1997 Jeep XJ Factory Service Manual – PDF DOWNLOAD
FILE DETAILS:
1997 Jeep XJ Factory Service Manual – PDF DOWNLOAD
Language : English
Pages : 1724
Downloadable : Yes
File Type : PDF
Size: 47.1 MB
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
1997 Jeep XJ Factory Service Manual – PDF DOWNLOAD
GENERAL INFORMATION:
INTRODUCTION:
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. PARTS AND LUBRICANT RECOMMENDATIONS When service is required, Chrysler Corporation recommends that only Mopart brand parts, lubricants and chemicals be used. Mopar provides the best engineered products for servicing Chrysler Corporation vehicles.
TABLE OF CONTENTS:
1997 Jeep XJ Factory Service Manual – PDF DOWNLOAD
INTRODUCTION 1715
GENERAL INFORMATION 1715
VEHICLE IDENTIFICATION NUMBER 1715
VEHICLE IDENTIFICATION NUMBER 1715
VEHICLE IDENTIFICATION NUMBER DECODING CHART 1715
VEHICLE SAFETY CERTIFICATION LABEL 1716
BODY CODE PLATE—LINE 3 1716
BODY CODE PLATE 1716
LOCATION AND DECODING 1716
BODY CODE PLATE—LINE 2 1716
VEHICLE DIMENSIONS 1717
BODY CODE PLATE LINE 1 1717
VEHICLE EXTERIOR DIMENSIONS 1717
VEHICLE INTERIOR DIMENSIONS 1717
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS 1718
INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS 1718
INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS 1718
FASTENER IDENTIFICATION 1718
FASTENER IDENTIFICATION 1718
FASTENER IDENTIFICATION 1719
FASTENER STRENGTH 1720
METRIC SYSTEM 1721
TORQUE REFERENCES 1721
CONVERSION FORMULAS AND EQUIVALENT VALUES 1721
METRIC CONVERSION 1722
TORQUE SPECIFICATIONS 1723
SPECIFIED TORQUE FOR STANDARD BOLTS 1723
LUBRICATION AND MAINTENANCE 1
GENERAL INFORMATION 1
GENERAL INFORMATION 1
INTRODUCTION 1
PARTS AND LUBRICANT RECOMMENDATIONS 1
INTERNATIONAL SYMBOLS 1
CLASSIFICATION OF LUBRICANTS 2
ENGINE OIL 2
FLUID CAPACITIES 3
FUEL TANK 3
ENGINE OIL 3
COOLING SYSTEM 3
AUTOMATIC TRANSMISSION 3
MANUAL TRANSMISSION 3
TRANSFER CASE 3
FRONT AXLE 3
REAR AXLE 3
POWER STEERING 3
MAINTENANCE SCHEDULES 4
GENERAL INFORMATION 4
MAINTENANCE SCHEDULES 4
EMISSION CONTROL SYSTEM MAINTENANCE 4
FLUID FILL LOCATIONS AND LUBRICATION POINTS 4
SCHEDULE “A” 4
SCHEDULE “B” 6
JUMP STARTING, TOWING AND HOISTING 9
SERVICE PROCEDURES 9
JUMP STARTING PROCEDURE 9
TO JUMP START A DISABLED VEHICLE: 9
TOWING RECOMMENDATIONS 10
SAFETY PRECAUTIONS 10
GROUND CLEARANCE 10
FLAT-BED TOWING RAMP ANGLE 10
TWO-WHEEL-DRIVE VEHICLE TOWING 10
TOWING-REAR END LIFTED (SLING-TYPE) 10
TOWING-REAR END LIFTED (WHEEL LIFT) 11
TOWING-FRONT END LIFTED 11
FOUR-WHEEL-DRIVE VEHICLE TOWING 11
TOWING-REAR END LIFTED (SLING TYPE) 11
TOWING-REAR END LIFTED (WHEEL LIFT) 11
TOWING-FRONT END LIFTED 11
EMERGENCY TOW HOOKS 11
HOISTING RECOMMENDATIONS 11
FLOOR JACK 11
HOIST 12
SUSPENSION 175
ALIGNMENT 175
GENERAL INFORMATION 175
WHEEL ALIGNMENT 175
DIAGNOSIS AND TESTING 177
SUSPENSION AND STEERING SYSTEM 177
SERVICE PROCEDURES 178
PRE-ALIGNMENT 178
WHEEL ALIGNMENT 178
CAMBER 178
CASTER 178
TOE POSITION (LHD) 178
TOE POSITION (RHD) 179
SPECIFICATIONS 180
ALIGNMENT 180
FRONT SUSPENSION 181
DESCRIPTION AND OPERATION 181
SUSPENSION COMPONENTS 181
DIAGNOSIS AND TESTING 182
SHOCK DIAGNOSIS 182
REMOVAL AND INSTALLATION 183
SHOCK ABSORBER 183
REMOVAL 183
INSTALLATION 183
COIL SPRING/JOUNCE BUMPER 183
REMOVAL 183
INSTALLATION 183
STEERING KNUCKLE 183
LOWER SUSPENSION ARM 184
REMOVAL 184
INSTALLATION 184
UPPER SUSPENSION ARM 184
REMOVAL 184
INSTALLATION 184
FRONT AXLE BUSHING 184
REMOVAL 184
INSTALLATION 184
STABILIZER BAR 185
REMOVAL 185
INSTALLATION 185
TRACK BAR 185
REMOVAL 185
INSTALLATION 185
FRONT HUB BEARING 186
REMOVAL 186
INSTALLATION 186
WHEEL MOUNTING STUDS-FRONT 186
REMOVAL 186
INSTALLATION 186
SPECIFICATIONS 187
TORQUE CHART 187
SPECIAL TOOLS 187
FRONT SUSPENSION 187
REAR SUSPENSION 188
DESCRIPTION AND OPERATION 188
SUSPENSION COMPONENT 188
DIAGNOSIS AND TESTING 188
SPRING AND SHOCK DIAGNOSIS 188
REMOVAL AND INSTALLATION 189
SHOCK ABSORBER 189
REMOVAL 189
INSTALLATION 189
STABILIZER BAR 189
REMOVAL 189
INSTALLATION 190
LEAF SPRING 190
REMOVAL 190
INSTALLATION 190
LEAF SPRING AND SHACKLE BUSHING 190
SPECIFICATIONS 191
TORQUE CHART 191
DIFFERENTIAL AND DRIVELINE 737
GENERAL INFORMATION 737
PROPELLER SHAFTS 737
LUBRICATION 737
PROPELLER SHAFT JOINT ANGLE 738
PROPELLER SHAFT JOINTS 738
DIAGNOSIS AND TESTING 739
VIBRATION 739
UNBALANCE 739
DRIVELINE VIBRATION 740
RUNOUT 740
SERVICE PROCEDURES 741
DRIVELINE ANGLE MEASUREMENT PREPARATION 741
PROPELLER SHAFT ANGLE MEASUREMENT 741
RUNOUT SPECIFICATIONS 741
REMOVAL AND INSTALLATION 742
FRONT PROPELLER SHAFT 742
REMOVAL 742
INSTALLATION 742
REAR PROPELLER SHAFT 742
REMOVAL 742
INSTALLATION 743
DISASSEMBLY AND ASSEMBLY 743
SINGLE CARDAN UNIVERSAL JOINT 743
DISASSEMBLY 743
ASSEMBLY 745
DOUBLE CARDAN JOINT 745
DISASSEMBLY 745
ASSEMBLY 747
CLEANING AND INSPECTION 748
PROPELLER SHAFT 748
ADJUSTMENTS 748
ADJUSTMENT AT AXLE WITH LEAF SPRINGS 748
FRONT AXLE ANGLE ADJUSTMENT 749
SPECIFICATIONS SPECIAL TOOLS 750
PROPELLER SHAFTS AND U–JOINTS PROPELLER SHAFT 750
GENERAL INFORMATION 751
FBI AXLE 751
LUBRICANT SPECIFICATIONS 751
DESCRIPTION AND OPERATION 752
STANDARD DIFFERENTIAL 752
DIAGNOSIS AND TESTING 752
GENERAL INFORMATION 752
GEAR NOISE 752
VIBRATION 753
BEARING NOISE 753
DRIVELINE SNAP 753
LOW SPEED KNOCK 753
FRONT AXLES 754
DIAGNOSIS 754
SERVICE PROCEDURES 756
LUBRICANT CHANGE 756
REMOVAL AND INSTALLATION 756
DRIVE AXLE ASSEMBLY 756
REMOVAL 756
TUBE AXLE ASSEMBLY 757
REMOVAL INSTALLATION 757
INSTALLATION 757
AXLE SHAFT—CARDAN U-JOINT 758
REMOVAL 758
INSTALLATION INSTALLATION 759
PINION SHAFT SEAL 759
REMOVAL 759
HUB BEARING AND AXLE SHAFT 760
REMOVAL 760
INSTALLATION 760
KNUCKLE REMOVAL 761
UPPER BALL STUD REPLACEMENT 761
LOWER BALL STUD REPLACEMENT 761
KNUCKLE INSTALLATION 761
STEERING KNUCKLE AND BALL STUDS 761
AXLE BUSHING REPLACEMENT 762
DIFFERENTIAL 762
REMOVAL 762
INSTALLATION 762
DIFFERENTIAL SIDE BEARINGS 764
REMOVAL 764
INSTALLATION 764
AXLE SHAFT OIL SEAL 765
REMOVAL 765
INSTALLATION 765
RING GEAR 765
REMOVAL 765
PINION GEAR 766
REMOVAL 766
INSTALLATION 766
INSTALLATION 767
DISASSEMBLY AND ASSEMBLY 770
STANDARD DIFFERENTIAL 770
DISASSEMBLY 770
ASSEMBLY 770
FINAL ASSEMBLY 770
CLEANING AND INSPECTION 771
CARDAN U-JOINT 771
AXLE COMPONENTS 771
ADJUSTMENTS 771
PINION GEAR DEPTH 771
GENERAL INFORMATION 771
PINION DEPTH MEASUREMENT AND ADJUSTMENT 772
PINION GEAR DEPTH VARIANCE 773
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH 774
INTRODUCTION 774
SHIM SELECTION 774
GEAR CONTACT PATTERN ANALYSIS 777
SPECIFICATIONS 779
FBI AXLE 779
FBI AXLE 779
SPECIAL TOOLS 779
FBI AXLE 779
GENERAL INFORMATION 783
RBI AXLE 783
LUBRICANT SPECIFICATIONS 783
DESCRIPTION AND OPERATION 784
STANDARD DIFFERENTIAL 784
TRAC-LOK OPERATION 784
GEAR NOISE 785
BEARING NOISE 785
DIAGNOSIS AND TESTING 785
GENERAL INFORMATION 785
LOW SPEED KNOCK 786
VIBRATION 786
TRAC–LOK DIFFERENTIAL NOISE 786
DRIVELINE SNAP 786
TRAC–LOK TEST 789
SERVICE PROCEDURES 789
LUBRICANT CHANGE 789
INSTALLATION 790
REMOVAL AND INSTALLATION 790
REAR AXLE 790
REMOVAL 790
PINION SHAFT SEAL 791
REMOVAL 791
INSTALLATION 791
REMOVAL W/PINION REMOVED 792
COLLAPSIBLE SPACER 792
REMOVAL W/PINION INSTALLED 792
INSTALLATION 793
AXLE SHAFT 794
REMOVAL 794
AXLE SHAFT SEAL AND BEARING 795
REMOVAL 795
INSTALLATION 795
INSTALLATION 795
DIFFERENTIAL 796
REMOVAL 796
INSTALLATION 797
DIFFERENTIAL SIDE BEARINGS 798
REMOVAL 798
INSTALLATION 798
RING GEAR 798
REMOVAL 798
INSTALLATION 798
PINION GEAR 799
REMOVAL 799
INSTALLATION 800
FINAL ASSEMBLY 803
ASSEMBLY 803
DISASSEMBLY AND ASSEMBLY 803
STANDARD DIFFERENTIAL 803
DISASSEMBLY 803
TRAC-LOK DIFFERENTIAL 804
DISASSEMBLY 804
ASSEMBLY 806
ADJUSTMENTS 808
PINION GEAR DEPTH 808
GENERAL INFORMATION 808
CLEANING AND INSPECTION 808
AXLE COMPONENTS 808
TRAC-LOK 808
PRESOAK PLATES AND DISC 808
PINION GEAR DEPTH VARIANCE 809
PINION DEPTH MEASUREMENT AND ADJUSTMENT 809
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH 810
SHIM SELECTION 810
GEAR CONTACT PATTERN ANALYSIS 812
SPECIFICATIONS 814
RBI AXLE 814
RBI AXLE 814
SPECIAL TOOLS 814
RBI AXLE 814
GENERAL INFORMATION 819
1/4 AXLES 819
AXLE IDENTIFICATION 819
LUBRICANT SPECIFICATIONS 819
DESCRIPTION AND OPERATION 820
STANDARD DIFFERENTIAL 820
TRAC-LOK OPERATION 821
