1997 Dodge Neon Complete Service Manual – PDF DOWNLOAD
FILE DETAILS:
1997 Dodge Neon Complete Service Manual – PDF DOWNLOAD
Language : English
Pages : 1088
Downloadable : Yes
File Type : PDF
Size: 35 MB
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DESCRIPTION:
1997 Dodge Neon Complete Service Manual – PDF DOWNLOAD
Service and maintenance procedures for components and systems listed in Schedule—A or B can be found by using the Group Tab Locator index at the front of this manual.
- If it is not clear which group contains the information needed, refer to the index at the back of this manual. There are two maintenance schedules that show proper service based on the conditions that the vehicle is subjected to.
- Schedule— A , lists scheduled maintenance to be performed when the vehicle is used for general transportation.
- Schedule— B , lists maintenance intervals for vehicles that are operated under the conditions listed at the beginning of the Maintenance Schedule section.
- Use the schedule that best describes your driving conditions. Where time and mileage are listed, follow the interval that occurs first.
TABLE OF CONTENTS:
1997 Dodge Neon Complete Service Manual – PDF DOWNLOAD
EPL_0 1
LUBRICATION AND MAINTENANCE 1
GENERAL INFORMATION 1
INTERNATIONAL SYMBOLS 1
INTRODUCTION 1
PARTS AND LUBRICANT RECOMMENDATIONS 1
CLASSIFICATION OF LUBRICANTS 2
ENGINE OIL 2
FLUID CAPACITIES 2
FUEL TANK 2
ENGINE OIL W/FILTER CHANGE 2
ENGINE OIL W/OUT FILTER CHANGE 2
COOLING SYSTEM 2
AUTOMATIC TRANSAXLE 2
MANUAL TRANSAXLE 2
POWER STEERING 2
GENERAL INFORMATION 3
INTRODUCTION 3
SCHEDULE—A 3
EMISSION CONTROL SYSTEM MAINTENANCE 3
UNSCHEDULED INSPECTION 3
SCHEDULE—B 4
SERVICE PROCEDURES 7
JUMP STARTING PROCEDURE 7
TO JUMP START A DISABLED VEHICLE: 7
TOWING RECOMMENDATIONS 8
LOCKED VEHICLE TOWING 8
FLAT TOWING WITH TOW BAR 8
TOWING—FRONT WHEEL LIFT 8
RECOMMENDED TOWING EQUIPMENT 8
TOWING—REAR WHEEL LIFT 8
GROUND CLEARANCE 8
HOISTING RECOMMENDATIONS 9
FLOOR JACK 9
HOIST 9
EPL_2 11
SUSPENSION 11
DESCRIPTION AND OPERATION 11
WHEEL ALIGNMENT GENERAL INFORMATION 11
DIAGNOSIS AND TESTING 13
SUSPENSION AND STEERING DIAGNOSIS 13
PRE-ALIGNMENT VEHICLE INSPECTION 14
SERVICE PROCEDURES 15
WHEEL ALIGNMENT CHECK AND ADJUSTMENT PROCEDURE 15
CASTER CAMBER 15
FRONT AND REAR TOE SETTING PROCEDURE 16
SPECIFICATIONS 18
VEHICLE ALIGNMENT SPECIFICATIONS AT CURB HEIGHT 18
GENERAL INFORMATION 19
GENERAL INFORMATION 19
DESCRIPTION AND OPERATION 19
FRONT SUSPENSION 19
McPHERSON STRUT ASSEMBLY 22
STEERING KNUCKLE 22
STABILIZER BAR 22
LOWER CONTROL ARM 22
FRONT WHEEL HUB BEARING 23
WHEEL MOUNTING STUDS 23
COIL SPRING 23
DIAGNOSIS AND TESTING 23
MCPHERSON STRUT ASSEMBLY 23
BALL JOINT 23
STEERING KNUCKLE 23
BALL JOINT ASSEMBLY 24
STABILIZER BAR 24
HUB/BEARING LOWER CONTROL ARM 24
REMOVAL AND INSTALLATION 25
MCPHERSON STRUT 25
REMOVE 25
INSTALL 25
STEERING KNUCKLE 26
REMOVE 26
INSTALL 28
LOWER CONTROL ARM 30
REMOVE 30
INSTALL 31
INSTALL 32
STABILIZER BAR 32
REMOVE 32
HUB BEARING 33
REMOVE 33
INSTALL 34
FRONT WHEEL MOUNTING STUDS 35
REMOVE 35
INSTALL 37
DISASSEMBLY AND ASSEMBLY 37
McPHERSON STRUT 37
DISASSEMBLY 37
ASSEMBLE 39
BALL JOINT 39
DISASSEMBLE 39
ASSEMBLE 40
LOWER CONTROL ARM FRONT ISOLATOR BUSHING 41
DISASSEMBLY 41
ASSEMBLY 41
LOWER CONTROL ARM REAR ISOLATOR BUSHING 42
DISASSEMBLY 42
ASSEMBLY 43
SPECIFICATIONS 43
FRONT SUSPENSION FASTENER TORQUES 43
SPECIAL TOOLS 44
FRONT SUSPENSION 44
GENERAL INFORMATION 46
GENERAL INFORMATION 46
DESCRIPTION AND OPERATION 46
REAR SUSPENSION 46
STRUT ASSEMBLY LATERAL LINKS AND TENSION STRUTS 48
COIL SPRING 48
DIAGNOSIS AND TESTING 48
STRUT INSPECTION (ON VEHICLE) STABILIZER BAR 48
KNUCKLE 48
STABILIZER BAR AND BUSHINGS 49
STABILIZER BAR ATTACHING LINKS 49
SUSPENSION KNUCKLE 49
SERVICE PROCEDURES 49
REAR WHEEL ALIGNMENT 49
REMOVAL AND INSTALLATION 49
LATERAL LINKS 49
STRUT ASSEMBLY 49
REMOVE 49
TENSION STRUT 49
INSTALL 50
STABILIZER BAR 51
REMOVE 51
COIL SPRING 51
KNUCKLE 52
REMOVE 52
INSTALL 52
INSTALL 54
LATERAL LINKS 55
REMOVE 55
INSTALL 55
DISASSEMBLY AND ASSEMBLY 57
STRUT ASSEMBLY 57
DISASSEMBLY 57
ASSEMBLY 59
STABILIZER BAR BUSHINGS 59
SPECIFICATIONS SPECIAL TOOLS 60
REAR SUSPENSION FASTENER TORQUE REAR SUSPENSION SPECIFICATIONS 60
EPL_3 61
DIFFERENTIAL AND DRIVELINE 61
GENERAL INFORMATION 61
FRONT DRIVESHAFTS 61
FRONT DRIVESHAFT IDENTIFICATION 62
DIAGNOSIS AND TESTING 62
DRIVESHAFT DIAGNOSIS 62
VEHICLE INSPECTION 62
NOISE AND/OR VIBRATION IN TURNS REMOVAL 63
CLUNKING NOISE DURING ACCELERATION 63
SHUDDER OR VIBRATION DURING ACCELERATION 63
VIBRATION AT HIGHWAY SPEEDS 63
REMOVAL AND INSTALLATION 63
FRONT DRIVESHAFTS 63
INSTALLATION 66
INNER TRIPOD JOINT SEAL BOOT 68
REMOVAL 68
DISASSEMBLY AND ASSEMBLY 68
DRIVESHAFT RECONDITION 68
INSTALLATION 70
OUTER C/V JOINT SEAL BOOT 73
REMOVAL 73
INSTALLATION 74
SPECIFICATIONS 76
TORQUE 76
SPECIAL TOOLS 76
DRIVESHAFT 76
EPL_5 77
BRAKES 77
GENERAL INFORMATION 77
BASE BRAKE SYSTEM DESCRIPTION 77
DESCRIPTION AND OPERATION 78
FRONT DISC BRAKES 78
REAR DISC BRAKES 80
REAR DRUM BRAKES 80
PARKING BRAKES 80
PROPORTIONING VALVES 81
CHASSIS TUBES AND HOSES 82
MASTER CYLINDER 82
VACUUM BOOSTER 83
RED BRAKE WARNING LAMP 83
STOP LAMP SWITCH 84
REAR WHEEL HUB AND BEARING ASSEMBLY 84
DIAGNOSIS AND TESTING 85
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE 85
BRAKE SYSTEM DIAGNOSIS CHARTS 86
MISCELLANEOUS BRAKE SYSTEM CONDITIONS 86
RED BRAKE WARNING LAMP FUNCTION 87
POWER BRAKE SYSTEM DIAGNOSTICS 88
BRAKE NOISE 89
VEHICLE ROAD TEST 89
DRUM BRAKE AUTOMATIC ADJUSTER 90
ROTOR THICKNESS AND RUNOUT 90
ROTOR RUNOUT AND THICKNESS VARIATION 90
PROPORTIONING VALVES 91
PROPORTIONING VALVE TESTING SPECIAL TOOLS 91
PROPORTIONING VALVE TESTING NON ABS BRAKE 92
PROPORTIONING VALVE TEST WITH ABS BRAKES 93
BRAKE PROPORTIONING VALVE APPLICATIONS AND PRESSURE SPECIFICATIONS 95
BRAKE FLUID CONTAMINATION 95
RED BRAKE WARNING LAMP TEST 95
BRAKE BLEEDING 95
STOP LAMP SWITCH TEST PROCEDURE 95
PRESSURE BLEEDING 95
SERVICE PROCEDURES 95
BRAKE FLUID LEVEL CHECK 95
BLEEDING WITHOUT A PRESSURE BLEEDER 96
MASTER CYLINDER BLEEDING 97
BRAKE ROTOR MACHINING 97
BRAKE ROTOR MACHINING PROCEDURES 97
BRAKE ROTOR REFINISHING LIMITS 98
BRAKE DRUM MACHINING 99
PARK BRAKE LEVER AUTO ADJUSTER MECHANISM 99
RELEASING PARK BRAKE AUTO ADJUSTER 100
BRAKE TUBE REPAIR 100
DOUBLE INVERTED TUBING FLARES 100
REMOVAL AND INSTALLATION 101
WHEEL AND TIRE ASSEMBLY 101
FRONT DISC BRAKE CALIPER 102
REMOVE 102
INSTALL 102
REMOVE 103
FRONT DISC BRAKE SHOES 103
INSTALL 104
CALIPER INSPECTION 104
REAR DISC BRAKE CALIPER 105
REMOVE 105
INSTALL 106
REMOVE 107
REAR DISC BRAKE SHOES 107
CALIPER INSPECTION 108
REAR BRAKE DRUM 109
REMOVE INSTALL 109
INSTALL 109
REAR BRAKE SHOES 110
REMOVE 110
CLEANING AND INSPECTION 111
INSTALL 111
REAR BRAKE SHOE SUPPORT PLATE 112
REMOVE 112
INSTALL 113
REAR BRAKE WHEEL CYLINDER 113
REMOVE 113
REAR HUB/BEARING 114
REMOVE 114
INSTALL 114
INSTALL 115
MASTER CYLINDER 116
REMOVE 116
BLEEDING MASTER CYLINDER 117
INSTALL 117
VACUUM BOOSTER 118
REMOVE 118
INSTALL 120
CHASSIS TUBES AND HOSES 122
REMOVE 122
PROPORTIONING VALVE (BASE BRAKES) 122
INSTALL 123
PARK BRAKE LEVER ASSEMBLY 123
REMOVE 123
INSTALL 124
PARK BRAKE LEVER OUTPUT CABLE 125
PARK BRAKE CABLES 125
REMOVE 125
INSTALL 129
PARK BRAKE SHOES WITH REAR DISC BRAKES 130
REMOVE 130
INSTALL 131
DISASSEMBLY AND ASSEMBLY 132
STOP LAMP SWITCH BRAKE FLUID RESERVOIR 132
REMOVE 132
INSTALL 132
BRAKE FLUID LEVEL SWITCH 133
FRONT AND REAR DISC BRAKE CALIPER 134
CLEANING AND INSPECTION 134
CALIPER GUIDE PIN BUSHING SERVICE 134
CALIPER DISASSEMBLY 136
CALIPER ASSEMBLY 137
WHEEL CYLINDER (REAR DRUM BRAKE) 138
DISASSEMBLE 138
ASSEMBLE 139
REAR DISC BRAKES 139
BRAKE PAD LINING WEAR 139
CLEANING AND INSPECTION 139
FRONT DISC BRAKES 139
BRAKE PAD LINING WEAR 139
CALIPER INSPECTION 139
CALIPER INSPECTION 139
REAR DRUM BRAKES 140
REAR WHEEL HUB AND BEARING ASSEMBLY 140
ADJUSTMENTS 140
STOP LAMP SWITCH 140
REAR DRUM BRAKE WHEEL CYLINDER 140
CHASSIS TUBES AND HOSES 140
REAR DRUM BRAKE SHOE ADJUSTMENT 141
PARKING BRAKE ADJUSTMENT 141
VEHICLE EQUIPPED REAR DRUM BRAKES 141
VEHICLE EQUIPPED REAR DISC BRAKES 141
SPECIFICATIONS 141
BRAKE FLUID 141
BRAKE FASTENER TORQUE SPECIFICATIONS 142
BRAKE ACTUATION SYSTEM 142
SPECIAL TOOLS 143
BASE BRAKE SYSTEM 143
DESCRIPTION AND OPERATION 144
ANTILOCK BRAKES OPERATION DESCRIPTION ABS COMPONENT ABBREVIATION LIST 144
ABS OPERATION AND VEHICLE PERFORMANCE 145
NOISE AND BRAKE PEDAL FEEL 145
NORMAL BRAKING SYSTEM FUNCTION 145
ABS SYSTEM OPERATION 145
TIRE NOISE AND MARKS 145
VEHICLE HANDLING PERFORMANCE DURING ABS BRAKING 145
ABS COMPONENTS 145
MASTER CYLINDER AND POWER BRAKE BOOSTER 146
HYDRAULIC CONTROL UNIT DECAY SOLENOIDS 146
HYDRAULIC CONTROL UNIT SHUTTLE VALVES 146
ABS HYDRAULIC CONTROL UNIT (HCU) 146
HYDRAULIC CONTROL UNIT FLUID SUMPS 146
HYDRAULIC CONTROL UNIT PUMP MOTOR SYSTEM RELAY OPERATION ASSEMBLY 147
