTS – 2 4L 294
DIAGNOSIS AND TESTING – ACCESSORY DRIVE BELT 294
VISUAL DIAGNOSIS 294
NOISE DIAGNOSIS 295
REMOVAL 297
REMOVAL 297
REMOVAL 297
INSTALLATION 297
INSTALLATION 297
INSTALLATION 299
ENGINE 300
DESCRIPTION 301
DESCRIPTION – HOAT COOLANT 301
COOLANT PERFORMANCE 301
COOLANT SELECTION AND ADDITIVES 301
DESCRIPTION – ENGINE COOLANT 302
ETHYLENE-GLYCOL MIXTURES 302
PROPYLENE-GLYCOL MIXTURES 302
OPERATION 302
COOLANT RECOVERY CONTAINER 302
DESCRIPTION 302
OPERATION 303
REMOVAL 303
INSTALLATION 303
ENGINE BLOCK HEATER 303
DESCRIPTION 303
OPERATION 303
REMOVAL 304
REMOVAL – 4 0L 304
REMOVAL – 2 4L 304
INSTALLATION 304
INSTALLATION 4 0L 304
INSTALLATION – 2 4L 304
ENGINE COOLANT TEMPERATURE SENSOR 305
DESCRIPTION 305
OPERATION 305
REMOVAL 305
INSTALLATION 305
ENGINE COOLANT THERMOSTAT 306
DESCRIPTION 306
OPERATION 306
REMOVAL 306
REMOVAL 306
REMOVAL 307
INSTALLATION 307
INSTALLATION 307
INSTALLATION 307
FAN DRIVE VISCOUS CLUTCH 308
DESCRIPTION 308
OPERATION 309
DIAGNOSIS AND TESTING 309
VISCOUS FAN DRIVE 309
NOISE 309
LEAKS 309
TESTING 309
REMOVAL 310
INSTALLATION 310
RADIATOR 311
DESCRIPTION 311
OPERATION 311
DIAGNOSIS AND TESTING – RADIATOR COOLANT FLOW 311
REMOVAL 311
CLEANING 313
INSPECTION 313
INSTALLATION 314
WATER PUMP – 2 4L 314
DESCRIPTION 314
OPERATION 314
DIAGNOSIS AND TESTING 314
WATER PUMP 314
REMOVAL – 2 4L 315
INSTALLATION 315
INSTALLATION 2 4L 315
WATER PUMP – 4 0L 315
DESCRIPTION 315
OPERATION 316
REMOVAL 316
INSTALLATION 317
RADIATOR PRESSURE CAP 318
DESCRIPTION 318
OPERATION 318
DIAGNOSIS AND TESTING 319
DIAGNOSIS AND TESTING – RADIATOR CAP-TO-FILLER NECK SEAL 319
DIAGNOSIS AND TESTING – RADIATOR CAP 319
CLEANING 319
INSPECTION 319
RADIATOR FAN 320
DESCRIPTION 320
REMOVAL 320
REMOVAL 320
REMOVAL – 4 0L 320
CLEANING 320
INSPECTION 320
INSTALLATION 321
INSTALLATION 321
INSTALLATION – 4 0L 321
RADIATOR FAN RELAY 321
DESCRIPTION 321
TRANSMISSION 322
TRANSMISSION COOLER 322
DESCRIPTION 322
OPERATION 322
8a-AUDIO/VIDEO 323
AUDIO 323
DESCRIPTION 323
OPERATION 323
DIAGNOSIS AND TESTING – AUDIO 323
AMPLIFIED SUBWOOFER 325
DESCRIPTION 325
OPERATION 325
DIAGNOSIS AND TESTING – AMPLIFIED SUBWOOFER 325
REMOVAL 325
INSTALLATION 325
ANTENNA BODY & CABLE 326
DESCRIPTION 326
DIAGNOSIS AND TESTING – ANTENNA BODY AND CABLE 326
TEST 1 326
TEST 2 326
TEST 3 326
TEST 4 327
REMOVAL 327
INSTALLATION 327
RADIO 328
DESCRIPTION 328
OPERATION 328
REMOVAL 328
INSTALLATION 329
RADIO NOISE SUPPRESSION COMPONENTS 329
DESCRIPTION 329
DIAGNOSIS AND TESTING – RADIO NOISE SUPPRESSION COMPONENTS 329
REMOVAL 330
ENGINE-TO-BODY GROUND STRAP 330
INSTALLATION 330
ENGINE-TO-BODY GROUND STRAP 330
SPEAKER 330
DESCRIPTION 330
OPERATION 330
DIAGNOSIS AND TESTING – SPEAKER 330
REMOVAL 331
FRONT 331
REAR 331
INSTALLATION 332
FRONT 332
REAR 332
8b-CHIME/BUZZER 333
CHIME WARNING SYSTEM 333
DESCRIPTION 333
OPERATION 333
DIAGNOSIS AND TESTING – CHIME WARNING SYSTEM 335
8e-ELECTRONIC CONTROL MODULES 339
COMMUNICATION 339
DESCRIPTION 339
OPERATION 339
CONTROLLER ANTILOCK BRAKE 340
DESCRIPTION 340
OPERATION 340
REMOVAL 341
INSTALLATION 341
DATA LINK CONNECTOR 341
DESCRIPTION – DATA LINK CONNECTOR 341
OPERATION – DATA LINK CONNECTOR 341
POWERTRAIN CONTROL MODULE 341
DESCRIPTION 341
DESCRIPTION 341
DESCRIPTION – MODES OF OPERATION 341
DESCRIPTION – 5 VOLT SUPPLIES 344
DESCRIPTION – IGNITION CIRCUIT SENSE 344
DESCRIPTION – POWER GROUNDS 344
DESCRIPTION – SENSOR RETURN 344
OPERATION 344
OPERATION 344
OPERATION – 5 VOLT SUPPLIES 345
OPERATION – IGNITION CIRCUIT SENSE 345
REMOVAL 345
INSTALLATION 346
SENTRY KEY IMMOBILIZER MODULE 346
DESCRIPTION 346
OPERATION 346
STANDARD PROCEDURE – PCM/SKIM PROGRAMMING 348
PROGRAMMING THE PCM (JTEC) 348
PROGRAMMING THE SKIM 348
PROGRAMMING IGNITION KEYS TO THE SKIM 348
REMOVAL 349
INSTALLATION 350
TRANSMISSION CONTROL MODULE 351
DESCRIPTION 351
OPERATION 351
CLUTCH VOLUME INDEX (CVI) 351
SHIFT SCHEDULES 352
STANDARD PROCEDURE – TCM QUICK LEARN 354
8f-ENGINE SYSTEMS 355
BATTERY SYSTEM 355
BATTERY SYSTEM 355
DESCRIPTION 355
OPERATION 356
DIAGNOSIS AND TESTING – BATTERY SYSTEM 356
MICRO 420 BATTERY TESTER 356
ABNORMAL BATTERY DISCHARGING 358
CLEANING 358
INSPECTION 360
SPECIFICATIONS 360
BATTERY SYSTEM SPECIFICATIONS 360
SPECIAL TOOLS 361
BATTERY SYSTEM SPECIAL TOOLS 361
BATTERY 361
DESCRIPTION 361
OPERATION 362
DIAGNOSIS AND TESTING – BATTERY 362
MICRO 420 BATTERY TESTER 362
STANDARD PROCEDURE 362
STANDARD PROCEDURE – BATTERY CHARGING 362
CHARGING A COMPLETELY DISCHARGED BATTERY 363
CHARGING TIME REQUIRED 364
STANDARD PROCEDURE – BUILT-IN INDICATOR TEST 364
STANDARD PROCEDURE – OPEN-CIRCUIT VOLTAGE TEST 365
STANDARD PROCEDURE – IGNITION-OFF DRAW TEST 365
STANDARD PROCEDURE – USING MICRO 420 BATTERY TESTER 366
BATTERY TESTING 366
REMOVAL 367
INSTALLATION 368
BATTERY HOLDDOWN 368
DESCRIPTION 368
OPERATION 369
REMOVAL 369
INSTALLATION 369
BATTERY CABLES 370
DESCRIPTION 370
OPERATION 370
DIAGNOSIS AND TESTING – BATTERY CABLES 370
VOLTAGE DROP TEST 370
REMOVAL 372
INSTALLATION 372
BATTERY TRAY 373
DESCRIPTION 373
OPERATION 373
REMOVAL 374
INSTALLATION 374
CHARGING 375
CHARGING 375
DESCRIPTION 375
OPERATION 375
DIAGNOSIS AND TESTING – CHARGING SYSTEM 376
SPECIFICATIONS 376
GENERATOR RATINGS 376
TORQUE 377
SPECIAL TOOLS 377
BATTERY TEMPERATURE SENSOR 377
DESCRIPTION 377
OPERATION 377
REMOVAL 377
INSTALLATION 378
GENERATOR 378
DESCRIPTION 378
OPERATION 378
REMOVAL 378
INSTALLATION 378
GENERATOR DECOUPLER PULLEY 380
DESCRIPTION 380
OPERATION 380
DIAGNOSIS AND TESTING – GENERATOR DECOUPLER 380
REMOVAL 380
INSTALLATION 383
VOLTAGE REGULATOR 384
DESCRIPTION 384
OPERATION 384
STARTING 385
STARTING 385
DESCRIPTION 385
OPERATION 385
DIAGNOSIS AND TESTING – STARTING SYSTEM 386
TESTING 387
INSPECTION – STARTING SYSTEM 390
SPECIFICATIONS 391
STARTER 391
TORQUE 391
STARTER MOTOR 391
DIAGNOSIS AND TESTING – STARTER MOTOR/SOLENOID 391
STARTER MOTOR TESTING 392
STARTER SOLENOID TESTING 392
REMOVAL 392
INSTALLATION 394
STARTER MOTOR RELAY 394
DESCRIPTION 394
OPERATION 394
DIAGNOSIS AND TESTING – STARTER RELAY 394
RELAY TEST 394
RELAY CIRCUIT TEST 395
REMOVAL 395
INSTALLATION 395
8g-HEATED SYSTEMS 397
HEATED GLASS 397
HEATED GLASS 397
DESCRIPTION 397
OPERATION 397
DIAGNOSIS AND TESTING 398
REAR WINDOW DEFOGGER SYSTEM 398
REAR WINDOW DEFOGGER RELAY 399
DESCRIPTION 399
OPERATION 399
REMOVAL 399
INSTALLATION 400
REAR WINDOW DEFOGGER SWITCH 400
DESCRIPTION 400
OPERATION 400
DIAGNOSIS AND TESTING 400
REAR WINDOW DEFOGGER SWITCH 400
REMOVAL 401
INSTALLATION 401
REAR WINDOW DEFOGGER GRID 402
STANDARD PROCEDURE 402
GRID LINE AND TERMINAL REPAIR PROCEDURE 402
HEATED MIRRORS 403
HEATED MIRRORS 403
DESCRIPTION 403
OPERATION 403
8h-HORN 405
HORN SYSTEM 405
DESCRIPTION 405
OPERATION 405
HORN 405
DESCRIPTION 405
OPERATION 405
DIAGNOSIS AND TESTING – HORN 405
REMOVAL 406
INSTALLATION 406
HORN SWITCH 406
DESCRIPTION 406
OPERATION 406
DIAGNOSIS AND TESTING – HORN SWITCH 406
REMOVAL 407
INSTALLATION 407
8i-IGNITION CONTROL 409
IGNITION CONTROL 409
DESCRIPTION 409
OPERATION 409
2 4L 409
4 0L 410
SPECIFICATIONS 410
SPECIFICATIONS – IGNITION TIMING 410
ENGINE FIRING ORDER – 2 4L 4-CYLINDER 410
ENGINE FIRING ORDER – 4 0L 6-CYLINDER ENGINE 410
IGNITION COIL RESISTANCE – 2 4L 410
IGNITION COIL RESISTANCE – 4 0L ENGINE 411
SPARK PLUGS 411
SPECIFICATIONS – SPARK PLUG CABLE RESISTANCE 411
SPECIFICATIONS – TORQUE – IGNITION SYSTEM 411
AUTO SHUT DOWN RELAY 412
DESCRIPTION – PCM OUTPUT 412
OPERATION 412
OPERATION – ASD SENSE – PCM INPUT 412
OPERATION – PCM OUTPUT 412
DIAGNOSIS AND TESTING – ASD AND FUEL PUMP RELAYS 412
REMOVAL 413
INSTALLATION 413
CAMSHAFT POSITION SENSOR – 2 4L 413
DESCRIPTION – 2 4L 413
OPERATION – 2 4L 413
REMOVAL – 2 4L 414
INSTALLATION – 2 4L 414
CAMSHAFT POSITION SENSOR – 4 0L 415
DESCRIPTION – 4 0L 415
OPERATION – 4 0L 415
REMOVAL – 4 0L 416
SENSOR ONLY – 4 0L 416
OIL PUMP DRIVE AND SENSOR – 4 0L 416
INSTALLATION – 4 0L 417
SENSOR ONLY – 4 0L 417
OIL PUMP DRIVE AND SENSOR – 4 0L 417
COIL RAIL – 4 0L 418
DESCRIPTION – 4 0L 418
OPERATION – 4 0L 419
REMOVAL – 4 0L 419
INSTALLATION – 4 0L 419
IGNITION COIL – 2 4L 420
DESCRIPTION – 2 4L 420
OPERATION – 2 4L 420
REMOVAL – 2 4L 421
INSTALLATION – 2 4L 421
SPARK PLUG 421
DESCRIPTION 421
OPERATION 421
DIAGNOSIS AND TESTING – SPARK PLUG CONDITIONS 421
NORMAL OPERATING 421
COLD FOULING/CARBON FOULING 422
WET FOULING OR GAS FOULING 422
OIL OR ASH ENCRUSTED 422
ELECTRODE GAP BRIDGING 422
SCAVENGER DEPOSITS 423
CHIPPED ELECTRODE INSULATOR 423
PREIGNITION DAMAGE 423
SPARK PLUG OVERHEATING 424
REMOVAL 424
2 4L 424
4 0L 424
CLEANING 424
CLEANING SPARK PLUGS 424
INSTALLATION 424
2 4L 424
4 0L 425
SPARK PLUG CABLE 425
DESCRIPTION 425
OPERATION 425
DIAGNOSIS AND TESTING 425
REMOVAL – 2 4L 426
INSTALLATION 426
8j-INSTRUMENT CLUSTER 427
INSTRUMENT CLUSTER 428
DESCRIPTION 428
OPERATION 431
INPUT AND OUTPUT CIRCUITS 436
DIAGNOSIS AND TESTING – INSTRUMENT CLUSTER 436
REMOVAL 442
DISASSEMBLY 443
ASSEMBLY 444
INSTALLATION 445
ABS INDICATOR 446
DESCRIPTION 446
OPERATION 446
DIAGNOSIS AND TESTING – ABS INDICATOR 446
AIRBAG INDICATOR 447
DESCRIPTION 447
OPERATION 447
BRAKE/PARK BRAKE INDICATOR 448
DESCRIPTION 448
OPERATION 448
DIAGNOSIS AND TESTING – BRAKE INDICATOR 449
CHECK GAUGES INDICATOR 450
DESCRIPTION 450
OPERATION 450
CRUISE INDICATOR 451
DESCRIPTION 451
OPERATION 451
ENGINE TEMPERATURE GAUGE 451
DESCRIPTION 451
OPERATION 452
FOG LAMP INDICATOR 452
DESCRIPTION 452
OPERATION 453
DIAGNOSIS AND TESTING – FRONT/REAR FOG LAMP INDICATOR 453
FRONT LOCK INDICATOR 453
DESCRIPTION 453
OPERATION 454
FUEL GAUGE 455
DESCRIPTION 455
OPERATION 455
HIGH BEAM INDICATOR 456
DESCRIPTION 456
OPERATION 456
DIAGNOSIS AND TESTING – HIGH BEAM INDICATOR 456
LOW FUEL INDICATOR 457
DESCRIPTION 457
OPERATION 457
MALFUNCTION INDICATOR LAMP (MIL) 458
DESCRIPTION 458
OPERATION 458
ODOMETER 459
DESCRIPTION 459
OPERATION 459
OIL PRESSURE GAUGE 460
DESCRIPTION 460
OPERATION 460
REAR LOCK INDICATOR 461
DESCRIPTION 461
OPERATION 461
SEATBELT INDICATOR 462
DESCRIPTION 462
OPERATION 462
SHIFT INDICATOR (TRANSFER CASE) 463
DESCRIPTION 463
OPERATION 463
DIAGNOSIS AND TESTING – 4WD INDICATOR 464
SKIS INDICATOR 465
DESCRIPTION 465
OPERATION 465
SPEEDOMETER 466
DESCRIPTION 466
OPERATION 466
TACHOMETER 467
DESCRIPTION 467
OPERATION 467
TURN SIGNAL INDICATOR 467
DESCRIPTION 467
OPERATION 468
UPSHIFT INDICATOR 468
DESCRIPTION 468
OPERATION 468
VOLTAGE GAUGE 469
DESCRIPTION 469
OPERATION 469
8l-LAMPS 471
LAMPS/LIGHTING – EXTERIOR 471
LAMPS/LIGHTING – EXTERIOR 472
DESCRIPTION – TURN SIGNAL & HAZARD WARNING SYSTEM 472
OPERATION – TURN SIGNAL & HAZARD WARNING SYSTEM 473
WARNING 473
DIAGNOSIS AND TESTING 473
DIAGNOSIS AND TESTING – TURN SIGNAL & HAZARD WARNING SYSTEM 473
DIAGNOSIS AND TESTING – HEADLAMP SYSTEM 475
ADJUSTMENTS 476
HEADLAMP ALIGNMENT PREPARATION 476
ALIGNMENT SCREEN PREPARATION 476
HEADLAMP ADJUSTMENT 477
SPECIFICATIONS 478
EXTERIOR LAMPS 478
SPECIAL TOOLS 478
HEADLAMP ALIGNMENT 478
BRAKE LAMP SWITCH 478
DESCRIPTION 478
OPERATION 478
DIAGNOSIS AND TESTING – BRAKE LAMP SWITCH 478
SWITCH CIRCUIT IDENTIFICATION 478
SWITCH CONTINUITY TEST 479
REMOVAL 479
INSTALLATION 479
ADJUSTMENTS 479
ADJUSTMENT 479
CENTER HIGH MOUNTED STOP LAMP UNIT 479
REMOVAL 479
INSTALLATION 479
CENTER HIGH MOUNTED STOP LAMP 480
REMOVAL 480
INSTALLATION 480
COMBINATION FLASHER 480
DESCRIPTION 480
OPERATION 481
REMOVAL 481
INSTALLATION 482
DAYTIME RUNNING LAMP MODULE 482