DIAGNOSIS AND TESTING 821
GENERAL INFORMATION 821
LOW SPEED KNOCK 822
GEAR NOISE VIBRATION 822
BEARING NOISE DRIVELINE SNAP 822
TRAC–LOK DIFFERENTIAL NOISE 823
TRAC–LOK TEST 826
SERVICE PROCEDURES 826
LUBRICANT CHANGE 826
INSTALLATION 827
AXLE SHAFT 827
REMOVAL AND INSTALLATION 827
REAR AXLE 827
REMOVAL 827
AXLE SEAL AND BEARING 828
REMOVAL 828
INSTALLATION 828
INSTALLATION 828
INSTALLATION 829
PINION SEAL 829
REMOVAL 829
DIFFERENTIAL 831
REMOVAL INSTALLATION 831
DIFFERENTIAL SIDE BEARINGS 831
REMOVAL 831
INSTALLATION 831
RING GEAR 832
REMOVAL 832
INSTALLATION 832
PINION GEAR 832
REMOVAL 832
INSTALLATION 834
DISASSEMBLY AND ASSEMBLY 836
STANDARD DIFFERENTIAL 836
DISASSEMBLY 836
ASSEMBLY 837
TRAC-LOK DIFFERENTIAL 837
DISASSEMBLY 837
ASSEMBLY 839
CLEANING AND INSPECTION 840
1/4 AXLES 840
TRAC-LOK 841
PRESOAK PLATES AND DISC 841
ADJUSTMENTS 841
1/4 AXLE PINION GEAR DEPTH 841
GENERAL INFORMATION 841
PINION GEAR DEPTH VARIANCE 842
PINION DEPTH MEASUREMENT AND ADJUSTMENT 842
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH 843
SIDE GEAR CLEARANCE 844
GEAR CONTACT PATTERN ANALYSIS 844
SPECIFICATIONS 846
1/4 INCH AXLE 846
1/4 INCH AXLE 846
SPECIAL TOOLS 847
1/4 AXLES 847
BRAKES 851
GENERAL INFORMATION 852
BRAKE SYSTEM 852
SERVICE WARNINGS & CAUTIONS 852
DESCRIPTION AND OPERATION 852
BRAKE PEDAL 852
STOP LAMP SWITCH 852
RED BRAKE WARNING LAMP 852
POWER BRAKE BOOSTER 852
FRONT DISC BRAKES 853
MASTER CYLINDER 853
COMBINATION VALVE 853
REAR DRUM BRAKE 853
PARKING BRAKE 854
PARKING BRAKE OPERATION 854
PRELIMINARY BRAKE CHECK 855
BRAKE HOSES AND LINES 855
ROAD TESTING 855
DIAGNOSIS AND TESTING 855
BASE BRAKE SYSTEM 855
RED BRAKE WARNING LAMP 858
STOP LAMP SWITCH 858
SWITCH CIRCUIT IDENTIFICATION 858
SWITCH CONTINUITY TEST 858
MASTER CYLINDER/POWER BOOSTER 858
POWER BOOSTER VACUUM TEST 859
COMBINATION VALVE 859
PRESSURE DIFFERENTIAL SWITCH 859
REAR PROPORTIONING VALVE 859
POWER BOOSTER CHECK VALVE TEST 859
DISC BRAKE ROTOR 859
ROTOR MINIMUM THICKNESS 860
ROTOR RUNOUT 860
BRAKE DRUM 860
BRAKE DRUM RUNOUT 860
BRAKE LINE AND HOSES 860
ROTOR THICKNESS VARIATION 860
BRAKE FLUID CONTAMINATION 861
SERVICE PROCEDURES 861
BRAKE FLUID LEVEL 861
BRAKE BLEEDING 861
MASTER CYLINDER BLEEDING 861
BLEEDING PROCEDURE 861
MANUAL BLEEDING 862
DISC ROTOR MACHINING 862
BRAKE DRUM MACHINING 862
PRESSURE BLEEDING 862
BRAKE LINE 862
FLARING PROCEDURE 863
REMOVAL AND INSTALLATION 863
STOP LAMP SWITCH 863
REMOVAL 863
COMBINATION VALVE 864
INSTALLATION 864
REMOVAL 864
BRAKE PEDAL 864
REMOVAL 864
INSTALLATION 864
POWER BRAKE BOOSTER 865
REMOVAL INSTALLATION 865
MASTER CYLINDER 865
REMOVAL 865
INSTALLATION 865
DISC BRAKE CALIPER 866
REMOVAL 866
INSTALLATION 866
INSTALLATION 866
DISC BRAKE SHOES 867
REMOVAL 867
DISC BRAKE ROTOR 868
REMOVAL 868
INSTALLATION 868
INSTALLATION INSTALLATION 869
DRUM BRAKE SHOES 869
REMOVAL 869
BRAKE SUPPORT PLATE 870
REMOVAL 870
WHEEL CYLINDER 870
REMOVAL INSTALLATION 870
INSTALLATION 870
INSTALLATION 871
REAR PARKING BRAKE CABLES 871
REMOVAL 871
PARKING BRAKE LEVER 871
REMOVAL 871
INSTALLATION 871
DISASSEMBLY AND ASSEMBLY 872
MASTER CYLINDER RESERVOIR 872
REMOVAL 872
INSTALLATION 872
DISC BRAKE CALIPER 873
DISASSEMBLY 873
ASSEMBLY 873
WHEEL CYLINDER 874
DISASSEMBLY 874
ASSEMBLY 875
CLEANING AND INSPECTION 875
CALIPER 875
CLEANING 875
INSPECTION 875
REAR DRUM BRAKE 875
CLEANING 875
INSPECTION 876
ADJUSTMENTS 876
STOP LAMP SWITCH 876
WHEEL CYLINDER 876
CLEANING 876
REAR DRUM BRAKE 876
INSPECTION 876
ADJUSTMENT WITH BRAKE GAUGE 876
ADJUSTMENT WITH ADJUSTING TOOL 877
PARKING BRAKE CABLE TENSIONER 878
ADJUSTMENT 878
SPECIFICATIONS 878
BRAKE FLUID 878
BRAKE COMPONENTS 879
SPCIAL TOOLS 879
BASE BRAKES 879
TORQUE CHART 879
GENERAL INFORMATION 880
ANTILOCK BRAKE SYSTEM 880
DESCRIPTION AND OPERATION 880
ANTILOCK BRAKE SYSTEM 880
NORMAL BRAKING 881
ANTILOCK BRAKING 881
HYDRAULIC CONTROL UNIT 881
CONTROLLER ANTILOCK BRAKES 881
WHEEL SPEED SENSORS AND TONE WHEEL 882
COMBINATION VALVE 882
SPEED SENSOR AIR GAP 882
ACCELERATION SWITCH 882
SERVICE PROCEDURES 883
BLEEDING ABS BRAKE SYSTEM 883
ABS WARNING LAMP 883
REMOVAL AND INSTALLATION 883
HYDRAULIC CONTROL UNIT/CONTROLLER ANTILOCK BRAKES 883
REMOVAL 883
DIAGNOSIS AND TESTING 883
ANTILOCK BRAKES 883
INSTALLATION 884
FRONT WHEEL SPEED SENSOR 884
REMOVAL 884
INSTALLATION 884
REAR WHEEL SPEED SENSOR 884
REMOVAL 884
INSTALLATION 885
ACCELERATION SWITCH 886
REMOVAL 886
DISASSEMBLY AND ASSEMBLY 886
HYDRAULIC CONTROL UNIT/CONTROLLER ANTILOCK BRAKE 886
DISASSEMBLY 886
INSTALLATION 886
ASSEMBLY 886
SPECIFICATIONS 887
T0RQUE CHART 887
CLUTCH 889
GENERAL INFORMATION 889
CLUTCH COMPONENTS 889
SAFETY PRECAUTIONS 889
HYDRAULIC LINKAGE COMPONENTS 889
CLUTCH HYDRAULIC FLUID 890
DESCRIPTION AND OPERATION 890
CLUTCH OPERATION 890
CLUTCH LUBRICATION 890
INSTALLATION METHODS AND PARTS USAGE 890
DIAGNOSIS AND TESTING 891
GENERAL INFORMATION 891
CLUTCH CONTAMINATION 891
CLUTCH RUNOUT 891
CLUTCH DISC 891
CLUTCH COVER 891
FLYWHEEL 891
IMPROPER CLUTCH RELEASE OR ENGAGEMENT 891
SERVICE PROCEDURES 893
CLUTCH COMPONENT LUBRICATION 893
MISALIGNMENT 893
RECOMMENDED LUBRICANTS 893
CLUTCH LINKAGE FLUID 893
DIAGNOSTIC CHARTS 893
CLUTCH FLUID LEVEL FLYWHEEL 898
INSTALLATION 899
REMOVAL AND INSTALLATION 899
CLUTCH COVER AND DISC 899
REMOVAL 899
INSTALLATION 900
CLUTCH HOUSING REPLACEMENT—AX15 900
REMOVAL 900
RELEASE BEARING 901
REMOVAL 901
INSTALLATION 902
PILOT BEARING 902
REMOVAL 902
REMOVAL 902
INSTALLATION 902
CLUTCH HYDRAULIC LINKAGE 902
INSTALLATION 902
SPECIFICATIONS 903
TORQUE 903
COOLING SYSTEM 905
GENERAL INFORMATION 905
COOLING SYSTEM 905
ENGINE ACCESSORY DRIVE BELTS 905
WATER PUMPS 906
COOLANT COOLING SYSTEM COMPONENTS 906
RADIATORS 906
SYSTEM COOLANT ROUTING 906
ENGINE BLOCK HEATER 907
DESCRIPTION AND OPERATION 907
AUTOMATIC TRANSMISSION OIL COOLER 907
WATER-TO-OIL COOLER 907
AIR-TO-OIL COOLER 907
ACCESSORY DRIVE BELT TENSION 907
DOMESTIC LEFT HAND DRIVE VEHICLES 907
COOLANT RESERVE/OVERFLOW SYSTEM 907
DOMESTIC RIGHT HAND DRIVE VEHICLES 907
ENGINE BLOCK HEATER 908
COOLING SYSTEM FANS 908
ACCESSORY DRIVE BELT TENSION 908
THERMOSTAT 908
COOLANT PERFORMANCE 909
ETHYLENE-GLYCOL MIXTURES 909
COOLANT SELECTION-ADDITIVES 909
RADIATOR PRESSURE CAP 909
COOLING SYSTEM HOSES 910
WATER PUMPS 910
VISCOUS FAN DRIVE 911
NOISE 912
DIAGNOSIS AND TESTING 912
ON-BOARD DIAGNOSTICS (OBD) 912
COOLING SYSTEM RELATED DIAGNOSTICS 912
AUXILIARY ELECTRIC COOLING FAN 912
ACCESSING DIAGNOSTIC TROUBLE CODES 912
DRB SCAN TOOL 912
ENGINE ACCESSORY DRIVE BELTS 913
BELT DIAGNOSIS 913
SERPENTINE BELT DIAGNOSIS CHAR T 913
PRELIMINARY CHECKS 914
ENGINE COOLING SYSTEM OVERHEATING 914
COOLING SYSTEM DIAGNOSIS 916
RADIATOR COOLANT FLOW CHECK 923
TESTING COOLING SYSTEM FOR LEAKS 923
ULTRAVIOLET LIGHT METHOD 923
PRESSURE TESTER METHOD 923
INTERNAL LEAKAGE INSPECTION 924
VISCOUS FAN DRIVE 924
LEAKS 924
TESTING 924
COMBUSTION LEAKAGE TEST (WITHOUT PRESSURE TESTER) 924
AUXILIARY ELECTRIC COOLING FAN 925
ELECTRIC COOLING FAN AND RELAY DIAGNOSIS 925
RADIATOR CAP-TO-FILLER NECK SEAL— PRESSURE RELIEF CHECK 925
PRESSURE TESTING RADIATOR CAPS 926
DEAERATION 926
SERVICE PROCEDURES 926
COOLANT LEVEL CHECK—ROUTINE 926
COOLANT SERVICE 926
ADDING ADDITIONAL COOLANT—ROUTINE 926
COOLANT LEVEL CHECK—SERVICE LOW COOLANT LEVEL-AERATION 926
DRAINING AND FILLING COOLING SYSTEM 927
DRAINING 2 5L 4-CYLINDER ENGINE 927
REFILLING COOLING SYSTEM 927
DRAINING 4 0L 6-CYLINDER ENGINE 927
REVERSE FLUSHING 927
CHEMICAL CLEANING 928
REMOVAL AND INSTALLATION 928
TRANSMISSION OIL COOLERS 928
WATER-TO-OIL COOLER 928
REVERSE FLUSHING RADIATOR 928
AIR-TO-OIL COOLER 928
REVERSE FLUSHING ENGINE 928
COOLANT RESERVE TANK 929
REMOVAL 929
INSTALLATION 929
WATER PUMP 929
REMOVAL-2 5L ENGINE (LHD/RHD) 930
INSTALLATION-2 5L ENGINE (LHD/RHD) 930
REMOVAL-4 0L ENGINE (LHD/RHD) 931
INSTALLATION-4 0L ENGINE (LHD/RHD) 932
THERMOSTAT 933
REMOVAL 933
INSTALLATION 933
RADIATOR 934
L 4-CYLINDER ENGINE 934
L 6-CYLINDER ENGINE 935
AUXILIARY ELECTRIC COOLING FAN 938
REMOVAL 938
INSTALLATION 938
INSTALLATION 938
ENGINE ACCESSORY DRIVE BELTS 938
ENGINE BLOCK HEATER 938
REMOVAL 938
BELT SCHEMATICS 938
INSTALLATION 939
BELT REPLACEMENT OR ADJUSTMENT— LEFT HAND DRIVE 939
INSTALLATION 940
BELT REPLACEMENT OR ADJUSTMENT— RIGHT HAND DRIVE (4 0L) 940