RELAY BOX 147
PROPORTIONING VALVES PUMP/MOTOR RELAY OPERATION 147
WHEEL SPEED SENSORS 148
CONTROLLER ANTILOCK BRAKE (CAB) 148
ABS WARNING LAMP FUNCTION AND LOCATION 149
ABS BRAKING MODE HYDRAULIC CIRCUIT SOLENOID AND VALVE FUNCTION 149
NORMAL BRAKING BUILD/DECAY VALVE FUNCTION 149
ABS BRAKING-DECAY MODE-DECAY CONTROLLER ANTILOCK BRAKE INPUTS SOLENOID FUNCTION 149
ABS BRAKING-BUILD MODE-DECAY SOLENOID FUNCTION CONTROLLER ANTILOCK BRAKE OUTPUTS 149
DIAGNOSIS AND TESTING 150
ABS GENERAL DIAGNOSTICS INFORMATION 150
SELF DIAGNOSTICS INFORMATION 150
START-UP CYCLE 150
DIAGNOSTICS MANUAL INFORMATION 150
DRIVE-OFF CYCLE 150
DIAGNOSTIC TESTER (DRB) 150
ONGOING TESTS 150
DRB DIAGNOSTIC CONNECTOR DIAGNOSTIC TROUBLE CODE INFORMATION 150
LATCHING VERSUS NON-LATCHING ABS FAULTS 151
TONEWHEEL INSPECTION 151
INTERMITTENT DIAGNOSTIC TROUBLE CODES 151
PROPORTIONING VALVES 151
BRAKE FLUID CONTAMINATION ABS SERVICE PRECAUTIONS 152
VEHICLE TEST DRIVE INFORMATION AND PROCEDURE 152
SERVICE PROCEDURES 152
BRAKE FLUID LEVEL INSPECTION 152
BLEEDING PROCEDURE INFORMATION 152
ABS BLEEDING PROCEDURE 153
REMOVAL AND INSTALLATION 153
GENERAL SERVICE CAUTIONS 153
ABS HYDRAULIC CONTROL UNIT 154
REMOVE 154
INSTALL 155
MASTER CYLINDER AND POWER BRAKE BOOSTER 157
RELAY BOX PROPORTIONING VALVES 157
REMOVE REMOVE 157
INSTALL 157
INSTALL 158
CONTROLLER ANTILOCK BRAKES (CAB) 159
INSTALL 159
REMOVE 159
FRONT WHEEL SPEED SENSOR 159
REMOVE 160
INSTALL 160
REAR WHEEL SPEED SENSOR 160
REMOVE 160
INSTALL 161
SPECIFICATIONS 161
SPEED SENSOR TONE WHEEL RUNOUT 161
WHEEL SPEED SENSOR TO TONE WHEEL CLEARANCE 161
FRONT WHEEL 161
REAR WHEEL 161
BRAKE FASTENER TORQUE SPECIFICATIONS 161
EPL_6 163
CLUTCH 163
GENERAL INFORMATION 163
CLUTCH COMPONENTS 163
CLUTCH DISC AND COVER APPLICATION 164
CLUTCH REPLACEMENT 164
DESCRIPTION AND OPERATION 164
CLUTCH CABLE 164
DIAGNOSIS AND TESTING 164
CLUTCH PEDAL POSITION SWITCH 164
CLUTCH PEDAL POSITION SWITCH–ELECTRICAL TEST 164
CLUTCH PEDAL POSITION SWITCH 164
CLUTCH PEDAL POSITION SWITCH–MECHANICAL TEST 165
SERVICE DIAGNOSIS–CLUTCH PEDAL POSITION SWITCH 165
CLUTCH DIAGNOSIS 166
SERVICE DIAGNOSIS—CLUTCH GRAB/CHATTER 166
SERVICE DIAGNOSIS—CLUTCH SLIPS 167
SERVICE DIAGNOSIS—IMPROPER CLUTCH RELEASE 168
SERVICE DIAGNOSIS–CLUTCH PEDAL NOISE 168
DRIVE PLATE MISALIGNMENT CLASH–INTO–REVERSE COMPLAINTS 169
CLUTCH COVER AND DISC RUNOUT 169
CLUTCH CHATTER COMPLAINTS 169
REMOVAL AND INSTALLATION 169
CLUTCH CABLE 169
REMOVAL 169
CLUTCH PEDAL POSITION SWITCH 170
INSTALLATION 170
REMOVAL 170
INSTALLATION 170
CLUTCH ASSEMBLY 171
TOLUCA BUILT VEHICLES 171
BELVIDERE BUILT VEHICLES 172
RELEASE BEARING AND FORK 172
REMOVAL 172
GREASE CONTAMINATION 173
ROAD SPLASH/WATER CONTAMINATION 173
INSTALLATION 173
CLEANING PRECAUTIONS 173
ADJUSTMENTS 173
CLEANING AND INSPECTION 173
CLUTCH CABLE 173
CLUTCH CONTAMINATION 173
ADJUSTER MECHANISM FUNCTION CHECK OIL CONTAMINATION 173
SPECIFICATIONS 174
TORQUE 174
MODULAR CLUTCH 174
CONVENTIONAL CLUTCH 174
SPECIAL TOOLS 174
CLUTCH 174
CLUTCH PEDAL POSITION SWITCH 174
EPL_7 175
COOLING 175
GENERAL INFORMATION 175
COOLING SYSTEM 175
ACCESSORY DRIVE BELTS 176
COOLANT RECOVERY SYSTEM (CRS) 176
ENGINE THERMOSTAT 177
WATER PUMP 177
COOLANT 177
RADIATOR 177
COOLANT REPLACEMENT 177
ENGINE BLOCK HEATER 177
COOLING SYSTEM PRESSURE CAP 177
DESCRIPTION AND OPERATION 177
ENGINE THERMOSTAT AUTOMATIC TRANSMISSION OIL COOLER 177
SELECTION AND ADDITIVES 178
COOLANT PERFORMANCE 178
COOLING SYSTEM PRESSURE CAP 179
ENGINE BLOCK HEATER RADIATOR HOSES AND CLAMPS 179
WATER PUMP 180
DIAGNOSIS AND TESTING 181
COOLING SYSTEM DIAGNOSIS 181
COOLING SYSTEM DIAGNOSIS CONT 182
COOLING SYSTEM DIAGNOSIS CONT 183
COOLING SYSTEM DIAGNOSIS CONT 184
COOLING SYSTEM DIAGNOSIS CONT 185
COOLING SYSTEM DIAGNOSIS CONT 186
ENGINE THERMOSTAT TESTING 187
ACCESSORY DRIVE BELT DIAGNOSIS 187
WATER PUMP DIAGNOSIS 188
ELECTRIC FAN MOTOR TEST 188
TESTING COOLING SYSTEM FOR LEAKS 188
COOLING SYSTEM FLOW CHECK 188
RADIATOR FAN CONTROL 188
PRESSURE CAP TO FILLER NECK SEAL PRESSURE RELIEF CHECK 189
LOW COOLANT LEVEL AERATION 189
PRESSURE TESTING COOLING SYSTEM PRESSURE CAP 189
DEAERATION 190
SERVICING COOLANT LEVEL 190
TEMPERATURE GAUGE INDICATION 190
SERVICE PROCEDURES 190
ROUTINE COOLANT LEVEL CHECK 190
DRAINING COOLANT 190
ADDING ADDITIONAL COOLANT 190
INSTALLATION 191
REFILLING COOLING SYSTEM 191
REMOVAL AND INSTALLATION 191
WATER PUMP 191
REMOVAL 191
WATER PUMP INLET TUBE 192
REMOVAL 192
ENGINE THERMOSTAT 192
REMOVAL 192
INSTALLATION 192
INSTALLATION 192
RADIATOR 193
REMOVAL 193
INSTALLATION 193
REMOVAL FAN MODULE 194
FAN BLADE 194
RADIATOR DRAINCOCK 194
REMOVAL 194
INSTALLATION 194
RADIATOR FANS AND MOTOR 194
INSTALLATION FAN MODULE 195
ELECTRIC FAN MOTOR—SERVICE 195
FAN SHROUD 195
ENGINE BLOCK HEATER 195
REMOVAL 195
INSTALLATION 195
GENERATOR BELT 195
ACCESSORY DRIVE BELTS 195
AIR CONDITIONING COMPRESSOR AND POWER STEERING PUMP 195
CLEANING AND INSPECTION 196
WATER PUMP 196
ACCESSORY DRIVE BELT INSPECTION 196
COOLING SYSTEM CAP 196
CLEANING COOLING SYSTEM 197
ADJUSTMENTS 197
PROPER BELT TENSION 197
RADIATOR FLUSHING 197
TORQUE EQUIVALENT METHOD 197
ENGINE FLUSHING BELT TENSION CHART 197
BELT TENSION GAUGE METHOD 197
REVERSE FLUSHING 197
BELT TENSION CHART GAUGE 197
CHEMICAL CLEANING 197
SPECIFICATIONS SPECIAL TOOLS 198
COOLING SYSTEM CAPACITY COOLING 198
TORQUE 198
EPL_8A 199
BATTERY 199
GENERAL INFORMATION 199
INTRODUCTION 199
DESCRIPTION AND OPERATION 199
BATTERY IGNITION OFF DRAW (IOD) 199
CHARGING TIME REQUIRED 200
SIZE OF BATTERY 200
DIAGNOSIS AND TESTING 200
BATTERY BUILT-IN TEST INDICATOR 200
USING TEST INDICATOR 200
TEMPERATURE 200
CHARGER CAPACITY 200
STATE OF CHARGE 200
CAUSES OF BATTERY DISCHARGING 201
ABNORMAL BATTERY DISCHARGING 202
BATTERY IGNITION OFF DRAW (IOD) 202
TEST LAMP STAYS ON 202
BATTERY LOAD TEST 203
BATTERY TEMPERATURE SENSOR 204
BATTERY OPEN CIRCUIT VOLTAGE TEST 204
SERVICE PROCEDURES 205
BATTERY CHARGING 205
CHARGING COMPLETELY DISCHARGED BATTERY 205
VISUAL INSPECTION 206
REMOVAL AND INSTALLATION 207
BATTERY 207
REMOVAL 207
INSTALLATION 207
BATTERY TRAY 207
REMOVAL 207
INSTALLATION 207
FRESH AIR INLET TUBE REMOVAL 208
REMOVAL 208
SPECIFICATIONS 208
BATTERY SPECIFICATIONS 208
COLD CRANK RATING 208
RESERVE CAPACITY RATING 208
TORQUE 208
INSTALLATION 208
EPL_8B 209
STARTING 209
GENERAL INFORMATION 209
INTRODUCTION 209
BOSCH STARTER 209
SUPPLY CIRCUIT AND CONTROL CIRCUIT 209
STARTER RELAY 210
DIAGNOSIS AND TESTING 210
CONTROL CIRCUIT TEST 210
RELAY TEST 210
STARTER SOLENOID 210
RELAY CIRCUIT TEST 210
SAFETY SWITCHES 211
IGNITION SWITCH 211
BATTERY 211
ALL RELATED WIRING AND CONNECTORS 211
FEED CIRCUIT RESISTANCE TEST 211
FEED CIRCUIT TEST 212
STARTING SYSTEM TEST 213
INSPECTION 213
REMOVAL AND INSTALLATION 215
SAFETY SWITCHES 215
STARTER 215
REMOVAL 215
INSTALLATION 215
SPECIFICATIONS 216
STARTER 216
TORQUE 216
STARTER RELAY 216
EPL_8C 217
EPL_8D 231
IGNITION SYSTEM 231
GENERAL INFORMATION DESCRIPTION AND OPERATION 231
INTRODUCTION IGNITION SYSTEM 231
POWERTRAIN CONTROL MODULE 232
SPARK PLUG CABLES 232
SPARK PLUGS 232
ELECTRONIC IGNITION COILS 233
AUTOMATIC SHUTDOWN RELAY 233
CRANKSHAFT POSITION SENSOR 233
CAMSHAFT POSITION SENSOR 234
COMBINATION ENGINE COOLANT TEMPERATURE SENSOR 235
KNOCK SENSOR 236
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP) 236
INTAKE AIR TEMPERATURE SENSOR 236
THROTTLE POSITION SENSOR (TPS) 237
IGNITION INTERLOCK 237
DIAGNOSIS AND TESTING 237
TESTING FOR SPARK AT COIL—2 0/2 4L 237
IGNITION SWITCH 237
LOCK KEY CYLINDER 237
CHECK COIL TEST 238
FAILURE TO START TEST—2 0/2 4L 238
IGNITION TIMING PROCEDURE 239
CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR 239
ENGINE COOLANT TEMPERATURE SENSOR 239
INTAKE AIR TEMPERATURE SENSOR 239
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST 239
THROTTLE POSITION SENSOR 239
COLD FOULING (CARBON FOULING) 240
FUEL FOULING 240
SPARK PLUG CONDITION 240
NORMAL OPERATING CONDITIONS 240
OIL FOULING 240
OIL OR ASH ENCRUSTED 240
HIGH SPEED MISS 241
ELECTRODE GAP BRIDGING 241
PREIGNITION DAMAGE 241
SCAVENGER DEPOSITS 241
SPARK PLUG OVERHEATING 241
CHIPPED ELECTRODE INSULATOR 241
SPARK PLUG SERVICE 242
REMOVAL 242
REMOVAL AND INSTALLATION 242
POWERTRAIN CONTROL MODULE (PCM) 242
REMOVAL 242
SPARK PLUG CABLE SERVICE 242
REMOVAL INSTALLATION 242
INSTALLATION 243
SPARK PLUG TUBES 243
IGNITION COIL 243
REMOVAL 243
INSTALLATION 243
CAMSHAFT POSITION SENSOR—SOHC 243
REMOVAL 243
AUTOMATIC SHUTDOWN RELAY 243
INSTALLATION 244
INSTALLATION 244
CAMSHAFT POSITION SENSOR—DOHC 244
REMOVAL 244
REMOVAL 245
CRANKSHAFT POSITION SENSOR 245
REMOVAL 245
INSTALLATION 245
INSTALLATION 245
COMBINATION ENGINE COOLANT TEMPERATURE SENSOR—DOHC 245
COMBINATION ENGINE COOLANT TEMPERATURE SENSOR—SOHC 245
REMOVAL 246
INSTALLATION 246
MAP/IAT SENSOR—SOHC 246
MAP/IAT SENSOR—DOHC 246
THROTTLE POSITION SENSOR 246
IGNITION SWITCH 246
INSTALLATION 246
REMOVAL 246