DESCRIPTION 482
OPERATION 482
DIAGNOSIS AND TESTING – DAYTIME RUNNING LAMP SYSTEM 482
REMOVAL 483
INSTALLATION 483
FOG LAMP UNIT 483
DIAGNOSIS AND TESTING – FRONT FOG LAMP SYSTEM 483
REMOVAL 485
INSTALLATION 485
ADJUSTMENTS 485
FOG LAMP 485
REMOVAL 485
INSTALLATION 485
FOG LAMP RELAY 486
DESCRIPTION 486
OPERATION 486
REMOVAL 486
INSTALLATION 486
FOG LAMP UNIT – REAR 487
DESCRIPTION 487
OPERATION 487
DIAGNOSIS AND TESTING – REAR FOG LAMP 487
REMOVAL 488
INSTALLATION 488
FOG LAMP – REAR 488
REMOVAL 488
INSTALLATION 488
FRONT PARK/TURN SIGNAL LAMP UNIT 489
DESCRIPTION 489
OPERATION 489
REMOVAL 489
INSTALLATION 489
FRONT PARK/TURN SIGNAL LAMP 489
REMOVAL 489
INSTALLATION 489
HEADLAMP 489
DESCRIPTION 489
OPERATION 490
REMOVAL 490
INSTALLATION 490
HEADLAMP LEVELING SWITCH 491
REMOVAL 491
HEADLAMP LEVELING SWITCH 491
INSTALLATION 491
HEADLAMP LEVELING MOTOR 491
DIAGNOSIS AND TESTING – HEADLAMP LEVELING SYSTEM 491
LEFT MULTI-FUNCTION SWITCH 493
DESCRIPTION 493
OPERATION 493
DIAGNOSIS AND TESTING – LEFT MULTI-FUNCTION SWITCH 495
REMOVAL 496
INSTALLATION 497
SIDE MARKER LAMP UNIT 498
REMOVAL 498
INSTALLATION 498
SIDE MARKER LAMP 498
REMOVAL 498
INSTALLATION 498
REPEATER LAMP 498
DESCRIPTION 498
OPERATION 498
DIAGNOSIS AND TESTING – SIDE REPEATER LAMP 498
TAIL LAMP UNIT 499
DESCRIPTION 499
OPERATION 499
REMOVAL 499
INSTALLATION 499
TAIL LAMP 500
REMOVAL 500
INSTALLATION 500
TURN SIGNAL CANCEL CAM 500
DESCRIPTION 500
OPERATION 500
UNDERHOOD LAMP UNIT 500
REMOVAL 500
INSTALLATION 500
UNDERHOOD LAMP 501
REMOVAL 501
INSTALLATION 501
LAMPS/LIGHTING – INTERIOR 502
LAMPS/LIGHTING – INTERIOR 502
SPECIFICATIONS 502
INTERIOR LAMPS 502
DOME LAMP UNIT 502
REMOVAL 502
INSTALLATION 502
DOME LAMP 503
REMOVAL 503
INSTALLATION 503
DOOR AJAR SWITCH 503
DESCRIPTION 503
OPERATION 503
DIAGNOSIS AND TESTING – DOOR AJAR SWITCH 504
REMOVAL 504
INSTALLATION 504
REAR WIPER/WASHER SWITCH ILLUMINATION LAMP 505
REMOVAL 505
INSTALLATION 505
8n-POWER SYSTEMS 507
AUTOMATIC DAY / NIGHT MIRROR 507
DESCRIPTION 507
OPERATION 507
DIAGNOSIS AND TESTING – AUTOMATIC DAY/NIGHT MIRROR 508
STANDARD PROCEDURE 508
STANDARD PROCEDURE – COMPASS CALIBRATION 508
AUTOMATIC CALIBRATION 508
MANUAL CALIBRATION 508
STANDARD PROCEDURE – COMPASS VARIATION ADJUSTMENT 509
8o-RESTRAINTS 511
RESTRAINTS 511
DESCRIPTION 511
ACTIVE RESTRAINTS 511
PASSIVE RESTRAINTS 513
OPERATION 514
ACTIVE RESTRAINTS 514
PASSIVE RESTRAINTS 514
WARNING 515
WARNINGS – RESTRAINT SYSTEM 515
DIAGNOSIS AND TESTING – SUPPLEMENTAL RESTRAINT SYSTEM 516
STANDARD PROCEDURE 516
STANDARD PROCEDURE – HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS 516
SUPPLEMENTAL RESTRAINT STORAGE 516
STANDARD PROCEDURE – SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT0 – 4 TJ (Continued) 516
CLEANUP PROCEDURE 516
STANDARD PROCEDURE – VERIFICATION TEST 517
AIRBAG CONTROL MODULE 518
DESCRIPTION 518
OPERATION 518
REMOVAL 520
INSTALLATION 521
CHILD RESTRAINT ANCHOR 522
DESCRIPTION 522
OPERATION 523
REMOVAL 523
INSTALLATION 524
CLOCKSPRING 524
DESCRIPTION 524
OPERATION 525
STANDARD PROCEDURE – CLOCKSPRING CENTERING 526
REMOVAL 526
INSTALLATION 528
DRIVER AIRBAG 529
DESCRIPTION 529
OPERATION 529
REMOVAL 530
DISASSEMBLY 531
ASSEMBLY 532
INSTALLATION 533
FRONT SEAT BELT & RETRACTOR 534
REMOVAL 534
INSTALLATION 535
FRONT SEAT BELT BUCKLE 536
REMOVAL 536
INSTALLATION 536
PASSENGER AIRBAG 537
DESCRIPTION 537
OPERATION 537
REMOVAL 538
INSTALLATION 538
PASSENGER AIRBAG DOOR 539
REMOVAL 539
INSTALLATION 540
PASSENGER AIRBAG ON/OFF SWITCH 541
DESCRIPTION 541
OPERATION 541
REMOVAL 542
INSTALLATION 542
REAR SEAT BELT & RETRACTOR 543
REMOVAL 543
INSTALLATION 544
REAR SEAT BELT BUCKLE 544
REMOVAL 544
INSTALLATION 545
SEAT BELT SWITCH 545
DESCRIPTION 545
OPERATION 545
DIAGNOSIS AND TESTING – SEAT BELT SWITCH 546
SEAT BELT TURNING LOOP ADJUSTER 546
REMOVAL 546
INSTALLATION 547
8p-SPEED CONTROL 549
SPEED CONTROL 549
DESCRIPTION 549
OPERATION 549
DIAGNOSIS AND TESTING – ROAD TEST 550
SPECIFICATIONS 550
TORQUE – SPEED CONTROL 550
CABLE 551
DESCRIPTION 551
OPERATION 551
REMOVAL 551
INSTALLATION 551
SERVO 552
DESCRIPTION 552
OPERATION 552
REMOVAL 552
INSTALLATION 553
SWITCH 553
DESCRIPTION 553
OPERATION 553
Multiplexing 554
REMOVAL 554
INSTALLATION 554
VACUUM RESERVOIR 555
DESCRIPTION 555
OPERATION 555
DIAGNOSIS AND TESTING – VACUUM RESERVOIR 555
REMOVAL 555
INSTALLATION 555
8q-VEHICLE THEFT SECURITY 557
VEHICLE THEFT SECURITY 557
DESCRIPTION 557
OPERATION 557
DIAGNOSIS AND TESTING – SENTRY KEY IMMOBILIZER SYSTEM 558
STANDARD PROCEDURE 560
STANDARD PROCEDURE – SKIS INITIALIZATION 560
STANDARD PROCEDURE – SENTRY KEY TRANSPONDER PROGRAMMING 560
SKIS INDICATOR 561
DESCRIPTION 561
OPERATION 561
TRANSPONDER KEY 562
DESCRIPTION 562
OPERATION 562
8r-WIPERS/WASHERS 563
FRONT WIPERS/WASHERS 563
FRONT WIPERS/WASHERS 563
DESCRIPTION 563
OPERATING MODES 565
OPERATION 565
OPERATING MODES 566
DIAGNOSIS AND TESTING – FRONT WIPER & WASHER SYSTEM 567
WIPER SYSTEM 567
WASHER SYSTEM 568
CLEANING – FRONT WIPER & WASHER SYSTEM 569
WIPER SYSTEM 569
WASHER SYSTEM 569
INSPECTION – FRONT WIPER & WASHER SYSTEM 569
WIPER SYSTEM 569
WASHER SYSTEM 570
FRONT CHECK VALVE 570
DESCRIPTION 570
OPERATION 571
REMOVAL 571
INSTALLATION 572
FRONT WASHER HOSES/TUBES 572
DESCRIPTION 572
OPERATION 572
FRONT WASHER NOZZLE 572
DESCRIPTION 572
OPERATION 573
REMOVAL 573
INSTALLATION 573
FRONT WASHER PUMP MOTOR 573
DESCRIPTION 573
OPERATION 574
REMOVAL 574
INSTALLATION 575
FRONT WIPER ARM 575
DESCRIPTION 575
OPERATION 575
REMOVAL 575
INSTALLATION 576
FRONT WIPER BLADE 576
DESCRIPTION 576
OPERATION 577
REMOVAL 577
INSTALLATION 577
FRONT WIPER MODULE 577
DESCRIPTION 577
OPERATION 578
REMOVAL 578
DISASSEMBLY 579
ASSEMBLY 579
INSTALLATION 579
RIGHT MULTI-FUNCTION SWITCH 580
DESCRIPTION 580
OPERATION 581
DIAGNOSIS AND TESTING – RIGHT MULTI-FUNCTION SWITCH 581
REMOVAL 582
INSTALLATION 583
WASHER RESERVOIR 584
DESCRIPTION 584
OPERATION 584
REMOVAL 584
INSTALLATION 585
REAR WIPERS/WASHERS 586
REAR WIPERS/WASHERS 586
DESCRIPTION 586
OPERATING MODES 588
OPERATION 588
OPERATING MODES 588
DIAGNOSIS AND TESTING – REAR WIPER & WASHER SYSTEM 589
WIPER SYSTEM 589
WASHER SYSTEM 590
CLEANING – REAR WIPER & WASHER SYSTEM 590
WIPER SYSTEM 590
WASHER SYSTEM 591
INSPECTION – REAR WIPER & WASHER SYSTEM 591
WIPER SYSTEM 591
WASHER SYSTEM 591
REAR CHECK VALVE 592
DESCRIPTION 592
OPERATION 592
REMOVAL 593
INSTALLATION 593
REAR WASHER HOSES/TUBES 593
DESCRIPTION 593
OPERATION 594
REAR WASHER NOZZLE 594
DESCRIPTION 594
OPERATION 594
REMOVAL 595
INSTALLATION 595
REAR WASHER PUMP MOTOR 595
DESCRIPTION 595
OPERATION 596
REMOVAL 596
INSTALLATION 596
REAR WIPER ARM 596
DESCRIPTION 596
OPERATION 597
REMOVAL 597
INSTALLATION 597
REAR WIPER BLADE 598
DESCRIPTION 598
OPERATION 599
REMOVAL 599
INSTALLATION 599
REAR WIPER MOTOR 599
DESCRIPTION 599
OPERATION 600
REMOVAL 600
INSTALLATION 601
REAR WIPER MOTOR TRIM COVER 601
REMOVAL 601
INSTALLATION 602
REAR WIPER/WASHER SWITCH 602
DESCRIPTION 602
OPERATION 602
DIAGNOSIS AND TESTING – REAR WIPER & WASHER SWITCH 603
REMOVAL 603
INSTALLATION 604
8w-WIRING 605
8W-01 WIRING DIAGRAM INFORMATION 607
WIRING DIAGRAM INFORMATION 607
DESCRIPTION 607
DESCRIPTION – HOW TO USE WIRING DIAGRAMS 607
SYMBOLS 607
TERMINOLOGY 611
DESCRIPTION – CIRCUIT INFORMATION 611
DESCRIPTION – CIRCUIT FUNCTIONS 612
DESCRIPTION – SECTION IDENTIFICATION AND INFORMATION 612
DESCRIPTION – CONNECTOR, GROUND AND SPLICE INFORMATION 613
IDENTIFICATION 613
LOCATIONS 613
WARNING 613
WARNINGS – GENERAL 613
DIAGNOSIS AND TESTING – WIRING HARNESS 613
TROUBLESHOOTING TOOLS 613
INTERMITTENT AND POOR CONNECTIONS 614
TROUBLESHOOTING WIRING PROBLEMS 614
STANDARD PROCEDURE 614
STANDARD PROCEDURE – ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES 614
STANDARD PROCEDURE – TESTING OF VOLTAGE POTENTIAL 615
STANDARD PROCEDURE – TESTING FOR CONTINUITY 615
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND 615
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 616
STANDARD PROCEDURE – TESTING FOR A VOLTAGE DROP 616
SPECIAL TOOLS 616
WIRING/TERMINAL 616
CONNECTOR 617
REMOVAL 617
INSTALLATION 617
DIODE 620
REMOVAL 620
INSTALLATION 620
TERMINAL 620
REMOVAL 620
INSTALLATION 620
WIRE 621
STANDARD PROCEDURE – WIRE SPLICING 621
8W-02 COMPONENT INDEX 623
8W-10 POWER DISTRIBUTION 625
8W-11 FUSE BLOCK 647
8W-15 GROUND DISTRIBUTION 659
8W-18 BUS COMMUNICATIONS 673
8W-20 CHARGING SYSTEM 677
8W-21 STARTING SYSTEM 681
8W-30 FUEL/IGNITION SYSTEM 685
8W-31 TRANSMISSION CONTROL SYSTEM 709
8W-33 VEHICLE SPEED CONTROL 725
8W-35 ANTILOCK BRAKES 729
8W-39 VEHICLE THEFT SECURITY SYSTEM 733
8W-40 INSTRUMENT CLUSTER 735
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 745
8W-42 AIR CONDITIONING-HEATER 749
8W-43 AIRBAG SYSTEM 759
8W-44 INTERIOR LIGHTING 763
8W-47 AUDIO SYSTEM 771
8W-48 REAR WINDOW DEFOGGER 777
8W-50 FRONT LIGHTING 781
8W-51 REAR LIGHTING 793
8W-52 TURN SIGNALS 801
8W-53 WIPERS 807
8W-70 SPLICE INFORMATION 811
8W-80 CONNECTOR PIN-OUTS 821
8W-91 CONNECTOR/GROUND/SPLICE LOCATION 875
CONNECTOR/GROUND/SPLICE LOCATION 875
DESCRIPTION 875
8W-97 POWER DISTRIBUTION 917
POWER DISTRIBUTION 917
DESCRIPTION 917
OPERATION 917
SPECIAL TOOLS 918
POWER DISTRIBUTION SYSTEMS 918
CIGAR LIGHTER OUTLET 918
DESCRIPTION 918
OPERATION 918
DIAGNOSIS AND TESTING – CIGAR LIGHTER OUTLET 918
FUSE BLOCK 919
DESCRIPTION 919
OPERATION 919
REMOVAL 919
INSTALLATION 920
IOD FUSE 921
DESCRIPTION 921
OPERATION 921
REMOVAL 921
INSTALLATION 921
MICRO-RELAY 922
DESCRIPTION 922
OPERATION 922
DIAGNOSIS AND TESTING – MICRO-RELAY 922
REMOVAL 922
INSTALLATION 922
POWER DISTRIBUTION CENTER 923
DESCRIPTION 923
OPERATION 923
REMOVAL 923
DISASSEMBLY 924
POWER DISTRIBUTION CENTER DISASSEMBLY 924
PDC HOUSING LOWER COVER REMOVAL 924
PDC B(+) TERMINAL MODULE REMOVAL 925
PDC RELAY WEDGE REMOVAL 925
PDC RELAY CASSETTE REMOVAL 925
ASSEMBLY 926
POWER DISTRIBUTION CENTER ASSEMBLY 926
PDC HOUSING LOWER COVER INSTALLATION 926
PDC B+ TERMINAL MODULE INSTALLATION 926
PDC RELAY WEDGE INSTALLATION 926
PDC RELAY CASSETTE INSTALLATION 927
INSTALLATION 927
POWER DISTRIBUTION CENTER SUPPORT BRACKET 928
REMOVAL 928
INSTALLATION 928
POWER OUTLET 928
DESCRIPTION 928
OPERATION 928
DIAGNOSIS AND TESTING – POWER OUTLET 928
REMOVAL 929
INSTALLATION 929
RELAY 929
DESCRIPTION 929
OPERATION 930
DIAGNOSIS AND TESTING – RELAY 930
DIAGNOSIS & TESTING – RELAY CIRCUIT TEST 930
REMOVAL 930
INSTALLATION 930
9-ENGINE 931
ENGINE 2 4L 931
ENGINE 2 4L 933
DESCRIPTION 933
DIAGNOSIS AND TESTING 933
DIAGNOSIS AND TESTING – CYLINDER COMBUSTION PRESSURE LEAKAGE TEST 933
DIAGNOSIS AND TESTING – CYLINDER COMPRESSION PRESSURE TEST 934
DIAGNOSIS AND TESTING – ENGINE OIL LEAK INSPECTION 934
INSPECTION FOR REAR SEAL AREA LEAKS 934
DIAGNOSIS AND TESTING – ENGINE 935
DIAGNOSIS AND TESTING – ENGINE MECHANICAL 936
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – PERFORMANCE 938
STANDARD PROCEDURE 940
STANDARD PROCEDURE – REPAIR OF DAMAGED OR WORN THREADS 940
STANDARD PROCEDURE – ENGINE CORE AND OIL GALLERY PLUGS 940
STANDARD PROCEDURE – ENGINE GASKET SURFACE PREPARATION 940
STANDARD PROCEDURE – MEASURING BEARING CLEARANCE USING PLASTIGAGE 940
STANDARD PROCEDURE – FORM-IN-PLACE GASKETS AND SEALERS 941
SEALER APPLICATION 942
STANDARD PROCEDURE – HYDROSTATIC LOCKED ENGINE 942
REMOVAL – ENGINE ASSEMBLY 942
INSTALLATION – ENGINE ASSEMBLY 943
SPECIFICATIONS 944
SPECIFICATIONS – 2 4L ENGINE 944