COOLING SYSTEM FANS 941
REMOVAL 941
INSTALLATION 941
VISCOUS FAN DRIVE REMOVAL/INSTALLATION 942
Viscous Fan Drive Fluid Pump Out Requirement: 942
CLEANING AND INSPECTION 942
COOLING SYSTEM HOSES RADIATOR PRESSURE CAP 942
INSPECTION INSPECTION 942
RADIATOR CLEANING 942
SPECIFICATIONS 942
COOLING SYSTEM CAPACITIES 942
BELT TENSION 942
COOLING SYSTEM CLEANING 942
FAN BLADE INSPECTION 942
TORQUE SPECIFICATIONS 943
SPECIAL TOOLS 943
COOLING 943
BATTERY 945
GENERAL INFORMATION 945
OVERVIEW 945
INTRODUCTION 945
DESCRIPTION AND OPERATION 946
BATTERY 946
BATTERY SIZE AND RATINGS 946
GROUP SIZE 946
COLD CRANKING AMPERAGE 946
RESERVE CAPACITY 947
AMPERE-HOURS 947
BATTERY MOUNTING 947
DIAGNOSIS AND TESTING 947
BATTERY 947
ABNORMAL BATTERY DISCHARGING 948
BUILT-IN TEST INDICATOR 948
HYDROMETER TEST 950
OPEN-CIRCUIT VOLTAGE TEST 951
LOAD TEST 952
IGNITION-OFF DRAW TEST 953
DIAGNOSIS 953
VOLTAGE DROP TEST 954
SERVICE PROCEDURES 955
BATTERY CHARGING 955
CHARGING A COMPLETELY DISCHARGED BATTERY 956
CHARGING TIME REQUIRED 957
REMOVAL AND INSTALLATION 957
BATTERY 957
SPECIFICATIONS 959
BATTERY 959
STARTING SYSTEMS 961
GENERAL INFORMATION 961
OVERVIEW 961
INTRODUCTION 961
DESCRIPTION AND OPERATION 962
STARTING SYSTEM 962
STARTER 962
STARTER RELAY 962
COLD CRANKING TEST 963
DIAGNOSIS AND TESTING 963
STARTING SYSTEM 963
INSPECTION 963
FEED CIRCUIT TEST 963
CONTROL CIRCUIT TEST 966
RELAY TEST 966
SOLENOID TEST 966
RELAY CIRCUIT TEST 966
PARK/NEUTRAL POSITION SWITCH TEST 967
IGNITION SWITCH TEST 967
STARTER NOISE – 2 5L ENGINE 967
REMOVAL AND INSTALLATION 968
STARTER 968
L ENGINE 968
STARTER RELAY 969
L ENGINE 969
SPECIFICATIONS 970
STARTING SYSTEM 970
CHARGING SYSTEM 971
GENERAL INFORMATION 971
OVERVIEW 971
DESCRIPTION AND OPERATION 971
CHARGING SYSTEM OPERATION 971
GENERATOR 972
DIAGNOSIS AND TESTING 972
CHARGING SYSTEM 972
INSPECTION 972
BATTERY TEMPERATURE SENSOR 972
ELECTRONIC VOLTAGE REGULATOR 972
TEST 973
CHARGING SYSTEM RESISTANCE TESTS 973
CURRENT OUTPUT TEST 973
PREPARATION 973
PREPARATION 974
TEST 2 974
TEST 1 974
RESULTS 975
ON-BOARD DIAGNOSTIC TEST FOR CHARGING SYSTEM 975
BATTERY TEMPERATURE SENSOR 975
REMOVAL AND INSTALLATION 975
GENERATOR 975
REMOVAL 975
INSTALLATION 976
REMOVAL 977
BATTERY TEMPERATURE SENSOR 977
INSTALLATION 977
SPECIFICATIONS 977
GENERATOR RATINGS 977
TORQUE CHART 977
IGNITION SYSTEM 979
GENERAL INFORMATION DESCRIPTION AND OPERATION 979
INTRODUCTION IGNITION SYSTEM 979
POWERTRAIN CONTROL MODULE 980
SPARK PLUGS 980
DISTRIBUTOR 980
SPARK PLUG CABLES 980
IGNITION COIL 981
SENSOR OPERATION 981
AUTOMATIC SHUTDOWN (ASD) RELAY 981
CRANKSHAFT POSITION SENSOR 981
CAMSHAFT POSITION SENSOR 981
INTAKE MANIFOLD AIR TEMPERATURE SENSOR 982
IGNITION SWITCH AND KEY LOCK CYLINDER 982
DIAGNOSIS AND TESTING 982
AUTOMATIC SHUTDOWN (ASD) RELAY TEST 982
TESTING FOR SPARK AT COIL 982
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR 982
ENGINE COOLANT TEMPERATURE SENSOR 982
THROTTLE POSITION SENSOR 982
IGNITION COIL TEST 983
FAILURE TO START TEST 984
DISTRIBUTOR CAP 985
IGNITION TIMING 985
MAP SENSOR 985
CRANKSHAFT POSITION SENSOR DISTRIBUTOR ROTOR 985
CAMSHAFT POSITION SENSOR 986
ENGINE COOLANT TEMPERATURE SENSOR 986
INTAKE MANIFOLD AIR TEMPERATURE SENSOR 986
SPARK PLUG CABLES 986
TESTING 986
SPARK PLUG CONDITIONS 987
NORMAL OPERATING 987
COLD FOULING/CARBON FOULING 987
WET FOULING OR GAS FOULING 987
OIL OR ASH ENCRUSTED 988
ELECTRODE GAP BRIDGING 988
CHIPPED ELECTRODE INSULATOR 988
SCAVENGER DEPOSITS PREIGNITION DAMAGE 988
SPARK PLUG OVERHEATING 989
REMOVAL AND INSTALLATION 989
SPARK PLUG CABLES 989
PLUG GAP ADJUSTMENT 990
SPARK PLUGS 990
SPARK PLUG GAP 990
PLUG REMOVAL 990
PLUG INSTALLATION 990
PLUG CLEANING 990
IGNITION COIL 990
REMOVAL 991
AUTOMATIC SHUTDOWN (ASD) RELAY 991
REMOVAL 991
INSTALLATION 991
CRANKSHAFT POSITION SENSOR 991
INSTALLATION 991
INSTALLATION 992
CAMSHAFT POSITION SENSOR 992
REMOVAL 992
REMOVAL 992
INSTALLATION 993
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR 993
ENGINE COOLANT TEMPERATURE SENSOR 993
THROTTLE POSITION SENSOR 993
INTAKE MANIFOLD AIR TEMPERATURE SENSOR 993
DISTRIBUTOR 993
REMOVAL—2 5L OR 4 0L ENGINE 994
INSTALLATION 995
POWERTRAIN CONTROL MODULE (PCM) 996
IGNITION SWITCH AND KEY CYLINDER 996
KEY CYLINDER REMOVAL 996
IGNITION SWITCH REMOVAL 997
KEY CYLINDER INSTALLATION 997
IGNITION SWITCH INSTALLATION 997
IGNITION TIMING 998
ENGINE FIRING ORDER—2 5L 4-CYLINDER ENGINE 998
ENGINE FIRING ORDER—4 0L 6-CYLINDER ENGINE 998
SHIFTER/IGNITION INTERLOCK 998
SPECIFICATIONS 998
VECI LABEL 998
SPARK PLUGS SPARK PLUG CABLE RESISTANCE 999
IGNITION COIL RESISTANCE 999
TORQUE CHART 999
INSTRUMENT PANEL SYSTEMS 1001
GENERAL INFORMATION 1001
INTRODUCTION 1001
INSTRUMENT CLUSTER 1002
INSTRUMENT PANEL 1002
INDICATOR LAMP 1003
JUNCTION BLOCK 1003
GAUGE 1003
DESCRIPTION AND OPERATION 1004
COOLANT TEMPERATURE GAUGE 1004
ODOMETER AND TRIP ODOMETER 1004
FUEL GAUGE 1004
TACHOMETER 1005
OIL PRESSURE GAUGE 1005
VOLTMETER 1005
SPEEDOMETER 1005
AIRBAG INDICATOR LAMP 1006
CHECK GAUGES LAMP 1006
ANTI-LOCK BRAKE SYSTEM LAMP 1006
CIGAR LIGHTER AND POWER OUTLET 1006
CIGAR LIGHTER RELAY 1006
BRAKE WARNING LAMP 1006
CLUSTER ILLUMINATION LAMP 1007
FOUR-WHEEL DRIVE INDICATOR LAMP 1007
PART TIME 1007
COOLANT TEMPERATURE WARNING LAMP 1007
FULL TIME 1007
CRUISE-ON INDICATOR LAMP 1007
HEADLAMP HIGH BEAM INDICATOR LAMP 1007
LOW FUEL WARNING LAMP 1008
LOW WASHER FLUID WARNING LAMP 1008
MALFUNCTION INDICATOR LAMP 1008
LOW OIL PRESSURE WARNING LAMP 1008
SEAT BELT REMINDER LAMP VOLTAGE WARNING LAMP 1009
TURN SIGNAL INDICATOR LAMP 1009
DIAGNOSIS AND TESTING 1009
INSTRUMENT CLUSTER 1009
UPSHIFT INDICATOR LAMP 1009
PRELIMINARY DIAGNOSIS 1010
ACTUATOR TEST 1010
COOLANT TEMPERATURE GAUGE 1010
FUEL GAUGE OIL PRESSURE GAUGE 1013
ODOMETER AND TRIP ODOMETER 1013
SPEEDOMETER 1014
AIRBAG INDICATOR LAMP 1014
TACHOMETER 1014
VOLTMETER 1014
ANTI-LOCK BRAKE SYSTEM LAMP 1014
BRAKE WARNING LAMP 1015
ACCESSORY POWER OUTLET 1016
CHECK GAUGES LAMP 1016
CIGAR LIGHTER 1016
CIGAR LIGHTER RELAY 1016
CIGAR LIGHTER AND POWER OUTLET 1016
RELAY TEST 1017
CLUSTER ILLUMINATION LAMP 1017
RELAY CIRCUIT TEST 1017
CRUISE-ON INDICATOR LAMP 1018
COOLANT TEMPERATURE WARNING LAMP 1018
FOUR-WHEEL DRIVE INDICATOR LAMP 1018
FULL TIME 1019
PART TIME 1019
HEADLAMP HIGH BEAM INDICATOR LAMP 1019
LOW OIL PRESSURE WARNING LAMP 1020
LOW FUEL WARNING LAMP 1020
LOW WASHER FLUID WARNING LAMP 1020
SEAT BELT REMINDER LAMP 1021
MALFUNCTION INDICATOR LAMP 1021
TURN SIGNAL INDICATOR LAMP 1021
VOLTAGE WARNING LAMP 1022
UPSHIFT INDICATOR LAMP 1022
REMOVAL AND INSTALLATION 1022
STEERING COLUMN OPENING COVER 1022
KNEE BLOCKER 1023
INSTRUMENT PANEL CENTER BEZEL 1023
CIGAR LIGHTER RELAY 1024
ACCESSORY SWITCH BEZEL 1024
CLUSTER BEZEL 1025
HEADLAMP SWITCH 1025
INSTRUMENT CLUSTER 1026
CLUSTER HOOD AND MASK 1027
CLUSTER COMPONENTS 1027
CLUSTER LENS AND ODOMETER RESET KNOB BOOT 1027
CLUSTER REAR COVER 1028
INSTRUMENT PANEL TOP COVER 1028
CLUSTER BULB 1028
GLOVE BOX 1029
ROLL DOWN 1029
GLOVE BOX LAMP AND SWITCH 1029
REMOVAL 1029
GLOVE BOX COMPONENTS 1030
HINGE, BIN, INNER DOOR AND LATCH 1030
LOCK CYLINDER 1030
OUTER DOOR 1030
INSTRUMENT PANEL END CAP 1031
DRIVER SIDE 1031
GLOVE BOX LATCH STRIKER 1031
PASSENGER SIDE 1031
JUNCTION BLOCK 1032
CENTER SUPPORT BRACKET 1032
INSTRUMENT PANEL ASSEMBLY 1033
AUDIO SYSTEMS 1035
GENERAL INFORMATION 1035
IGNITION-OFF DRAW FUSE 1035
INTRODUCTION 1035
DESCRIPTION AND OPERATION 1035
SPEAKER RADIO 1035
ANTENNA 1036
RADIO NOISE SUPPRESSION 1036
DIAGNOSIS AND TESTING 1036
AUDIO SYSTEM 1036
AUDIO SYSTEM DIAGNOSIS 1037
RADIO 1038
SPEAKER 1039
ANTENNA 1040
TEST 2 1040
TEST 3 1040
TEST 1 1040
TEST 4 1041
RADIO FREQUENCY INTERFERENCE 1041
REMOVAL AND INSTALLATION 1041
RADIO 1041
SPEAKER 1042
FRONT DOOR 1042
AMPLIFIER 1042
SOUND BAR 1043
ANTENNA 1044
SOUND BAR 1044
HORN SYSTEMS 1047
GENERAL INFORMATION 1047
INTRODUCTION 1047
HORN SWITCH 1047
HORN 1047
DESCRIPTION AND OPERATION 1047
HORN RELAY 1047
RELAY CIRCUIT TEST 1048
DIAGNOSIS AND TESTING 1048
HORN RELAY 1048
RELAY TEST 1048
HORN SWITCH 1048
HORN 1049
REMOVAL AND INSTALLATION 1049
HORN RELAY 1049
HORN SWITCH 1050
HORN 1050
VEHICLE SPEED CONTROL SYSTEM 1051
GENERAL INFORMATION 1051
INTRODUCTION 1051
DESCRIPTION AND OPERATION 1051