LOCK KEY CYLINDER 247
REMOVAL 247
IGNITION INTERLOCK 247
LOCK CYLINDER HOUSING 247
INSTALLATION 247
SPECIFICATIONS 248
TORQUE SPECIFICATION 248
VECI LABEL 248
FIRING ORDER—2 0L 248
SPARK PLUG CABLE RESISTANCE—SOHC 248
SPARK PLUG CABLE RESISTANCE—DOHC 248
SPARK PLUG 248
IGNITION COIL 248
EPL_8E 251
INSTRUMENT PANEL AND SYSTEMS 251
GENERAL INFORMATION 251
INTRODUCTION 251
WARNING AND INDICATOR LAMPS 252
DESCRIPTION AND OPERATION 252
DOME LAMP 252
ELECTRONIC DIGITAL CLOCK 252
DIAGNOSIS AND TESTING 252
AIRBAG WARNING SYSTEM 252
BRAKE SYSTEM WARNING LAMP TEST 252
INSTRUMENT CLUSTER 252
To test the system: GAUGES 252
If lamp fails to light inspect for: 252
FOG LAMP SWITCH TEST 253
REAR EXPORT 253
FOG LAMP SWITCH TEST EXPORT 253
FUEL TANK SENDING UNIT TEST 253
FRONT EXPORT 253
HEADLAMP LEVELING SWITCH 253
HEATER A/C BLOWER SWITCH TEST 254
HEATER BLOWER SWITCH TEST 254
HEADLAMP SWITCH TEST 254
INSTRUMENT PANEL AND COMPONENTS 255
MULTIPLE GAUGE INOPERATIVE TEST 255
LOW OIL PRESSURE WARNING LAMP TEST 255
INDIVIDUAL GAUGE INOPERATIVE 256
FUEL GAUGE 256
FUEL GAUGE INCORRECTLY INDICATES EMPTY 256
LOW FUEL WARNING CIRCUIT 256
TACHOMETER CIRCUIT 257
SPEEDOMETER SYSTEM 257
SEAT BELT REMINDER SYSTEM TEST 257
SENDING UNIT 257
TEMPERATURE GAUGE 257
SERVICE ENGINE SOON INDICATOR 257
VEHICLE SPEED SENSOR TEST 257
REMOVAL AND INSTALLATION 258
ASH RECEIVER RETAINER AND LAMP 258
REMOVAL 258
INSTALLATION 258
CLUSTER 258
INSTALLATION REMOVAL 258
CENTER BEZEL 258
REMOVAL 258
INSTALLATION INSTALLATION 258
CLUSTER LAMP CIGAR LIGHTER RECEPTACLE 258
REMOVAL 258
CLUSTER PRINTED CIRCUIT BOARD 259
REMOVAL 259
INSTALLATION 259
END CAP RHD 259
Removal 259
Installation 259
FLOOR CONSOLE 259
REMOVAL 259
INSTALLATION 259
FRONT FOG LAMP SWITCH EXPORT 259
REMOVAL 259
DOME LENS/LAMP 259
REMOVAL 259
INSTALLATION INSTALLATION 259
GLOVE BOX SWITCH/LAMP 260
REMOVAL 260
INSTALLATION 260
HEADLAMP LEVELING SWITCH EXPORT GAUGE 260
REMOVAL REMOVAL 260
INSTALLATION 260
INSTALLATION 260
GLOVE BOX DOOR/BIN 260
REMOVAL 260
HEADLAMP SWITCH 260
REMOVAL 260
installation 260
INSTALLATION 261
HEATER A/C CONTROL BLOWER SWITCH 261
HEATER A/C CONTROL LAMP 261
REMOVAL 261
HEATER A/C CONTROL 261
INSTALLATION REMOVAL 261
HEATER CONTROL BLOWER SWITCH 261
IGNITION KEY LAMP 261
REMOVAL 261
INSTALLATION 261
INSTALLATION 261
INSTRUMENT PANEL 262
REMOVAL 262
INSTALLATION 262
INSTALLATION 264
RADIO LEFT TRIM PANEL 264
REMOVAL 264
REAR WINDOW DEFOGGER AND/OR FOG LAMP SWITCH 264
REMOVAL 264
INSTALLATION 264
ODOMETER 264
REMOVAL INSTALLATION 264
INSTALLATION 265
SHIFTER KNOB 265
ATX SHIFTER 265
REAR WINDOW DEFOGGER AND/OR REAR FOG LAMP SWITCH EXPORT 265
REMOVAL 265
MTX SHIFTER 265
INSTALLATION 265
STEERING COLUMN COVER 265
REMOVAL 265
INSTALLATION 265
STEERING COLUMN COVER LINER 265
RIGHT TRIM PANEL 265
REMOVAL 265
REMOVAL 265
INSTALLATION 265
STEERING COLUMN SHROUDS 266
INSTALLATION 266
TOP COVER AND CLUSTER BEZEL REMOVAL 266
REMOVAL 266
INSTALLATION 266
TRANSMISSION RANGE INDICATOR LAMP 266
REMOVAL 266
INSTALLATION 267
TRUNK LAMP/LENS 267
REMOVAL 267
INSTALLATION 267
VEHICLE SPEED SENSOR 267
REMOVAL 267
INSTALLATION 267
EPL_8F 269
AUDIO SYSTEM 269
GENERAL INFORMATION 269
INTRODUCTION 269
DIAGNOSIS AND TESTING 269
AUDIO DIAGNOSTIC TEST PROCEDURES 269
DESCRIPTION AND OPERATION 269
INTERFERENCE ELIMINATION 269
TESTING 275
REMOVAL AND INSTALLATION 275
ANTENNA 275
REMOVAL 275
BENCH TEST FOR ANTENNA MALFUNCTION 275
INSTALLATION 275
INSTALLATION 276
INSTRUMENT PANEL SPEAKER 276
REMOVAL 276
INSTALLATION 276
RADIO 276
REMOVAL 276
FRONT DOOR SPEAKER 277
INSTALLATION 277
REMOVAL 277
INSTALLATION 277
REAR SHELF SPEAKER(S) 277
REMOVAL 277
EPL_8G 279
HORNS 279
DESCRIPTION AND OPERATION 279
INTRODUCTION 279
HORN SWITCH 279
DIAGNOSIS AND TESTING 280
HORN 280
HORN SWITCH 280
HORN RELAY 280
SYSTEM TEST 281
REMOVAL AND INSTALLATION 283
HORN 283
REMOVAL 283
INSTALLATION 283
HORN RELAY 283
REMOVAL 283
INSTALLATION 283
HORN SWITCHES 283
EPL_8H 285
VEHICLE SPEED CONTROL SYSTEM 285
GENERAL INFORMATION 285
INTRODUCTION 285
SPEED CONTROL SWITCHES 286
DESCRIPTION AND OPERATION 286
SPEED CONTROL SERVO 286
DIAGNOSIS AND TESTING 287
STOP LAMP SWITCH ROAD TEST 287
SERVO CABLE 287
POWERTRAIN CONTROL MODULE 287
VACUUM RESERVOIR 287
CHECKING FOR DIAGNOSTIC CODES 287
VEHICLE SPEED SENSOR 287
SPEED CONTROL SLOWS DOWN BY ITSELF SPEED CONTROL ACCELERATES OR TAPS UP BY ITSELF 288
SPEED CONTROL DIAGNOSTIC TROUBLE CODES 288
SPEED CONTROL ELECTRICAL TEST 289
SPEED CONTROL WILL NOT RESUME-SETS OK 289
SPEED CONTROL WILL NOT SLOW DOWN 289
OVERSHOOT/UNDERSHOOT ON SPEED CONTROL SET 291
SERVO VACUUM TEST 291
SPEED CONTROL SWITCH TEST 291
OHMMETER CHECK OF SWITCH 292
STOP LAMP SWITCH TEST 292
ELECTRICAL TESTS AT POWERTRAIN CONTROL MODULE 292
VACUUM SUPPLY TEST 293
VEHICLE SPEED SENSOR 293
REMOVAL AND INSTALLATION 293
SPEED CONTROL SERVO 293
REMOVAL 293
INSTALLATION 293
SPEED CONTROL SWITCH 294
INSTALLATION 294
REMOVAL 294
INSTALLATION 294
STOP LAMP SWITCH 294
REMOVAL 294
INSTALLATION 294
SPEED CONTROL SERVO CABLE 294
REMOVAL 294
POWERTRAIN CONTROL MODULE 295
VACUUM RESERVOIR 295
REMOVAL 295
INSTALLATION 295
VEHICLE SPEED SENSOR 295
EPL_8J 297
TURN SIGNAL AND FLASHERS 297
GENERAL INFORMATION 297
INTRODUCTION 297
DESCRIPTION AND OPERATION 297
HAZARD WARNING SYSTEM 297
COMBINATION FLASHER 297
DIAGNOSIS AND TESTING 298
MULTI-FUNCTION SWITCH 298
INSTALLATION 299
REMOVAL AND INSTALLATION 299
MULTI-FUNCTION SWITCH 299
REMOVAL 299
EPL_8K 301
WINDSHIELD WIPERS AND WASHERS 301
GENERAL INFORMATION 301
INTRODUCTION 301
DESCRIPTION AND OPERATION 301
WIPER BLADES 301
DIAGNOSIS AND TESTING 302
WINDSHIELD WIPER CONDITION 302
MOTOR WILL NOT OPERATE IN SOME OR ALL SWITCH POSITIONS 302
MOTOR OPERATES SLOWLY AT ALL SPEEDS 302
WIPERS RUN AT HIGH SPEED WITH SWITCH IN LOW SPEED POSITION OR WIPERS RUN AT LOW SPEED WITH SWITCH IN HIGH SPEED POSITION 303
WIPERS WILL OPERATE CONTINUOUSLY WITH SWITCH IN THE INTERMITTENT POSITION—WHEN WIPER SWITCH IS TURNED OFF, WIPERS STOP WHEREVER THEY ARE, WITHOUT RETURNING TO PARK POSITION 303
WIPERS DO NOT OPERATE WHEN WASHER MOTOR IS ENGAGED (PULSE WIPE) OR WIPERS DO OPERATE IN INTERMITTENT POSITION 303
WIPER MOTOR 303
WIPER SWITCH 305
WIPER BLADE ELEMENT 305
REMOVAL AND INSTALLATION 305
WIPER ARM 305
REMOVAL 305
INSTALLATION INSTALLATION 305
WIPER BLADE 305
REMOVAL 305
INSTALLATION 305
WIPER LINKAGE WIPER MOTOR 306
REMOVAL REMOVAL 306
INSTALLATION 306
INSTALLATION 306
WIPER MODULE 306
REMOVAL 306
WIPER SWITCH 306
REMOVAL 306
INSTALLATION 306
INSTALLATION 306
ADJUSTMENTS 307
WIPER ARM ADJUSTMENT 307
CLEANING AND INSPECTION 307
WIPER BLADES 307
DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING 308
WASHER NOZZLE WINDSHIELD WASHERS 308
WASHER RESERVOIR 309
REMOVAL 309
INSTALLATION 309
REMOVAL AND INSTALLATION 309
WASHER NOZZLE 309
REMOVAL 309
INSTALLATION 309
INSTALLATION 310
WASHER RESERVOIR PUMP 310
REMOVAL 310
EPL_8L 311
LAMPS 311
GENERAL INFORMATION 311
GENERAL INFORMATION 311
DAYTIME RUNNING LAMP MODULE 311
SAFETY PRECAUTIONS 311
DIAGNOSIS AND TESTING 311
DIAGNOSTIC PROCEDURES 311
HEADLAMP DIAGNOSIS 312
HEADLAMP DIAGNOSIS 313
FOG LAMP DIAGNOSIS 314
GENERAL INFORMATION 315
HEADLAMP ALIGNMENT 315
SERVICE PROCEDURES 315
HEADLAMP ALIGNMENT PREPARATION 315
HEADLAMP ADJUSTMENT 315
ADJUSTMENTS 315
HEADLAMP ADJUSTMENT USING ALIGNMENT SCREEN FOG LAMP ALIGNMENT 315
ALIGNMENT SCREEN PREPARATION 315
SPECIAL TOOLS 317
SPECIAL TOOLS—HEADLAMP ALIGNMENT 317
REMOVAL AND INSTALLATION 318
FOG LAMP BULB 318
REMOVAL 318
HEADLAMP BULB 318
REMOVAL 318
INSTALLATION 318
INSTALLATION 318
PARK AND TURN SIGNAL LAMP BULB 318
REMOVAL 318
INSTALLATION 318
FRONT SIDE MARKER LAMP BULB TAIL, STOP, BACK-UP AND TURN SIGNAL LAMP BULB 319
REMOVAL REMOVAL 319
INSTALLATION 319
CENTER HIGH MOUNTED STOP LAMP BULB 319
INSTALLATION 319
REMOVAL 319
INSTALLATION 319
LICENSE PLATE LAMP BULB DOME LAMP BULB 320
REMOVAL REMOVAL 320
INSTALLATION 320
VISOR VANITY LAMP BULB 320
REMOVAL 320
INSTALLATION 320
INSTALLATION 320
REAR CARGO LAMP BULB 320
UNDERHOOD LAMP BULB 320
REMOVAL REMOVAL 320
INSTALLATION INSTALLATION 320
REMOVAL AND INSTALLATION 321
FOG LAMP 321
REMOVAL 321
HEADLAMP MODULE 321
REMOVAL 321
INSTALLATION 321
PARK AND TURN SIGNAL LAMP 321
REMOVAL INSTALLATION 321
INSTALLATION INSTALLATION 322
FRONT SIDE MARKER LAMP TAIL, STOP AND TURN SIGNAL LAMP 322
REMOVAL REMOVAL 322
INSTALLATION 322
CENTER HIGH MOUNTED STOP LAMP (CHMSL) 322
INSTALLATION 322
REMOVAL 322
LICENSE PLATE LAMP 323
INSTALLATION REMOVAL 323
DOME LAMP 323
REMOVAL 323
INSTALLATION 323
VISOR VANITY LAMP 323
INSTALLATION 323
REAR CARGO LAMP UNDERHOOD LAMP 323
REMOVAL REMOVAL 323
INSTALLATION 323
REMOVAL AND INSTALLATION 324
DAYTIME RUNNING LAMP (CANADA) 324
INSTALLATION 324
SPECIFICATIONS 325
INTERIOR LAMPS 325
GENERAL INFORMATION 325
EXTERIOR LAMPS 325
EPL_8M 327
RESTRAINT SYSTEM 327
GENERAL INFORMATION 327
WARNINGS AND PRECAUTIONS 327
DESCRIPTION AND OPERATION 328