SPECIFICATIONS – TORQUE 947
SPECIAL TOOLS 948
2 4L ENGINE 948
AIR CLEANER ELEMENT – 2 4L 950
REMOVAL – 2 4L 950
INSTALLATION – 2 4L 950
AIR CLEANER HOUSING 950
REMOVAL 950
INSTALLATION 950
CYLINDER HEAD 951
DESCRIPTION 951
OPERATION 951
DIAGNOSIS AND TESTING – CYLINDER HEAD GASKET 951
CYLINDER-TO-CYLINDER LEAKAGE TEST 951
CYLINDER-TO-WATER JACKET LEAKAGE TEST 952
REMOVAL – CYLINDER HEAD 952
CLEANING 952
INSPECTION 952
INSTALLATION – CYLINDER HEAD 953
CAMSHAFT OIL SEAL(S) 954
REMOVAL 954
INSTALLATION 954
CAMSHAFT(S) 955
DESCRIPTION 955
OPERATION 955
STANDARD PROCEDURE – CAMSHAFT END-PLAY 955
REMOVAL 956
CLEANING 956
INSPECTION 956
INSTALLATION 957
CYLINDER HEAD COVER 957
REMOVAL 957
CLEANING 957
INSPECTION 957
INSTALLATION 958
INTAKE/EXHAUST VALVES & SEATS 959
DESCRIPTION 959
CLEANING 959
VALVE SPRINGS 959
REMOVAL 959
REMOVAL – CYLINDER HEAD ON 959
REMOVAL – CYLINDER HEAD OFF 959
INSPECTION 959
INSTALLATION 960
INSTALLATION – CYLINDER HEAD ON 960
INSTALLATION – CYLINDER HEAD OFF 960
HYDRAULIC LIFTERS 960
DIAGNOSIS AND TESTING – LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS 960
REMOVAL 961
INSTALLATION 961
ROCKER ARMS 961
REMOVAL 961
INSPECTION 961
INSTALLATION 961
ENGINE BLOCK 962
DESCRIPTION 962
STANDARD PROCEDURE 962
STANDARD PROCEDURE – PISTON TO CYLINDER BORE FITTING 962
STANDARD PROCEDURE – CYLINDER BORE HONING 962
CLEANING 963
INSPECTION 963
ENGINE BLOCK 963
CYLINDER BORE 963
CONNECTING ROD BEARINGS 964
STANDARD PROCEDURE 964
CONNECTING ROD – FITTING 964
CRANKSHAFT 964
DESCRIPTION 964
OPERATION 964
STANDARD PROCEDURE – CRANKSHAFT END PLAY 964
REMOVAL 965
INSPECTION 966
INSTALLATION 966
CRANKSHAFT MAIN BEARINGS 968
STANDARD PROCEDURE – MAIN BEARING – FITTING 968
CRANKSHAFT MAIN BEARINGS 968
MAIN BEARING INSTALLATION 968
CRANKSHAFT OIL SEAL – FRONT 969
REMOVAL 969
INSTALLATION 970
CRANKSHAFT OIL SEAL – REAR 971
REMOVAL 971
INSTALLATION 971
PISTON & CONNECTING ROD 972
DESCRIPTION 972
OPERATION 972
REMOVAL 972
INSTALLATION 973
PISTON RINGS 974
STANDARD PROCEDURE 974
PISTON RING – FITTING 974
PISTON RINGS – INSTALLATION 975
VIBRATION DAMPER 976
REMOVAL 976
INSTALLATION 976
STRUCTURAL COLLAR 976
REMOVAL 976
INSTALLATION 976
ENGINE MOUNTING 976
DESCRIPTION 976
FRONT MOUNT 976
REMOVAL 976
INSTALLATION 976
REAR MOUNT 977
REMOVAL 977
MANUAL TRANSMISSION 977
AUTOMATIC TRANSMISSION 977
INSTALLATION 977
MANUAL TRANSMISSION: 977
AUTOMATIC TRANSMISSION: 977
LUBRICATION 979
DESCRIPTION 979
OPERATION 979
DIAGNOSIS AND TESTING – ENGINE OIL PRESSURE CHECKING 979
OIL 979
STANDARD PROCEDURE 979
ENGINE OIL LEVEL CHECK 979
STANDARD PROCEDURE – ENGINE OIL AND FILTER CHANGE 979
OIL FILTER 980
DESCRIPTION 980
REMOVAL 980
INSTALLATION 980
OIL PAN 980
REMOVAL 980
INSTALLATION 980
OIL PRESSURE SENSOR/SWITCH 981
DESCRIPTION 981
OPERATION 981
OIL PUMP 981
REMOVAL 981
DISASSEMBLY 982
CLEANING 982
INSPECTION 982
ASSEMBLY 982
INSTALLATION 983
INTAKE MANIFOLD 984
DESCRIPTION 984
OPERATION 984
DIAGNOSIS AND TESTING – INTAKE MANIFOLD LEAKS 984
REMOVAL 984
INSPECTION 984
INSTALLATION 985
EXHAUST MANIFOLD 985
DESCRIPTION 985
OPERATION 985
REMOVAL 985
CLEANING 986
INSPECTION 986
INSTALLATION 986
TIMING BELT COVER(S) 986
REMOVAL 986
FRONT COVER 986
REAR COVER 986
INSTALLATION 986
REAR COVER 986
FRONT COVER 986
TIMING BELT AND SPROCKET(S) 987
REMOVAL 987
REMOVAL – TIMING BELT 987
REMOVAL – CRANKSHAFT SPROCKET 988
CLEANING 988
INSTALLATION 988
INSTALLATION – CRANKSHAFT SPROCKET 988
INSTALLATION – TIMING BELT 989
TIMING BELT TENSIONER & PULLEY 991
REMOVAL 991
INSTALLATION 991
BALANCE SHAFTS AND CARRIER ASSEMBLY 991
DESCRIPTION 991
OPERATION 991
REMOVAL 992
BALANCE SHAFTS/CHAIN/SPROCKETS 992
BALANCE SHAFT CARRIER 993
INSTALLATION 993
BALANCE SHAFT INSTALLATION/TIMING 993
BALANCE SHAFT CARRIER 995
DESCRIPTION 995
OPERATION 995
REMOVAL 995
INSTALLATION 995
BALANCE SHAFT CHAIN 996
REMOVAL 996
INSTALLATION 996
ENGINE 4 0L 997
ENGINE 4 0L 998
DESCRIPTION 998
DESCRIPTION – ENGINE BLOCK 998
DESCRIPTION – ENGINE 998
DIAGNOSIS AND TESTING 999
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – INTRODUCTION 999
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – PERFORMANCE 1000
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – MECHANICAL 1002
DIAGNOSIS AND TESTING—CYLINDER COMPRESSION PRESSURE 1004
DIAGNOSIS AND TESTING – CYLINDER COMBUSTION PRESSURE LEAKAGE 1004
STANDARD PROCEDURE 1005
STANDARD PROCEDURE – FORM-IN-PLACE GASKETS 1005
MOPAR SILICONE RUBBER ADHESIVE SEALANT 1005
MOPAR GASKET MAKER 1005
SURFACE PREPARATION 1005
GASKET APPLICATION 1005
STANDARD PROCEDURE – HYDROSTATIC LOCK 1006
STANDARD PROCEDURE – SERVICE ENGINE ASSEMBLY (SHORT BLOCK) 1006
STANDARD PROCEDURE – REPAIR DAMAGED OR WORN THREADS 1006
STANDARD PROCEDURE – ENGINE PERFORMANCE 1006
REMOVAL 1006
INSTALLATION 1008
SPECIFICATIONS 1009
ENGINE – 4 0L 1009
TORQUE – 4 0L ENGINE 1013
AIR CLEANER ELEMENT 1014
REMOVAL 1014
INSTALLATION 1014
AIR CLEANER HOUSING 1014
REMOVAL 1014
INSTALLATION 1014
CYLINDER HEAD 1015
DESCRIPTION 1015
DIAGNOSIS AND TESTING – ENGINE CYLINDER HEAD GASKET FAILURE 1015
CYLINDER-TO-CYLINDER LEAKAGE TEST 1015
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1015
REMOVAL 1015
CLEANING 1016
INSPECTION 1016
INSTALLATION 1016
CYLINDER HEAD COVER(S) 1018
DESCRIPTION 1018
REMOVAL 1018
CLEANING 1018
INSPECTION 1018
INSTALLATION 1018
INTAKE/EXHAUST VALVES & SEATS 1019
DESCRIPTION 1019
STANDARD PROCEDURE – VALVE SERVICE 1019
VALVE REFACING 1019
VALVE SEAT REFACING 1019
VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT 1020
REMOVAL 1021
INSTALLATION 1021
ROCKER ARM / ADJUSTER ASSEMBLY 1021
DESCRIPTION 1021
OPERATION 1021
REMOVAL 1022
CLEANING 1022
INSPECTION 1022
INSTALLATION 1022
VALVE STEM SEALS 1023
DESCRIPTION 1023
VALVE SPRINGS 1023
DESCRIPTION 1023
STANDARD PROCEDURE – VALVE SPRING TENSION TEST 1023
REMOVAL 1023
INSTALLATION 1025
ENGINE BLOCK 1025
CLEANING 1025
INSPECTION 1025
CAMSHAFT & BEARINGS (IN BLOCK) 1026
DESCRIPTION 1026
REMOVAL 1026
REMOVAL – CAMSHAFT BEARINGS 1026
REMOVAL – CAMSHAFT 1026
INSTALLATION 1027
INSTALLATION – CAMSHAFT BEARINGS 1027
INSTALLATION – CAMSHAFT 1027
CONNECTING ROD BEARINGS 1028
STANDARD PROCEDURE – FITTING CONNECTING ROD BEARINGS 1028
BEARING-TO-JOURNAL CLEARANCE 1028
SIDE CLEARANCE MEASUREMENT 1030
CRANKSHAFT 1031
DESCRIPTION 1031
CRANKSHAFT MAIN BEARINGS 1031
STANDARD PROCEDURE – FITTING CRANKSHAFT MAIN BEARINGS 1031
FITTING BEARINGS (CRANKSHAFT INSTALLED) 1031
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT INSTALLED) 1031
JOURNAL DIAMETER (CRANKSHAFT REMOVED) 1032
REMOVAL 1033
INSPECTION 1034
INSTALLATION 1035
CRANKSHAFT OIL SEAL – FRONT 1036
REMOVAL 1036
INSTALLATION 1036
CRANKSHAFT OIL SEAL – REAR 1036
REMOVAL 1036
INSTALLATION 1037
HYDRAULIC LIFTERS 1037
DESCRIPTION 1037
REMOVAL 1037
CLEANING 1037
INSPECTION 1038
INSTALLATION 1038
PISTON & CONNECTING ROD 1039
DESCRIPTION 1039
STANDARD PROCEDURE – PISTON FITTING 1039
REMOVAL 1040
INSTALLATION 1041
PISTON RINGS 1042
STANDARD PROCEDURE – PISTON RING FITTING 1042
VIBRATION DAMPER 1044
REMOVAL 1044
INSTALLATION 1044
STRUCTURAL SUPPORT 1044
REMOVAL 1044
INSTALLATION 1045
FRONT MOUNT 1045
REMOVAL 1045
INSTALLATION 1045
REAR MOUNT 1046
REMOVAL 1046
ALL TRANSMISSIONS 1046
MANUAL TRANSMISSIONS0 – 6 TJ (Continued) 1046
AUTOMATIC TRANSMISSIONS 1046
INSTALLATION 1047
MANUAL TRANSMISSION 1047
AUTOMATIC TRANSMISSION 1047
ALL TRANSMISSIONS 1047
LUBRICATION 1047
DESCRIPTION 1047
OPERATION 1047
DIAGNOSIS AND TESTING 1049
DIAGNOSIS AND TESTING – ENGINE OIL PRESSURE 1049
DIAGNOSIS AND TESTING – ENGINE OIL LEAK 1049
Air Leak Detection Test Method 1049
INSPECTION FOR REAR SEAL AREA LEAKS 1049
OIL 1050
STANDARD PROCEDURE – ENGINE OIL SERVICE 1050
ENGINE OIL CHANGE 1050
CRANKCASE OIL LEVEL INSPECTION 1050
USED ENGINE OIL DISPOSAL 1051
OIL FILTER 1051
REMOVAL 1051
INSTALLATION 1051
OIL PAN 1051
DESCRIPTION 1051
REMOVAL 1051
INSTALLATION 1052
ENGINE OIL PRESSURE SENSOR 1053
DESCRIPTION 1053
OPERATION 1053
OIL PUMP 1053
REMOVAL 1053
INSTALLATION 1053
VALVE TIMING 1054
STANDARD PROCEDURE – VALVE TIMING 1054
TIMING BELT / CHAIN COVER(S) 1054
REMOVAL 1054
INSTALLATION 1054
TIMING BELT/CHAIN AND SPROCKETS 1055
REMOVAL 1055
INSTALLATION 1056
INTAKE MANIFOLD 1056
DESCRIPTION 1056
DIAGNOSIS AND TESTING – INTAKE MANIFOLD LEAKAGE 1056
REMOVAL 1056
INSTALLATION 1057
EXHAUST MANIFOLD 1058
DESCRIPTION 1058
REMOVAL 1058
11-EXHAUST SYSTEM 1059
EXHAUST SYSTEM 1059
DESCRIPTION 1059
DIAGNOSIS AND TESTING – EXHAUST SYSTEM 1062
SPECIFICATIONS 1062
TORQUE 1062
CATALYTIC CONVERTER 1062
DESCRIPTION 1062
REMOVAL 1063
REMOVAL – 2 4L 1063
REMOVAL – 4 0L 1063
INSTALLATION 1064
INSTALLATION – 2 4L 1064
INSTALLATION – 4 0L 1064
EXHAUST PIPE 1064
REMOVAL 1064
REMOVAL – 2 4L 1064
REMOVAL – 4 0L 1065
INSTALLATION 1065
INSTALLATION – 2 4L 1065
INSTALLATION – 4 0L 1066
HEAT SHIELDS 1066
DESCRIPTION 1066
REMOVAL 1066
INSTALLATION 1066
MUFFLER 1067
DESCRIPTION 1067
REMOVAL 1067
INSTALLATION 1068
TAILPIPE 1069
DESCRIPTION 1069
TAILPIPE 1069
DESCRIPTION 1069
OPERATION 1069
13-FRAME & BUMPERS 1071
FRAME & BUMPERS 1071
SPECIFICATIONS 1071
TORQUE SPECIFICATIONS 1071
FRONT EXTENSION 1072
REMOVAL 1072
INSTALLATION 1072
FRONT BUMPER 1072
REMOVAL 1072
INSTALLATION 1072
REAR EXTENSION 1072
REMOVAL 1072
INSTALLATION 1072
REAR BUMPER 1072
REMOVAL 1072
INSTALLATION 1073
FRAME 1073
STANDARD PROCEDURE – FRAME SERVICE 1073
SAFETY PRECAUTIONS AND WARNINGS 1073
FRAME STRAIGHTENING 1073
FRAME REPAIRS 1073
FRAME FASTENERS 1074
SPECIFICATIONS 1074
FRAME DIMENSIONS 1074
VEHICLE PREPARATION 1074
TRANSFER CASE SKID PLATE 1079
REMOVAL 1079
INSTALLATION 1079
FUEL TANK SKID PLATE 1080
REMOVAL 1080
INSTALLATION 1080
FRONT TOW HOOK 1080
REMOVAL 1080
INSTALLATION 1080
REAR TOW HOOK 1081
REMOVAL 1081
INSTALLATION 1081
TRANSMISSION SKID PLATE 1081
REMOVAL 1081
INSTALLATION 1081
14-FUEL SYSTEM 1083
FUEL DELIVERY 1083
FUEL DELIVERY 1083
DESCRIPTION 1083
OPERATION 1084
STANDARD PROCEDURE – FUEL SYSTEM PRESSURE RELEASE 1084
SPECIFICATIONS 1085
FUEL SYSTEM PRESSURE 1085
TORQUE – FUEL DELIVERY 1085
SPECIAL TOOLS 1086
FUEL SYSTEM 1086
FUEL FILTER/PRESSURE REGULATOR 1087
DESCRIPTION 1087
OPERATION 1087
REMOVAL 1087
INSTALLATION 1088
FUEL LEVEL SENDING UNIT / SENSOR 1088
DESCRIPTION 1088
OPERATION 1088
REMOVAL 1089
INSTALLATION 1089
FUEL LINES 1089
DESCRIPTION 1089
FUEL PUMP 1090
DESCRIPTION 1090
OPERATION 1090
FUEL PUMP MODULE 1090
DESCRIPTION 1090
OPERATION 1091
REMOVAL 1091
INSTALLATION 1091
FUEL RAIL/FUEL DAMPER – 2 4L 1092
DESCRIPTION – 2 4L 1092
OPERATION – 2 4L 1092
REMOVAL – 2 4L 1092
INSTALLATION – 2 4L 1092
FUEL RAIL – 4 0L ENGINE 1094
DESCRIPTION – 4 0L 1094
OPERATION – 4 0L 1094
REMOVAL – 4 0L 1094
INSTALLATION – 4 0L 1094
FUEL TANK 1095
DESCRIPTION 1095
OPERATION 1095
REMOVAL 1096
INSTALLATION 1097
INLET FILTER 1098
REMOVAL 1098
INSTALLATION 1099
QUICK CONNECT FITTING 1099
DESCRIPTION 1099
STANDARD PROCEDURE – QUICK-CONNECT FITTINGS 1099
DISCONNECTING 1099
CONNECTING 1102
FLOW MANAGEMENT VALVE 1102
DESCRIPTION 1102
OPERATION 1102
REMOVAL 1102
FUEL INJECTION 1103
FUEL INJECTION 1103
DESCRIPTION 1103
SPECIFICATIONS 1104
TORQUE – FUEL INJECTION 1104
ACCELERATOR PEDAL 1104
REMOVAL 1104
INSTALLATION 1104
CRANKSHAFT POSITION SENSOR 1105
DESCRIPTION 1105
OPERATION 1105
REMOVAL 1106
INSTALLATION 1107
FUEL INJECTOR 1108
DESCRIPTION 1108
OPERATION 1108
OPERATION – PCM OUTPUT 1108
OPERATION – FUEL INJECTOR 1109
REMOVAL 1109