SPEED CONTROL SERVO 1051
STOP LAMP SWITCH 1051
SPEED CONTROL SWITCHES 1051
SERVO CABLE 1052
POWERTRAIN CONTROL MODULE 1052
VACUUM RESERVOIR 1052
ON-BOARD DIAGNOSTIC TEST FOR SPEED CONTROL SYSTEM VEHICLE SPEED SENSOR 1052
SPEED CONTROL ELECTRICAL TEST 1052
DIAGNOSIS AND TESTING 1052
ROAD TEST 1052
VEHICLE SPEED SENSOR 1053
SPEED CONTROL SWITCHES 1053
SPEED CONTROL SERVO 1053
STOP LAMP SWITCH 1053
VACUUM SUPPLY TEST 1053
REMOVAL AND INSTALLATION 1054
SPEED CONTROL SERVO 1054
REMOVAL 1054
POWERTRAIN CONTROL MODULE (PCM) 1054
OVERSHOOT/UNDERSHOOT FOLLOWING SPEED CONTROL SET 1054
INSTALLATION 1054
STOP LAMP SWITCH 1055
SPEED CONTROL SWITCH SERVO CABLE 1055
REMOVAL 1055
REMOVAL 1055
INSTALLATION 1055
INSTALLATION 1055
POWERTRAIN CONTROL MODULE 1056
VACUUM RESERVOIR 1056
REMOVAL 1056
SPECIFICATIONS 1056
TORQUE CHART 1056
INSTALLATION 1056
VEHICLE SPEED SENSOR 1056
TURN SIGNAL AND HAZARD WARNING SYSTEMS 1057
GENERAL INFORMATION 1057
INTRODUCTION 1057
HAZARD WARNING SYSTEM 1057
DESCRIPTION AND OPERATION 1057
TURN SIGNAL SYSTEM 1057
COMBINATION FLASHER 1057
TURN SIGNAL LAMP 1058
DIAGNOSIS AND TESTING 1058
INTRODUCTION TURN SIGNAL SWITCH AND HAZARD WARNING SWITCH 1058
TURN SIGNAL AND HAZARD WARNING SYSTEMS 1058
TURN SIGNAL INDICATOR LAMP 1058
MULTI-FUNCTION SWITCH 1059
REMOVAL AND INSTALLATION 1059
COMBINATION FLASHER 1059
MULTI-FUNCTION SWITCH 1060
WIPER AND WASHER SYSTEMS 1063
GENERAL INFORMATION 1063
INTRODUCTION 1063
WINDSHIELD WASHER SYSTEM 1063
DESCRIPTION AND OPERATION 1063
WINDSHIELD WIPER SYSTEM 1063
REAR WIPER AND WASHER SYSTEM 1064
WIPER ARM AND BLADE 1064
WIPER MOTOR 1064
FRONT 1064
REAR 1064
WIPER LINKAGE AND PIVOT 1064
REAR 1065
WIPER SWITCH AND WASHER SWITCH 1065
FRONT 1065
WASHER RESERVOIR 1065
WASHER PUMP 1065
DIAGNOSIS AND TESTING 1066
WIPER SYSTEM 1066
WASHER FLUID LEVEL SENSOR 1066
FRONT 1066
WASHER NOZZLE AND PLUMBING 1066
FRONT 1066
REAR 1066
REAR 1067
WASHER SYSTEM 1067
FRONT 1067
WIPER SWITCH AND WASHER SWITCH 1068
REAR FRONT 1068
REMOVAL AND INSTALLATION 1069
WIPER BLADE AND ELEMENT 1069
FRONT 1069
REAR 1069
WIPER ARM 1070
FRONT 1070
REAR 1070
WIPER LINKAGE AND PIVOT 1071
REAR 1071
WIPER MOTOR 1071
FRONT 1071
REAR 1072
WIPER SWITCH AND WASHER SWITCH 1073
FRONT 1073
REAR 1074
WASHER SYSTEM 1075
WASHER RESERVOIR 1075
WASHER FLUID LEVEL SENSOR 1075
WASHER PUMP 1075
WASHER NOZZLE 1076
CHECK VALVE 1076
LAMPS 1077
GENERAL INFORMATION 1077
GENERAL INFORMATION 1077
SENTINEL HEADLAMP DELAY MODULE 1077
SAFETY PRECAUTIONS DAYTIME RUNNING LAMP MODULE 1077
DIAGNOSIS AND TESTING 1078
HEADLAMP DIAGNOSIS 1078
DIAGNOSTIC PROCEDURES 1078
HEADLAMP DIAGNOSIS 1078
FOG LAMP DIAGNOSIS 1079
HEADLAMP DELAY MODULE 1079
DELAY FUNCTION INOPERATIVE 1079
GENERAL INFORMATION SERVICE PROCEDURES 1080
HEADLAMP ALIGNMENT HEADLAMP ALIGNMENT PREPARATION 1080
ALIGNMENT SCREEN PREPARATION 1081
HEADLAMP ADJUSTMENT 1081
FOG LAMP ADJUSTMENT 1082
SPECIAL TOOLS 1082
HEADLAMP ALIGNMENT 1082
REMOVAL AND INSTALLATION 1083
FOG LAMP BULB 1083
REMOVAL 1083
HEADLAMP BULB 1083
REMOVAL 1083
INSTALLATION 1083
INSTALLATION 1083
FRONT PARK/TURN SIGNAL LAMP BULB 1083
REMOVAL 1083
BACK-UP/REAR TURN SIGNAL/TAIL LAMP BULB 1084
REMOVAL 1084
INSTALLATION 1084
INSTALLATION 1084
SIDE MARKER LAMP BULB 1084
REMOVAL 1084
LICENSE PLATE LAMP BULB 1084
REMOVAL 1084
INSTALLATION 1084
CENTER HIGH MOUNTED STOP LAMP (CHMSL) BULB 1084
REMOVAL 1084
INSTALLATION 1084
MAP READING LAMP BULB 1085
REMOVAL 1085
INSTALLATION 1085
UNDERHOOD LAMP BULB 1085
REMOVAL 1085
INSTALLATION INSTALLATION 1085
VISOR VANITY LAMP BULB DOME LAMP BULB 1085
REMOVAL REMOVAL 1085
INSTALLATION 1085
INSTALLATION 1085
REMOVAL AND INSTALLATION 1086
HEADLAMP 1086
REMOVAL 1086
FOG LAMP 1086
REMOVAL 1086
INSTALLATION 1086
INSTALLATION 1086
FRONT PARK/TURN SIGNAL LAMP 1086
REMOVAL 1086
BACK-UP/REAR TURN SIGNAL/TAIL LAMP 1087
REMOVAL 1087
INSTALLATION 1087
SIDE MARKER LAMP 1087
REMOVAL INSTALLATION 1087
CENTER HIGH MOUNTED STOP LAMP (CHMSL) 1087
REMOVAL 1087
INSTALLATION 1087
INSTALLATION 1087
DOME LAMP LICENSE PLATE LAMP 1088
REMOVAL REMOVAL 1088
INSTALLATION 1088
UNDERHOOD LAMP 1088
REMOVAL 1088
INSTALLATION 1088
INSTALLATION 1088
MAP/READING LAMP 1089
INSTALLATION 1089
VISOR VANITY LAMP 1089
REMOVAL 1089
REMOVAL AND INSTALLATION 1090
DAYTIME RUNNING LAMP MODULE 1090
REMOVAL 1090
SENTINEL HEADLAMP DELAY MODULE 1090
REMOVAL 1090
INSTALLATION 1090
INSTALLATION 1090
GENERAL INFORMATION 1091
GENERAL INFORMATION 1091
INDICATOR LAMPS 1091
SPECIFICATIONS 1091
EXTERIOR LAMPS 1091
INTERIOR LAMPS 1091
PASSIVE RESTRAINT SYSTEMS 1093
GENERAL INFORMATION 1093
INTRODUCTION 1093
DESCRIPTION AND OPERATION 1094
AIRBAG MODULE 1094
DRIVER SIDE 1094
PASSENGER SIDE 1094
STORAGE 1094
IMPACT SENSOR 1095
DIAGNOSIS AND TESTING 1095
AIRBAG SYSTEM 1095
CLOCKSPRING 1095
AIRBAG CONTROL MODULE 1095
CLEANUP PROCEDURE 1096
SERVICE PROCEDURES 1096
AIRBAG SYSTEM 1096
NON-DEPLOYED 1096
DEPLOYED 1096
REMOVAL AND INSTALLATION 1097
AIRBAG MODULE 1097
PASSENGER SIDE 1097
DRIVER SIDE 1097
DRIVER SIDE AIRBAG TRIM COVER AND HORN SWITCH 1098
PASSENGER SIDE AIRBAG DOOR 1099
AIRBAG CONTROL MODULE 1100
CLOCKSPRING 1101
ADJUSTMENTS 1102
CLOCKSPRING CENTERING 1102
ELECTRICALLY HEATED SYSTEMS 1103
GENERAL INFORMATION 1103
INTRODUCTION 1103
DESCRIPTION AND OPERATION 1103
REAR GLASS HEATING GRID 1103
OUTSIDE MIRROR HEATING GRID 1104
DEFOGGER RELAY 1104
DEFOGGER SWITCH 1104
DIAGNOSIS AND TESTING 1104
DEFOGGER SYSTEM 1104
INSTRUMENT CLUSTER 1104
DEFOGGER SWITCH 1105
REAR GLASS HEATING GRID 1105
RELAY CIRCUIT TEST 1106
DEFOGGER RELAY 1106
RELAY TEST 1106
SERVICE PROCEDURES 1107
REAR GLASS HEATING GRID REPAIR 1107
INSTRUMENT CLUSTER 1107
REMOVAL AND INSTALLATION 1108
DEFOGGER SWITCH 1108
DEFOGGER RELAY 1109
POWER LOCK SYSTEMS 1111
GENERAL INFORMATION 1111
INTRODUCTION POWER LOCK SYSTEM 1111
REMOTE KEYLESS ENTRY SYSTEM 1111
POWER LOCK MOTOR 1112
REMOTE KEYLESS ENTRY TRANSMITTER 1112
DESCRIPTION AND OPERATION 1112
POWER LOCK SWITCH 1112
DOOR MODULE REMOTE KEYLESS ENTRY RECEIVER 1112
DIAGNOSIS AND TESTING 1113
POWER LOCK SYSTEM AND REMOTE KEYLESS ENTRY SYSTEM 1113
DOOR MODULE 1113
DRIVER DOOR MODULE 1113
PASSENGER DOOR MODULE 1113
POWER LOCK MOTOR 1115
REMOTE KEYLESS ENTRY RECEIVER 1115
REMOTE KEYLESS ENTRY TRANSMITTER 1115
REMOTE KEYLESS ENTRY RECEIVER PROGRAMMING 1116
REMOVAL AND INSTALLATION 1116
DOOR MODULE 1116
SERVICE PROCEDURES 1116
REMOTE KEYLESS ENTRY TRANSMITTER BATTERY REPLACEMENT 1116
REMOTE KEYLESS ENTRY TRANSMITTER PROGRAMMING 1116
LIFTGATE 1117
POWER LOCK MOTOR 1117
FRONT DOOR 1117
REAR DOOR 1117
OVERHEAD CONSOLE MOUNTED TYPE 1118
REMOTE KEYLESS ENTRY RECEIVER 1118
MINI-DOME MOUNTED TYPE 1118
POWER SEAT SYSTEMS 1121
GENERAL INFORMATION 1121
INTRODUCTION POWER SEAT ADJUSTER AND MOTORS 1121
DESCRIPTION AND OPERATION 1121
POWER SEAT SWITCH 1121
CIRCUIT BREAKER 1122
DIAGNOSIS AND TESTING 1122
POWER SEAT SYSTEM 1122
POWER SEAT SWITCH 1122
CIRCUIT BREAKER 1122
REMOVAL AND INSTALLATION 1122
POWER SEAT SWITCH 1122
POWER SEAT ADJUSTER AND MOTORS 1122
POWER SEAT ADJUSTER AND MOTORS 1123
POWER WINDOW SYSTEMS 1125
GENERAL INFORMATION 1125
INTRODUCTION 1125
DESCRIPTION AND OPERATION 1125
POWER WINDOW SWITCH 1125
DOOR MODULE 1126
ONE WINDOW INOPERATIVE 1126
POWER WINDOW MOTOR 1126
CIRCUIT BREAKER 1126
DIAGNOSIS AND TESTING 1126
POWER WINDOW SYSTEM 1126
ALL WINDOWS INOPERATIVE 1126
CIRCUIT BREAKER 1127
DOOR MODULE 1127
POWER WINDOW SWITCH 1127
POWER WINDOW MOTOR 1128
REMOVAL AND INSTALLATION 1128
DOOR MODULE 1128
POWER WINDOW SWITCH 1129
POWER WINDOW MOTOR 1129
FRONT DOOR 1129
REAR DOOR 1129
POWER MIRROR SYSTEMS 1131
GENERAL INFORMATION 1131
INTRODUCTION 1131
POWER MIRROR SWITCH 1131
DESCRIPTION AND OPERATION 1131
POWER MIRROR 1131
DOOR MODULE 1131
DIAGNOSIS AND TESTING 1132
POWER MIRROR SYSTEM 1132
REMOVAL AND INSTALLATION 1132
POWER MIRROR SWITCH 1132
DOOR MODULE 1134
POWER MIRROR 1134
CHIME/BUZZER WARNING SYSTEMS 1137
GENERAL INFORMATION DESCRIPTION AND OPERATION 1137
INTRODUCTION INSTRUMENT CLUSTER 1137
DRIVER DOOR JAMB SWITCH 1138
DIAGNOSIS AND TESTING 1138
DRIVER DOOR JAMB SWITCH 1138
DRIVER SEAT BELT SWITCH 1138
KEY-IN IGNITION SWITCH 1138
DRIVER SEAT BELT SWITCH 1138
HEADLAMP SWITCH 1138
HEADLAMP SWITCH 1139
KEY-IN IGNITION SWITCH 1139
INSTRUMENT CLUSTER 1139