AIRBAG CONTROL MODULE 328
CLOCKSPRING 328
DRIVER AND PASSENGER AIRBAG MODULE 328
DIAGNOSIS AND TESTING 329
AIRBAG SYSTEM TEST 329
SERVICE PROCEDURES 329
CLEANUP PROCEDURE HANDLING AIRBAG MODULE 329
DEPLOYED MODULE 329
UNDEPLOYED 329
SERVICE OF DEPLOYED AIRBAG MODULE 329
MAINTENANCE INSPECTION 330
REMOVAL AND INSTALLATION 330
AIRBAG CONTROL MODULE (ACM) 330
REMOVAL 330
INSTALLATION 331
CLOCKSPRING 334
REMOVAL 334
INSTALLATION 334
DRIVER AIRBAG MODULE 335
REMOVAL 335
PASSENGER AIRBAG MODULE 335
NON-DEPLOYED MODULE 335
INSTALLATION 335
DEPLOYED MODULE 336
STEERING WHEEL 336
REMOVAL 336
ADJUSTMENTS 337
CLOCKSPRING CENTERING PROCEDURE 337
INSTALLATION 337
EPL_8N 339
ELECTRICALLY HEATED SYSTEMS 339
DESCRIPTION AND OPERATION 339
INTRODUCTION 339
REAR WINDOW DEFOGGER SWITCH 339
DIAGNOSIS AND TESTING 339
DEFOGGER SYSTEM 339
GRID LINES 340
REAR WINDOW DEFOGGER SWITCH 341
SERVICE PROCEDURES 341
GRID LINE AND TERMINAL REPAIR 341
EPL_8P 343
POWER DOOR LOCKS 343
DESCRIPTION AND OPERATION 343
INTRODUCTION 343
DIAGNOSIS AND TESTING 343
DOOR LOCK MOTOR 343
CHILD PROTECTION LOCK 343
DOOR LOCK SWITCH 343
WIRING 344
REMOVAL AND INSTALLATION 344
DOOR LOCK MOTOR 344
REMOVAL 344
INSTALLATION 344
DOOR LOCK SWITCH 344
REMOVAL 344
INSTALLATION 344
GENERAL INFORMATION 345
INTRODUCTION 345
OPERATION 345
DESCRIPTION AND OPERATION 345
VEHICLE ACCESS CODE (VAC) PROGRAMMING 345
DIAGNOSIS AND TESTING 345
REMOTE KEYLESS ENTRY CONDITION 345
REMOTE KEYLESS ENTRY GENERAL CHECKS BEFORE OTHER CHECKS 346
DRIVER DOOR WILL UNLOCK WITH THE TRANSMITTER, BUT ALL OTHER DOORS WILL NOT UNLOCK 346
ALL DOORS WILL NOT LOCK WITH THE TRANSMITTER 346
DOORS WILL LOCK USING THE TRANSMITTER BUT THERE IS NO HORN CHIRP 346
ILLUMINATED ENTRY FAILS TO WORK IN INITIAL UNLOCKING WITH TRANSMITTER 346
PARKING LAMPS AND/OR HEAD LAMPS FAIL TO FLASH WITH PANIC BUTTON 346
DRIVER DOOR WILL NOT UNLOCK WITH THE TRANSMITTER 346
PANIC FUNCTION CANCELLATION REMOTE KEYLESS ENTRY SYSTEM 347
PROGRAM REMOTE KEYLESS ENTRY MODULE 347
SERVICE PROCEDURES 347
HORN CHIRP CANCELLATION 347
REMOVAL AND INSTALLATION 348
REMOTE KEYLESS ENTRY MODULE 348
REMOVAL 348
INSTALLATION 348
SPECIFICATIONS 348
RKE TRANSMITTER BATTERY 348
RKE TRANSMITTER RANGE 348
EPL_8S 349
POWER WINDOWS 349
GENERAL INFORMATION 349
INTRODUCTION 349
WINDOW SWITCH TEST 349
DIAGNOSIS AND TESTING 349
WIRING TEST 349
WINDOW MOTOR TEST 349
REMOVAL AND INSTALLATION 350
WINDOW SWITCH 350
REMOVAL 350
INSTALLATION 350
DOOR WINDOW MOTOR 350
REMOVAL 350
DOOR WINDOW MOTOR 351
REMOVAL 351
INSTALLATION 351
INSTALLATION 351
EPL_8T 353
POWER MIRRORS 353
GENERAL INFORMATION 353
INTRODUCTION 353
DIAGNOSIS AND TESTING 354
MIRROR SWITCH TEST 354
MIRROR MOTOR 354
REMOVAL AND INSTALLATION 357
INSIDE MIRROR/READING LAMPS ASSEMBLY 357
REMOVAL 357
INSTALLATION 357
INSIDE MIRROR/READING LAMPS BULB/LENS 357
REMOVAL 357
INSTALLATION 357
INSTALLATION 357
MIRROR SWITCH MIRROR ASSEMBLY 357
REMOVAL 357
EPL_8U 359
CHIME WARNING/REMINDER SYSTEM 359
GENERAL INFORMATION DIAGNOSIS AND TESTING 359
INTRODUCTION FASTEN SEAT BELTS 359
HEADLAMPS LEFT ON 359
KEY LEFT IN IGNITION SWITCH 359
CHIME SYSTEM CONDITIONS 359
NO TONE WHEN IGNITION SWITCH IS TURNED ON AND DRIVERS SEAT BELT IS UNBUCKLED 359
CHIMES CONTINUE WHEN HEADLAMPS ARE TURNED OFF AND/OR KEY IS REMOVED FROM IGNITION 360
REMOVAL AND INSTALLATION 360
CHIME 360
NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS ON 360
SEAT BELT BUCKLE 360
HEADLAMP SWITCH 360
NO TONE WHEN HEADLAMPS ARE ON AND 360
KEY-IN SWITCH 360
DRIVERS DOOR IS OPEN 360
NO TONE WHEN KEY IS LEFT IN IGNITION AND DRIVERS DOOR IS OPEN 360
EPL_8W 361
WIRING DIAGRAMS 361
DESCRIPTION AND OPERATION 363
SECTION IDENTIFICATION 363
HOW TO USE THIS GROUP 363
CONNECTOR/GROUND LOCATIONS 363
SPLICE LOCATIONS 363
NOTES, CAUTIONS, and WARNINGS 364
WIRE CODE IDENTIFICATION 364
CIRCUIT IDENTIFICATION 365
TAKE OUTS 365
SYMBOLS 365
CONNECTORS 365
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES 367
POSITIVE TEMPERATURE COEFFICIENT 367
FASTENERS 367
DIAGNOSIS AND TESTING 367
TROUBLESHOOTING TOOLS 367
CHECKING FOR TERMINAL SPREADING 368
TROUBLESHOOTING TESTS 368
TESTING FOR VOLTAGE 368
INTERMITTENT AND POOR CONNECTIONS 368
TESTING FOR CONTINUITY 368
TROUBLESHOOTING WIRING PROBLEMS 369
TESTING FOR A SHORT TO GROUND 369
TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 369
SERVICE PROCEDURES 369
WIRING REPAIR 369
TESTING FOR A VOLTAGE DROP 369
TERMINAL/CONNECTOR REPAIR-MOLEX CONNECTORS 370
FUSIBLE LINK REPLACEMENT 370
CONNECTOR REPLACEMENT 371
CONNECTOR AND TERMINAL REPLACEMENT 371
TERMINAL REPLACEMENT 372
DIODE REPLACEMENT 373
SPECIAL TOOLS 373
WIRING/TERMINAL 373
GENERAL INFORMATION 377
INTRODUCTION 377
DESCRIPTION AND OPERATION 391
DESCRIPTION AND OPERATION 407
GENERAL INFORMATION 418
DESCRIPTION AND OPERATION 421
CHARGING SYSTEM 421
HELPFUL INFORMATION 421
DESCRIPTION AND OPERATION 425
STARTING SYSTEM (AUTOMATIC TRANSMISSION) 425
STARTING SYSTEM- MANUAL TRANSMISSION 425
HELPFUL INFORMATION 425
HELPFUL INFORMATION 425
DESCRIPTION AND OPERATION 440
POWER (DEVICE) GROUND 440
IGNITION SWITCH 440
HELPFUL INFORMATION 440
SIGNAL GROUND 440
BATTERY FEED 440
HELPFUL INFORMATION 440
HELPFUL INFORMATION 440
FUEL PUMP MOTOR 441
DATA LINK CONNECTOR 441
HELPFUL INFORMATION 441
HELPFUL INFORMATION 441
VEHICLE SPEED SENSOR 441
AUTOMATIC SHUT DOWN RELAY 441
HELPFUL INFORMATION 441
HELPFUL INFORMATION 441
HEATED OXYGEN SENSORS 442
CAMSHAFT POSITION SENSOR 442
HELPFUL INFORMATION 442
HELPFUL INFORMATION 442
CRANKSHAFT POSITION SENSOR ENGINE COOLANT TEMPERATURE SENSOR 442
HELPFUL INFORMATION 442
HELPFUL INFORMATION HELPFUL INFORMATION 443
THROTTLE POSITION SENSOR INTAKE AIR TEMPERATURE SENSOR 443
HELPFUL INFORMATION 443
HELPFUL INFORMATION 443
MANIFOLD ABSOLUTE PRESSURE SENSOR KNOCK SENSOR 443
HELPFUL INFORMATION 444
HELPFUL INFORMATION 444
IGNITION COIL PACK BATTERY TEMPERATURE SENSOR 444
HELPFUL INFORMATION 444
HELPFUL INFORMATION 444
FUEL INJECTORS 444
IDLE AIR CONTROL MOTOR 444
POWER STEERING PRESSURE SWITCH EGR TRANSDUCER (EET) SOLENOID 445
TORQUE CONVERTER CLUTCH SOLENOID (TCC) 445
HELPFUL INFORMATION 445
HELPFUL INFORMATION 445
LOW FUEL DETECT INPUT 445
DUTY CYCLE EVAP/PURGE SOLENOID 445
PARK/NEUTRAL POSITION SWITCH INPUT (3–SPD TRANSMISSION) 445
HELPFUL INFORMATION 445
HELPFUL INFORMATION 445
DESCRIPTION AND OPERATION 452
ABS SYSTEM RELAY 452
ANTI-LOCK BRAKES 452
ABS PUMP MOTOR RELAY 452
HYDRAULIC MODULATOR 452
ABS WARNING LAMP 452
WHEEL SPEED SENSORS DATA LINK CONNECTOR 453
HELPFUL INFORMATION 453
BRAKE SWITCH INPUT 453
DESCRIPTION AND OPERATION 461
INSTRUMENT CLUSTER 461
HIGH SPEED WARNING MODULE 461
TACHOMETER 461
ENGINE COOLANT TEMPERATURE GAUGE 461
SPEEDOMETER 461
FUEL GAUGE 462
HEADLAMP ON CHIME 462
KEY-IN CHIME 462
ODOMETER 462
CHARGE INDICATOR LAMP 462
SERVICE ENGINE SOON LAMP 462
AIRBAG WARNING LAMP 462
SEAT BELT WARNING INDICATOR 462
LOW OIL PRESSURE LAMP 462
HIGH BEAM INDICATOR LAMP LOW FUEL LAMP 462
RIGHT AND LEFT TURN SIGNAL INDICATORS 463
ANTI-LOCK WARNING LAMP 463
BRAKE WARNING INDICATOR LAMP 463
HELPFUL INFORMATION 463
DESCRIPTION AND OPERATION 468
HORNS 468
CIGAR LIGHTER 468
DESCRIPTION AND OPERATION 474
AIR CONDITIONING-HEATER SYSTEM 474
RADIATOR FAN OPERATION 474
A/C OPERATION 474
BLOWER MOTOR OPERATION 474
HELPFUL INFORMATION 475
DESCRIPTION AND OPERATION 481
AIRBAG SQUIB (AIRBAG IGNITER) 481
DRIVERS SIDE AIRBAG 481
AIRBAG CONTROL MODULE (ACM) 481
PASSENGERS SIDE AIRBAG 481
AIRBAG WARNING LAMP 481
HELPFUL INFORMATION 481
AIRBAG IMPACT SENSOR 481
DESCRIPTION AND OPERATION 487
INTRODUCTION 487
PRNDL (TRANSMISSION RANGE INDICATOR) LAMP 487
HALO LAMP/TIME DELAY RELAY 487
VISOR/VANITY LAMPS 487
DOME LAMP 487
TIME OUT RELAY 487
ASH RECEIVER LAMP 488
MAP/READING LAMPS 488
UNDERHOOD LAMP 488
TRUNK LAMP 488
HELPFUL INFORMATION 488
GLOVE BOX LAMP 488
DESCRIPTION AND OPERATION 493
SPEAKERS 493
RADIO OPERATION 493
RADIO MEMORY 493
HELPFUL INFORMATION 493
RADIO ILLUMINATION 493
DESCRIPTION AND OPERATION 497
REAR WINDOW DEFOGGER 497
HELPFUL INFORMATION 497
GENERAL INFORMATION 505
INTRODUCTION 505
DESCRIPTION AND OPERATION 505
PARKING LAMPS HEADLAMPS 505
HEADLAMP SWITCH IN OFF OR PARKING LAMP POSITION 505
GROUND CIRCUIT 505
HELPFUL INFORMATION 505
HEADLAMP SWITCH IN ON POSITION 505
HEADLAMP GROUND 506
FOG LAMPS (FRONT) 506
HELPFUL INFORMATION 506
HEADLAMP LEVELING MOTORS 506
HELPFUL INFORMATION 506
DESCRIPTION AND OPERATION 515
FOG LAMPS (REAR) 515
TAIL LAMPS AND LICENSE LAMPS 515
GROUND CIRCUIT 515
HELPFUL INFORMATION 515
GROUND CIRCUIT 515
HELPFUL INFORMATION 515
STOP LAMPS BACK-UP LAMPS 516
GROUND CIRCUIT 516
GROUND CIRCUIT HELPFUL INFORMATION 516
HELPFUL INFORMATION 516
DESCRIPTION AND OPERATION 521
TURN SIGNALS 521
HELPFUL INFORMATION 521
RIGHT TURN SIGNAL 521
LEFT TURN SIGNAL 521
HAZARD FLASHERS 521
GROUND CIRCUIT 521
HELPFUL INFORMATION 522
GROUND CIRCUITS 522
DESCRIPTION AND OPERATION 526