INSTALLATION 1109
FUEL PUMP RELAY 1109
DESCRIPTION 1109
OPERATION 1109
REMOVAL 1110
INSTALLATION 1110
IDLE AIR CONTROL MOTOR 1110
DESCRIPTION 1110
OPERATION 1110
REMOVAL 1111
INSTALLATION 1111
INTAKE AIR TEMPERATURE SENSOR 1111
DESCRIPTION 1111
OPERATION 1112
REMOVAL 1112
INSTALLATION 1113
MAP SENSOR 1113
DESCRIPTION 1113
OPERATION 1113
REMOVAL 1114
INSTALLATION 1115
O2 HEATER RELAY 1115
DESCRIPTION 1115
OPERATION 1115
REMOVAL 1115
INSTALLATION 1115
O2 SENSOR 1115
DESCRIPTION 1115
OPERATION 1115
REMOVAL 1116
INSTALLATION 1118
THROTTLE BODY 1118
DESCRIPTION 1118
OPERATION 1118
REMOVAL 1118
INSTALLATION 1119
THROTTLE CONTROL CABLE 1119
REMOVAL 1119
INSTALLATION 1121
THROTTLE POSITION SENSOR 1122
DESCRIPTION 1122
OPERATION 1122
REMOVAL 1122
INSTALLATION 1123
19-STEERING 1125
STEERING 1125
DESCRIPTION 1125
OPERATION 1126
DIAGNOSIS AND TESTING 1126
DIAGNOSIS AND TESTING – POWER STEERING SYSTEM DIAGNOSIS CHARTS 1126
DIAGNOSIS AND TESTING – POWER STEERING FLOW AND PRESSURE 1128
FLOW AND PRESSURE TEST 1128
COLUMN 1130
COLUMN 1130
DESCRIPTION 1130
OPERATION – SERVICE PRECAUTIONS 1130
REMOVAL 1130
INSTALLATION 1132
SPECIFICATIONS 1133
TORQUE CHART 1133
IGNITION SWITCH 1133
DESCRIPTION 1133
DIAGNOSIS AND TESTING – IGNITION SWITCH 1133
ELECTRICAL DIAGNOSIS 1133
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE) 1133
REMOVAL 1133
INSTALLATION 1134
KEY-IN IGNITION SWITCH 1134
DESCRIPTION 1134
DIAGNOSIS AND TESTING – KEY-IN IGNITION SWITCH 1134
KEY CYLINDER 1135
REMOVAL 1135
INSTALLATION 1135
STEERING WHEEL 1135
REMOVAL 1135
INSTALLATION 1136
GEAR 1137
GEAR 1137
DESCRIPTION 1137
OPERATION 1137
DIAGNOSIS AND TESTING – POWER STEERING GEAR LEAKAGE AREAS 1137
REMOVAL 1137
INSTALLATION 1138
ADJUSTMENTS 1139
WORM THRUST BEARING PRELOAD 1139
OVER-CENTER ROTATING TORQUE 1139
SPECIFICATIONS 1140
POWER STEERING GEAR 1140
TORQUE CHART 1140
SPECIAL TOOLS 1140
POWER STEERING GEAR 1140
LINKAGE 1141
LINKAGE 1141
DESCRIPTION 1141
STANDARD PROCEDURE 1141
STANDARD PROCEDURE – LUBRICATION 1141
STANDARD PROCEDURE – STEERING LINKAGE 1141
SPECIFICATIONS 1142
TORQUE CHART 1142
SPECIAL TOOLS 1142
STEERING LINKAGE 1142
DAMPER 1142
REMOVAL 1142
INSTALLATION 1142
DRAG LINK 1143
REMOVAL 1143
INSTALLATION 1143
PITMAN ARM 1143
REMOVAL 1143
INSTALLATION 1143
TIE ROD END 1143
REMOVAL 1143
INSTALLATION 1143
PUMP 1144
PUMP 1144
DESCRIPTION 1144
OPERATION 1144
DIAGNOSIS AND TESTING – PUMP LEAKAGE 1144
STANDARD PROCEDURE – POWER STEERING PUMP – INITIAL OPERATION 1144
REMOVAL 1145
REMOVAL – 4 0L 1145
REMOVAL – 2 4L 1145
INSTALLATION 1145
INSTALLATION – 4 0L 1145
INSTALLATION – 2 4L 1146
SPECIFICATIONS 1147
TORQUE CHART 1147
SPECIAL TOOLS 1147
POWER STEERING PUMP 1147
HOSES 1148
DESCRIPTION 1148
DESCRIPTION – PRESSURE LINE 1148
DESCRIPTION – RETURN LINE 1148
OPERATION 1148
OPERATION – PRESSURE LINE 1148
OPERATION – RETURN LINE 1148
FLUID 1148
DESCRIPTION 1148
STANDARD PROCEDURE – POWER STEERING FLUID LEVEL CHECKING 1148
POWER STEERING PRESSURE SWITCH 1148
DESCRIPTION 1148
OPERATION 1148
REMOVAL 1149
INSTALLATION 1149
PULLEY 1149
REMOVAL 1149
INSTALLATION 1149
RESERVOIR 1150
REMOVAL 1150
REMOVAL – 4 0L 1150
REMOVAL – 2 4L 1150
INSTALLATION 1150
INSTALLATION – 4 0L 1150
INSTALLATION – 2 4L 1150
21-TRANSMISSION AND TRANSFER CASE 1151
MANUAL – NV1500 1151
MANUAL – NV1500 1151
DESCRIPTION 1151
OPERATION 1151
DIAGNOSIS AND TESTING 1152
LOW LUBRICANT LEVEL 1152
HARD SHIFTING 1152
TRANSMISSION NOISE 1152
REMOVAL 1152
DISASSEMBLY 1153
CLEANING 1160
INSPECTION 1160
SHIFT LEVER ASSEMBLY 1160
SHIFT SHAFT AND FORKS 1160
FRONT/REAR HOUSINGS AND BEARING RETAINERS 1160
COUNTERSHAFT BEARINGS AND RACES 1161
REVERSE IDLER COMPONENTS 1161
Shift Socket 1162
Output Shaft And Geartrain 1162
ASSEMBLY 1162
INSTALLATION 1178
SPECIFICATIONS 1179
MANUAL 1179
SPECIAL TOOLS 1180
MANUAL – NV3550 1182
MANUAL – NV3550 1182
DESCRIPTION 1182
OPERATION 1182
DIAGNOSIS AND TESTING 1182
LOW LUBRICANT LEVEL 1182
HARD SHIFTING 1183
TRANSMISSION NOISE 1183
REMOVAL 1183
DISASSEMBLY 1184
FRONT HOUSING 1184
SHIFT/FORK SHAFTS AND REVERSE IDLER SEGMENT 1187
REAR ADAPTER HOUSING 1190
GEARTRAIN FROM FIXTURE 1190
OUTPUT SHAFT 1190
REVERSE IDLER 1194
CLEANING 1194
INSPECTION 1194
SHIFT LEVER ASSEMBLY 1194
SHIFT SHAFT AND FORKS 1194
FRONT/REAR HOUSINGS AND BEARING RETAINERS 1194
COUNTERSHAFT BEARINGS AND RACES 1195
REVERSE IDLER COMPONENTS 1196
Shift Socket 1196
Output Shaft And Geartrain 1196
ASSEMBLY 1196
SYNCHRONIZER 1196
OUTPUT SHAFT 1196
REVERSE IDLER ASSEMBLY 1203
SHIFT SHAFT AND BUSHINGS/BEARINGS 1205
DETENT PLUNGER BUSHING 1205
GEARTRAIN ASSEMBLY 1206
ADAPTER HOUSING 1208
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET 1209
FRONT HOUSING AND INPUT SHAFT BEARING RETAINER 1213
SHIFT TOWER AND LEVER 1216
INSTALLATION 1216
SPECIFICATIONS 1217
MANUAL 1217
SPECIAL TOOLS 1217
VEHICLE SPEED SENSOR 1219
DESCRIPTION 1219
OPERATION 1219
REMOVAL 1219
INSTALLATION 1219
AUTOMATIC TRANSMISSION – 42RLE 1220
AUTOMATIC TRANSMISSION – 42RLE 1222
DESCRIPTION 1222
TRANSMISSION IDENTIFICATION 1223
OPERATION 1223
FIRST GEAR POWERFLOW 1224
SECOND GEAR POWERFLOW 1225
THIRD GEAR POWERFLOW 1226
FOURTH GEAR POWERFLOW 1227
REVERSE GEAR POWERFLOW 1228
DIAGNOSIS AND TESTING 1229
DIAGNOSIS AND TESTING – AUTOMATIC TRANSMISSION 1229
DIAGNOSIS AND TESTING – ROAD TEST 1229
DIAGNOSIS AND TESTING – HYDRAULIC PRESSURE TESTS 1230
TEST ONE-SELECTOR IN L (1st Gear) 1231
TEST TWO-SELECTOR IN DRIVE (Second Gear) 1231
TEST TWO A–SELECTOR IN OD (Fourth Gear) 1231
TEST THREE-SELECTOR IN OVERDRIVE (Third and Second Gear) 1231
TEST FOUR-SELECTOR IN OD (Fourth Gear) 1231
TEST FIVE-SELECTOR IN OVERDRIVE (Fourth Gear, CC on) 1231
TEST SIX-SELECTOR IN REVERSE 1231
TEST RESULT INDICATIONS 1232
DIAGNOSIS AND TESTING – CLUTCH AIR PRESSURE TESTS 1232
OVERDRIVE CLUTCH 1233
UNDERDRIVE CLUTCH 1233
REVERSE CLUTCH 1233
2/4 CLUTCH 1233
LOW/REVERSE CLUTCH 1233
DIAGNOSIS AND TESTING – FLUID LEAKAGE 1233
FLUID LEAKAGE – TORQUE CONVERTER HOUSING AREA 1233
TORQUE CONVERTER LEAKAGE 1234
STANDARD PROCEDURE – ALUMINUM THREAD REPAIR 1234
REMOVAL 1234
DISASSEMBLY 1236
ASSEMBLY 1251
INSTALLATION 1267
SCHEMATICS AND DIAGRAMS – 42RLE TRANSMISSION 1270
SPECIFICATIONS 1283
42RLE AUTOMATIC TRANSMISSION 1283
SPECIAL TOOLS 1285
42RLE AUTOMATIC TRANSMISSION 1285
ACCUMULATOR 1288
DESCRIPTION 1288
OPERATION 1288
ADAPTER HOUSING SEAL 1288
REMOVAL 1288
INSTALLATION 1288
BEARINGS 1289
ADJUSTMENTS 1289
BEARING ADJUSTMENT PROCEDURES 1289
BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM 1289
DESCRIPTION 1289
OPERATION 1290
REMOVAL 1290
INSTALLATION 1290
ADJUSTMENTS 1290
ADJUSTMENT – BRAKE TRANSMISSION SHIFT INTERLOCK CABLE 1290
DRIVING CLUTCHES 1292
DESCRIPTION 1292
OPERATION 1292
UNDERDRIVE CLUTCH 1292
OVERDRIVE CLUTCH 1292
REVERSE CLUTCH 1292
FLUID AND FILTER 1292
DIAGNOSIS AND TESTING 1292
DIAGNOSIS AND TESTING – CAUSES OF BURNT FLUID 1292
DIAGNOSIS AND TESTING – EFFECTS OF INCORRECT FLUID LEVEL 1292
DIAGNOSIS AND TESTING – FLUID CONTAMINATION 1293
STANDARD PROCEDURE 1293
STANDARD PROCEDURE – FLUID LEVEL CHECK 1293
FLUID LEVEL CHECK 1293
FLUID LEVEL CHECK USING DRB 1293
STANDARD PROCEDURE – FLUID/FILTER SERVICE 1293
STANDARD PROCEDURE – TRANSMISSION FILL 1294
GEARSHIFT CABLE 1295
REMOVAL 1295
INSTALLATION 1295
HOLDING CLUTCHES 1296
DESCRIPTION 1296
OPERATION 1296
2/4 CLUTCH 1296
LOW/REVERSE CLUTCH 1296
INPUT CLUTCH ASSEMBLY 1296
DISASSEMBLY 1296
ASSEMBLY 1304
INPUT SPEED SENSOR 1313
DESCRIPTION 1313
OPERATION 1313
REMOVAL 1313
INSTALLATION 1314
OIL PUMP 1314
DESCRIPTION 1314
OPERATION 1314
DISASSEMBLY 1314
ASSEMBLY 1315
OUTPUT SPEED SENSOR 1316
DESCRIPTION 1316
OPERATION 1316
REMOVAL 1316
INSTALLATION 1316
OVERDRIVE SWITCH 1317
DESCRIPTION 1317
OPERATION 1317
REMOVAL 1317
INSTALLATION 1317
PLANETARY GEARTRAIN 1317
DESCRIPTION 1317
OPERATION 1318
SEAL – OIL PUMP 1318
REMOVAL 1318
INSTALLATION 1318
SHIFT MECHANISM 1318
DESCRIPTION 1318
OPERATION 1318
DIAGNOSIS AND TESTING – SHIFT MECHANISM 1318
ADJUSTMENTS – SHIFT MECHANISM 1318
Gearshift Adjustment Procedure 1318
SOLENOID 1319
DESCRIPTION 1319
OPERATION 1320
SOLENOID/PRESSURE SWITCH ASSY 1320
DESCRIPTION 1320
OPERATION 1320
SOLENOIDS 1320
PRESSURE SWITCHES 1321
REMOVAL 1321
INSTALLATION 1321
TORQUE CONVERTER 1322
DESCRIPTION 1322
IMPELLER 1323
TURBINE 1324
STATOR 1325
TORQUE CONVERTER CLUTCH (TCC) 1325
OPERATION 1326
TURBINE 1326
STATOR 1327
TORQUE CONVERTER CLUTCH (TCC) 1327
REMOVAL 1327
INSTALLATION 1327
TRANSMISSION CONTROL RELAY 1328
DESCRIPTION 1328
OPERATION 1328
TRANSMISSION RANGE SENSOR 1328
DESCRIPTION 1328
OPERATION 1328
REMOVAL 1329
INSTALLATION 1329
TRANSMISSION TEMPERATURE SENSOR 1329
DESCRIPTION 1329
OPERATION 1330
CALCULATED TEMPERATURE 1330
VALVE BODY 1330
DESCRIPTION 1330
OPERATION 1330
THERMAL VALVE 1330
REGULATOR VALVE 1330
SOLENOID SWITCH VALVE 1332
MANUAL VALVE 1332
CONVERTER CLUTCH SWITCH VALVE 1333
CONVERTER CLUTCH CONTROL VALVE 1333
T/C REGULATOR VALVE 1333
LOW/REVERSE SWITCH VALVE 1333
REMOVAL 1333
DISASSEMBLY 1335
ASSEMBLY 1340
INSTALLATION 1345
TRANSFER CASE – NV231 1346
TRANSFER CASE – NV231 1346
DESCRIPTION 1346
OPERATING RANGES 1346
SHIFT MECHANISM 1346
IDENTIFICATION 1346
OPERATION 1347
DIAGNOSIS AND TESTING – TRANSFER CASE – NV231 1347
REMOVAL 1348
DISASSEMBLY 1348
REAR RETAINER AND OIL PUMP 1348
YOKE AND RANGE LEVER 1350
FRONT OUTPUT SHAFT AND DRIVE CHAIN 1350
SHIFT FORKS AND MAINSHAFT 1352
MAINSHAFT 1353
INPUT GEAR AND LOW RANGE GEAR 1353
INPUT AND LOW RANGE GEAR 1354
CLEANING 1355
INSPECTION 1356
MAINSHAFT/SPROCKET/HUB 1356
INPUT GEAR AND PLANETARY CARRIER 1356
SHIFT FORKS/HUBS/SLEEVES 1357
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT 1357
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN 1357
LOW RANGE ANNULUS GEAR 1357
FRONT/REAR CASES AND FRONT RETAINER 1359
OIL PUMP/OIL PICKUP 1359
ASSEMBLY 1359
BEARINGS AND SEALS 1359
INPUT AND LOW RANGE GEAR 1363
INPUT GEAR AND LOW RANGE GEAR 1364
MAINSHAFT 1364
SHIFT FORKS AND MAINSHAFT 1365
FRONT OUTPUT SHAFT AND DRIVE CHAIN 1367
OIL PUMP AND REAR CASE 1367
YOKE AND RANGE LEVER 1368
REAR RETAINER 1369
INSTALLATION 1370
SPECIFICATIONS 1371
TRANSFER CASE – NV231 1371
SPECIAL TOOLS 1371
NV231 1371
FLUID 1373
STANDARD PROCEDURE – FLUID DRAIN AND FILL 1373
FRONT OUTPUT SHAFT SEAL 1373
REMOVAL 1373
INSTALLATION 1374
REAR OUTPUT SHAFT SEAL 1374
REMOVAL 1374
INSTALLATION 1375
SHIFT LEVER 1377
REMOVAL 1377
INSTALLATION 1377
ADJUSTMENTS – SHIFT LINKAGE 1378
SPEEDOMETER DRIVE ADAPTER 1378
REMOVAL 1378
INSTALLATION 1378
VEHICLE SPEED SENSOR 1379
DESCRIPTION 1379
OPERATION 1379
REMOVAL 1380
INSTALLATION 1380
TRANSFER CASE – NV241 1381
TRANSFER CASE – NV241 1381
DESCRIPTION 1381
IDENTIFICATION 1382
OPERATION 1382
OPERATING RANGES 1382
SHIFT MECHANISM 1382
SHIFTING 1382
DIAGNOSIS AND TESTING – TRANSFER CASE 1382
REMOVAL 1384
DISASSEMBLY 1384
REAR EXTENSION, RETAINER, AND REAR CASE 1384
YOKE AND SHIFT LEVER 1386
MAINSHAFT, FRONT OUTPUT SHAFT, AND DRIVE CHAIN 1388
SHIFT FORKS 1389
MAINSHAFT 1391
INPUT AND PLANETARY GEAR 1392
CLEANING 1395
INSPECTION 1395
MAINSHAFT/SPROCKET/HUB 1395
INPUT GEAR AND PLANETARY CARRIER 1395
SHIFT FORKS/HUBS/SLEEVES 1395
DRIVE CHAIN 1395
LOW RANGE ANNULUS GEAR 1395
FRONT-REAR CASES 1395
OIL PUMP/OIL PICKUP 1395
ASSEMBLY 1396
BEARINGS AND SEALS0 – 8 TJ (Continued) 1396
INPUT AND PLANETARY GEAR 1398
SHIFT FORKS AND MAINSHAFT 1399
FRONT OUTPUT SHAFT AND DRIVE CHAIN 1402
OIL PUMP AND REAR CASE 1403