REMOVAL AND INSTALLATION 1140
CHIME WARNING SYSTEM SWITCHES 1140
OVERHEAD CONSOLE SYSTEMS 1141
GENERAL INFORMATION DESCRIPTION AND OPERATION 1141
INTRODUCTION TRIP COMPUTER 1141
COMPASS 1142
READING AND COURTESY LAMP 1142
GARAGE DOOR OPENER STORAGE BIN 1142
THERMOMETER 1142
SUNGLASSES STORAGE BIN 1143
SELF-DIAGNOSTIC TEST 1143
DIAGNOSIS AND TESTING 1143
TRIP COMPUTER, COMPASS, AND THERMOMETER DISPLAY MODULE 1143
THERMOMETER 1144
SERVICE PROCEDURES 1144
COMPASS VARIATION ADJUSTMENT 1144
SENSOR TEST 1144
SENSOR CIRCUIT TEST 1144
COMPASS CALIBRATION 1145
COMPASS DEMAGNETIZING 1145
REMOVAL AND INSTALLATION 1146
OVERHEAD CONSOLE 1146
PUSH BUTTON MODULE 1147
TRIP COMPUTER, COMPASS, AND THERMOMETER DISPLAY MODULE 1147
READING AND COURTESY LAMP BULB 1147
GARAGE DOOR OPENER STORAGE BIN DOOR 1147
AMBIENT TEMPERATURE SENSOR 1148
SUNGLASSES STORAGE BIN 1148
WIRING DIAGRAMS 1149
DESCRIPTION AND OPERATION 1151
HOW TO USE THIS GROUP 1151
CONNECTOR/GROUND LOCATIONS 1151
SPLICE LOCATIONS 1151
NOTES, CAUTIONS, and WARNINGS 1151
SECTION IDENTIFICATION 1151
WIRE CODE IDENTIFICATION 1152
CIRCUIT IDENTIFICATION 1153
TAKE OUTS 1153
SYMBOLS 1153
CONNECTORS 1153
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES 1155
INTERMITTENT AND POOR CONNECTIONS 1155
DIAGNOSIS AND TESTING 1155
TROUBLESHOOTING TOOLS 1155
TROUBLESHOOTING TESTS 1156
TESTING FOR VOLTAGE 1156
TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1156
TESTING FOR A VOLTAGE DROP 1156
TESTING FOR CONTINUITY 1156
TROUBLESHOOTING WIRING PROBLEMS 1156
TESTING FOR A SHORT TO GROUND 1156
TERMINAL/CONNECTOR REPAIR-MOLEX CONNECTORS 1157
SERVICE PROCEDURES 1157
WIRING REPAIR 1157
TERMINAL/CONNECTOR REPAIR—THOMAS AND BETTS CONNECTORS 1158
CONNECTOR REPLACEMENT 1158
CONNECTOR AND TERMINAL REPLACEMENT TERMINAL REPLACEMENT 1159
DIODE REPLACEMENT 1160
SPECIAL TOOLS 1161
WIRING/TERMINAL 1161
GENERAL INFORMATION 1165
INTRODUCTION 1165
DESCRIPTION AND OPERATION 1258
CHARGING SYSTEM 1258
HELPFUL INFORMATION 1258
CHARGING SYSTEM (DIESEL) 1258
DESCRIPTION AND OPERATION 1263
STARTING SYSTEM—AUTOMATIC TRANSMISSIONS 1263
STARTING SYSTEM (DIESEL) 1263
STARTING SYSTEM—MANUAL TRANSMISSION 1263
HELPFUL INFORMATION (DIESEL) 1263
DESCRIPTION AND OPERATION 1296
IGNITION SWITCH 1296
ACCESSORY OR RUN POSITIONS 1296
BATTERY FEED 1296
START POSITION 1296
HELPFUL INFORMATION 1296
START OR RUN POSITION 1296
BATTERY FEED (DIESEL) 1296
HELPFUL INFORMATION 1297
DIESEL POWER RELAY GROUND 1297
HELPFUL INFORMATION 1297
HELPFUL INFORMATION 1297
POWER GROUND (DIESEL) FUEL PUMP RELAY 1297
DATA LINK CONNECTOR 1297
HELPFUL INFORMATION 1297
FUEL PUMP MODULE 1297
AUTOMATIC SHUT DOWN (ASD) RELAY 1297
FUEL PUMP MOTOR 1297
FUEL LEVEL SENSOR 1297
FUEL PUMP MODULE (DIESEL) 1298
HELPFUL INFORMATION 1298
VEHICLE SPEED SENSOR 1298
HELPFUL INFORMATION 1298
BATTERY TEMPERATURE SENSOR 1298
CRANKSHAFT POSITION SENSOR 1298
VEHICLE SPEED SENSOR (DIESEL) 1298
HELPFUL INFORMATION 1298
HEATED OXYGEN SENSORS 1298
HELPFUL INFORMATION 1299
CRANKSHAFT POSITION SENSOR (DIESEL) 1299
CAMSHAFT POSITION SENSOR 1299
ENGINE COOLANT TEMPERATURE SENSOR (DIESEL) 1299
HELPFUL INFORMATION 1299
THROTTLE POSITION SENSOR 1299
HELPFUL INFORMATION 1299
ENGINE COOLANT TEMPERATURE SENSOR 1299
MASS AIR FLOW SENSOR (DIESEL) 1300
ACCELERATOR PEDAL POSITION SENSOR (DIESEL) INTAKE AIR TEMPERATURE SENSOR 1300
LOW IDLE POSITION SWITCH (DIESEL) 1300
HELPFUL INFORMATION 1300
MANIFOLD ABSOLUTE PRESSURE SENSOR 1300
HELPFUL INFORMATION 1300
OIL PRESSURE SENSOR (DIESEL) 1300
WATER IN FUEL SENSOR (DIESEL) 1300
PARK/NEUTRAL POSITION SWITCH 1301
HELPFUL INFORMATION 1301
FUEL INJECTION PUMP (DIESEL) 1301
FUEL SHUTDOWN SOLENOID 1301
POWER STEERING PRESSURE SWITCH 1301
FUEL TIMING SOLENOID 1301
FUEL TEMPERATURE SENSOR 1301
STOP LAMP SWITCH INPUT 1301
CONTROL SLEEVE POSITION SENSOR 1301
FUEL INJECTORS 1301
FUEL QUANTITY ACTUATOR 1301
FUEL HEATER (DIESEL) 1301
NEEDLE MOVEMENT SENSOR (DIESEL) 1302
ELECTRIC VACUUM MODULATOR (DIESEL) 1302
GLOW PLUGS (DIESEL) 1302
LOW COOLANT LEVEL SWITCH (DIESEL) 1302
TORQUE CONVERTER CLUTCH (TCC) SOLENOID 1302
IGNITION COIL 1302
HELPFUL INFORMATION 1302
EXTENDED IDLE SWITCH 1302
IDLE AIR CONTROL (IAC) MOTOR 1302
CCD BUS 1302
DUTY CYCLE EVAP\PURGE SOLENOID 1302
DESCRIPTION AND OPERATION 1307
TORQUE CONVERTER CLUTCH (TCC) SOLENOID 1307
TRANSMISSION CONTROL MODULE—4 0L ENGINE ONLY 1307
FOUR-WHEEL DRIVE (4WD) SWITCH 1307
SHIFT INTERLOCK 1307
DESCRIPTION AND OPERATION 1314
VEHICLE SPEED CONTROL 1314
HELPFUL INFORMATION 1314
VEHICLE SPEED CONTROL (DIESEL) 1314
DESCRIPTION AND OPERATION 1321
G-SWITCH 1321
INTRODUCTION 1321
ABS RELAY 1321
ABS WARNING LAMP 1321
WHEEL SPEED SENSORS 1321
STOP LAMP SWITCH INPUT 1321
DATA LINK CONNECTOR 1321
DESCRIPTION AND OPERATION 1331
OVERHEAD MODULE 1331
IMMOBILIZER 1331
REMOTE KEYLESS ENTRY 1331
DESCRIPTION AND OPERATION 1350
INTRODUCTION 1350
HELPFUL INFORMATION 1350
BRAKE WARNING LAMP ILLUMINATION LAMPS 1350
WARNING LAMPS—EXCEPT ABS and BRAKE 1350
SPEEDOMETER 1350
TACHOMETER ABS WARNING LAMP 1350
VOLTMETER 1351
FUEL GAUGE 1351
HIGH BEAM INDICATOR LAMP 1351
ENGINE COOLANT TEMPERATURE GAUGE 1351
TURN SIGNAL INDICATOR LAMPS 1351
OIL PRESSURE GAUGE 1351
MANUAL TRANSMISSION UP-SHIFT LAMP 1351
FOUR-WHEEL DRIVE (4WD) SWITCH 1351
CHIME 1351
SEAT BELT WARNING LAMP 1351
TELL TALE MODULE 1352
DESCRIPTION AND OPERATION 1356
HORN 1356
HELPFUL INFORMATION 1356
POWER OUTLET 1356
HELPFUL INFORMATION 1356
CIGAR LIGHTER 1356
GENERAL INFORMATION 1365
A/C OPERATION 1365
INTRODUCTION 1365
DESCRIPTION AND OPERATION 1365
BLOWER MOTOR 1365
A/C OPERATION 1365
DESCRIPTION AND OPERATION 1370
AIRBAG IMPACT SENSOR 1370
INTRODUCTION 1370
AIRBAG SQUIB (AIRBAG IGNITER) 1370
DESCRIPTION AND OPERATION 1377
UNDERHOOD LAMP 1377
INTRODUCTION 1377
CARGO LAMP, COURTESY LAMPS AND DOME LAMP 1377
INSTRUMENT PANEL ILLUMINATION LAMPS 1377
GLOVE BOX LAMP VISOR VANITY MIRROR LAMPS 1377
READING LAMPS 1378
DESCRIPTION AND OPERATION 1384
RADIO 1384
AMPLIFIER AND SPEAKERS—PREMIUM 1384
RADIO MEMORY 1384
RADIO ILLUMINATION 1384
SPEAKERS—STANDARD SYSTEM 1384
DESCRIPTION AND OPERATION 1388
REAR WINDOW DEFOGGER 1388
HELPFUL INFORMATION 1388
DESCRIPTION AND OPERATION 1392
INTRODUCTION 1392
AMBIENT TEMPERATURE SENSOR 1392
DESCRIPTION AND OPERATION 1402
PARKING LAMPS 1402
HEADLAMP GROUND 1402
HEADLAMP LEVELING 1402
HELPFUL INFORMATION 1402
HEADLAMP DELAY MODULE 1402
HEADLAMPS 1402
HEADLAMP SWITCH IN ON POSITION 1402
FOG LAMPS 1402
WITHOUT DAYTIME RUNNING LAMPS 1402
HEADLAMP SWITCH IN OFF OR PARKING LAMP POSITION 1402
HELPFUL INFORMATION 1403
DAYTIME RUNNING LAMP (DRL) MODULE 1403
WITH DAYTIME RUNNING LAMPS 1403
DESCRIPTION AND OPERATION 1411
REAR FOG LAMPS 1411
TAIL LAMPS AND REAR LICENSE PLATE LAMPS 1411
BACK-UP LAMPS 1411
GROUND CIRCUIT 1411
STOP LAMPS AND CHMSL LAMPS 1411
HELPFUL INFORMATION 1411
HELPFUL INFORMATION 1411
DESCRIPTION AND OPERATION 1416
TURN SIGNALS 1416
HAZARD FLASHERS 1416
HELPFUL INFORMATION 1416
COMBINATION FLASHER 1416
HELPFUL INFORMATION 1416
DESCRIPTION AND OPERATION 1420
INTERMITTENT WIPERS 1420
HELPFUL INFORMATION 1420
REAR WIPER SYSTEM 1420
DESCRIPTION AND OPERATION 1424
LEFT TURN RELAY 1424
TRAILER TOW 1424
RIGHT TURN RELAY 1424
HELPFUL INFORMATION 1424
HELPFUL INFORMATION 1424
HELPFUL INFORMATION 1424
DESCRIPTION AND OPERATION 1430
POWER WINDOW OPERATION 1430
LEFT REAR WINDOW 1430
LEFT FRONT WINDOW OPERATION 1430
RIGHT FRONT WINDOW OPERATION 1430
RIGHT REAR WINDOW 1430
HELPFUL INFORMATION 1431
DESCRIPTION AND OPERATION 1439
INTRODUCTION 1439
POWER DOOR LOCK OPERATION 1439
REMOTE KEYLESS ENTRY AND ILLUMINATED ENTRY 1439
DOOR LOCK SWITCH OPERATION—LOCK POSITION 1439
GROUND CIRCUIT 1439
HELPFUL INFORMATION 1439
DESCRIPTION AND OPERATION 1446
POWER MIRRORS 1446
LEFT POWER MIRROR OPERATION 1446
RIGHT POWER MIRROR OPERATION 1446
HELPFUL INFORMATION 1446
HELPFUL INFORMATION 1447
HEATER ELEMENTS 1447
DESCRIPTION AND OPERATION 1452
POWER SEAT OPERATION 1452
HELPFUL INFORMATION 1452
DESCRIPTION AND OPERATION 1551
INTRODUCTION CONNECTOR/GROUND LOCATIONS 1551
DESCRIPTION AND OPERATION 1599
INTRODUCTION SPLICE LOCATIONS 1599
ENGINE 1621
GENERAL INFORMATION 1621
FORM-IN-PLACE GASKETS 1621
SURFACE PREPARATION 1621
MOPAR SILICONE RUBBER ADHESIVE SEALANT 1621
GASKET APPLICATION 1621