WIPERS—INTERMITTENT 526
HELPFUL INFORMATION 526
DESCRIPTION AND OPERATION 529
POWER WINDOWS 529
RIGHT WINDOW SWITCH OPERATION 529
MASTER WINDOW SWITCH (LEFT WINDOW OPERATION) 529
HELPFUL INFORMATION 529
MASTER WINDOW SWITCH (RIGHT WINDOW OPERATION) 529
DESCRIPTION AND OPERATION 535
POWER DOOR LOCKS 535
RIGHT DOOR SWITCH OPERATION (UNLOCK) 535
LEFT DOOR SWITCH OPERATION (LOCK) 535
POWER DOOR LOCKS W/ REMOTE KEYLESS ENTRY 535
LEFT DOOR SWITCH OPERATION (UNLOCK) 535
RIGHT DOOR SWITCH OPERATION (LOCK) 535
LEFT DOOR UNLOCK (USING RKE TRANSMITTER) 536
LOCK/ UNLOCK (USING DOOR SWITCHES) 536
UNLOCK- ALL (USING RKE TRANSMITTER) PANIC FUNCTION 536
ILLUMINATED ENTRY 536
HELPFUL INFORMATION 536
LOCK- ALL (USING RKE TRANSMITTER) 536
DESCRIPTION AND OPERATION 539
POWER MIRRORS 539
HELPFUL INFORMATION 539
DESCRIPTION AND OPERATION 543
POWER SUNROOF 543
TILT OPEN/CLOSE 543
SUNROOF OPEN/CLOSE 543
DESCRIPTION AND OPERATION 585
INTRODUCTION CONNECTOR/GROUND LOCATIONS 585
DESCRIPTION AND OPERATION 607
SPLICE LOCATIONS 607
INTRODUCTION 607
EPL_9 617
ENGINE 617
GENERAL INFORMATION 617
FORM-IN-PLACE GASKETS 617
ENGINE PERFORMANCE 618
CRANKSHAFT SPROCKET BOLT ACCESS PLUG 618
ENGINE CORE PLUGS 618
REMOVAL 618
PERFORM CYLINDER COMPRESSION TEST 618
INSTALLATION 618
HONING CYLINDER BORES 619
MEASURING MAIN BEARING AND CONNECTING ROD BEARING CLEARANCES 619
ALTERNATIVE METHOD 620
PLASTIGAGE PROCEDURE PREFERRED METHOD 620
CONNECTING ROD BEARING CLEARANCE 620
CHECKING ENGINE OIL LEVEL 621
REPAIR OF DAMAGED OR WORN THREADS 621
ENGINE OIL SERVICE 621
HYDROSTATIC LOCKED ENGINE 621
ENGINE OIL SPECIFICATION 622
API SERVICE GRADE CERTIFIED 622
SAE VISCOSITY ENGINE OIL ADDITIVES 622
ENGINE OIL CHANGE 622
ENERGY CONSERVING OIL 622
CONTAINER IDENTIFICATION 622
DIAGNOSIS AND TESTING 623
CYLINDER COMPRESSION PRESSURE TEST 623
GENERAL INFORMATION 623
INTAKE MANIFOLD LEAKAGE DIAGNOSIS 623
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS 624
CYLINDER COMBUSTION PRESSURE LEAKAGE TEST 624
INSPECTION (ENGINE OIL LEAKS IN GENERAL) 624
INSPECTION FOR REAR SEAL AREA LEAKS 625
ENGINE DIAGNOSIS—PERFORMANCE 626
ENGINE DIAGNOSIS—MECHANICAL 627
DESCRIPTION AND OPERATION 628
GENERAL SPECIFICATION 628
ENGINE IDENTIFICATION 628
ENGINE LUBRICATION SYSTEM 629
ENGINE LUBRICATION 629
PRESSURE LUBRICATION 629
MAIN/ROD BEARINGS 629
CAMSHAFT/HYDRAULIC LASH ADJUSTERS 630
SPLASH LUBRICATION 630
ENGINE COMPONENTS 630
DIAGNOSIS AND TESTING 630
CHECKING ENGINE OIL PRESSURE 630
CYLINDER BORE AND PISTON SPECIFICATIONS TABLE 631
SERVICE PROCEDURES 631
CYLINDER BORE AND PISTON SIZING 631
FITTING PISTON RINGS 631
SIZING PISTONS 631
FITTING CONNECTING RODS 631
FITTING CRANKSHAFT BEARINGS 633
FEELER GAGE METHOD 633
REMOVAL AND INSTALLATION 633
FRONT MOUNT 633
CRANKSHAFT END PLAY 633
DIAL INDICATOR METHOD 633
LEFT MOUNT 634
RIGHT MOUNT POWER HOP DAMPER 634
ENGINE ASSEMBLY 635
REMOVAL 635
INSTALLATION 635
CYLINDER HEAD COVER 636
REMOVAL 636
INSTALLATION 636
SPARK PLUG TUBE SEALS 637
SPARK PLUG TUBE 637
CAMSHAFT 637
REMOVAL 637
CAMSHAFT END PLAY 638
ROCKER ARM/HYDRAULIC LASH ADJUSTER 638
REMOVAL 638
INSTALLATION 638
INSTALLATION 639
HYDRAULIC LASH ADJUSTER NOISE 639
VALVE SEALS AND SPRINGS IN VEHICLE 639
REMOVAL 639
INSTALLATION 640
INSTALLATION 640
CYLINDER HEAD 640
REMOVAL 640
TIMING BELT COVER 641
REMOVAL 641
INSTALLATION 642
CAMSHAFT OIL SEAL 643
REMOVAL 643
INSTALLATION 643
TIMING BELT SYSTEM 644
CHECKING BELT TIMING—COVER INSTALLED 644
REMOVAL—TIMING BELT 644
CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE AND BELT INSTALLATION —SOHC ENGINE 645
INSTALLATION 647
OIL PAN 647
REMOVAL 647
FRONT CRANKSHAFT OIL SEAL 648
REMOVAL 648
INSTALLATION 648
REAR CRANKSHAFT SEAL 649
REMOVAL 649
INSTALLATION 649
CRANKSHAFT 650
REMOVAL 650
CRANKSHAFT MAIN BEARINGS LOCATION 650
CRANKSHAFT MAIN JOURNALS INSPECTION 650
INSTALLATION 651
OIL FILTER ADAPTER 652
REMOVE AND INSTALL 652
OIL FILTER 652
REMOVE AND INSTALL 652
OIL PUMP 653
REMOVAL 653
INSTALLATION 654
PISTON AND CONNECTING ROD 654
REMOVAL 654
PISTON RING—REMOVAL 655
PISTON RINGS—INSTALLATION 655
VIBRATION DAMPER 656
PISTON AND ROD —INSTALLATION 656
REMOVAL 656
DISASSEMBLY AND ASSEMBLY 657
OIL PUMP 657
INSTALLATION 657
VALVE SERVICE WITH THE CYLINDER HEAD REMOVED 658
REMOVAL 658
VALVE INSPECTION 658
TESTING VALVE SPRINGS 658
VALVE GUIDES 658
REFACING VALVES AND VALVE SEATS 659
CLEANING 659
VALVE INSTALLATION 660
CLEANING AND INSPECTION 660
CYLINDER HEAD AND CAMSHAFT JOURNALS 660
INSPECTING CYLINDER HEAD 660
CLEANING 660
OIL PUMP 661
CYLINDER BLOCK AND BORE 662
CYLINDER BORE INSPECTION 662
SPECIFICATIONS 663
ENGINE 2 0L SOHC 663
TORQUE CHART 2 0L SOHC 664
SPECIAL TOOLS 665
ENGINE 2 0L SOHC 665
DESCRIPTION AND OPERATION 668
GENERAL SPECIFICATION 668
ENGINE IDENTIFICATION NUMBER 668
ENGINE LUBRICATION SYSTEM 669
MAIN/ROD BEARINGS 669
CAMSHAFT/HYDRAULIC LASH ADJUSTERS 669
SPLASH LUBRICATION 670
ENGINE COMPONENTS 670
DIAGNOSIS AND TESTING 670
CHECKING ENGINE OIL PRESSURE 670
CYLINDER BORE AND PISTON 671
SERVICE PROCEDURES 671
CYLINDER BORE AND PISTON SIZING 671
SIZING PISTONS 671
FITTING PISTON RINGS 672
FITTING CRANKSHAFT BEARINGS FITTING CONNECTING RODS 672
CRANKSHAFT END PLAY 672
DIAL INDICATOR METHOD 672
FEELER GAGE METHOD 673
REMOVAL AND INSTALLATION 673
FRONT MOUNT 673
LEFT MOUNT 674
RIGHT MOUNT POWER HOP DAMPER 674
ENGINE ASSEMBLY 675
REMOVAL 675
INSTALLATION 675
CYLINDER HEAD COVER 676
REMOVAL 676
COVER INSTALLATION 677
CAMSHAFT END PLAY 677
CAMSHAFT 677
REMOVAL 677
INSTALLATION 678
INSTALLATION 678
CAM FOLLOWER AND HYDRAULIC LASH ADJUSTER ASSEMBLY 678
REMOVAL 678
HYDRAULIC LASH ADJUSTER NOISE 678
INSTALLATION 679
VALVE SPRING AND SEALS—CYLINDER HEAD NOT REMOVED 679
REMOVAL 679
CYLINDER HEAD 679
REMOVAL CYLINDER HEAD FLATNESS 681
INSTALLATION 681
VIBRATION DAMPER 682
INSTALLATION 682
REMOVAL 682
TIMING BELT COVER 683
REMOVAL 683
INSTALLATION 683
TIMING BELT 684
CHECKING BELT TIMING —COVER REMOVAL INSTALLED 684
CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE AND BELT INSTALLATION —DOHC ENGINE 685
OIL PAN 686
REMOVAL 686
INSTALLATION 686
CAMSHAFT OIL SEALS 687
REMOVAL 687
INSTALLATION 687
FRONT CRANKSHAFT OIL SEAL 688
REMOVAL 688
INSTALLATION 688
REAR CRANKSHAFT SEAL 689
REMOVAL 689
INSTALLATION 689
CRANKSHAFT 691
REMOVAL 691
CRANKSHAFT MAIN BEARINGS LOCATION 691
CRANKSHAFT MAIN JOURNALS INSPECTION 691
INSTALLATION 692
OIL PUMP 693
REMOVAL 693
OIL FILTER ADAPTER 693
REMOVE AND INSTALL 693
OIL FILTER 693
REMOVE AND INSTALL 693
INSTALLATION 694
PISTON AND CONNECTING ROD 695
REMOVAL 695
PISTON RING—REMOVAL 695
PISTON RINGS—INSTALLATION 696
PISTON AND ROD —INSTALLATION 696
DISASSEMBLY AND ASSEMBLY 697
OIL PUMP 697
VALVE GUIDES 697
VALVE SERVICE WITH CYLINDER HEAD REMOVED 697
REMOVAL 697
CHECK VALVE GUIDE HEIGTH 698
TESTING VALVE SPRINGS 698
REFACING VALVES AND VALVE SEATS 698
VALVE INSTALLATION 699
OIL PUMP 700
CLEANING AND INSPECTION 700
CYLINDER HEAD AND CAMSHAFT JOURNALS 700
INSPECTING CYLINDER HEAD 700
CLEANING 700
CYLINDER BLOCK AND BORE 701
CYLINDER BORE INSPECTION 701
SPECIFICATIONS 702
ENGINE 2 0L DOHC 702
TORQUE CHART 2 0L DOHC 704
SPECIAL TOOLS 704
ENGINE 2 0L DOHC 704
EPL_11 707
EXHAUST SYSTEM AND INTAKE MANIFOLD 707
GENERAL INFORMATION 707
EXHAUST SYSTEMS 707
CATALYTIC CONVERTER EXHAUST BALL JOINT COUPLING 707
HEAT SHIELDS 708
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 708
DESCRIPTION AND OPERATION 709
INTAKE MANIFOLD SOHC EXHAUST MANIFOLD 709
INTAKE MANIFOLD DOHC 709
DIAGNOSIS AND TESTING 709
EXHAUST SYSTEM DIAGNOSIS 709
REMOVAL AND INSTALLATION 710
EXHAUST PIPE AND MUFFLER 710
REMOVAL 710
INSTALLATION 711
INTAKE MANIFOLD—SINGLE OVERHEAD CAM ENGINE (SOHC) 711
REMOVAL 711
INSTALLATION 713
INTAKE MANIFOLD—DUAL OVERHEAD CAM ENGINE (DOHC) 713
REMOVAL 713
INSTALLATION 715
EXHAUST MANIFOLD 716
REMOVAL 716
CLEANING AND INSPECTION 716
INTAKE MANIFOLD SOHC 716
INSPECT AND CLEAN 716
INSTALLATION 716
INTAKE MANIFOLD DOHC 716
INSPECT AND CLEAN 716
SPECIFICATIONS 717
TORQUE CHART 717
EXHAUST MANIFOLD 717
CLEAN AND INSPECT 717
EPL_13 719
FRAME AND BUMPERS 719
REMOVAL AND INSTALLATION 719
FRONT BUMPER FASCIA 719
REMOVAL 719
FRONT BUMPER REINFORCEMENT 719
REMOVAL 719
INSTALLATION 719
REAR BUMPER FASCIA 719
REMOVAL 719
INSTALLATION 720
REAR BUMPER REINFORCEMENT 720
REMOVAL 720
INSTALLATION 720
REMOVAL AND INSTALLATION 721
FRONT SUSPENSION CROSSMEMBER 721
INSTALLATION 721
REMOVAL 721
SPECIFICATIONS 723
STRUCTURAL DIMENSIONS 723
TORQUE SPECIFICATIONS 728
EPL_14 729
FUEL SYSTEM 729
GENERAL INFORMATION 729
INTRODUCTION 729
GASOLINE/OXYGENATE BLENDS 729
FUEL REQUIREMENTS 729
DESCRIPTION AND OPERATION 731
FUEL DELIVERY SYSTEM 731
FUEL PUMP MODULE 731
ELECTRIC FUEL PUMP 732
FUEL GAUGE SENDING UNIT 732
FUEL TANK 732
FUEL FILTER/FUEL PRESSURE REGULATOR 732
FUEL RAIL 732
FUEL INJECTORS 733
QUICK-CONNECT FITTINGS 733
PRESSURE-VACUUM FILLER CAP 733
ROLLOVER VALVES 734
DIAGNOSIS AND TESTING 734