YOKE 1405
REAR EXTENSION 1406
INSTALLATION 1408
SPECIFICATIONS 1408
TRANSFER CASE – NV241 1408
SPECIAL TOOLS 1409
TRANSFER CASE – NV241 1409
REAR EXTENSION SEAL 1411
REMOVAL 1411
INSTALLATION 1411
FLUID 1411
STANDARD PROCEDURE – FLUID DRAIN AND FILL 1411
FRONT OUTPUT SHAFT SEAL 1411
REMOVAL 1411
INSTALLATION 1412
POSITION SENSOR 1413
DESCRIPTION 1413
OPERATION 1413
REMOVAL 1413
INSTALLATION 1413
SHIFT LEVER 1414
REMOVAL 1414
INSTALLATION 1414
ADJUSTMENTS – SHIFT LINKAGE 1414
VEHICLE SPEED SENSOR 1415
DESCRIPTION 1415
OPERATION 1415
REMOVAL 1415
INSTALLATION 1415
22-TIRES/WHEELS 1417
TIRES/WHEELS 1417
DIAGNOSIS AND TESTING – TIRE AND WHEEL RUNOUT 1417
METHOD 1 (RELOCATE WHEEL ON HUB) 1417
METHOD 2 (RELOCATE TIRE ON WHEEL) 1417
STANDARD PROCEDURE 1418
STANDARD PROCEDURE – ROTATION 1418
STANDARD PROCEDURE – MATCH MOUNTING 1419
STANDARD PROCEDURE – TIRE AND WHEEL BALANCE 1420
TIRES 1421
DESCRIPTION 1421
DESCRIPTION – TIRES 1421
TIRE IDENTIFICATION 1421
TIRE CHAINS 1421
DESCRIPTION – RADIAL-PLY TIRES 1422
DESCRIPTION – TIRE INFLATION PRESSURES 1422
DESCRIPTION – TIRE PRESSURE FOR HIGH SPEED 1423
DESCRIPTION – REPLACEMENT TIRES 1423
DIAGNOSIS AND TESTING 1423
DIAGNOSIS AND TESTING – PRESSURE GAUGES 1423
DIAGNOSIS AND TESTING – TREAD WEAR INDICATORS 1423
DIAGNOSIS AND TESTING – TIRE WEAR PATTERNS 1423
DIAGNOSIS AND TESTING – TIRE NOISE OR VIBRATION 1424
DIAGNOSIS AND TESTING – TIRE/VEHICLE LEAD 1424
STANDARD PROCEDURE – REPAIRING LEAKS 1426
CLEANING – TIRES 1426
SPECIFICATIONS 1426
TIRE SIZE 1426
SPARE TIRE 1426
DESCRIPTION 1426
DESCRIPTION – SPARE/TEMPORARY 1426
DESCRIPTION – FULL SIZE, SPARE WHEEL WITH MATCHING TIRE 1426
SPARE TIRE CARRIER 1427
REMOVAL 1427
INSTALLATION 1427
WHEELS 1427
DESCRIPTION 1427
DIAGNOSIS AND TESTING – WHEEL INSPECTION 1428
STANDARD PROCEDURE 1428
STANDARD PROCEDURE – WHEEL INSTALLATION 1428
WHEEL REPLACEMENT 1428
STANDARD PROCEDURE – WHEEL REPLACEMENT 1428
SPECIFICATIONS 1429
TORQUE CHART 1429
STUDS 1429
REMOVAL 1429
INSTALLATION 1429
23-BODY 1431
BODY 1431
WARNING 1431
SAFETY PRECAUTIONS AND WARNINGS 1431
STANDARD PROCEDURE 1431
STANDARD PROCEDURE – BODY LUBRICATION 1431
STANDARD PROCEDURE – PLASTIC BODY PANEL REPAIR 1432
Rigid Plastics: 1432
Semi-Rigid Plastics: 1432
Flexible Plastics: 1432
Repair Procedure: 1432
Adhesion Promoter/Surface Modifier: 1432
SAFETY PRECAUTION AND WARNINGS 1432
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES 1433
PANEL SECTIONING 1435
PANEL REINFORCEMENT 1435
VISUAL INSPECTION 1436
PANEL SURFACE PREPARATION 1436
PATCHING PANELS 1436
PANEL PATCH FABRICATIONS 1436
PANEL PATCH INSTALLATION 1437
PATCHED PANEL SURFACING 1438
STANDARD PROCEDURE – BUZZ, SQUEAK & RATTLE 1439
SPECIFICATIONS – TORQUE 1440
SPECIAL TOOLS 1441
BODY 1441
TAILGATE 1442
TAILGATE OUTSIDE HANDLE 1442
REMOVAL 1442
INSTALLATION 1442
TAILGATE HINGE 1442
REMOVAL 1442
INSTALLATION 1442
TAILGATE LATCH 1443
REMOVAL 1443
INSTALLATION 1443
TAILGATE LATCH STRIKER 1443
REMOVAL 1443
INSTALLATION 1443
LIFTGATE GLASS HINGE 1443
REMOVAL 1443
INSTALLATION 1443
LIFTGATE GLASS 1444
REMOVAL 1444
INSTALLATION 1444
LIFTGATE GLASS WEATHERSTRIP 1444
DESCRIPTION 1444
TAILGATE LOCK CYLINDER 1444
REMOVAL 1444
INSTALLATION 1444
LIFTGATE GLASS SUPPORT CYLINDER 1445
REMOVAL 1445
INSTALLATION 1445
TAILGATE 1445
REMOVAL 1445
INSTALLATION 1446
ADJUSTMENTS 1446
ADJUSTMENT 1446
FULL DOOR 1447
DOOR 1447
REMOVAL 1447
INSTALLATION 1447
ADJUSTMENTS 1447
ADJUSTMENT 1447
DOOR GLASS 1447
REMOVAL 1447
INSTALLATION 1448
WINDOW REGULATOR 1448
REMOVAL 1448
INSTALLATION 1448
EXTERIOR HANDLE 1449
REMOVAL 1449
INSTALLATION 1449
GLASS RUN CHANNEL 1450
REMOVAL 1450
INSTALLATION 1450
HINGE 1450
REMOVAL 1450
INSTALLATION 1450
INSIDE HANDLE ACTUATOR 1451
REMOVAL 1451
INSTALLATION 1451
LATCH 1451
REMOVAL 1451
INSTALLATION 1451
LATCH STRIKER 1452
REMOVAL 1452
INSTALLATION 1452
LOCK CYLINDER 1452
REMOVAL 1452
INSTALLATION 1452
TRIM PANEL 1452
REMOVAL 1452
INSTALLATION 1452
HALF DOOR 1453
DOOR 1453
REMOVAL 1453
INSTALLATION 1453
WINDOW 1453
REMOVAL 1453
INSTALLATION 1453
EXTERIOR HANDLE 1454
REMOVAL 1454
INSTALLATION 1454
HINGE 1454
DESCRIPTION 1454
INSIDE HANDLE ACTUATOR 1454
REMOVAL 1454
INSTALLATION 1454
LATCH 1454
REMOVAL 1454
INSTALLATION 1455
LATCH STRIKER 1455
REMOVAL 1455
INSTALLATION 1455
LOCK CYLINDER 1455
REMOVAL 1455
INSTALLATION 1455
TRIM PANEL 1455
REMOVAL 1455
INSTALLATION 1455
EXTERIOR 1456
BODY DECALS 1456
DESCRIPTION 1456
REMOVAL 1456
INSTALLATION 1456
COWL GRILLE AND SCREEN 1457
REMOVAL 1457
INSTALLATION 1457
RIGHT FRONT FENDER 1457
REMOVAL 1457
INSTALLATION 1457
LEFT FRONT FENDER 1458
REMOVAL 1458
INSTALLATION 1458
RADIATOR GRILLE PANEL 1459
REMOVAL 1459
INSTALLATION 1460
WHEELHOUSE SPLASH SHIELD 1460
REMOVAL 1460
INSTALLATION 1460
SIDE VIEW MIRROR 1460
REMOVAL 1460
INSTALLATION 1460
WHEEL OPENING FLARE MOLDING 1461
REMOVAL 1461
INSTALLATION 1461
EXHAUSTER 1462
REMOVAL 1462
INSTALLATION 1462
BODY SIDE GUARD 1462
REMOVAL 1462
INSTALLATION 1462
SIDE STEP 1462
REMOVAL 1462
INSTALLATION 1463
LICENSE PLATE BRACKET 1463
REMOVAL 1463
INSTALLATION 1463
HOOD 1464
HINGE 1464
REMOVAL 1464
INSTALLATION 1464
HOOD 1464
REMOVAL 1464
INSTALLATION 1464
ADJUSTMENTS 1464
ADJUSTMENT 1464
HOOD SAFETY LATCH 1465
REMOVAL 1465
INSTALLATION 1465
INSTRUMENT PANEL 1466
ACCESSORY SWITCH BEZEL 1466
REMOVAL 1466
INSTALLATION 1467
AXLE LOCK SWITCH 1467
DESCRIPTION 1467
OPERATION 1467
DIAGNOSIS AND TESTING – AXLE LOCK SWITCH 1467
REMOVAL 1468
INSTALLATION 1468
BASE TRIM 1469
REMOVAL 1469
INSTALLATION 1469
CENTER BEZEL 1470
REMOVAL 1470
INSTALLATION 1470
CLUSTER BEZEL 1471
REMOVAL 1471
INSTALLATION 1471
GLOVE BOX 1472
REMOVAL 1472
DISASSEMBLY 1472
ASSEMBLY 1473
INSTALLATION 1473
GLOVE BOX CHECK STRAP 1474
REMOVAL 1474
INSTALLATION 1474
GLOVE BOX LATCH STRIKER 1474
REMOVAL 1474
INSTALLATION 1475
GRAB HANDLE 1475
REMOVAL 1475
INSTALLATION 1475
GRAB HANDLE BEZEL 1476
REMOVAL 1476
INSTALLATION 1476
INSTRUMENT PANEL ASSEMBLY 1477
REMOVAL 1477
INSTALLATION 1478
STEERING COLUMN OPENING COVER 1479
REMOVAL 1479
INSTALLATION 1479
TOP COVER 1480
REMOVAL 1480
INSTALLATION 1480
INTERIOR 1481
ADD-A-TRUNK 1481
REMOVAL 1481
INSTALLATION 1481
FRONT CARPET 1482
REMOVAL 1482
INSTALLATION 1482
CENTER CARPET 1482
REMOVAL 1482
INSTALLATION 1482
CARGO AREA CARPET 1482
REMOVAL 1482
INSTALLATION 1482
WHEELHOUSE CARPET 1482
REMOVAL 1482
INSTALLATION 1482
REAR VIEW MIRROR 1483
REMOVAL 1483
INSTALLATION 1483
REAR VIEW MIRROR SUPPORT BRACKET 1483
INSTALLATION 1483
SUNVISOR 1484
REMOVAL 1484
INSTALLATION 1484
SHIFT BEZEL – AUTOMATIC TRANSMISSION 1484
REMOVAL 1484
INSTALLATION 1484
SHIFT BOOT 1485
REMOVAL 1485
INSTALLATION 1485
CENTER CONSOLE 1485
REMOVAL 1485
INSTALLATION 1485
CENTER CONSOLE CUP HOLDER 1486
REMOVAL 1486
INSTALLATION 1486
CONSOLE LOCK CYLINDER 1487
REMOVAL 1487
INSTALLATION 1487
SPORT BAR 1487
REMOVAL 1487
INSTALLATION 1487
A-PILLAR TRIM 1488
REMOVAL 1488
INSTALLATION 1488
REAR HEADER TRIM 1488
REMOVAL 1488
INSTALLATION 1488
WINDSHIELD HEADER 1489
REMOVAL 1489
INSTALLATION 1489
SPORT BAR – SPEAKER POD 1490
REMOVAL 1490
INSTALLATION 1490
PAINT 1491
PAINT 1491
SPECIFICATIONS – PAINT CODES 1491
PAINT CODE 1491
DESCRIPTION 1491
BASECOAT/CLEARCOAT FINISH 1492
DESCRIPTION 1492
PAINT TOUCH-UP 1492
STANDARD PROCEDURE – PAINT TOUCH-UP 1492
FINESSE SANDING, BUFFING & POLISHING 1492
DESCRIPTION 1492
REMOVEABLE TOP 1493
REMOVEABLE TOP 1493
STANDARD PROCEDURE 1493
HARD TOP REPAIR 1493
Hard Top Locators 1493
HARD TOP REPAIR 1493
HARD TOP FRACTURE REPAIR 1494
HARD TOP SAG REPAIR 1494
HARD TOP 1494
REMOVAL 1494
INSTALLATION 1494
SOFT TOP 1495
REMOVAL 1495
INSTALLATION 1496
SOFT TOP FABRIC 1497
REMOVAL 1497
INSTALLATION 1497
DOOR OPENING FRAME 1497
REMOVAL 1497
INSTALLATION 1497
HARD/SOFT TOP LATCH 1497
REMOVAL 1497
INSTALLATION 1497
SEATS 1498
FRONT SEAT 1498
REMOVAL 1498
INSTALLATION 1498
FRONT SEAT BACK 1499
REMOVAL 1499
INSTALLATION 1499
FRONT SEAT BACK COVER 1499
REMOVAL 1499
INSTALLATION 1500
FRONT SEAT CUSHION COVER 1500
REMOVAL 1500
INSTALLATION 1500
FRONT SEAT BACK RECLINER/COVER 1500
REMOVAL 1500
INSTALLATION 1500
FRONT SEAT BACK RECLINER CABLE 1500
REMOVAL 1500
INSTALLATION 1501
FRONT SEAT FOLDING RELEASE CABLE 1501
REMOVAL 1501
INSTALLATION 1502
FRONT SEAT BACK DUMP CABLE 1502
REMOVAL 1502
INSTALLATION 1502
FRONT SEAT TRACK ADJUSTER 1502
REMOVAL 1502
INSTALLATION 1502
REAR SEAT 1503
REMOVAL 1503
INSTALLATION 1503
REAR SEAT BACK 1504
REMOVAL 1504
INSTALLATION 1504
REAR SEAT BACK HINGE 1504
REMOVAL 1504
INSTALLATION 1504
REAR SEAT BACK COVER 1504
REMOVAL 1504
INSTALLATION 1504
REAR SEAT CUSHION COVER 1505
REMOVAL 1505
INSTALLATION 1505
REAR SEAT RELEASE CABLE 1506
REMOVAL 1506
INSTALLATION 1506
REAR SEAT STRIKERS 1506
REMOVAL 1506
Rear Strikers 1506
Front Strikers 1506
INSTALLATION 1506
Front Strikers 1506
Rear Strikers 1506
STATIONARY GLASS 1507
STATIONARY GLASS 1507
DESCRIPTION 1507
WINDSHIELD SAFETY PRECAUTIONS 1507
DESCRIPTION 1507
QUARTER GLASS 1507
REMOVAL 1507
INSTALLATION 1508
WINDSHIELD 1508
REMOVAL 1508
INSTALLATION 1509
WINDSHIELD HINGE 1510
REMOVAL 1510
INSTALLATION 1510
WINDSHIELD FRAME 1510
REMOVAL 1510
INSTALLATION 1511
WEATHERSTRIP/SEALS 1512
HOOD TO COWL WEATHERSTRIP 1512
REMOVAL 1512
INSTALLATION 1512
FULL DOOR INNER BELT WEATHERSTRIP 1512
DESCRIPTION – FULL DOOR INNER BELT WEATHERSTRIP 1512
FULL DOOR OUTER BELT SEAL 1512
REMOVAL 1512
INSTALLATION 1513
FULL DOOR WEATHERSTRIP 1513
REMOVAL 1513
INSTALLATION 1513
HALF DOOR WEATHERSTRIP 1513
REMOVAL 1513
INSTALLATION 1513
TAILGATE WEATHERSTRIP AND CHANNEL 1514
REMOVAL 1514
INSTALLATION 1514
WINDSHIELD FRAME WEATHERSTRIP 1514
REMOVAL 1514
UPPER (Header) 1514
LOWER 1514
INSTALLATION 1514
UPPER (Header) 1514
LOWER 1515
BODY STRUCTURE 1516
GAP AND FLUSH 1516
SPECIFICATIONS – GAP AND FLUSH 1516
OPENING DIMENSIONS 1519
SPECIFICATIONS 1519
BODY OPENING DIMENSIONS 1519
SEALER LOCATIONS 1524
SPECIFICATIONS 1524
SEALER LOCATIONS 1524
STRUCTURAL ADHESIVE LOCATIONS 1541
SPECIFICATIONS 1541
WELD LOCATIONS 1550
SPECIFICATIONS 1550
WELD LOCATIONS 1550
24-HEATING & AIR CONDITIONING 1603
HEATING & AIR CONDITIONING 1603
DESCRIPTION 1603
ENGINE COOLING SYSTEM REQUIREMENTS 1603
HEATER AND AIR CONDITIONER 1603
OPERATION 1604
DIAGNOSIS AND TESTING 1605
A/C PERFORMANCE 1605
A/C PERFORMANCE TEST 1605
HEATER PERFORMANCE 1608
MAXIMUM HEATER OUTPUT: TEST AND ACTION 1608
TEMPERATURE CONTROL 1608
SPECIFICATIONS 1609
HEATING AND A/C SYSTEM 1609
CONTROLS 1611
A/C COMPRESSOR CLUTCH/COIL 1612
DESCRIPTION 1612
OPERATION 1612
DIAGNOSIS AND TESTING 1612
A/C COMPRESSOR CLUTCH/COIL 1612
REMOVAL 1613
INSPECTION 1615
INSTALLATION 1615
CLUTCH BREAK-IN 1616
A/C COMPRESSOR CLUTCH RELAY 1616
DESCRIPTION 1616
OPERATION 1616
REMOVAL 1617
INSTALLATION 1617
A/C HEATER CONTROL 1617
DESCRIPTION 1617
DIAGNOSIS AND TESTING 1618
VACUUM CONTROL SYSTEM 1618
VACUUM CHECK VALVE 1618
HEATER-A/C CONTROLS 1618
LOCATING VACUUM LEAKS 1619
REMOVAL 1622
INSTALLATION 1622
A/C HIGH PRESSURE SWITCH 1623
DESCRIPTION 1623
OPERATION 1623
DIAGNOSIS AND TESTING 1623
A/C HIGH PRESSURE SWITCH 1623
REMOVAL 1623
INSTALLATION 1623
A/C LOW PRESSURE SWITCH 1624
DESCRIPTION 1624
OPERATION 1624
DIAGNOSIS AND TESTING 1624
A/C LOW PRESSURE SWITCH 1624
REMOVAL 1624
INSTALLATION 1624
BLEND DOOR ACTUATOR 1625
DESCRIPTION 1625
OPERATION 1625
REMOVAL 1625
INSTALLATION 1625
BLOWER MOTOR RELAY 1626
DESCRIPTION 1626
OPERATION 1626
REMOVAL 1626
INSTALLATION 1627
BLOWER MOTOR RESISTOR BLOCK 1627