ENGINE PERFORMANCE 1622
HONING CYLINDER BORES 1622
MEASURING WITH PLASTIGAGE 1623
CRANKSHAFT MAIN BEARING CLEARANCE 1623
CONNECTING ROD BEARING CLEARANCE 1623
REPAIR DAMAGED OR WORN THREADS 1624
SERVICE ENGINE ASSEMBLY (SHORT BLOCK) 1624
ENGINE OIL 1624
HYDROSTATIC LOCK 1624
ENGINE OIL SPECIFICATION 1624
API SERVICE GRADE CERTIFIED 1625
CRANKCASE OIL LEVEL INSPECTION 1625
SAE VISCOSITY 1625
ENERGY CONSERVING OIL 1625
CONTAINER IDENTIFICATION 1625
ENGINE OIL ADDITIVES 1625
ENGINE OIL CHANGE 1626
ENGINE OIL FILTER CHANGE 1626
DIAGNOSIS AND TESTING 1628
CYLINDER COMPRESSION PRESSURE TEST 1628
GENERAL INFORMATION 1628
ENGINE CYLINDER HEAD GASKET FAILURE INTAKE MANIFOLD LEAKAGE DIAGNOSIS DIAGNOSIS 1628
CYLINDER-TO-CYLINDER LEAKAGE TEST 1628
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1629
INSPECTION (ENGINE OIL LEAKS IN GENERAL) 1629
CYLINDER COMBUSTION PRESSURE LEAKAGE TEST 1629
Air Leak Detection Test Method 1630
ENGINE OIL PRESSURE 1630
INSPECTION FOR REAR SEAL AREA LEAKS 1630
SERVICE DIAGNOSIS—PERFORMANCE 1631
ENGINE PER FOR MANCE DIAGNOSIS CHAR T 1631
SERVICE DIAGNOSIS—MECHANICAL 1633
ENGINE MECHANICAL DIAGNOSIS CHART 1633
DESCRIPTION AND OPERATION 1635
ENGINE DESCRIPTION 1635
BUILD DATE CODE 1635
LUBRICATION SYSTEM 1636
OIL PUMP PRESSURE 1638
OVERSIZE AND UNDERSIZE COMPONENT CODES 1638
PISTON FITTING 1638
SERVICE PROCEDURES 1638
VALVE TIMING 1638
PISTON RING FITTING 1639
FITTING CONNECTING ROD BEARINGS 1641
INSPECTION 1641
BEARING-TO-JOURNAL CLEARANCE 1642
SIDE CLEARANCE MEASUREMENT 1643
FITTING CRANKSHAFT MAIN BEARINGS 1643
INSPECTION FITTING BEARINGS (CRANKSHAFT INSTALLED) 1643
MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED) 1645
MAIN BEARING FITTING CHART 1646
REMOVAL AND INSTALLATION 1647
ENGINE MOUNTS—FRONT 1647
REMOVAL 1647
INSTALLATION 1647
ENGINE MOUNT—REAR 1648
REMOVAL 1648
INSTALLATION 1648
ENGINE ASSEMBLY 1648
REMOVAL 1648
INSTALLATION 1649
INSTALLATION 1650
CYLINDER HEAD COVER 1650
REMOVAL 1650
ROCKER ARMS AND PUSH RODS 1651
REMOVAL 1651
VALVE SPRINGS AND OIL SEALS 1651
REMOVAL 1651
INSTALLATION INSTALLATION 1651
ENGINE CYLINDER HEAD 1652
REMOVAL 1652
INSTALLATION 1653
VALVES AND VALVE SPRINGS 1654
REMOVAL 1654
INSTALLATION 1654
INSTALLATION 1655
HYDRAULIC TAPPETS 1655
REMOVAL 1655
VIBRATION DAMPER 1655
REMOVAL 1655
INSTALLATION 1655
TIMING CASE COVER OIL SEAL TIMING CASE COVER 1656
REMOVAL REMOVAL 1656
INSTALLATION 1656
INSTALLATION 1656
REMOVAL 1657
TIMING CHAIN AND SPROCKETS 1657
INSTALLATION 1657
CAMSHAFT 1658
INSTALLATION REMOVAL 1658
CAMSHAFT PIN REPLACEMENT 1659
REMOVAL 1659
INSTALLATION 1660
CAMSHAFT BEARINGS 1661
CRANKSHAFT MAIN BEARINGS 1661
REMOVAL 1661
INSTALLATION 1662
OIL PAN 1663
REMOVAL 1663
INSTALLATION 1663
INSTALLATION 1664
OIL PUMP 1664
PISTONS AND CONNECTING RODS 1664
REMOVAL 1664
REMOVAL 1664
INSTALLATION 1665
DISASSEMBLY AND ASSEMBLY 1666
VALVE SERVICE 1666
REAR MAIN OIL SEALS 1666
REMOVAL 1666
VALVE REFACING 1666
INSTALLATION 1666
VALVE SEAT REFACING 1666
VALVE STEM OIL SEAL REPLACEMENT 1667
VALVE GUIDES 1667
VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT 1667
ASSEMBLY 1668
CLEANING AND INSPECTION 1668
ROCKER ARMS AND PUSH RODS 1668
CLEANING 1668
CYLINDER BLOCK 1668
DISASSEMBLY INSPECTION 1668
ENGINE CYLINDER HEAD 1669
CLEANING 1669
INSPECTION 1669
CYLINDER BLOCK 1669
CLEANING 1669
INSPECTION—CYLINDER BORE 1669
HONING—CYLINDER BORE 1670
SPECIFICATIONS 1670
L ENGINE SPECIFICATIONS 1670
L TORQUE SPECIFICATIONS 1672
SPECIAL TOOLS 1673
L ENGINE 1673
DESCRIPTION AND OPERATION 1674
ENGINE DESCRIPTION 1674
LUBRICATION SYSTEM 1675
OIL PUMP PRESSURE 1677
OVERSIZE AND UNDERSIZE COMPONENT CODES 1677
PISTON FITTING 1677
SERVICE PROCEDURES 1677
VALVE TIMING 1677
PISTON RING FITTING 1678
FITTING CONNECTING ROD BEARINGS 1680
INSPECTION 1680
FITTING CRANKSHAFT MAIN BEARINGS 1682
INSPECTION 1682
FITTING BEARINGS (CRANKSHAFT INSTALLED) 1682
SIDE CLEARANCE MEASUREMENT 1682
MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED) 1684
MAIN BEARING FITTING CHART 1685
REMOVAL AND INSTALLATION 1686
ENGINE MOUNTS—FRONT 1686
REMOVAL 1686
ENGINE MOUNT—REAR 1686
REMOVAL 1686
INSTALLATION 1686
INSTALLATION 1687
ENGINE ASSEMBLY 1687
REMOVAL 1687
INSTALLATION 1689
ENGINE CYLINDER HEAD COVER 1689
INSTALLATION 1690
REMOVAL 1690
ROCKER ARMS AND PUSH RODS 1690
REMOVAL 1690
INSTALLATION 1691
VALVE STEM SEAL AND SPRING 1691
REMOVAL INSTALLATION 1691
ENGINE CYLINDER HEAD 1691
REMOVAL 1692
INSTALLATION 1692
VALVES AND VALVE SPRINGS 1693
REMOVAL 1693
INSTALLATION 1694
VIBRATION DAMPER 1694
REMOVAL 1694
HYDRAULIC TAPPETS 1694
REMOVAL 1694
INSTALLATION INSTALLATION 1694
TIMING CASE COVER 1695
REMOVAL 1695
INSTALLATION 1695
TIMING CHAIN AND SPROCKETS 1695
REMOVAL 1695
INSTALLATION 1696
CAMSHAFT 1697
REMOVAL 1697
INSTALLATION 1697
CAMSHAFT PIN REPLACEMENT 1698
REMOVAL 1698
CAMSHAFT BEARINGS 1699
INSTALLATION 1699
CRANKSHAFT MAIN BEARINGS 1700
REMOVAL 1700
INSTALLATION 1700
INSTALLATION 1701
OIL PAN 1701
REMOVAL 1701
INSTALLATION 1702
PISTONS AND CONNECTING RODS 1702
REMOVAL 1702
REAR MAIN OIL SEAL 1703
REMOVAL 1703
INSTALLATION 1703
REMOVAL 1704
INSTALLATION 1704
TIMING CASE COVER OIL SEAL OIL PUMP 1704
REMOVAL 1704
DISASSEMBLY AND ASSEMBLY 1705
VALVE SERVICE 1705
INSTALLATION 1705
VALVE REFACING 1705
VALVE SEAT REFACING 1705
VALVE STEM OIL SEAL REPLACEMENT 1705
VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT 1706
VALVE GUIDES 1706
ASSEMBLY 1707
VALVE SPRING TENSION TEST 1707
CLEANING AND INSPECTION 1707
ENGINE CYLINDER HEAD 1707
CLEANING 1707
CYLINDER BLOCK 1707
DISASSEMBLY 1707
HYDRAULIC TAPPETS 1708
CLEANING INSPECTION 1708
INSPECTION 1708
ENGINE CYLINDER HEAD COVER 1708
CLEANING 1708
LEAK-DOWN TEST 1708
INSPECTION 1708
ROCKER ARMS AND PUSH RODS 1708
CLEANING 1708
INSPECTION 1708
CYLINDER BLOCK 1708
CLEANING 1708
INSPECTION—CYLINDER BORE 1709
HONING—CYLINDER BORE 1709
SPECIFICATIONS 1710
L ENGINE SPECIFICATIONS 1710
L TORQUE SPECIFICATIONS 1712
SPECIAL TOOLS 1713
L ENGINE 1713
EXHAUST SYSTEM 17
GENERAL INFORMATION 17
EXHAUST SYSTEM 17
CATALYTIC CONVERTER 17
DIAGNOSIS AND TESTING 18
EXHAUST SYSTEM 18
REMOVAL AND INSTALLATION 18
EXHAUST PIPE 18
REMOVAL 18
INSTALLATION 18
CATALYTIC CONVERTER 19
REMOVAL 19
INSTALLATION 19
MUFFLER AND EXHAUST TAILPIPE 20
REMOVAL 20
INSTALLATION 21
SPECIFICATIONS 21
TORQUE SPECIFICATIONS 21
FRAME AND BUMPERS 33
BUMPERS 33
REMOVAL AND INSTALLATION 33
FRONT BUMPER END CAP 33
REMOVAL 33
INSTALLATION 33
FRONT BUMPER 33
REMOVAL 33
INSTALLATION 33
FRONT TOW HOOK 34
REMOVAL 34
INSTALLATION 34
REAR BUMPER END CAP 34
REMOVAL 34
INSTALLATION 35
REAR BUMPER 35
REMOVAL 35
INSTALLATION 35
REAR TOW HOOK 36
REMOVAL 36
INSTALLATION 36
SPARE TIRE CARRIER 41
FRAME 37
REMOVAL AND INSTALLATION 37
FRONT SKID PLATE 37
REMOVAL 37
INSTALLATION 37
TRANSFER CASE SKID PLATE 37
REMOVAL 37
INSTALLATION 37
FUEL TANK SKID PLATE 37
REMOVAL 37
INSTALLATION 37
TRAILER HITCH 38
REMOVAL 38
INSTALLATION 38
SPECIFICATIONS 38
FRAME DIMENSIONS 38
FRAME TORQUE SPECIFICATIONS 40
FUEL SYSTEM 43
FUEL DELIVERY SYSTEM 43
DESCRIPTION AND OPERATION 43
PCM REPLACEMENT 43
FUEL REQUIREMENTS 43
REFORMULATED GASOLINE 44
GASOLINE/OXYGENATE BLENDS 44
MMT 44
SULFUR IN GASOLINE 44
MATERIALS ADDED TO FUEL 44
FUEL SYSTEM CAUTIONS 44
FUEL DELIVERY SYSTEM 45
FUEL PUMP MODULE 45
FUEL PUMP 45
DESCRIPTION 45
OPERATION 46
FUEL GAUGE SENDING UNIT 46
DESCRIPTION 46
OPERATION 46
FUEL FILTER/FUEL PRESSURE REGULATOR 46
FUEL TANK 47
DESCRIPTION 47
OPERATION 47
ROLLOVER VALVE(S) 47
FUEL INJECTORS 47
FUEL RAIL/FUEL DAMPER-2 5L ENGINE 47
FUEL RAIL-4 0L ENGINE 47
FUEL TANK FILLER TUBE CAP 48
QUICK-CONNECT FITTINGS 48
DIAGNOSIS AND TESTING 48
FUEL PUMP PRESSURE TEST-ALL ENGINES WITH PRESSURE TEST PORT 48
FUEL PUMP CAPACITY TEST 49
FUEL PRESSURE LEAK DOWN TEST 49
FUEL PUMP AMPERAGE TEST 50
FUEL GAUGE SENDING UNIT 52
FUEL INJECTOR TEST 52
SERVICE PROCEDURES 52
FUEL SYSTEM PRESSURE RELEASE PROCEDURE 52
FUEL TUBES/LINES/HOSES AND CLAMPS 52
OPERATION 52
QUICK-CONNECT FITTINGS 53
DISCONNECTING 53
CONNECTING 55
REMOVAL AND INSTALLATION 55
FUEL FILTER/FUEL PRESSURE REGULATOR 55
REMOVAL 55
INSTALLATION 55
FUEL PUMP MODULE 56
REMOVAL 56
INSTALLATION 56
FUEL PUMP INLET FILTER 57
REMOVAL 57
INSTALLATION 57
FUEL GAUGE SENDING UNIT 57
REMOVAL 57
INSTALLATION 58