FUEL PUMP PRESSURE TEST 734
FUEL LEVEL SENSOR 736
FUEL INJECTORS 736
SERVICE PROCEDURES 738
DRAINING FUEL TANK 738
FUEL SYSTEM PRESSURE RELEASE PROCEDURE 738
HOSES AND CLAMPS 738
QUICK-CONNECT FITTINGS 739
REMOVAL 739
PLASTIC RETAINER RING TYPE FITTING 739
INSTALLATION 739
REMOVAL AND INSTALLATION 740
AUTOMATIC SHUTDOWN RELAY 740
FUEL PUMP RELAY 740
INSTALLATION 740
FUEL PUMP MODULE 740
REMOVAL 740
INSTALLATION 741
FUEL FILTER / PRESSURE REGULATOR 741
REMOVAL 741
FUEL PUMP INLET STRAINER 742
REMOVAL 742
INSTALLATION 742
FUEL LEVEL SENSOR 742
REMOVAL 742
INSTALLATION 743
FUEL INJECTORS 743
REMOVAL 743
FUEL TANK 744
REMOVAL 744
INSTALLATION 744
INSTALLATION 745
INSTALLATION 745
FUEL FILLER TUBE ROLLOVER VALVE 745
REMOVAL 745
FUEL FILLER NECK 745
REMOVAL INSTALLATION 745
ACCELERATOR PEDAL 746
INSTALLATION 746
REMOVAL 746
THROTTLE CABLE—MANUAL TRANSMISSION 746
REMOVAL 746
INSTALLATION 747
INSTALLATION 747
THROTTLE CABLE—AUTOMATIC TRANSMISSION 747
REMOVAL 747
SPECIFICATIONS 748
TORQUE SPECIFICATION 748
GENERAL INFORMATION 750
INTRODUCTION 750
MODES OF OPERATION 750
IGNITION SWITCH ON (ZERO RPM) MODE 750
ENGINE WARM-UP MODE 751
ENGINE START-UP MODE 751
CRUISE OR IDLE MODE 751
WIDE-OPEN-THROTTLE MODE 752
ACCELERATION MODE 752
IGNITION SWITCH OFF MODE 752
DECELERATION MODE 752
DESCRIPTION AND OPERATION 752
SYSTEM DIAGNOSIS 752
POWER DISTRIBUTION CENTER 753
POWERTRAIN CONTROL MODULE 753
AUTOMATIC SHUTDOWN (ASD) SENSE—PCM INPUT 754
BATTERY VOLTAGE—PCM INPUT 754
BATTERY TEMPERATURE SENSOR—PCM INPUT 754
BRAKE SWITCH—PCM INPUT 754
AIR CONDITIONING PRESSURE TRANSDUCER— PCM INPUT 754
CAMSHAFT POSITION SENSOR—PCM INPUT 755
CRANKSHAFT POSITION SENSOR—PCM INPUT 755
ENGINE COOLANT TEMPERATURE SENSOR—PCM INPUT 756
SOHC 757
DOHC 757
UPSTREAM OXYGEN SENSOR 757
FUEL LEVEL SENSOR—PCM INPUT 757
HEATED OXYGEN SENSOR (O2S SENSOR)—PCM INPUT 757
DOWNSTREAM OXYGEN SENSOR 758
IGNITION CIRCUIT SENSE—PCM INPUT 758
INTAKE AIR TEMPERATURE SENSOR—PCM INPUT 758
KNOCK SENSOR—PCM INPUT POWER STEERING PRESSURE SWITCH—PCM INPUT 759
SENSOR RETURN—PCM INPUT MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR—PCM INPUT 759
SPEED CONTROL—PCM INPUT 759
SCI RECEIVE—PCM INPUT 760
PARK/NEUTRAL POSITION SWITCH—PCM INPUT 760
THROTTLE POSITION SENSOR—PCM INPUT 760
VEHICLE SPEED SENSOR—PCM INPUT 761
AUTOMATIC SHUTDOWN RELAY—PCM OUTPUT 761
AIR CONDITIONING CLUTCH RELAY—PCM OUTPUT 761
CHARGING SYSTEM INDICATOR LAMP—PCM OUTPUT 761
FUEL PUMP RELAY—PCM OUTPUT 762
DUTY CYCLE EVAP PURGE SOLENOID—PCM OUTPUT 762
GENERATOR FIELD—PCM OUTPUT 762
IDLE AIR CONTROL MOTOR—PCM OUTPUT ELECTRIC EGR TRANSDUCER—PCM OUTPUT 762
FUEL INJECTORS—PCM OUTPUT 763
DATA LINK CONNECTOR 763
IGNITION COIL—PCM OUTPUT MALFUNCTION INDICATOR (CHECK ENGINE) LAMP—PCM OUTPUT 764
RADIATOR FAN CONTROL MODULE—PCM OUTPUT 764
SPEED CONTROL—PCM INPUT 765
SCI RECEIVE—PCM INPUT 765
TACHOMETER—PCM OUTPUT 765
TORQUE CONVERTOR CLUTCH SOLENOID—PCM OUTPUT 765
DIAGNOSIS AND TESTING 765
VISUAL INSPECTION—SOHC 765
VISUAL INSPECTION—DOHC 770
TESTING 775
ASD AND FUEL PUMP RELAYS 775
OPERATION 775
CAMSHAFT AND CRANKSHAFT POSITION SENSOR 775
ENGINE COOLANT TEMPERATURE SENSOR 776
HEATED OXYGEN SENSOR 776
IDLE AIR CONTROL (IAC) MOTOR TEST 776
KNOCK SENSOR 776
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR 776
THROTTLE BODY MINIMUM AIR FLOW 777
THROTTLE POSITION SENSOR 777
VEHICLE SPEED SENSOR 778
REMOVAL AND INSTALLATION 778
THROTTLE BODY—MANUAL TRANSMISSION 778
REMOVAL 778
INSTALLATION 779
THROTTLE BODY—AUTOMATIC TRANSMISSION 779
REMOVAL 779
THROTTLE POSITION SENSOR (TPS) 780
INSTALLATION 780
REMOVAL 780
INSTALLATION 781
INSTALLATION 781
IDLE AIR CONTROL MOTOR MAP/IAT SENSOR—SOHC 781
REMOVAL 781
REMOVAL 781
INSTALLATION 782
INSTALLATION 782
MAP/IAT SENSOR—DOHC 782
REMOVAL 782
DUTY CYCLE EVAP PURGE SOLENOID VALVE 782
REMOVAL 782
INSTALLATION 782
POWERTRAIN CONTROL MODULE (PCM) 782
CRANKSHAFT POSITION SENSOR 783
CAMSHAFT POSITION SENSOR 783
UPSTREAM HEATED OXYGEN SENSOR 783
REMOVAL 783
REMOVAL 783
INSTALLATION 783
INSTALLATION 783
DOWNSTREAM HEATED OXYGEN SENSOR 784
REMOVAL 784
REMOVAL INSTALLATION 784
AIR CLEANER ELEMENT 784
INSTALLATION 785
INSTALLATION 785
ENGINE COOLANT TEMPERATURE SENSOR 785
REMOVAL 785
VEHICLE SPEED SENSOR KNOCK SENSOR 786
REMOVAL 786
SPECIFICATIONS 786
VECI LABEL 786
INSTALLATION 786
TORQUE SPECIFICATIONS 786
SPECIAL TOOLS 787
FUEL 787
EPL_19 789
STEERING 789
GENERAL INFORMATION DIAGNOSIS AND TESTING 789
STEERING SYSTEM AND COMPONENT STEERING SYSTEM DIAGNOSIS CHARTS DESCRIPTION 789
STEERING NOISE 789
BINDING STICKING SEIZED 792
SHAKE SHUDDER VIBRATION 793
LOW ASSIST, NO ASSIST, HARD STEERING 793
POOR RETURN TO CENTER 794
LOOSE STEERING 795
VEHICLE LEADS TO THE SIDE 796
POWER STEERING FLUID LEAK 797
FOAMY OR MILKY POWER STEERING FLUID 797
DESCRIPTION AND OPERATION 798
POWER STEERING PUMP 798
POWER STEERING PUMP FLOW AND PRESSURE TEST PROCEDURE 799
DIAGNOSIS AND TESTING 799
POWER STEERING SYSTEM TEST PROCEDURE 799
POWER STEERING PUMP INITIAL OPERATION 800
POWER STEERING PUMP FLOW CONTROL VALVE SEAL 800
SERVICE PROCEDURES 800
POWER STEERING SYSTEM FLUID LEVEL CHECK 800
INSTALL 800
INSTALL 801
REMOVAL AND INSTALLATION 801
POWER STEERING PRESSURE SWITCH 801
POWER STEERING PUMP SUCTION PORT SEAL 801
REMOVE 801
REMOVE 802
POWER STEERING FLUID PRESSURE HOSE 802
REMOVE 802
INSTALL 802
INSTALL 803
POWER STEERING FLUID RETURN HOSE 804
REMOVE 804
INSTALL 805
POWER STEERING FLUID SUPPLY HOSE RESERVOIR TO POWER STEERING PUMP 806
REMOVE 806
INSTALL 806
POWER STEERING PUMP (ALL ENGINES) 807
REMOVE 807
INSTALL 808
POWER STEERING FLUID RESERVOIR 810
REMOVE 810
DISASSEMBLY AND ASSEMBLY 811
POWER STEERING PUMP DRIVE PULLEY 811
REMOVE 811
INSTALL 811
INSTALL 812
POWER STEERING PUMP MOUNTING BRACKET 812
DISASSEMBLE 812
ASSEMBLE 812
SPECIFICATIONS 813
POWER STEERING PUMP FLOW SPECIFICATIONS 813
POWER STEERING PUMP FASTENER TORQUE 814
SPECIAL TOOLS 814
SPECIFICATIONS POWER STEERING PUMP 814
DESCRIPTION AND OPERATION 815
STEERING GEAR 815
DIAGNOSIS AND TESTING 816
POWER STEERING SYSTEM TEST PROCEDURE 816
POWER STEERING PUMP FLOW AND PRESSURE TEST PROCEDURE 816
REMOVAL AND INSTALLATION 817
MANUAL AND POWER STEERING GEAR 817
REMOVE 817
INSTALL 820
ASSEMBLE 821
DISASSEMBLY AND ASSEMBLY 821
OUTER TIE ROD END 821
DISASSEMBLE 821
SPECIFICATIONS 822
STEERING GEAR FASTENER TORQUE SPECIFICATIONS 822
SPECIAL TOOLS 822
POWER STEERING GEAR 822
DESCRIPTION AND OPERATION 823
STEERING COLUMN ASSEMBLY 823
STEERING GEAR TO STEERING COLUMN COUPLING 825
STEERING COUPLING INSPECTION PROCEDURE 825
DIAGNOSIS AND TESTING 825
STEERING COLUMN 825
STEERING COLUMN TO STEERING GEAR COUPLING 825
STEERING COLUMN COUPLING INSPECTION 825
STEERING COLUMN 826
REMOVE 826
REMOVAL AND INSTALLATION 826
STEERING COLUMN SERVICE PROCEDURE WARNINGS 826
INSTALL 830
SPECIFICATIONS 831
STEERING COLUMN FASTENER TORQUE SPECIFICATIONS 831
EPL_21 833
TRANSAXLE 833
GENERAL INFORMATION 834
NV T350 MANUAL TRANSAXLE 834
TRANSAXLE IDENTIFICATION INFORMATION SELECTION OF LUBRICANT 834
SPECIAL ADDITIVES 834
SEALANTS GEARSHIFT PATTERN 835
GEAR RATIOS 835
DESCRIPTION AND OPERATION 836
NOISY OPERATION 836
SHIFT LEVERS 836
SELECTOR LEVER 836
SLIPS OUT OF GEAR 836
LOW LUBRICANT LEVEL 836
CLUTCH PROBLEMS 836
AXLE SEALS 836
SERVICE PROCEDURES 836
DIAGNOSIS AND TESTING 836
FLUID DRAIN AND FILL 836
COMMON PROBLEM CAUSES 836
HARD SHIFTING 836
REMOVAL AND INSTALLATION 837
GEARSHIFT KNOB 837
INSTALLATION REMOVAL 837
GEARSHIFT CABLES 837
INSTALLATION REMOVAL 837
GEARSHIFT BOOT 837
REMOVAL 837
INSTALLATION 838
GEARSHIFT CROSSOVER CABLE ADJUSTMENT 839
GEARSHIFT MECHANISM REPLACEMENT 839
REMOVAL 839
INSTALLATION 840
VEHICLE SPEED SENSOR DRIVE GEAR 840
REMOVAL 840
INSTALLATION 840
CROSSOVER LEVER 840
REMOVAL 840
INSTALLATION 840
SELECTOR LEVER 840
INSTALLATION 840
REMOVAL 840
BACK-UP LAMP SWITCH 840
REMOVAL 840
INSTALLATION 841
SHIFT SHAFT SEALS 841
REMOVAL 841
INSTALLATION 841
TRANSAXLE 841
AXLE SEALS 841
REMOVAL 841
REMOVAL 841
INSTALLATION 841
INSTALLATION 843
DISASSEMBLY AND ASSEMBLY 843
TRANSAXLE 843
DISASSEMBLY 843
ASSEMBLY 848
INPUT SHAFT 853
DISASSEMBLY 853
ASSEMBLY 855
DIFFERENTIAL BEARINGS 857
OUTPUT SHAFT 857
DIFFERENTIAL 857
RING GEAR 858
SPEEDOMETER DRIVE GEAR 858
DIFFERENTIAL GEARS 859
SYNCHRONIZER 860
DISASSEMBLY 860
ASSEMBLY 860
SHIFT RAILS OVERHAUL 860
TRANSAXLE CASE OVERHAUL 860
AXLE SHAFT SEALS OUTPUT BEARING 861
INPUT BEARING AND SLEEVE 863
DIFFERENTIAL BEARING CUPS SHIFT RAIL BUSHINGS 865
SHIFT SHAFT SEALS 865
SHIFT SELECTOR SHAFT 865
SHIFT CROSSOVER SHAFT 866
SHIFT SELECTOR SHAFT BUSHING 866
SHIFT CROSSOVER SHAFT BUSHING 866
SYNCHRONIZER 867
REAR BEARING OIL FEED TROUGH CLEAN 867
INSPECT 867
ADJUSTMENTS 867
GEARSHIFT CROSSOVER CABLE 867
CLEANING AND INSPECTION 867
TRANSAXLE 867
BEARING ADJUSTMENT PROCEDURE 868
GENERAL RULES ON SERVICING BEARINGS 868
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT 868