DESCRIPTION 1627
OPERATION 1627
DIAGNOSIS AND TESTING 1627
BLOWER MOTOR RESISTOR BLOCK 1627
REMOVAL 1627
INSTALLATION 1628
BLOWER MOTOR SWITCH 1628
DESCRIPTION 1628
OPERATION 1628
DIAGNOSIS AND TESTING 1628
BLOWER MOTOR SWITCH 1628
REMOVAL 1629
INSTALLATION 1629
MODE DOOR ACTUATOR 1629
DESCRIPTION 1629
REMOVAL 1630
INSTALLATION 1631
RECIRCULATION DOOR ACTUATOR 1631
DESCRIPTION 1631
REMOVAL 1632
INSTALLATION 1632
VACUUM CHECK VALVE 1633
DESCRIPTION 1633
OPERATION 1633
REMOVAL 1633
INSTALLATION 1633
VACUUM RESERVOIR 1634
DESCRIPTION 1634
OPERATION 1634
REMOVAL 1634
INSTALLATION 1634
DISTRIBUTION 1635
AIR OUTLETS 1635
DESCRIPTION 1635
REMOVAL 1635
INSTALLATION 1635
BLEND DOOR 1636
REMOVAL 1636
INSTALLATION 1636
BLOWER MOTOR 1636
DESCRIPTION 1636
OPERATION 1636
DIAGNOSIS AND TESTING 1637
BLOWER MOTOR 1637
REMOVAL 1640
INSTALLATION 1640
DEFROSTER DUCT 1640
REMOVAL 1640
INSTALLATION 1641
FLOOR DISTRIBUTION DUCT 1641
REMOVAL 1641
INSTALLATION 1641
HVAC HOUSING 1642
REMOVAL 1642
DISASSEMBLY 1642
ASSEMBLY 1643
INSTALLATION 1644
INSTRUMENT PANEL DEMISTER DUCTS 1644
REMOVAL 1644
INSTALLATION 1645
INSTRUMENT PANEL DUCTS 1645
REMOVAL 1645
INSTALLATION 1646
MODE DOOR 1646
REMOVAL 1646
INSTALLATION 1647
RECIRCULATION AIR DOOR 1648
REMOVAL 1648
PLUMBING 1649
PLUMBING 1650
DESCRIPTION 1650
OPERATION 1650
WARNING 1650
ENGINE COOLING SYSTEM 1650
A/C SYSTEM 1650
CAUTION 1651
DIAGNOSIS AND TESTING 1651
REFRIGERANT SYSTEM LEAKS 1651
SYSTEM EMPTY 1651
SYSTEM LOW 1651
STANDARD PROCEDURE 1652
REFRIGERANT SYSTEM SERVICE EQUIPMENT 1652
MANIFOLD GAUGE SET CONNECTIONS 1653
REFRIGERANT CHARGE LEVEL TEST 1653
REFRIGERANT SYSTEM RECOVERY 1653
REFRIGERANT SYSTEM EVACUATE 1653
REFRIGERANT SYSTEM CHARGE 1655
A/C COMPRESSOR 1655
DESCRIPTION 1655
A/C COMPRESSOR 1655
HIGH PRESSURE RELIEF VALVE 1655
OPERATION 1656
A/C COMPRESSOR 1656
HIGH PRESSURE RELIEF VALVE 1656
DIAGNOSIS AND TESTING 1656
A/C COMPRESSOR NOISE 1656
REMOVAL 1657
INSTALLATION 1657
A/C CONDENSER 1658
DESCRIPTION 1658
OPERATION 1658
REMOVAL 1658
INSTALLATION 1659
A/C DISCHARGE LINE 1660
DESCRIPTION 1660
REMOVAL 1660
INSTALLATION 1661
A/C EVAPORATOR 1661
DESCRIPTION 1661
OPERATION 1661
REMOVAL 1662
INSTALLATION 1662
A/C ORIFICE TUBE 1662
DESCRIPTION 1662
OPERATION 1662
DIAGNOSIS AND TESTING 1662
A/C ORIFICE TUBE 1662
ACCUMULATOR 1663
DESCRIPTION 1663
OPERATION 1663
REMOVAL 1663
INSTALLATION0 – 10 TJ (Continued) 1664
HEATER CORE 1664
DESCRIPTION 1664
OPERATION 1664
REMOVAL 1665
INSTALLATION 1665
LIQUID LINE 1665
DESCRIPTION 1665
REMOVAL 1665
INSTALLATION 1666
REFRIGERANT 1666
DESCRIPTION 1666
OPERATION 1666
REFRIGERANT LINE COUPLER 1666
DESCRIPTION 1666
OPERATION 1666
REMOVAL 1667
INSTALLATION 1667
REFRIGERANT OIL 1668
DESCRIPTION 1668
OPERATION 1668
STANDARD PROCEDURE 1668
REFRIGERANT OIL LEVEL 1668
SERVICE PORT VALVE CORE 1668
DESCRIPTION 1668
REMOVAL 1668
INSTALLATION 1669
SUCTION LINE 1669
DESCRIPTION 1669
REMOVAL 1669
INSTALLATION 1670
25-EMISSIONS CONTROL 1671
EMISSIONS CONTROL 1671
DESCRIPTION 1671
DESCRIPTION – EMISSION CONTROL SYSTEM 1671
DESCRIPTION – STATE DISPLAY TEST MODE 1672
DESCRIPTION – CIRCUIT ACTUATION TEST MODE 1672
DESCRIPTION – DIAGNOSTIC TROUBLE CODES 1672
DESCRIPTION – TASK MANAGER 1672
DESCRIPTION – MONITORED SYSTEMS 1672
OXYGEN SENSOR (O2S) MONITOR 1672
OXYGEN SENSOR HEATER MONITOR 1673
LEAK DETECTION PUMP MONITOR (IF EQUIPPED) 1673
MISFIRE MONITOR 1674
FUEL SYSTEM MONITOR 1674
CATALYST MONITOR 1674
DESCRIPTION – TRIP DEFINITION 1674
DESCRIPTION – COMPONENT MONITORS 1675
DESCRIPTION – NON-MONITORED CIRCUITS 1675
DESCRIPTION – HIGH AND LOW LIMITS 1676
DESCRIPTION – LOAD VALUE 1676
OPERATION – TASK MANAGER 1676
Test Sequence 1676
MIL Illumination 1677
Diagnostic Trouble Codes (DTCs) 1677
DTC Self Erasure 1677
Trip Indicator 1677
Freeze Frame Data Storage 1678
Similar Conditions Window 1678
EVAPORATIVE EMISSIONS 1680
EVAPORATIVE EMISSIONS 1680
DESCRIPTION – EVAPORATION CONTROL SYSTEM 1680
SPECIFICATIONS 1681
TORQUE – EMISSIONS 1681
CCV SYSTEM 1681
DESCRIPTION – CCV SYSTEM 1681
OPERATION – CCV SYSTEM 1681
DIAGNOSIS AND TESTING – CCV SYSTEM 1681
TESTING/CLEANING 1681
PCV VALVE 1682
DESCRIPTION 1682
2 4L 1682
OPERATION 1683
2 4L 1683
REMOVAL 1683
EVAP/PURGE SOLENOID 1683
DESCRIPTION 1683
OPERATION 1683
REMOVAL 1684
INSTALLATION 1684
FUEL FILLER CAP 1684
DESCRIPTION 1684
OPERATION 1684
REMOVAL 1684
LEAK DETECTION PUMP 1684
DESCRIPTION 1684
EVAP LEAK DETECTION SYSTEM COMPONENTS 1685
OPERATION 1685
LDP AT REST (NOT POWERED) 1686
DIAPHRAGM UPWARD MOVEMENT 1686
DIAPHRAGM DOWNWARD MOVEMENT 1687
PUMPING ACTION 1687
REMOVAL 1687
INSTALLATION 1689
ORVR 1689
DESCRIPTION 1689
OPERATION 1690
VACUUM LINES 1690
DESCRIPTION 1690
VAPOR CANISTER 1690
DESCRIPTION 1690
OPERATION 1690
REMOVAL 1690
INSTALLATION 1690
INDEX 1691
COMMENTS 0
2004-TJ-Powertrain pdf 0
MAIN WELCOME PAGE 0
INSTRUCTIONS 0
TJ Service Manual 0
TJ Body 0
TJ Chassis 0
TJ Transmission 0
TJ Powertrain 0
TABLE OF CONTENTS 1694
1 0 INTRODUCTION 1700
1 1 SYSTEM COVERAGE 1700
1 2 SIX-STEP TROUBLE SHOOTING PROCEDURE 1700
2 0 IDENTIFICATION OF SYSTEM 1700
3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 1700
3 1 GENERAL DESCRIPTION 1700
3 2 FUNCTION OPERATION 1700
3 2 1 FUEL CONTROL (GAS) 1700
3 2 2 ON-BOARD DIAGNOSTICS 1701
3 2 3 OTHER CONTROLS 1704
3 2 4 NON-MONITORED CIRCUITS 1709
3 2 5 SKIS OVERVIEW 1709
3 2 6 SKIM ON-BOARD DIAGNOSTICS 1709
3 2 7 SKIS OPERATION 1709
3 2 8 PROGRAMMING THE POWERTRAIN CONTROL MODULE 1710
3 2 9 PROGRAMMING THE SENTRY KEY IMMOBILIZER MODULE 1710
3 2 10 PROGRAMMING THE IGNITION KEYS TO THE SENTRY KEY IMMOBILIZER MODULE 1711
3 3 DIAGNOSTIC TROUBLE CODES 1711
3 3 1 HARD CODE 1711
3 3 2 INTERMITTENT CODE 1711
3 3 3 STARTS SINCE SET COUNTER 1712
3 3 4 NO START INFORMATION 1712
3 4 USING THE DRBIII 1712
3 5 DRBIII ERROR MESSAGES AND BLANK SCREEN 1712
3 5 1 DRBIII DOES NOT POWER UP 1712
3 5 2 DISPLAY IS NOT VISIBLE 1713
4 0 DISCLAIMERS, SAFETY, WARNINGS 1713
4 1 DISCLAIMERS 1713
4 2 SAFETY 1713
4 2 1 TECHNICIAN SAFETY INFORMATION 1713
4 2 2 VEHICLE PREPARATION FOR TESTING 1713
4 2 3 SERVICING SUB-ASSEMBLIES 1713
4 2 4 DRBIII SAFETY INFORMATION 1713
4 3 WARNINGS AND CAUTIONS 1714
4 3 1 ROAD TEST WARNINGS 1714
4 3 2 VEHICLE DAMAGE CAUTIONS 1714
5 0 REQUIRED TOOLS AND EQUIPMENT 1714
6 0 ACRONYMS 1714
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 1718
COMMUNICATION 1719
*NO RESPONSE FROM PCM (PCI BUS) 1719
*NO RESPONSE FROM PCM (SCI ONLY) 1720
*NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE 1723
*PCI BUS COMMUNICATION FAILURE 1725
DRIVEABILITY – GAS 1727
INTERMITTENT CONDITION 1727
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW 1728
P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH 1728
P0037-O2 SENSOR 1/2 HEATER CIRCUIT LOW 1728
P0038-O2 SENSOR 1/2 HEATER CIRCUIT HIGH 1728
P0051-O2 SENSOR 2/1 HEATER CIRCUIT LOW 1728
P0052-O2 SENSOR 2/1 HEATER CIRCUIT HIGH 1728
P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE 1731
P0107-MAP SENSOR VOLTAGE TOO LOW 1734
P0108-MAP SENSOR VOLTAGE TOO HIGH 1736
P0111-INTAKE AIR TEMP PERFORMANCE 1738
P0112-INTAKE AIR TEMP SENSOR VOLTAGE TOO LOW 1740
P0113-INTAKE AIR TEMP SENSOR VOLTAGE TOO HIGH 1742
P0117-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO LOW 1744
P0118-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO HIGH 1746
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP SENSOR 1748
P0122-THROTTLE POSITION SENSOR VOLTAGE TOO LOW 1753
P0123-THROTTLE POSITION SENSOR VOLTAGE TOO HIGH 1756
P0125-CLOSED LOOP TEMP NOT REACHED 1759
P0131-O2 SENSOR 1/1 CIRCUIT VOLTAGE LOW 1761
P0137-O2 SENSOR 1/2 CIRCUIT VOLTAGE LOW 1761
P0151-O2 SENSOR 2/1 CIRCUIT VOLTAGE LOW 1761
P0157-O2 SENSOR 2/2 CIRCUIT VOLTAGE LOW 1761
P0132-O2 SENSOR 1/1 CIRCUIT VOLTAGE HIGH 1764
P0138-O2 SENSOR 1/2 CIRCUIT VOLTAGE HIGH 1764
P0152-O2 SENSOR 2/1 CIRCUIT VOLTAGE HIGH 1764
P0158-O2 SENSOR 2/2 CIRCUIT VOLTAGE HIGH 1764
P0133-O2 SENSOR 1/1 SLOW RESPONSE 1767
P0139-O2 SENSOR 1/2 SLOW RESPONSE 1767
P0153-O2 SENSOR 2/1 SLOW RESPONSE 1767
P0159-O2 SENSOR 2/2 SLOW RESPONSE 1767
P0135-O2 SENSOR 1/1 HEATER FAILURE 1770
P0141-O2 SENSOR 1/2 HEATER FAILURE 1770
P0155-O2 SENSOR 2/1 HEATER FAILURE 1770
P0161-O2 SENSOR 2/2 HEATER FAILURE 1770
P0136-O2 SENSOR 1/2 HEATER CIRCUIT MALFUNCTION 1773
P0171-1/1 FUEL SYSTEM LEAN 1776
P0174-2/1 FUEL SYSTEM LEAN 1776
P0172-1/1 FUEL SYSTEM RICH 1781
P0175-2/1 FUEL SYSTEM RICH 1781
P0201-INJECTOR #1 CONTROL CIRCUIT 1786
P0202-INJECTOR #2 CONTROL CIRCUIT 1786
P0203-INJECTOR #3 CONTROL CIRCUIT 1786
P0204-INJECTOR #4 CONTROL CIRCUIT 1786
P0205-INJECTOR #5 CONTROL CIRCUIT 1786
P0206-INJECTOR #6 CONTROL CIRCUIT 1786
P0300-MULTIPLE CYLINDER MIS-FIRE 1789
P0301-CYLINDER #1 MISFIRE 1789
P0302-CYLINDER #2 MISFIRE 1789
P0303-CYLINDER #3 MISFIRE 1789
P0304-CYLINDER #4 MISFIRE 1789
P0305-CYLINDER #5 MISFIRE 1789
P0306-CYLINDER #6 MISFIRE 1789
P0320-NO CRANK REFERENCE SIGNAL AT PCM 1796
P0340-NO CAM REFERENCE SIGNAL AT PCM 1800
P0351-IGNITION COIL # 1 PRIMARY CIRCUIT 1804
P0352-IGNITION COIL # 2 PRIMARY CIRCUIT 1804
P0353-IGNITION COIL # 3 PRIMARY CIRCUIT 1804
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY 1807
P0432-2/1 CATALYTIC CONVERTER EFFICIENCY 1807
P0441-EVAP PURGE FLOW MONITOR 1809
P0442-EVAP LEAK MONITOR MEDIUM (0 040) LEAK DETECTED 1811
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED 1811
P0456-EVAP LEAK MONITOR SMALL (0 020) LEAK DETECTED 1811
P0443-EVAP PURGE SOLENOID CIRCUIT 1815
P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES 1817
P0461-FUEL LEVEL UNIT NO CHANGE OVER TIME 1817
P0462-FUEL LEVEL SENDING UNIT VOLTAGE TOO LOW 1818
P0463-FUEL LEVEL SENDING UNIT VOLTAGE TOO HIGH 1820
P0500-NO VEHICLE SPEED SIGNAL CIRCUIT 1822
P0505-IDLE AIR CONTROL MOTOR CIRCUITS 1825
P0523-OIL PRESSURE VOLTAGE TOO HIGH 1827
P0551-POWER STEERING SWITCH FAILURE 1829
P0601-PCM INTERNAL CONTROLLER FAILURE 1831
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY 1832
P0645-A/C CLUTCH RELAY CIRCUIT 1834
P0700-EATX CONTROLLER DTC PRESENT 1836
P1195-1/1 O2 SENSOR SLOW DURING CATALYST MONITOR 1837
P1196-2/1 O2 SENSOR SLOW DURING CATALYST MONITOR 1837
P1281-ENGINE IS COLD TOO LONG 1839
P1282-FUEL PUMP/SYSTEM RELAY CONTROL CIRCUIT 1840
P1294-TARGET IDLE NOT REACHED 1842
P1296-NO 5-VOLTS TO MAP SENSOR 1844
P1297-NO CHANGE IN MAP FROM START TO RUN 1846
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT 1849
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM 1851
P1391-INTERMITTENT LOSS OF CMP OR CKP 1853
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT 1857
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND 1859
P1489-HIGH SPEED FAN RELAY CONTROL CIRCUIT 1861
P1490-LOW SPEED FAN RELAY CONTROL CIRCUIT 1863
P1491-COOLING FAN RELAY CONTROL CIRCUIT 1865
P1492-BATTERY TEMPERATURE SENSOR VOLTAGE TOO HIGH 1867
P1493-BATTERY TEMPERATURE SENSOR VOLTAGE TOO LOW 1869
P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT 1871
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT 1873
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH 1875
P1595-SPEED CONTROL SOLENOID CIRCUITS 1877
P1683-SPD CTRL PWR RELAY; OR S/C 12V DRIVER CKT 1877
P1596-SPEED CONTROL SWITCH ALWAYS HIGH 1881
P1597-SPEED CONTROL SWITCH ALWAYS LOW 1884
P1682-CHARGING SYSTEM VOLTAGE TOO LOW 1886
P1685 WRONG OR INVALID KEY MSG RECEIVED FROM SKIM 1889
P1686 NO SKIM BUS MESSAGE RECEIVED 1891
P1687-NO CLUSTER BUS MESSAGE 1892