FUEL INJECTOR RAIL-2 5L ENGINE 58
REMOVAL 58
INSTALLATION 59
FUEL INJECTOR RAIL-4 0L ENGINE 59
REMOVAL 59
INSTALLATION 59
FUEL INJECTORS 60
REMOVAL 60
INSTALLATION 60
FUEL TANK 60
REMOVAL 60
INSTALLATION 62
FUEL TANK FILLER TUBE CAP 62
ACCELERATOR PEDAL 62
REMOVAL 62
INSTALLATION 63
THROTTLE CABLE 63
REMOVAL 63
INSTALLATION 63
SPECIFICATIONS 64
FUEL TANK CAPACITY 64
FUEL SYSTEM PRESSURE 64
TORQUE CHART 64
FUEL INJECTION SYSTEM 65
DESCRIPTION AND OPERATION 66
POWERTRAIN CONTROL MODULE (PCM) 66
MODES OF OPERATION 67
IGNITION SWITCH (KEY-ON) MODE 67
ENGINE START-UP MODE 67
ENGINE WARM-UP MODE 68
IDLE MODE 68
CRUISE MODE 68
ACCELERATION MODE 69
DECELERATION MODE 69
WIDE OPEN THROTTLE MODE 69
IGNITION SWITCH OFF MODE 69
AIR CONDITIONING (A/C) CONTROLS-PCM INPUT 69
OPERATION 69
AUTOMATIC SHUTDOWN (ASD) RELAY SENSE-PCM INPUT 70
BATTERY TEMPERATURE SENSOR-PCM INPUT 70
OPERATION 70
BATTERY VOLTAGE-PCM INPUT 70
OPERATION 70
BRAKE SWITCH-PCM INPUT 70
OPERATION 70
FIVE VOLT SENSOR SUPPLY-PRIMARY 70
OPERATION 70
FIVE VOLT SENSOR SUPPLY-SECONDARY 70
OPERATION 70
FUEL LEVEL SENSOR-PCM INPUT 70
OPERATION 70
CAMSHAFT POSITION SENSOR-PCM INPUT 71
CRANKSHAFT POSITION SENSOR-PCM INPUT 71
ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT 71
EXTENDED IDLE SWITCH-PCM INPUT 72
OPTIONAL POLICE PACKAGE WITH 4 0L ENGINE ONLY 72
GENERATOR OUTPUT-PCM INPUT 72
OPERATION 72
OXYGEN SENSOR (HO2S)-PCM INPUT 72
UPSTREAM HEATED OXYGEN SENSOR 72
DOWNSTREAM HEATED OXYGEN SENSOR 72
IGNITION CIRCUIT SENSE-PCM INPUT 72
OPERATION 72
INTAKE MANIFOLD AIR TEMPERATURE SENSOR-PCM INPUT 72
LEAK DETECTION PUMP (SWITCH) SENSE-PCM INPUT 73
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-PCM INPUT 73
OIL PRESSURE SENSOR-PCM INPUT 73
DESCRIPTION 73
OPERATION 73
POWER GROUND 73
OPERATION 73
POWER STEERING PRESSURE SWITCH-PCM INPUT 73
SENSOR RETURN-PCM INPUT 74
OPERATION 74
SPEED CONTROL SWITCHES-PCM INPUT 74
TRANSMISSION PARK/NEUTRAL SWITCH-PCM INPUT 74
THROTTLE POSITION SENSOR (TPS)-PCM INPUT 74
VEHICLE SPEED AND DISTANCE SENSOR-PCM INPUT 74
AIR CONDITIONING (A/C) CLUTCH RELAY-PCM OUTPUT 75
AUTO SHUTDOWN (ASD) RELAY-PCM OUTPUT 75
DESCRIPTION 75
OPERATION 75
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS 76
DATA LINK CONNECTOR-PCM INPUT AND OUTPUT 76
DUTY CYCLE EVAP PURGE SOLENOID VALVE-PCM OUTPUT 76
FUEL INJECTORS-PCM OUTPUT 76
FUEL PUMP RELAY-PCM OUTPUT 77
DESCRIPTION 77
OPERATION 77
GENERATOR FIELD SOURCE (+)-PCM OUTPUT 77
OPERATION 77
GENERATOR FIELD DRIVER (-)-PCM OUTPUT 77
OPRATION 77
GENERATOR LAMP-PCM OUTPUT 77
IDLE AIR CONTROL (IAC) MOTOR-PCM OUTPUT 77
IGNITION COIL-PCM OUTPUT 77
LEAK DETECTION PUMP-PCM OUTPUT 77
RADIATOR FAN RELAY-PCM OUTPUT 77
MALFUNCTION INDICATOR LAMP-ECM/PCM OUTPUT 77
SPEED CONTROL SOLENOIDS-PCM OUTPUT 77
TACHOMETER-PCM OUTPUT 77
THROTTLE BODY 77
DIAGNOSIS AND TESTING 78
VISUAL INSPECTION 78
ASD AND FUEL PUMP RELAYS 81
OPERATION 81
TESTING 82
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST 82
OXYGEN (O2S) SENSORS 83
ENGINE COOLANT TEMPERATURE SENSOR 83
IDLE AIR CONTROL (IAC) MOTOR 84
INTAKE MANIFOLD AIR TEMPERATURE SENSOR 84
POWER STEERING PRESSURE SWITCH 84
2 5L 4-Cylinder Engine Only 84
VEHICLE SPEED SENSOR 85
EXTENDED IDLE SWITCH TEST 85
OPTIONAL POLICE PACKAGE ONLY 85
THROTTLE POSITION SENSOR (TPS) 86
THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE 86
REMOVAL AND INSTALLATION 87
AUTOMATIC SHUTDOWN (ASD) RELAY 87
REMOVAL 87
INSTALLATION 87
FUEL PUMP RELAY 87
REMOVAL 87
INSTALLATION 87
THROTTLE BODY 87
REMOVAL 87
INSTALLATION 88
THROTTLE POSITION SENSOR (TPS) 88
REMOVAL 88
INSTALLATION 88
IDLE AIR CONTROL (IAC) MOTOR 89
REMOVAL 89
INSTALLATION 89
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR 89
REMOVAL 89
INSTALLATION 89
DUTY CYCLE EVAP CANISTER PURGE SOLENOID 89
POWERTRAIN CONTROL MODULE (PCM) 89
REMOVAL 89
INSTALLATION 90
POWER STEERING PRESSURE SWITCH-2 5L ENGINE 90
REMOVAL 90
INSTALLATION 90
OXYGEN SENSOR 90
REMOVAL 91
INSTALLATION 91
AIR CLEANER ELEMENT (FILTER) 91
REMOVAL 91
INSTALLATION 91
ENGINE COOLANT TEMPERATURE SENSOR 92
REMOVAL 92
INSTALLATION 92
INTAKE MANIFOLD AIR TEMPERATURE SENSOR 92
REMOVAL 92
INSTALLATION 92
VEHICLE SPEED SENSOR 92
REMOVAL 93
INSTALLATION 93
SPECIFICATIONS 93
TORQUE CHART 93
SPECIAL TOOLS 94
FUEL SYSTEM 94
STEERING 133
POWER STEERING 133
GENERAL INFORMATION 133
STEERING SYSTEM 133
DIAGNOSIS AND TESTING 134
POWER STEERING SYSTEM DIAGNOSIS CHARTS 134
POWER STEERING PUMP 137
DESCRIPTION AND OPERATION 137
POWER STEERING PUMP 137
DIAGNOSIS AND TESTING 137
POWER FLOW AND PRESSURE 137
FLOW AND PRESSURE TEST 137
PUMP LEAKAGE DIAGNOSIS 138
SERVICE PROCEDURES 138
POWER STEERING PUMP – INITIAL OPERATION 138
REMOVAL AND INSTALLATION 139
POWER STEERING PUMP 139
REMOVAL 139
INSTALLATION 139
PUMP RESERVOIR-2 5L 140
REMOVAL 140
INSTALLATION 140
DISASSEMBLY AND ASSEMBLY 140
PUMP PULLEY 140
DISASSEMBLY 140
ASSEMBLY 140
PUMP RESERVOIR 141
DISASSEMBLY 141
ASSEMBLY 141
FLOW CONTROL VALVE 141
DISASSEMBLY 141
ASSEMBLY 141
SPECIFICATIONS 142
TORQUE CHART 142
SPECIAL TOOLS 142
POWER STEERING PUMP 142
POWER STEERING GEAR 143
DESCRIPTION AND OPERATION 143
POWER STEERING GEAR 143
DIAGNOSIS AND TESTING 145
POWER STEERING GEAR LEAKAGE DIAGNOSIS 145
REMOVAL AND INSTALLATION 145
STEERING GEAR 145
REMOVAL 145
INSTALLATION 145
DISASSEMBLY AND ASSEMBLY 145
HOUSING END PLUG 145
DISASSEMBLY 145
ASSEMBLY 146
PITMAN SHAFT/SEALS/BEARING 146
DISASSEMBLY 146
ASSEMBLY 147
SPOOL VALVE 147
DISASSEMBLY 147
ASSEMBLY 148
RACK PISTON AND WORM SHAFT 149
DISASSEMBLY 149
ASSEMBLY 150
ADJUSTMENTS 151
STEERING GEAR 151
WORM THRUST BEARING PRELOAD 151
OVER-CENTER 152
SPECIFICATIONS 153
POWER STEERING GEAR 153
TORQUE CHART 153
SPECIAL TOOLS 154
POWER STEERING GEAR 154
STEERING LINKAGE 155
GENERAL INFORMATION 155
STEERING LINKAGE 155
SERVICE PROCEDURES 155
STEERING LINKAGE 155
REMOVAL AND INSTALLATION 156
TIE ROD 156
REMOVAL 156
INSTALLATION 156
PITMAN ARM 157
REMOVAL 157
INSTALLATION 157
DRAG LINK 157
REMOVAL 157
INSTALLATION 157
STEERING DAMPER 157
REMOVAL 157
INSTALLATION 157
SPECIFICATIONS 157
TORQUE CHART 157
SPECIAL TOOLS 158
STEERING LINKAGE 158
STEERING COLUMN 159
GENERAL INFORMATION 159
STEERING COLUMN 159
SERVICE PRECAUTIONS 159
REMOVAL AND INSTALLATION 159
STEERING COLUMN 159
REMOVAL 159
INSTALLATION 160
SPECIFICATIONS 161
TORQUE CHART 161
TRANSMISSION AND TRANSFER CASE 193
AX5 MANUAL TRANSMISSION 193
GENERAL INFORMATION 193
AX5 MANUAL TRANSMISSION 193
TRANSMISSION IDENTIFICATION 193
GEAR RATIOS 193
RECOMMENDED LUBRICANT 193
TRANSMISSION ASSEMBLY INFORMATION 194
DIAGNOSIS AND TESTING 195
LOW LUBRICANT LEVEL 195
HARD SHIFTING 195
TRANSMISSION NOISE 196
REMOVAL AND INSTALLATION 196
TRANSMISSION 196
REMOVAL 196
INSTALLATION 197
FRONT BEARING RETAINER SEAL 198
REMOVAL 198
INSTALLATION 198
EXTENSION HOUSING SEAL 199
REMOVAL 199
INSTALLATION 199
ADAPTER HOUSING SEAL 199
REMOVAL 199
INSTALLATION 199
DISASSEMBLY AND ASSEMBLY 200
ADAPTER/EXTENSION HOUSING AND FRONT BEARING RETAINER 200
DISASSEMBLY 200
ASSEMBLY 203
SHIFT MECHANISM AND GEARTRAIN 207
DISASSEMBLY 207
ASSEMBLY 212
COUNTERSHAFT 218
DISASSEMBLY 218
ASSEMBLY 218
INPUT SHAFT 218
DISASSEMBLY 218
ASSEMBLY 218
OUTPUT SHAFT 219
DISASSEMBLY 219
ASSEMBLY 221
SEMI-SYNCHRONIZED REVERSE IDLER GEAR 224
DISASSEMBLY 224
ASSEMBLY 224
CLEANING AND INSPECTION 224
AX5 MANUAL TRANSMISSION COMPONENTS 224
GENERAL INFORMATION 224
GEAR CASE, ADAPTER/EXTENSION HOUSING, INTERMEDIATE PLATE 225
OUTPUT SHAFT 225
COUNTERSHAFT 225
GEAR AND SYNCHRONIZER 225
SPECIFICATIONS 227
TORQUE 227
SPECIAL TOOLS 227
AX5 227
AX15 MANUAL TRANSMISSION 229
GENERAL INFORMATION 229
AX15 MANUAL TRANSMISSION 229
TRANSMISSION IDENTIFICATION 229
TRANSMISSION GEAR RATIOS 229
RECOMMENDED LUBRICANT 229
TRANSMISSION ASSEMBLY INFORMATION 230
DIAGNOSIS AND TESTING 230
LOW LUBRICANT LEVEL 230
HARD SHIFTING 231
TRANSMISSION NOISE 232
REMOVAL AND INSTALLATION 232
TRANSMISSION 232
REMOVAL 232
INSTALLATION 233
FRONT BEARING RETAINER SEAL 234
REMOVAL 234
INSTALLATION 234
EXTENSION HOUSING SEAL 235
REMOVAL 235
INSTALLATION 235
ADAPTER HOUSING SEAL 235
REMOVAL 235
INSTALLATION 235
DISASSEMBLY AND ASSEMBLY 236
ADAPTER/EXTENSION HOUSING AND FRONT BEARING RETAINER 236
DISASSEMBLY 236
ASSEMBLY 239
SHIFT MECHANISM AND GEARTRAIN 243
DISASSEMBLY 243