NV T350 (A-578) MANUAL TRANSAXLE FLUID FILL 869
SPECIFICATIONS 869
NV T350 (A-578) SPECIFICATIONS 869
SPECIAL TOOLS 870
SPECIAL TOOLS–NV T350 (A-578) MANUAL TRANSAXLE 870
GENERAL INFORMATION 874
GENERAL INFORMATION 874
FLUID LEVEL AND CONDITION 874
SELECTION OF LUBRICANT 875
FLOW CONTROL VALVES 875
SPECIAL ADDITIVES 875
DESCRIPTION AND OPERATION 875
TORQUE CONVERTER CLUTCH 875
HYDRAULIC CONTROL SYSTEM 875
CLUTCHES, BAND SERVOS, AND ACCUMULATOR 875
PRESSURE SUPPLY SYSTEM 875
PRESSURE REGULATING VALVES 875
AUTOMATIC TRANSMISSION SHIFTER/IGNITION INTERLOCK 876
DIAGNOSIS AND TESTING 876
TH TRANSAXLE DIAGNOSIS AND TESTS 876
GEARSHIFT AND PARKING LOCK CONTROLS 876
TH HYDRAULIC TROUBLE CODE CHARTS 876
TORQUE CONVERTER CLUTCH SOLENOID WIRING CONNECTOR ROAD TEST 876
GOVERNOR 876
TEST TWO (SELECTOR IN 2) 885
HYDRAULIC PRESSURE TESTS 885
TEST ONE (SELECTOR IN 1) 885
TEST THREE (SELECTOR IN D) 885
TEST FOUR (SELECTOR IN REVERSE) 886
TEST RESULT INDICATIONS 886
REAR CLUTCH 887
GOVERNOR PRESSURE 887
KICKDOWN SERVO (FRONT) 887
LOW AND REVERSE SERVO (REAR) 887
THROTTLE PRESSURE 887
FLUID LEAKAGE-TRANSAXLE TORQUE CONVERTER HOUSING AREA 887
CLUTCH AND SERVO AIR PRESSURE TESTS 887
TORQUE CONVERTER LEAKAGE 887
FRONT CLUTCH 887
INTERLOCK SYSTEM OPERATION CHECK 888
FLUID DRAIN AND REFILL 888
SERVICE PROCEDURES 888
FLUID AND FILTER CHANGE 888
ALUMINUM THREAD REPAIR 889
FLUSHING COOLERS AND TUBES 889
COOLER FLUSH USING SUCTION GUN AND MINERAL SPIRITS 889
COOLER FLUSH USING TOOL 6906 889
OIL COOLER FLOW CHECK 890
REMOVAL AND INSTALLATION 890
GEARSHIFT CABLE 890
REMOVAL 890
INSTALLATION 891
GEARSHIFT MECHANISM 891
REMOVAL 891
THROTTLE PRESSURE CABLE 892
REMOVAL 892
INSTALLATION 892
INSTALLATION THROTTLE PRESSURE CABLE ADJUSTMENT PROCEDURE 892
SHIFTER IGNITION INTERLOCK CABLE 893
REMOVAL 893
INSTALLATION 895
INTERLOCK SYSTEM ADJUSTMENT 895
INSTALLATION 896
VEHICLE SPEED SENSOR PINION GEAR INTERLOCK MECHANISM 896
REMOVAL 896
REMOVAL 897
INSTALLATION 897
PARK/NEUTRAL STARTING AND BACK-UP LAMP SWITCH 897
TEST 897
REMOVAL 897
INSTALLATION 897
TRANSAXLE 897
REMOVAL 897
REMOVAL 900
INSTALLATION 900
INSTALLATION 900
DISASSEMBLY AND ASSEMBLY 900
TRANSAXLE 900
PUMP OIL SEAL 900
DISASSEMBLY 901
ASSEMBLY 904
VALVE BODY RECONDITION 906
OIL PUMP-RECONDITION 910
FRONT CLUTCH-RECONDITION 911
DISASSEMBLY 911
REAR CLUTCH-RECONDITION 912
INSPECTION 912
DISASSEMBLY 912
ASSEMBLY 912
ASSEMBLY 912
FRONT PLANETARY AND ANNULUS GEAR- RECONDITION 914
LOW/REVERSE (REAR) SERVO-RECONDITION 914
DISASSEMBLY 914
ACCUMULATOR-RECONDITION 915
DISASSEMBLY 915
ASSEMBLY 915
ASSEMBLY 916
KICKDOWN SERVO (CONTROLLED LOAD)- RECONDITION 916
DISASSEMBLY 916
ASSEMBLY 916
TRANSFER SHAFT REPAIR 916
DISASSEMBLY 916
DETERMINING SHIM THICKNESS 920
PARKING PAWL 921
DISASSEMBLY 921
ASSEMBLY 921
ASSEMBLY 922
OUTPUT SHAFT REPAIR 922
STIRRUP AND RETAINING STRAP 922
OUTPUT GEAR AND SHAFT 923
DETERMINING SHIM THICKNESS 925
STIRRUP AND RETAINING STRAP 926
DIFFERENTIAL REPAIR 927
DETERMINING SHIM THICKNESS 931
CLEANING AND INSPECTION 931
VALVE BODY 931
ADJUSTMENTS 932
GEARSHIFT CABLE 932
THROTTLE PRESSURE CABLE ADJUSTMENT PROCEDURE 932
ADJUSTMENT 932
SHIFTER/IGNITION INTERLOCK SYSTEM 933
BAND ADJUSTMENT 934
KICKDOWN BAND (FRONT) 934
BEARING ADJUSTMENT PROCEDURES 934
LOW/REVERSE BAND (REAR) 934
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS 934
LINE PRESSURE 934
OUTPUT SHAFT BEARING 934
THROTTLE PRESSURE 934
DIFFERENTIAL BEARING 935
TRANSFER SHAFT BEARING 936
DIFFERENTIAL BEARING SHIM CHART 936
SCHEMATICS AND DIAGRAMS 938
TH TRANSAXLE HYDRAULIC SCHEMATIC 938
SPECIFICATIONS 946
TH TRANSAXLE SPECIFICATIONS 946
TH TRANSAXLE TORQUE SPECIFICATIONS 948
SPECIAL TOOLS 948
TH AUTOMATIC TRANSAXLE 948
EPL_22 955
TIRES AND WHEELS 955
DESCRIPTION AND OPERATION 955
TIRE INFORMATION 955
TIRE CHAINS 955
SPARE TIRE (TEMPORARY) 956
TIRE INFLATION PRESSURES 956
RADIAL-PLY TIRES 956
DIAGNOSIS AND TESTING 957
PRESSURE GAUGES 957
TREAD WEAR INDICATORS 957
TIRE PRESSURE FOR HIGH—SPEED OPERATION 957
REPLACEMENT TIRES 957
TIRE WEAR PATTERNS 957
TIRE NOISE OR VIBRATION LEAD CORRECTION CHART 958
SERVICE PROCEDURES 960
TIRE AND WHEEL ROTATION 960
NON-DIRECTIONAL TREAD PATTERN TIRES 960
REPAIRING TIRE LEAKS 960
TIRE AND WHEEL MATCH MOUNTING 960
DIRECTIONAL TREAD PATTERN TIRES 960
CLEANING AND INSPECTION 961
CLEANING OF TIRES 961
SPECIFICATIONS 962
TIRE SPECIFICATIONS 962
DESCRIPTION AND OPERATION 963
WHEEL INFORMATION 963
WHEEL COVER (LOCK-ON) 963
METHOD 1 (RELOCATE WHEEL ON HUB) 964
DIAGNOSIS AND TESTING 964
WHEEL INSPECTION 964
TIRE AND WHEEL RUNOUT 964
SERVICE PROCEDURES 965
TIRE AND WHEEL BALANCE 965
METHOD 2 (RELOCATE TIRE ON WHEEL) 965
REMOVAL AND INSTALLATION 966
WHEEL COVER (LOCK-ON) 966
REMOVE 966
INSTALL 967
WHEEL AND TIRE 967
CAST ALUMINUM WHEEL 967
STEEL WHEEL 967
WHEEL COVER RETAINING NUT 968
REMOVE 968
SPECIFICATIONS 969
WHEEL SPECIFICATIONS 969
INSTALL 969
EPL_23 971
BODY 971
GENERAL INFORMATION 971
SAFETY PRECAUTIONS AND WARNINGS 971
GENERAL INFORMATION 972
PAINTED SURFACE TOUCHUP 972
PAINT CODE 972
TOUCHUP PROCEDURE 972
BASE COAT/CLEAR COAT FINISH 972
WET SANDING, BUFFING, AND POLISHING 972
AFTERMARKET PAINT REPAIR PRODUCTS 973
EXTERIOR COLORS 973
INTERIOR COLORS 973
DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION 974
SAFETY PRECAUTIONS WINDSHIELD 974
RECOMMENDED TOOLS AND ADHESIVE 974
WINDSHIELD REMOVAL—EXTERIOR METHOD 974
WINDSHIELD REMOVAL—INTERIOR METHOD 975
WINDSHIELD INSTALLATION 975
QUARTER GLASS 976
REMOVAL 976
INSTALLATION 976
REAR WINDOW INSTALLATION 977
REAR WINDOW 977
REAR WINDOW REMOVAL 977
REMOVAL AND INSTALLATION 978
FRONT SEAT 978
REMOVAL 978
REAR SEAT CUSHION 978
REMOVAL 978
INSTALLATION INSTALLATION 978
REAR SEAT BACK CHILD RESTRAINT SEAT BACK 979
REMOVAL REMOVAL 979
INSTALLATION 979
INSTALLATION 979
CHILD SEAT MODULE 980
REMOVAL 980
INSTALLATION 980
DIAGNOSIS AND TESTING 981
DIAGNOSTIC PROCEDURES 981
SUNROOF GLASS PANEL 981
REMOVAL 981
SUNROOF DIAGNOSIS 981
INSTALLATION 981
REMOVAL AND INSTALLATION 981
SUNROOF PROCEDURE INFORMATION 981
SUNROOF MODULE 981
REMOVAL 981
SUNROOF DRIVE MOTOR 981
INSTALLATION 981
REMOVAL 982
SUNROOF WIND DEFLECTOR 982
REMOVAL 982
INSTALLATION 982
INSTALLATION 983
SUNROOF CABLES 983
REMOVAL 983
SUNROOF SUNSHADE 983
REMOVAL 983
INSTALLATION INSTALLATION 983
SUNROOF GUIDE AND MECHANISM ASSEMBLY 983
REMOVAL 983
INSTALLATION 983
SUNROOF COMPONENTS 984
VENT HEIGHT 985
ADJUSTMENTS 985
SUNROOF GLASS HEIGHT ADJUSTMENT 985
FLUSHNESS 985
DIAGNOSIS AND TESTING 987
WATER LEAKS 987
WATER LEAK DETECTION 987
VISUAL INSPECTION BEFORE WATER LEAK TESTS 987
WATER LEAK TESTS 987
WIND NOISE 988
INSTALLATION VISUAL INSPECTION BEFORE TESTS 988
HOOD LATCH 988
REMOVAL 988
REMOVAL AND INSTALLATION 988
GRILLE 988
REMOVAL 988
INSTALLATION 989
HOOD RELEASE CABLE 989
REMOVAL 989
INSTALLATION 989
HOOD HINGE 989
REMOVAL 989
INSTALLATION 989
INSTALLATION 989
HOOD 989
REMOVAL 989
COWL COVER 990
REMOVAL 990
INSTALLATION 990
FRONT DOOR TRIM—2 DOOR 990
REMOVAL 990
INSTALLATION 990
FRONT DOOR TRIM—4 DOOR 991
REMOVAL 991
INSTALLATION 992
LOCK BUTTON BELL-CRANK 992
REMOVAL 992
FRONT DOOR WATER SHIELD 992
REMOVAL 992
INSTALLATION 992
FRONT DOOR INNER BELT WEATHERSTRIP 992
REMOVAL 992
INSTALLATION 992
WINDOW INNERBELT STABILIZER 992
REMOVAL INSTALLATION 992
INSTALLATION 993
FRONT DOOR GLASS—2 DOOR 993
REMOVAL 993
INSTALLATION 994
WINDOW REGULATOR—2 DOOR 994
REMOVAL 994
FRONT DOOR GLASS—4 DOOR 994
REMOVAL 994
INSTALLATION 994
WINDOW REGULATOR—4 DOOR 995
REMOVAL 995
INSTALLATION 995
INSTALLATION 996
REAR VERTICAL GUIDE BAR FRONT VERTICAL GUIDE BAR 996
REMOVAL REMOVAL 996
INSTALLATION 996
INSTALLATION 996
FRONT DOOR LATCH 996
REMOVAL 996
FRONT DOOR OUTSIDE HANDLE 997
REMOVAL 997
INSTALLATION 997
DOOR LOCK CYLINDER 997
REMOVAL 997
INSTALLATION 997
INSTALLATION 997
SIDE VIEW MIRROR TRIM COVER 998
REMOVAL 998
FRONT DOOR CHECK STOP 998
REMOVAL 998
INSTALLATION 998
SIDE VIEW MIRROR 998
REMOVAL 998
INSTALLATION 998
INSTALLATION 998
INSTALLATION 999
SIDE VIEW MIRROR STANCHION 999
REMOVAL 999
FRONT DOOR OUTER BELT WEATHERSTRIP 999
REMOVAL 999
INSTALLATION 1000
DOOR 1000
DOOR HINGE 1000
REMOVAL 1000
REMOVAL 1000
INSTALLATION INSTALLATION 1000
FRONT DOOR LATCH STRIKER 1001
REMOVAL 1001
INSTALLATION 1001
INSTALLATION 1001
FRONT DOOR WEATHERSTRIP 1001
REMOVAL 1001
INSTALLATION 1001
ROOF RAIL WEATHERSTRIP 1001
REMOVAL 1001
ROOF RAIL WEATHERSTRIP 1002
REMOVAL 1002
INSTALLATION 1002
B-PILLAR APPLIQUE—4 DOOR 1002
REMOVAL 1002
INSTALLATION 1002
B-PILLAR APPLIQUE—2 DOOR 1002
REMOVAL INSTALLATION 1002
REAR DOOR TRIM 1003
REMOVAL 1003
B-PILLAR WEATHERSTRIP CHANNEL 1003
REMOVAL 1003
INSTALLATION 1003
INSTALLATION 1003
REAR DOOR INNER BELT WEATHERSTRIP 1004
REMOVAL 1004
REAR DOOR WINDOW REGULATOR 1004
REMOVAL 1004
INSTALLATION 1004
REAR DOOR GLASS 1004
REMOVAL 1004
INSTALLATION 1004
INSTALLATION 1005
REAR DOOR LOCK BELL CRANK 1005
REMOVAL 1005
REAR DOOR LATCH 1005
REMOVAL INSTALLATION 1005