P1692-CLUSTER SOFTWARE MISMATCH 1893
P1696-PCM FAILURE EEPROM WRITE DENIED 1894
P1698-NO BUS MESSAGE FROM TRANS CONTROL MODULE 1895
P1899-P/N SWITCH PERFORMANCE 1897
*BRAKE SWITCH SENSE STATUS DOES NOT CHANGE ON DRBIII 1899
*CHECKING A/C SYSTEM OPERATION WITH NO DTCS 1902
*CHECKING EVAPORATIVE EMISSION OPERATION WITH NO DTCS 1905
*CHECKING HARD TO FILL WITH FUEL 1907
*CHECKING THE PCM POWER AND GROUNDS 1908
STARTING 1909
*CHECKING FUEL DELIVERY 1909
*CHECKING HARD START (FUEL DELIVERY SYSTEM) 1912
*ENGINE CRANKS DOES NOT START 1914
*FUEL PRESSURE LEAK DOWN 1917
*NO CRANK CONDITION 1918
*NO RESPONSE FROM PCM WITH A NO START CONDITION 1921
*START AND STALL CONDITION 1924
VERIFICATION TESTS 1926
VERIFICATION TESTS 1926
8 0 COMPONENT LOCATIONS 1932
8 1 CONTROL MODULES AND PDC 1932
8 2 DATA LINK CONNECTOR 1932
8 3 SENSORS AND SOLENOIDS 1933
8 4 FUEL SYSTEM 1936
8 5 SWITCHES 1937
9 0 CONNECTOR PINOUTS 1938
A/C COMPRESSOR CLUTCH – BLACK 2 WAY 1938
A/C HIGH PRESSURE SWITCH (4 0L) – BLACK 2 WAY 1938
A/C LOW PRESSURE SWITCH (2 4L) – GREEN 2 WAY 1938
A/C LOW PRESSURE SWITCH (4 0L) – GREEN 2 WAY 1938
A/C PRESSURE TRANSDUCER (2 4L) – 4 WAY 1939
BATTERY TEMPERATURE SENSOR – BLACK 2 WAY 1939
BRAKE LAMP SWITCH – GRAY 6 WAY 1939
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID – WHITE 2 WAY 1939
CAMSHAFT POSITION SENSOR (2 4L) – BLACK 3 WAY 1939
CAMSHAFT POSITION SENSOR (4 0L) – 3 WAY 1940
CLOCKSPRING C1 – 4 WAY 1940
CLUTCH PEDAL POSITION SWITCH (M/T) – BLACK 2 WAY 1940
CRANKSHAFT POSITION SENSOR (2 4L/4 0L A/T) – BLACK 3 WAY 1940
CRANKSHAFT POSITION SENSOR (4 0L M/T) – 3 WAY 1940
DATA LINK CONNECTOR – BLACK 16 WAY 1941
ENGINE COOLANT TEMPERATURE SENSOR – BLACK 2 WAY 1941
ENGINE OIL PRESSURE SWITCH – BLACK 2 WAY 1941
EVAP/PURGE SOLENOID – BLACK 2 WAY 1941
FUEL INJECTOR NO 1 (2 4L) – 2 WAY 1942
FUEL INJECTOR NO 1 (4 0L) – 2 WAY 1942
FUEL INJECTOR NO 2 (2 4L) – 2 WAY 1942
FUEL INJECTOR NO 2 (4 0L) – 2 WAY 1942
FUEL INJECTOR NO 3 (2 4L) – 2 WAY 1942
FUEL INJECTOR NO 3 (4 0L) – 2 WAY 1942
FUEL INJECTOR NO 4 (2 4L) – 2 WAY 1943
FUEL INJECTOR NO 4 (4 0L) – 2 WAY 1943
FUEL INJECTOR NO 5 (4 0L) – 2 WAY 1943
FUEL INJECTOR NO 6 (4 0L) – 2 WAY 1943
FUEL PUMP MODULE – 4 WAY 1943
FUSES (FUSE/RELAY BLOCK) 1945
GENERATOR – 3 WAY 1945
GENERATOR – BLACK 2 WAY 1946
IDLE AIR CONTROL MOTOR – BLACK 4 WAY 1946
IGNITION COIL PACK (2 4L) – BLACK 3 WAY 1946
IGNITION COIL PACK (4 0L) – BLACK 4 WAY 1946
IGNITION SWITCH – 10 WAY 1947
INTAKE AIR TEMPERATURE SENSOR – GRAY 2 WAY 1947
LEAK DETECTION PUMP – BLACK 4 WAY 1947
MANIFOLD ABSOLUTE PRESSURE SENSOR (2 4L) – BLACK 3 WAY 1947
MANIFOLD ABSOLUTE PRESSURE SENSOR (4 0L) – 3 WAY 1948
OVERDRIVE OFF SWITCH – 4 WAY 1948
OXYGEN SENSOR 1/1 UPSTREAM – 4 WAY 1948
OXYGEN SENSOR 1/2 DOWNSTREAM – BLACK 4 WAY 1948
OXYGEN SENSOR 2/1 UPSTREAM (EXCEPT EXPORT/JAPAN LOW EMISSION VEHICLE) – 4 WAY 1949
OXYGEN SENSOR 2/2 DOWNSTREAM (EXCEPT EXPORT/JAPAN LOW EMISSION VEHICLE) – 4 WAY 1949
FUSES (PDC) 1951
A/C COMPRESSOR CLUTCH RELAY (IN PDC) 1951
AUTOMATIC SHUT DOWN RELAY (IN PDC) 1951
ENGINE STARTER MOTOR RELAY (IN PDC) 1952
FUEL PUMP RELAY (IN PDC) 1952
HIGH SPEED RADIATOR FAN RELAY (2 4L) 1952
LOW SPEED RADIATOR FAN RELAY (2 4L) 1952
OXYGEN SENSOR DOWNSTREAM HEATER RELAY 1952
POWER STEERING PRESSURE SWITCH (2 4L) – BLACK 2 WAY 1953
POWERTRAIN CONTROL MODULE C1 – BLACK 32 WAY 1953
POWERTRAIN CONTROL MODULE C2 – WHITE 32 WAY 1954
POWERTRAIN CONTROL MODULE C3 – GRAY 32 WAY 1955
SENTRY KEY IMMOBILIZER MODULE – BLACK 6 WAY 1955
SPEED CONTROL SERVO – BLACK 4 WAY 1956
THROTTLE POSITION SENSOR (2 4L) – WHITE/BLUE 3 WAY 1956
THROTTLE POSITION SENSOR (4 0L) – 3 WAY 1956
VEHICLE SPEED SENSOR – BLACK 3 WAY 1956
10 0 SCHEMATIC DIAGRAMS 1958
11 0 CHARTS AND GRAPHS 1962
COMMENTS 0
2004-TJ-Body pdf 0
MAIN WELCOME PAGE 0
INSTRUCTIONS 0
TJ Service Manual 0
TJ Powertrain 0
TJ Chassis 0
TJ Transmission 0
TJ Body 1966
TABLE OF CONTENTS 1966
1 0 INTRODUCTION 1972
1 1 SYSTEM COVERAGE 1972
1 2 SIX-STEP TROUBLESHOOTING PROCEDURE 1972
2 0 IDENTIFICATION OF SYSTEM 1972
3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 1972
3 1 AIRBAG SYSTEM 1972
3 1 1 PASSENGER AIRBAG ON-OFF SWITCH 1973
3 1 2 SPECIAL TOOLS 1974
3 1 3 DIAGNOSTIC TROUBLE CODES 1974
3 1 3 1 ACTIVE CODES 1974
3 1 3 2 STORED CODES 1974
3 2 AUDIO SYSTEM 1975
3 3 ELECTROCHROMIC COMPASS/TEMPERATURE MIRROR WITH LIGHTS 1975
3 4 ELECTRICALLY HEATED SYSTEMS 1978
3 4 1 REAR WINDOW DEFOGGER 1978
3 5 ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) 1978
3 5 1 SMART CLUSTER FEATURES 1978
3 5 2 INSTRUMENT CLUSTER SELF TEST 1979
3 6 VEHICLE COMMUNICATION 1979
3 7 USING THE DRBIII 1980
3 7 1 DRBIII ERROR MESSAGES AND BLANK SCREEN 1980
3 7 2 DRBIII DOES NOT POWER UP 1980
3 7 3 DISPLAY IS NOT VISIBLE 1980
4 0 DISCLAIMERS, SAFETY, WARNING 1980
4 1 DISCLAIMERS 1980
4 2 SAFETY 1981
4 2 1 TECHNICIAN SAFETY INFORMATION 1981
4 2 2 VEHICLE PREPARATION FOR TESTING 1981
4 2 3 SERVICING SUB-ASSEMBLIES 1981
4 2 4 DRBIII SAFETY INFORMATION 1981
4 3 WARNINGS 1982
4 3 1 VEHICLE DAMAGE WARNINGS 1982
4 3 2 ROAD TESTING A COMPLAINT VEHICLE 1982
5 0 REQUIRED TOOLS AND EQUIPMENT 1982
6 0 GLOSSARY OF TERMS 1982
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 1984
AIRBAG 1985
ACCELEROMETER 1 1985
INTERNAL 1 1985
OUTPUT DRIVER 1 1985
SAFING SENSOR 1985
STORED ENERGY FIRING 1 1985
STORED ENERGY LOGIC 1985
AIRBAG WARNING INDICATOR OPEN 1987
AIRBAG WARNING INDICATOR SHORT 1987
CLUSTER MESSAGE MISMATCH 1990
DRIVER SQUIB 1 CIRCUIT OPEN 1992
DRIVER SQUIB 1 CIRCUIT SHORT 1995
DRIVER SQUIB 1 SHORT TO BATTERY 1998
DRIVER SQUIB 1 SHORT TO GROUND 2001
LOSS OF IGNITION RUN – START 2004
LOSS OF IGNITION RUN ONLY 2008
MODULE NOT CONFIGURED FOR PAB OFF SWITCH 2011
NO CLUSTER MESSAGE 2014
NO PCI TRANSMISSION 2016
PASSENGER AIRBAG ON – OFF SWITCH OPEN 2018
PASSENGER AIRBAG ON – OFF SWITCH SHORT TO BATTERY 2021
PASSENGER AIRBAG ON – OFF SWITCH SHORT TO GROUND 2024
PASSENGER OFF INDICATOR CIRCUIT SHORT TO BATTERY 2027
PASSENGER OFF INDICATOR CIRCUIT SHORT TO GROUND 2030
PASSENGER SQUIB 1 CIRCUIT OPEN 2033
PASSENGER SQUIB 1 CIRCUIT SHORT 2036
PASSENGER SQUIB 1 SHORT TO BATTERY 2039
PASSENGER SQUIB 1 SHORT TO GROUND 2042
*AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES 2045
AUDIO 2046
ALL OUTPUTS SHORT – BASE AUDIO SYSTEM 2046
ALL OUTPUTS SHORT – PREMIUM AUDIO SYSTEM 2048
CASSETTE PLAYER INOP 2051
CD MECHANICAL FAILURE 2051
NO PCI TRANSMISSION 2051
*AM/FM SWITCH INOPERATIVE 2051
*ANY STATION PRESET SWITCH INOPERATIVE 2051
*BALANCE INOPERATIVE 2051
*CD EJECT SWITCH INOPERATIVE 2051
*EQUALIZER INOPERATIVE 2051
*FADER INOPERATIVE 2051
*FF/RW SWITCH INOPERATIVE 2051
*HOUR/MINUTE SWITCHES INOPERATIVE 2051
*PAUSE/PLAY SWITCH INOPERATIVE 2051
*PWR SWITCH INOPERATIVE 2051
*SCAN SWITCH INOPERATIVE 2051
*SEEK SWITCH INOPERATIVE 2051
*SET SWITCH INOPERATIVE 2051
*TAPE EJECT SWITCH INOPERATIVE 2051
*TIME SWITCH INOPERATIVE 2051
*TUNE SWITCH INOPERATIVE 2051
CD PLAY FAILURE 2053
CD READ FAILURE 2054
CD TEMPERATURE HIGH 2055
LOW VOLTAGE LEVEL 2056
NO ANTENNA CONNECTION 2057
POWER AMP SHUTDOWN – BASE AUDIO SYSTEM 2058
POWER AMP SHUTDOWN – PREMIUM AUDIO SYSTEM 2060
*POOR SOUND QUALITY 2063
CHIME 2064
*CHIME INOPERATIVE AT ALL TIMES 2064
*CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED 2065
*CHIME INOPERATIVE WITH EXTERIOR LAMPS ON AND DRIVER DOOR OPEN 2066
*CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER’S DOOR OPEN 2067
*CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED 2070
*CHIME SOUNDS WITH DRIVER’S DOOR OPEN, KEY REMOVED 2072
COMMUNICATION 2073
*NO RESPONSE FROM AIRBAG CONTROL MODULE 2073
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE 2075
*NO RESPONSE FROM INSTRUMENT CLUSTER 2077
*NO RESPONSE FROM PCM (PCI BUS) 2079
*NO RESPONSE FROM PCM (SCI ONLY) 2080
*NO RESPONSE FROM RADIO 2083
*NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE 2085
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE 2087
*PCI BUS COMMUNICATION FAILURE 2090
COMPASS/MINI-TRIP COMPUTER 2092
*COMPASS/TEMP MODULE WILL NOT CALIBRATE 2092
*COMPASS/TEMPERATURE MODULE INOPERATIVE 2093
*TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE 2094
ELECTRICALLY HEATED SYSTEMS 2096
*REAR WINDOW DEFOGGER INOPERATIVE 2096
*REAR WINDOW DEFOGGER SWITCH INDICATOR LAMP INOPERATIVE 2099
INSTRUMENT CLUSTER 2100
ACM MESSAGE NOT REC’D BY MIC 2100
AIR BAG LAMP CIRCUIT OPEN 2101
AIR BAG LAMP CIRCUIT SHORT 2102
CHECKSUM FAILURE 2103
PANEL DIMMER OPEN 2104
PCM MESSAGE NOT REC’D BY MIC 2106
SKIM MESSAGE NOT REC’D BY MIC 2107
*”NO BUS” IN VF DISPLAY 2108
*”NO FUSE” IN VF DISPLAY 2109
*4WD INDICATOR INOPERATIVE 2110
*ABS INDICATOR INOPERATIVE 2113
*AIR BAG INDICATOR INOPERATIVE 2114
*ALL GAUGES INOPERATIVE 2115
*ANY PCI BUS INDICATOR INOPERATIVE 2117
*AXLE LOCK INDICATOR PROBLEMS 2118
*BRAKE WARNING INDICATOR ALWAYS ON 2121
*BRAKE WARNING INDICATOR INOPERATIVE 2122
*FOG LAMP INDICATOR INOPERATIVE – DOMESTIC 2124
*HIGH BEAM INDICATOR INOPERATIVE 2125
*ONE GAUGE INOPERATIVE 2126
*PANEL DIMMNG INOPERATIVE 2127
*REAR FOG LAMP INDICATOR INOPERATIVE – BUX ONLY 2128
*SEAT BELT INDICATOR NOT OPERATING PROPERLY 2129
*SPEEDOMETER INACCURATE OR INOPERATIVE 2131
*VF DISPLAY INOPERATIVE 2132
*VF ODOMETER INOPERATIVE WITH DOOR OPEN 2133
INTERIOR LIGHTING 2135
*COURTESY LAMPS INOPERATIVE – ALL LAMPS 2135
*COURTESY LAMPS ON AT ALL TIMES 2136
*ILLUMINATED ENTRY INOPERATIVE 2138
VERIFICATION TESTS 2139
VERIFICATION TESTS 2139
8 0 SYSTEM COMPONENT LOCATIONS 2142
8 1 DATA LINK CONNECTOR 2142
8 2 AIRBAG 2142
8 2 1 DRIVER AIRBAG MODULE & CLOCKSPRING 2142
8 2 2 DRIVER/PASSENGER AIRBAG MODULES & MECHANICAL INSTRUMENT CLUSTER 2143
8 2 3 AIRBAG CONTROL MODULE AND PASSENGER AIRBAG ON/OFF SWITCH 2143
8 3 FUSE BLOCK 2144
8 4 INSTRUMENT CLUSTER 2144
8 4 1 FRONT VIEW 2144
8 4 2 REAR VIEW 2145
8 5 POWER DISTRIBUTION CENTER (PDC) 2145
8 6 POWERTRAIN CONTROL MODULE 2146
9 0 CONNECTOR PINOUTS 2148
AIRBAG CONTROL MODULE – YELLOW 22 WAY 2148
AMBIENT TEMPERATURE SENSOR – GRAY 2 WAY 2148
BRAKE WARNING INDICATOR SWITCH – BLACK 2 WAY 2148
CLOCKSPRING C2 – YELLOW 2 WAY 2149
COMPASS/TEMPERATURE MIRROR – BLACK 7 WAY 2149
CONTROLLER ANTILOCK BRAKE – 25 WAY 2149
DATA LINK CONNECTOR – BLACK 16 WAY 2150
DRIVER AIRBAG SQUIB 1 – YELLOW 2 WAY 2150
FUSES (FUSE/RELAY BLOCK) 2152
IGNITION SWITCH – 10 WAY 2152
INSTRUMENT CLUSTER C1 – 12 WAY 2153
INSTRUMENT CLUSTER C2 – 16 WAY 2153
LEFT FRONT SPEAKER – BLACK 2 WAY 2153
LEFT REAR SPEAKER – BLACK 3 WAY 2154
PASSENGER AIRBAG ON-OFF SWITCH (LHD) – 6 WAY 2154
PASSENGER AIRBAG SQUIB 1 – YELLOW 2 WAY 2154
FUSES (PDC) 2156
REAR WINDOW DEFOGGER RELAY (IN PDC) 2156
POWERTRAIN CONTROL MODULE C1 – BLACK 32 WAY 2157
POWERTRAIN CONTROL MODULE C2 – WHITE 32 WAY 2158
POWERTRAIN CONTROL MODULE C3 – GRAY 32 WAY 2159
RADIO – GRAY 22 WAY 2160
REAR WINDOW DEFOGGER SWITCH (HARD TOP) – 4 WAY 2160
RIGHT FRONT SPEAKER – BLACK 2 WAY 2160
RIGHT REAR SPEAKER – BLACK 3 WAY 2160
SEAT BELT SWITCH (EXCEPT LHD EXPORT) – BLACK 2 WAY 2161
SENTRY KEY IMMOBILIZER MODULE – BLACK 6 WAY 2161
SUBWOOFER – 12 WAY 2161
TRANSMISSION CONTROL MODULE – 60 WAY 2162
10 0 SCHEMATIC DIAGRAMS 2164
10 1 AIRBAG SYSTEM 2164
10 2 AUDIO SYSTEM 2165
10 2 1 BASE AUDIO SYSTEM 2165
10 2 2 PREMIUM AUDIO SYSTEM 2166
10 3 CHIME SYSTEM 2167
10 4 COMPASS/TEMPERATURE MIRROR 2167
10 5 INSTRUMENT CLUSTER 2168
10 5 1 INSTRUMENT CLUSTER/AXLE LOCKER SYSTEM 2169
10 6 INTERIOR LIGHTING 2170