REAR DOOR OUTER BELT WEATHERSTRIP 1005
REMOVAL 1005
INSTALLATION 1005
INSTALLATION 1005
REAR DOOR LATCH STRIKER 1005
REMOVAL 1005
INSTALLATION 1006
REAR DOOR INTERLOCK LATCH STRIKER 1006
REMOVAL 1006
INSTALLATION 1006
INSTALLATION 1006
FLOOR CONSOLE DOOR SILL TRIM 1006
REMOVAL REMOVAL 1006
A-PILLAR TRIM 1007
REMOVAL 1007
INSTALLATION 1007
INSTALLATION 1007
DOOR OPENING TRIM WELT 1007
REMOVAL 1007
SIDE COWL TRIM 1007
REMOVAL 1007
INSTALLATION 1007
INSTALLATION 1007
QUARTER TRIM PANEL—2 DOOR 1008
REMOVAL 1008
B-PILLAR TRIM—4 DOOR 1008
REMOVAL 1008
INSTALLATION 1008
INSTALLATION 1008
UPPER QUARTER TRIM—4 DOOR 1009
REMOVAL 1009
PARCEL SHELF TRIM 1009
REMOVAL 1009
INSTALLATION 1009
LOWER QUARTER TRIM—4 DOOR 1009
REMOVAL 1009
INSTALLATION INSTALLATION 1009
FRONT OUTBOARD SEAT BELT 1010
REMOVAL 1010
INSTALLATION 1010
FRONT SEAT BELT BUCKLE 1010
REMOVAL 1010
INSTALLATION 1010
FRONT SEAT BELT RETRACTOR 1010
INSTALLATION REMOVAL 1010
FRONT SHOULDER BELT ADJUSTER 1011
REMOVAL 1011
CARPET 1011
REMOVAL INSTALLATION 1011
REAR SEAT BELT BUCKLE 1011
REMOVAL 1011
INSTALLATION 1011
REAR SEAT BELT RETRACTOR 1011
REMOVAL 1011
INSTALLATION 1011
INSTALLATION 1012
HEADLINING 1012
REMOVAL 1012
INSTALLATION 1012
BODY VENT 1013
REMOVAL 1013
TRUNK LID LIFT SPRINGS 1013
INSTALLATION REMOVAL 1013
TRUNK LID 1013
REMOVAL 1013
INSTALLATION 1013
INSTALLATION 1014
TRUNK WEATHERSTRIP 1014
REMOVAL 1014
INSTALLATION 1014
TRUNK LATCH STRIKER 1014
REMOVAL 1014
INSTALLATION 1014
INSTALLATION 1014
TRUNK LOCK CYLINDER 1014
REMOVAL 1014
TRUNK LATCH 1014
REMOVAL 1014
INSTALLATION 1014
TRUNK TRIM PANEL 1015
Removal 1015
TRUNK CARPET 1015
REMOVAL 1015
Installation 1015
REAR SPOILER 1015
REMOVAL 1015
INSTALLATION 1015
INSTALLATION 1016
ROOF APERTURE (RAP) MOLDING 1016
REMOVAL 1016
INSTALLATION 1016
ROOF RACK 1016
REMOVAL 1016
INSTALLATION 1016
ROOF RACK CROSS RAILS 1017
REMOVAL 1017
INSTALLATION 1017
ADJUSTMENTS 1017
FRONT DOOR GLASS ADJUSTMENT 1017
UP-STOP ADJUSTMENTS 1017
GLASS—FRONT/REAR ADJUSTMENT 1017
TOP OF GLASS—INBOARD/OUTBOARD ADJUSTMENTS 1017
FRONT DOOR LATCH ADJUSTMENT 1018
REAR DOOR GLASS ADJUSTMENT 1018
UP-STOP ADJUSTMENTS 1018
TOP OF GLASS—INBOARD/OUTBOARD ADJUSTMENTS 1018
LUBRICANT APPLICATION 1019
REAR DOOR LATCH ADJUSTMENT 1019
SPECIFICATIONS 1019
BODY LUBRICATION SPECIFICATIONS 1019
LUBRICATION REQUIREMENTS 1019
LUBRICANT USAGE 1020
SPECIAL TOOLS 1020
BODY 1020
EPL_24 1021
HEATING AND AIR CONDITIONING 1021
GENERAL INFORMATION 1021
INTRODUCTION 1021
SAFETY PRECAUTIONS AND WARNINGS 1022
DESCRIPTION AND OPERATION 1023
A/C REFRIGERANT LINES 1023
DISCHARGE LINE A/C SERVICE PORT VALVE CORES 1023
LIQUID LINE 1023
SUCTION LINE 1023
BLOWER MOTOR RESISTOR 1023
CONDENSATION DRAIN TUBE 1024
ENGINE COOLING SYSTEM REQUIREMENTS 1024
COMPRESSOR 1024
EVAPORATOR PROBE 1024
NOISE 1024
HANDLING TUBING AND FITTINGS 1024
COMPRESSOR FRONT SHAFT SEAL 1024
HIGH PRESSURE CUT OUT SWITCH 1025
LOW PRESSURE CUT OFF SWITCH 1025
SYSTEM AIRFLOW 1025
SIDE WINDOW DEMISTERS 1025
REFRIGERANT OIL CAPACITIES 1026
SYSTEM OIL LEVEL 1026
VACUUM CONTROL SYSTEM 1026
DIAGNOSIS AND TESTING 1026
A/C PERFORMANCE TEST 1026
REFRIGERANT OIL LEVEL CHECK 1026
PERFORMANCE TEST PROCEDURE 1027
BLOWER MOTOR VIBRATION AND/OR NOISE DIAGNOSIS 1027
COMPRESSOR NOISE DIAGNOSIS 1027
BLOWER MOTOR ELECTRICAL DIAGNOSIS 1027
EXPANSION VALVE 1030
EVAPORATOR PROBE TEST 1030
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW 1031
HEATER PERFORMANCE TEST 1031
PRE-DIAGNOSTIC PREPARATIONS POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT 1031
TEMPERATURE CONTROL 1031
LOW PRESSURE CUT-OFF SWITCH 1031
MAXIMUM HEATER OUTPUT: TEST AND ACTION 1031
TEMPERATURE REFERENCE CHART 1031
SYSTEM CHARGE LEVEL TEST 1032
VACUUM CONTROL SYSTEM 1033
ONE-WAY CHECK VALVE 1033
HEATER-A/C CONTROLS 1034
LOCATING PINCHED VACUUM LINES 1034
LOCATING VACUUM LEAKS 1034
SERVICE PROCEDURES 1034
CHARGING A/C SYSTEM 1034
PARTIAL CHARGE 1034
EVACUATION 1034
CHARGING A/C SYSTEM 1035
EVACUATING REFRIGERANT SYSTEM 1035
SERVICING REFRIGERANT OIL LEVEL R-134a REFRIGERANT 1036
EMPTY REFRIGERANT SYSTEM LEAK TEST 1037
LOW REFRIGERANT LEVEL LEAK TEST 1037
SYSTEM LEAK CHECKING 1037
REMOVAL AND INSTALLATION 1038
A/C SERVICE PORT VALVE CORES 1038
REMOVAL 1038
WITHOUT AIR CONDITIONING 1038
INSTALLATION 1038
BLOWER MOTOR AND WHEEL ASSEMBLY 1038
WITH AIR CONDITIONING 1038
BLOWER MOTOR RESISTOR 1039
REMOVAL 1039
INSTALLATION 1039
COMPRESSOR CLUTCH/COIL ASSEMBLY 1039
INSTALLATION 1039
BLOWER MOTOR WHEEL 1039
REMOVAL 1039
COMPRESSOR 1039
REMOVAL 1039
INSTALLATION 1040
CONDENSATION DRAIN TUBE 1041
REMOVAL 1041
INSTALLATION 1041
CONDENSER 1041
REMOVAL 1041
CLUTCH BREAK-IN 1041
INSTALLATION 1041
DISCHARGE LINE 1042
ASSEMBLE REMOVAL 1042
INSTALLATION 1042
EVAPORATOR 1042
EVAPORATOR PROBE 1042
REMOVAL DISASSEMBLE 1042
INSTALLATION 1043
INSTALLATION 1043
A/C FILTER/DRIER EXPANSION VALVE 1043
REMOVAL 1043
REMOVAL 1044
REMOVAL INSTALLATION 1044
HIGH PRESSURE CUT OUT SWITCH 1044
INSTALLATION 1044
REMOVAL 1044
HEATER CORE 1044
HEATER HOSES 1044
INSTALLATION 1044
REMOVAL 1044
HIGH PRESSURE RELIEF VALVE 1044
INSTALLATION 1044
LIQUID LINE 1045
REMOVAL REMOVAL 1045
INSTALLATION 1045
LOW PRESSURE CUT OFF SWITCH 1045
INSTALLATION 1045
REMOVAL 1045
INSTALLATION 1045
MODE CONTROL CABLE 1045
INSTALLATION 1046
SUCTION LINE 1046
REMOVAL 1046
RECIRCULATION CONTROL CABLE (RHD) 1046
INSTALLATION 1046
REMOVAL 1046
TEMPERATURE CONTROL CABLE 1046
INSTALLATION REMOVAL 1046
RECIRCULATION DOOR ACTUATOR 1046
INSTALLATION REMOVAL 1046
UNIT HOUSING 1048
REMOVAL 1048
INSTALLATION 1048
DISASSEMBLY AND ASSEMBLY 1049
AIR DISTRIBUTION MODULE – RECONDITION 1049
DISASSEMBLE 1049
ASSEMBLE 1050
RECIRCULATION CONTROL CABLE (RHD) 1051
TEMPERATURE CONTROL CABLE 1051
ADJUSTMENTS 1051
MODE CONTROL CABLE 1051
EPL_25 1053
EMISSION CONTROL SYSTEMS 1053
GENERAL INFORMATION 1053
SYSTEM DESCRIPTION 1053
DESCRIPTION AND OPERATION 1053
MALFUNCTION INDICATOR LAMP (MIL) 1053
CIRCUIT ACTUATION TEST MODE 1054
DIAGNOSTIC TROUBLE CODES 1054
BULB CHECK 1054
STATE DISPLAY TEST MODE 1054
OBTAINING DTC’S USING DRB SCAN TOOL 1054
OBTAINING DTC’S USING MIL LAMP 1055
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS 1055
MONITORED SYSTEMS 1059
DTC 21—HEX 66, and 7A—OXYGEN SENSOR (O2S) MONITOR 1059
DTC 32—HEX 2E—EGR MONITOR 1060
DTC 43—HEX 6A,6B, 6C, 6D, 6E, AE, and AF—MISFIRE MONITOR 1060
DTC 21—HEX 67, 69, 7C, and 7D—OXYGEN SENSOR HEATER MONITOR 1060
DTC 51/52—HEX 76, 77, 78, and 79—FUEL SYSTEM MONITOR 1060
DTC 31—HEX A0, A1, B7, and B8—LEAK DETECTION PUMP MONITOR DTC 64—HEX 70, and B4—CATALYST MONITOR 1061
COMPONENT MONITORS 1062
TRIP DEFINITION 1062
NON-MONITORED CIRCUITS 1062
FUEL PRESSURE 1062
SECONDARY IGNITION CIRCUIT 1062
CYLINDER COMPRESSION 1063
EXHAUST SYSTEM PCM SYSTEM GROUND 1063
FUEL INJECTOR MECHANICAL MALFUNCTIONS PCM CONNECTOR ENGAGEMENT 1063
HIGH AND LOW LIMITS 1063
EXCESSIVE OIL CONSUMPTION 1063
THROTTLE BODY AIR FLOW 1063
VACUUM ASSIST 1063
LOAD VALUE 1063
DESCRIPTION AND OPERATION 1064
EVAPORATION CONTROL SYSTEM 1064
PRESSURE RELIEF/ROLLOVER VALVE 1064
DUTY CYCLE EVAP PURGE SOLENOID VALVE 1064
EVAP CANISTER 1064
PRESSURE-VACUUM FILLER CAP 1065
LEAK DETECTION PUMP 1065
POSITIVE CRANKCASE VENTILATION (PCV) SYSTEMS 1066
PCV VALVE 1066
DIAGNOSIS AND TESTING 1067
LEAK DETECTION PUMP 1067
PCV VALVE TEST 1067
VEHICLE EMISSION CONTROL INFORMATION LABEL VACUUM SCHEMATIC 1067
REMOVAL AND INSTALLATION 1070
LEAK DETECTION PUMP REPLACEMENT 1070
REMOVAL 1070
INSTALLATION 1070
DESCRIPTION AND OPERATION 1071
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 1071
DIAGNOSIS AND TESTING 1072
EGR SYSTEM ON-BOARD DIAGNOSTICS 1072
EGR SYSTEM TEST 1072
EGR GAS FLOW TEST 1072
EGR VALVE LEAKAGE TEST 1073
EGR VALVE CONTROL (TRANSDUCER) TEST 1074
TESTING ELECTRICAL SOLENOID PORTION OF VALVE 1074
TESTING VACUUM TRANSDUCER PORTION OF VALVE 1074
REMOVAL AND INSTALLATION 1075
EGR VALVE 1075
REMOVAL 1075
INSTALLATION 1075
EGR TUBE 1075
REMOVAL 1075
SPECIFICATIONS 1075
TORQUE 1075
INSTALLATION 1075
EPL_IN 1077
INTRODUCTION 1077
GENERAL INFORMATION 1077
VEHICLE IDENTIFICATION NUMBER 1077
VIN CODE DECODING 1078
VEHICLE SAFETY CERTIFICATION LABEL 1078
BODY CODE EMBOSS 1078
BODY CODE EMBOSS LINE 2 1078
BODY CODE EMBOSS LINE 1 1078
STANDARD BODY DIMENSIONS 1079
INTERIOR DIMENSIONS 1079
EXTERIOR DIMENSIONS 1079
INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS 1079
INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS 1079
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS 1079
FASTENER IDENTIFICATION 1080
FASTENER IDENTIFICATION 1080
FASTENER IDENTIFICATION 1081
FASTENER STRENGTH 1082
METRIC SYSTEM 1083
CONVERSION FORMULAS AND EQUIVALENT VALUES 1083
METRIC CONVERSION 1084
TORQUE REFERENCES 1086
TORQUE SPECIFICATIONS 1086
SPECIFIED TORQUE FOR STANDARD BOLTS 1086
EPL_TAB 1087
GO 1088
VIDEO PREVIEW OF THE MANUAL:
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