10 7 REAR DEFOGGER 2171
10 8 VEHICLE COMMUNICATIONS 2172
COMMENTS 0
2004-TJ-Chassis pdf 0
MAIN WELCOME PAGE 0
INSTRUCTIONS 0
TJ Service Manual 0
TJ Powertrain 0
TJ Body 0
TJ Transmission 0
TJ Chassis 2242
TABLE OF CONTENTS 2173
1 0 INTRODUCTION 2177
1 1 SYSTEM COVERAGE 2177
1 2 SIX-STEP TROUBLESHOOTING PROCEDURE 2177
2 0 IDENTIFICATION OF SYSTEM 2177
3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 2177
3 1 TEVES MARK 20I SYSTEM DESCRIPTION 2177
3 1 1 PEDAL FEEL/VEHICLE CHARACTERISTICS 2178
3 1 2 SYSTEM COMPONENTS 2178
3 1 3 ABS AND BRAKE WARNING INDICATORS 2178
3 1 4 CONTROLLER ANTILOCK BRAKE (CAB) 2178
3 1 5 HYDRAULIC CONTROL UNIT 2179
3 1 6 RELAYS/SWITCHES 2179
3 1 7 SENSORS 2179
3 2 DIAGNOSTIC TROUBLE CODES 2180
3 2 1 SYSTEM INITIALIZATION 2180
3 2 2 DIAGNOSTIC MODE 2180
3 2 3 INTERMITTENT DIAGNOSTIC TROUBLE CODES 2180
3 3 AXLE LOCK 2180
3 3 1 GENERAL 2180
3 3 2 DESCRIPTION 2180
3 4 USING THE DRBIII 2181
3 5 DRBIII ERROR MESSAGES 2181
3 5 1 DRBIII DOES NOT POWER UP (BLANK SCREEN) 2181
3 5 2 DISPLAY IS NOT VISIBLE 2181
4 0 DISCLAIMERS, SAFETY WARNINGS 2181
4 1 DISCLAIMERS 2181
4 2 SAFETY 2182
4 2 1 TECHNICIAN SAFETY INFORMATION 2182
4 2 2 VEHICLE PREPARATION FOR TESTING 2182
4 2 3 SERVICING SUB-ASSEMBLIES 2182
4 2 4 DRBIII SAFETY INFORMATION 2182
4 3 WARNING 2182
4 3 1 VEHICLE DAMAGE WARNINGS 2182
4 3 2 ROAD TESTING A COMPLAINT VEHICLE 2183
4 4 DIAGNOSIS 2183
5 0 REQUIRED TOOLS AND EQUIPMENT 2183
6 0 GLOSSARY OF TERMS 2184
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 2185
BRAKES (CAB) 2186
CAB POWER FEED CIRCUIT 2186
CONTROLLER FAILURE 2189
G-SWITCH NOT PROCESSABLE 2191
LEFT FRONT SENSOR CIRCUIT FAILURE 2195
LEFT REAR SENSOR CIRCUIT FAILURE 2195
RIGHT FRONT SENSOR CIRCUIT FAILURE 2195
RIGHT REAR SENSOR CIRCUIT FAILURE 2195
LEFT FRONT SENSOR SIGNAL FAILURE 2198
LEFT REAR SENSOR SIGNAL FAILURE 2198
RIGHT FRONT SENSOR SIGNAL FAILURE 2198
RIGHT REAR SENSOR SIGNAL FAILURE 2198
PUMP MOTOR NOT WORKING PROPERLY 2201
SYSTEM OVER VOLTAGE 2205
SYSTEM UNDER VOLTAGE 2207
*ABS WARNING INDICATOR ALWAYS ON 2209
*ABS WARNING INDICATOR INOPERATIVE 2211
*BRAKE LAMP SWITCH 2213
*FRONT AXLE LOCK INDICATOR REMAINS FLASHING 2214
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE 2216
*REAR AXLE LOCK INDICATOR REMAINS FLASHING 2218
*REAR AXLE LOCK INOPERATIVE 2221
VERIFICATION TESTS 2223
VERIFICATION TESTS 2223
8 0 COMPONENT LOCATIONS 2225
8 1 CONTROLLER ANTILOCK BRAKE 2225
8 2 DATA LINK CONNECTOR 2225
8 3 G-SWITCH 2225
8 4 FUSES & RELAYS 2226
8 5 WHEEL SPEED SENSORS 2226
8 6 WHEEL SPEED SENSOR CONNECTORS 2226
8 7 BRAKE SWITCHES 2227
8 7 1 PARKING BRAKE 2227
8 7 2 BRAKE SWITCH 2227
9 0 CONNECTOR PINOUTS 2229
AXLE LOCK SWITCH (OFF-ROAD PACKAGE) – 8 WAY 2229
BRAKE LAMP SWITCH – GRAY 6 WAY 2229
BRAKE WARNING INDICATOR SWITCH – BLACK 2 WAY 2229
C115 (OFF-ROAD PACKAGE) – BLACK (ENGINE SIDE) 2229
C115 (OFF-ROAD PACKAGE) – BLACK (FRONT FEEDBACK OVERLAY SIDE) 2230
C116 (OFF-ROAD PACKAGE) – LT GRAY (ENGINE SIDE) 2230
C116 (OFF-ROAD PACKAGE) – LT GRAY (REAR FEEDBACK OVERLAY SIDE) 2230
CLUTCH PEDAL POSITION SWITCH (M/T) – BLACK 2 WAY 2230
CONTROLLER ANTILOCK BRAKE – 25 WAY 2231
DATA LINK CONNECTOR – BLACK 16 WAY 2231
FRONT LOCKER INDICATOR SWITCH (OFF-ROAD PACKAGE) – BLACK 2 WAY 2232
FRONT LOCKER PUMP (OFF-ROAD PACKAGE) – LT GRAY 3 WAY 2232
G-SWITCH (LHD) – 3 WAY 2232
INSTRUMENT CLUSTER C1 – 12 WAY 2232
INSTRUMENT CLUSTER C2 – 16 WAY 2233
LEFT FRONT WHEEL SPEED SENSOR – 2 WAY 2233
LEFT FRONT WHEEL SPEED SENSOR (SENSOR SIDE) – 2 WAY 2233
LEFT REAR WHEEL SPEED SENSOR – 2 WAY 2234
LEFT REAR WHEEL SPEED SENSOR (SENSOR SIDE) – 2 WAY 2234
FUSES (PDC) 2236
FRONT LOCKER RELAY (IN PDC/OFF-ROAD PACKAGE) 2236
REAR LOCKER RELAY (IN PDC/OFF-ROAD PACKAGE) 2236
REAR LOCKER INDICATOR SWITCH (OFF-ROAD PACKAGE) – BLACK 2 WAY 2237
REAR LOCKER PUMP (OFF-ROAD PACKAGE) – LT GRAY 3 WAY 2237
RIGHT FRONT WHEEL SPEED SENSOR – BLACK 2 WAY 2237
RIGHT FRONT WHEEL SPEED SENSOR (SENSOR SIDE) – 2 WAY 2238
RIGHT REAR WHEEL SPEED SENSOR – BLACK 2 WAY 2238
RIGHT REAR WHEEL SPEED SENSOR (SENSOR SIDE) – 2 WAY 2238
VEHICLE SPEED SENSOR – BLACK 3 WAY 2239
10 0 SCHEMATIC DIAGRAMS 2241
10 1 TEVES MARK 20I CONTROLLER ANTILOCK BRAKE – ABS 2241
10 2 AXLE LOCK 2242
COMMENTS 0
2004-TJ-Transmission pdf 0
MAIN WELCOME PAGE 0
INSTRUCTIONS 0
TJ Service Manual 0
TJ Powertrain 0
TJ Body 0
TJ Chassis 0
TJ Transmission 0
TABLE OF CONTENTS 2243
1 0 INTRODUCTION 2247
1 1 SYSTEM COVERAGE 2247
1 2 SIX-STEP TROUBLESHOOTING PROCEDURE 2247
2 0 IDENTIFICATION OF SYSTEM 2247
3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 2247
3 1 GENERAL DESCRIPTION 2247
3 2 FUNCTIONAL OPERATION 2247
3 2 1 AUTOSTICK FEATURE (IF APPLICABLE) 2247
3 2 2 TRANSMISSION OPERATION AND SHIFT SCHEDULING AT VARIOUS OIL TEMPERATURES 2248
3 3 DIAGNOSTIC TROUBLE CODES 2249
3 3 1 HARD CODE 2249
3 3 2 ONE TRIP FAILURES 2249
3 3 3 INTERMITTENT CODE 2249
3 3 4 STARTS SINCE SET COUNTER 2249
3 3 5 TROUBLE CODE ERASURE 2250
3 3 6 EATX DTC EVENT DATA 2250
3 3 7 LIST OF DIAGNOSTIC TROUBLE CODES (DETAILED DESCRIPTIONS FOLLOW LIST) 2250
3 3 8 DTC DESCRIPTIONS 2251
3 3 9 QUICK LEARN 2264
3 3 10 CLUTCH VOLUMES 2264
3 3 11 ELECTRONIC PINION FACTOR (IF APPLICABLE) 2265
3 4 USING THE DRBIII 2265
3 5 DRBIII ERROR MESSAGES 2265
3 5 1 DRBIII DOES NOT POWER UP (BLANK SCREEN) 2265
3 5 2 DISPLAY IS NOT VISIBLE 2265
3 6 TRANSMISSION SIMULATOR (MILLER TOOL # 8333) AND ELECTRONIC TRANSMISSION ADAPTER KIT (MILLER TOOL #8333-1A) 2265
4 0 DISCLAIMERS, SAFETY, AND WARNINGS 2266
4 1 DISCLAIMERS 2266
4 2 SAFETY 2266
4 2 1 TECHNICIAN SAFETY INFORMATION 2266
4 2 2 VEHICLE PREPARATION FOR TESTING 2266
4 2 3 SERVICING SUB-ASSEMBLIES 2266
4 2 4 DRBIII SAFETY INFORMATION 2266
4 3 WARNINGS 2267
4 3 1 VEHICLE DAMAGE WARNINGS 2267
4 3 2 ROAD TESTING A COMPLAINT VEHICLE 2267
4 3 3 ELECTRONIC PINION FACTOR WARNINGS (IF APPLICABLE) 2268
4 3 4 BULLETINS AND RECALLS 2268
5 0 REQUIRED TOOLS AND EQUIPMENT 2268
6 0 GLOSSARY OF TERMS 2268
6 1 ACRONYMS 2268
6 2 DEFINITIONS 2268
7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 2269
COMMUNICATION 2270
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE 2270
TRANSMISSION – 42RLE 2273
P0122-THROTTLE POSITION SENSOR/APPS LOW 2273
P0123-THROTTLE POSITION SENSOR/APPS HIGH 2275
P0124- THROTTLE POSITION SENSOR/APPS INTERMITTENT 2277
P0218-HIGH TEMPERATURE OPERATION ACTIVATED 2279
P0562-LOW BATTERY VOLTAGE 2281
P0604-INTERNAL TCM 2284
P0605-INTERNAL TCM 2285
P0613-INTERNAL TCM 2286
P0706-CHECK SHIFTER SIGNAL 2287
P0711-TRANSMISSION TEMPERATURE SENSOR PERFORMANCE 2293
P0712-TRANSMISSION TEMPERATURE SENSOR LOW 2296
P0713-TRANSMISSION TEMPERATURE SENSOR HIGH 2299
P0714-TRANSMISSION TEMPERATURE SENSOR INTERMITTENT 2302
P0715-INPUT SPEED SENSOR ERROR 2304
P0720-OUTPUT SPEED SENSOR ERROR 2308
P0725-ENGINE SPEED SENSOR CIRCUIT 2312
P0731-GEAR RATIO ERROR IN 1ST 2315
P0732-GEAR RATIO ERROR IN 2ND 2317
P0733-GEAR RATIO ERROR IN 3RD 2320
P0734-GEAR RATIO ERROR IN 4TH 2323
P0736-GEAR RATIO ERROR IN REVERSE 2326
P0740-TORQUE CONVERTER CLUTCH CONTROL CIRCUIT 2328
P0750-LR SOLENOID CIRCUIT 2330
P0755-2/4 SOLENOID CIRCUIT 2334
P0760-OD SOLENOID CIRCUIT 2338
P0765-UD SOLENOID CIRCUIT 2342
P0841-LR PRESSURE SWITCH SENSE CIRCUIT 2346
P0845-2/4 HYDRAULIC PRESSURE TEST FAILURE 2350
P0846-2/4 PRESSURE SWITCH SENSE CIRCUIT 2354
P0870-OD HYDRAULIC PRESSURE TEST FAILURE 2358
P0871-OD PRESSURE SWITCH SENSE CIRCUIT 2362
P0884-POWER UP AT SPEED 2366
P0888-RELAY OUTPUT ALWAYS OFF 2367
P0890-SWITCHED BATTERY 2369
P0891-TRANSMISSION RELAY ALWAYS ON 2371
P0897-WORN OUT/BURNT TRANSAXLE FLUID 2374
P0944-LOSS OF PRIME 2376
P0992- 2-4/OD HYDRAULIC PRESSURE TEST FAILURE 2379
P1652-SERIAL COMMUNICATION LINK MALFUNCTION 2381
P1684-BATTERY WAS DISCONNECTED 2383
P1687-NO COMMUNICATION WITH THE MIC 2386
P1694-BUS COMMUNICATION WITH ENGINE MODULE 2388
P1775-SOLENOID SWITCH VALVE LATCHED IN TCC POSITION 2390
P1776-SOLENOID SWITCH VALVE LATCHED IN LR POSITION 2394
P1790-FAULT IMMEDIATELY AFTER SHIFT 2398
P1793-TRD LINK COMMUNICATION ERROR 2399
P1794-SPEED SENSOR GROUND ERROR 2402
P1797-MANUAL SHIFT OVERHEAT 2404
*BACKUP LAMPS COME ON WHILE SHIFTER IS NOT IN REVERSE POSITION 2406
*BACKUP LAMPS INOPERATIVE 2408
*CHECKING PARK/NEUTRAL SWITCH OPERATION 2411
*INCORRECT TRANSMISSION FLUID LEVEL 2413
*NO SPEEDOMETER OPERATION 2414
*TRANSMISSION NOISY WITH NO DTC’S PRESENT 2415
*TRANSMISSION SHIFTS EARLY WITH NO DTC’S 2416
*TRANSMISSION SIMULATOR 8333 WILL NOT POWER UP 2417
VERIFICATION TESTS 2418
VERIFICATION TESTS 2418
8 0 COMPONENT LOCATIONS 2421
8 1 POWERTRAIN CONTROL MODULE 2421
8 2 INPUT/OUTPUT SPEED SENSORS/TRS COMPONENT LOCATIONS 2421
8 3 TRANSMISSION CONTROL MODULE 2421
8 4 TRANSMISSION SOLENOID/PRESSURE SWITCH ASSEMBLY 2422
9 0 CONNECTOR PINOUTS 2423
CRANKSHAFT POSITION SENSOR (2 4L/4 0L A/T) – BLACK 3 WAY 2423
DATA LINK CONNECTOR – BLACK 16 WAY 2423
INPUT SPEED SENSOR – 2 WAY 2423
OUTPUT SPEED SENSOR – 2 WAY 2423
OVERDRIVE OFF SWITCH – 4 WAY 2424
TRANSMISSION CONTROL RELAY (IN PDC) 2426
POWERTRAIN CONTROL MODULE C1 – BLACK 32 WAY 2426
POWERTRAIN CONTROL MODULE C2 – WHITE 32 WAY 2427
POWERTRAIN CONTROL MODULE C3 – GRAY 32 WAY 2428
THROTTLE POSITION SENSOR (2 4L) – WHITE/BLUE 3 WAY 2428
THROTTLE POSITION SENSOR (4 0L) – 3 WAY 2429
TRANSFER CASE SWITCH (EXCEPT OFF-ROAD PACKAGE) – BLACK 2 WAY 2429
TRANSFER CASE SWITCH (OFF-ROAD PACKAGE) – BLACK 2 WAY 2429
TRANSMISSION CONTROL MODULE – 60 WAY 2430
TRANSMISSION RANGE SENSOR – 10 WAY 2431
TRANSMISSION SOLENOID/PRESSURE SWITCH ASSEMBLY – 10 WAY 2431
10 0 SCHEMATIC DIAGRAMS 2433
11 0 CHARTS AND GRAPHS 2435
11 1 PRESSURE SWITCH STATES 2435
11 2 SOLENOID APPLICATION CHART 2435
11 3 SHIFT LEVER ERROR CODES 2435
11 4 TRANSMISSION TEMPERATURE SENSOR 2436
COMMENTS 0
DESCRIPTION:
2004 Jeep TJ Wrangler Service Manual – PDF DOWNLOAD
FOREWORD:
The information contained in this service manual has been prepared for the professional automotive tech- nician involved in daily repair operations. Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle.
- Information in this manual is divided into groups. These groups contain description, operation, diagnosis. testing. adjustments, removal. installation, disassembly. and assembly procedures for the systems and compo- nents. To assist in locating a group title page. use the Group Tab Locator on the following page. The solid bar after the group title is aligned to a solid tab on the first page of each group.
- The first page of the group has a contents section that lists major topics within the group. If you are not sure which Group contains the infor- mation you need, look up the Component/System in the alphabetical index located in the rear of this manual. A Service Manual Comment form is included at the rear of this manual. Use the form to provide DaimlerChrysler Corporation with your comments and suggestions.
- Tightening torques are provided as a specific value throughout this manual. This value represents the midpoint of the acceptable engineering torque range for a given fastener application. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners.
- When replacing fasteners. always use the same type (part number) fastener as removed. DaimlerChrysler Corporation reserves the right to change testing procedures. specifications. diagnosis. repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
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