ASSEMBLY 250
COUNTERSHAFT 255
DISASSEMBLY 255
ASSEMBLY 255
INPUT SHAFT 256
DISASSEMBLY 256
ASSEMBLY 256
OUTPUT SHAFT 256
DISASSEMBLY 257
ASSEMBLY 259
CLEANING AND INSPECTION 261
AX15 MANUAL TRANSMISSION COMPONENTS 261
GENERAL INFORMATION 261
GEAR CASE, ADAPTER/EXTENSION HOUSING, INTERMEDIATE PLATE 261
OUTPUT SHAFT 261
COUNTERSHAFT 262
GEAR AND SYNCHRONIZER 262
SPECIFICATIONS 263
TORQUE 263
SPECIAL TOOLS 263
AX15 263
AUTOMATIC TRANSMISSION-30RH 265
GENERAL INFORMATION 266
30RH AUTOMATIC TRANSMISSION 266
TRANSMISSION IDENTIFICATION 266
RECOMMENDED FLUID 266
EFFECTS OF INCORRECT FLUID LEVEL 266
CAUSES OF BURNT FLUID 266
FLUID CONTAMINATION 266
TORQUE CONVERTER-ELECTRONIC CLUTCH 268
TRANSMISSION GEAR RATIOS 268
GEARSHIFT MECHANISM 268
DESCRIPTION AND OPERATION 268
HYDRAULIC CONTROL SYSTEM 268
PRESSURE SUPPLY 268
Pressure Regulation 268
Flow Control And Lubrication 268
Clutch/Band Application 269
CONVERTER CLUTCH ENGAGEMENT 269
CONVERTER DRAINBACK VALVE 269
BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM 269
DIAGNOSIS AND TESTING 269
AUTOMATIC TRANSMISSION DIAGNOSIS 269
PRELIMINARY DIAGNOSIS 269
VEHICLE IS DRIVEABLE 269
VEHICLE IS DISABLED 270
PARK/NEUTRAL POSITION SWITCH 270
SWITCH TEST 270
GEARSHIFT CABLE 271
THROTTLE VALVE CABLE 271
ROAD TESTING 271
ANALYZING ROAD TEST 271
HYDRAULIC PRESSURE TEST 272
Pressure Test Port Locations 272
PRESSURE TEST PROCEDURE 272
CONVERTER STALL TEST 273
STALL TEST PROCEDURE 274
STALL TEST ANALYSIS 274
Stall Speed Too High 274
Stall Speed Low 274
Stall Speed Normal But Acceleration Poor 274
Converter Noise During Test 274
AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION 274
Front Clutch Air Test 274
Rear Clutch Air Test 274
Front Servo Apply Air Test 274
Rear Servo Air Test 275
CONVERTER HOUSING FLUID LEAK DIAGNOSIS 275
TORQUE CONVERTER LEAK POINTS 275
CONVERTER HOUSING AREA LEAK CORRECTION 275
DIAGNOSIS CHARTS 275
SERVICE PROCEDURES 283
FLUID LEVEL CHECK 283
FLUID LEVEL CHECK PROCEDURE 283
FLUID AND FILTER REPLACEMENT 283
REMOVAL 283
INSPECTION 284
CLEANING 284
INSTALLATION 284
TRANSMISSION FILL PROCEDURE 284
CONVERTER DRAINBACK CHECK VALVE SERVICE 284
OIL PUMP VOLUME CHECK 284
FLUSHING COOLERS AND TUBES 285
COOLER FLUSH USING TOOL 6906 285
ALUMINUM THREAD REPAIR 285
REMOVAL AND INSTALLATION 286
TRANSMISSION 286
REMOVAL 286
INSTALLATION 287
TORQUE CONVERTER 288
REMOVAL 288
INSTALLATION 288
YOKE SEAL REPLACEMENT 289
REMOVAL 289
INSTALLATION 289
EXTENSION HOUSING BUSHING 289
REMOVAL 289
INSTALLATION 289
EXTENSION HOUSING 290
REMOVAL 290
INSTALLATION 290
SPEEDOMETER ADAPTER 290
REMOVAL 290
INSTALLATION 290
PARK/NEUTRAL POSITION SWITCH 291
REMOVAL 291
INSTALLATION 291
GEARSHIFT CABLE 292
REMOVAL 292
INSTALLATION 292
BRAKE TRANSMISSION SHIFT INTERLOCK 292
REMOVAL 292
INSTALLATION 292
VALVE BODY 292
REMOVAL 292
INSTALLATION 293
OUTPUT SHAFT REAR BEARING 294
REMOVAL 294
INSTALLATION 294
GOVERNOR AND PARK GEAR 294
REMOVAL 294
INSTALLATION 294
PARK LOCK 295
REMOVAL 295
INSTALLATION 295
DISASSEMBLY AND ASSEMBLY 296
GOVERNOR AND PARK GEAR 296
DISASSEMBLY 296
ASSEMBLY 296
VALVE BODY 297
DISASSEMBLY 297
ASSEMBLY 300
TRANSMISSION 304
DISASSEMBLY 304
ASSEMBLY 308
OVERRUNNING CLUTCH/LOW-REVERSE DRUM 313
DISASSEMBLY 313
ASSEMBLY 313
FRONT SERVO PISTON 313
DISASSEMBLY 313
ASSEMBLY 314
REAR SERVO PISTON 314
DISASSEMBLY 314
ASSEMBLY 314
OIL PUMP AND REACTION SHAFT SUPPORT 315
DISASSEMBLY 315
ASSEMBLY 316
FRONT CLUTCH 318
DISASSEMBLY 318
ASSEMBLY 318
REAR CLUTCH 319
DISASSEMBLY 319
ASSEMBLY 320
PLANETARY GEARTRAIN/OUTPUT SHAFT 322
DISASSEMBLY 322
ASSEMBLY 322
CLEANING AND INSPECTION 326
GOVERNOR AND PARK GEAR 326
EXTENSION HOUSING AND PARK LOCK 328
VALVE BODY 328
TRANSMISSION 329
OVERRUNNING CLUTCH/LOW-REVERSE DRUM/OVERDRIVE PISTON RETAINER 330
FRONT SERVO 330
REAR SERVO 330
OIL PUMP AND REACTION SHAFT SUPPORT 331
FRONT CLUTCH 331
REAR CLUTCH 331
PLANETARY GEARTRAIN/OUTPUT SHAFT 332
ADJUSTMENTS 332
GEARSHIFT CABLE 332
Gearshift Adjustment Procedure 332
BRAKE TRANSMISSION SHIFT INTERLOCK CABLE ADJUSTMENT 333
TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT 333
Checking Throttle Valve Cable Adjustment 334
Throttle Valve Cable Adjustment Procedure 334
FRONT BAND ADJUSTMENT 334
REAR BAND ADJUSTMENT 335
VALVE BODY 335
CONTROL PRESSURE ADJUSTMENTS 335
SCHEMATICS AND DIAGRAMS 336
HYDRAULIC SCHEMATICS 336
SPECIFICATIONS 349
30RH AUTOMATIC TRANSMISSION 349
GENERAL 349
THRUST WASHER/SPACER/SNAP RING DIMENSIONS 349
PRESSURE TEST-ALL 349
TORQUE 350
SPECIAL TOOLS 350
30RH TRANSMISSIONS 350
AW-4 AUTOMATIC TRANSMISSION 355
GENERAL INFORMATION 356
AW-4 AUTOMATIC TRANSMISSION 356
TRANSMISSION IDENTIFICATION 356
RECOMMENDED FLUID CAPACITY 356
EFFECTS OF INCORRECT FLUID LEVEL 356
CAUSES OF BURNT FLUID 357
FLUID CONTAMINATION 357
TRANSMISSION RANGES AND SHIFT LEVER POSITIONS 357
DESCRIPTION AND OPERATION 358
ELECTRONIC CONTROLS 358
TRANSMISSION CONTROL MODULE (TCM) 358
TRANSMISSION VALVE BODY SOLENOIDS 358
SENSORS 358
TORQUE CONVERTER 358
FOURTH GEAR OVERDRIVE COMPONENTS 358
FIRST/SECOND/THIRD/REVERSE GEAR COMPONENTS 359
GEARTRAIN OPERATION AND APPLICATION CHARTS 360
HYDRAULIC SYSTEM 361
OIL PUMP 361
TRANSMISSION VALVE BODY COMPONENTS 361
MANUAL VALVE 362
PRIMARY REGULATOR VALVE 362
THROTTLE VALVE AND DOWNSHIFT PLUG 363
CUT-BACK VALVE 363
SECONDARY REGULATOR VALVE 363
CONVERTER CLUTCH RELAY VALVE 364
1-2 SHIFT VALVE 364
2-3 SHIFT VALVE 364
3-4 SHIFT VALVE 365
SECOND COAST MODULATOR VALVE 366
LOW COAST MODULATOR VALVE 366
ACCUMULATOR CONTROL VALVE 367
ACCUMULATORS 367
TRANSMISSION VALVE BODY SOLENOIDS 367
TRANSMISSION COOLER 368
MAIN COOLER 368
AUXILIARY COOLER 368
COOLER SERVICE 368
BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM 368
DIAGNOSIS AND TESTING 369
GENERAL DIAGNOSIS INFORMATION 369
PRELIMINARY INSPECTION AND ADJUSTMENT 369
MANUAL SHIFTING TEST 370
HYDRAULIC PRESSURE TEST 371
Pressure Test Procedure 371
PRESSURE TEST ANALYSIS 371
TORQUE CONVERTER STALL TEST 371
STALL SPEED TEST ANALYSIS 372
TIME LAG TEST 372
TEST PROCEDURE 372
TIME LAG TEST ANALYSIS 372
SERVICE DIAGNOSIS 372
TRANSMISSION SOLENOID TESTING 372
PARK/NEUTRAL POSITION SWITCH 375
SWITCH TESTING 375
GEARSHIFT CABLE 375
THROTTLE VALVE CABLE 375
SPEED SENSOR TESTING 375
FLOW TESTING TRANSMISSION MAIN COOLER 376
TORQUE CONVERTER STATOR CLUTCH INSPECTION 376
SERVICE PROCEDURES 377
CHECKING FLUID LEVEL 377
CHECKING FLUID CONDITION 377
REFILLING AFTER OVERHAUL OR FLUID/FILTER CHANGE 377
TRANSMISSION CONTROL MODULE (TCM) SERVICE 377
OIL PUMP VOLUME CHECK 377
FLUSHING COOLERS AND TUBES 378
COOLER FLUSH USING TOOL 6906 378
ALUMINUM THREAD REPAIR 378
REMOVAL AND INSTALLATION 379
TRANSMISSION AND TORQUE CONVERTER 379
REMOVAL 379
INSTALLATION 379
TORQUE CONVERTER 380
REMOVAL 380
INSTALLATION 380
ADAPTER HOUSING SEAL 381
REMOVAL 381
INSTALLATION 381
SPEED SENSOR 381
REMOVAL 381
INSTALLATION 381
SPEEDOMETER ADAPTER 381
REMOVAL 381
INSTALLATION 382
SPEED SENSOR ROTOR-SPEEDOMETER DRIVE GEAR 382
REMOVAL 382
INSTALLATION 382
PARK/NEUTRAL POSITION SWITCH 383
REMOVAL 383
INSTALLATION 383
GEARSHIFT CABLE 384
REMOVAL 384
INSTALLATION 384
BRAKE TRANSMISSION SHIFT INTERLOCK 385
REMOVAL 385
INSTALLATION 385
TRANSMISSION VALVE BODY SOLENOIDS 385
REMOVAL 385
INSTALLATION 385
TRANSMISSION VALVE BODY 386
REMOVAL 386
INSTALLATION 387
TRANSMISSION CONTROL MODULE 388
SOLENOID HARNESS ADAPTER SEAL 388
REMOVAL 388
INSTALLATION 389
MANUAL VALVE SHAFT SEAL 390
REMOVAL 390
INSTALLATION 390
ACCUMULATOR PISTONS AND SPRINGS 391
REMOVAL 391
INSTALLATION 392
SECOND COAST BRAKE SERVO 392
REMOVAL 392
INSTALLATION 393
PARK ROD AND PAWL 393
REMOVAL 393
INSTALLATION 394
TRANSMISSION THROTTLE CABLE 394
REMOVAL 394
INSTALLATION 395
OIL PUMP SEAL 395
REMOVAL 395
INSTALLATION 395
DISASSEMBLY AND ASSEMBLY 396
TRANSMISSION 396
DISASSEMBLY 396
ASSEMBLY 407
OIL PUMP 424
DISASSEMBLY 424
ASSEMBLY 424
OVERDRIVE PLANETARY GEAR AND CLUTCH 426
DISASSEMBLY 426
ASSEMBLY 430
OVERDRIVE SUPPORT 432
DISASSEMBLY 432
ASSEMBLY 434
DIRECT CLUTCH 435
DISASSEMBLY 435
ASSEMBLY 437
FORWARD CLUTCH 439
DISASSEMBLY 439
ASSEMBLY 441
FRONT PLANETARY GEAR 444
DISASSEMBLY 444
ASSEMBLY 445
SUN GEAR AND NO 1 ONE-WAY CLUTCH 446
DISASSEMBLY 447
ASSEMBLY 448
SECOND BRAKE 448
DISASSEMBLY 448
ASSEMBLY 450
PLANETARY/BRAKE PACK/OUTPUT SHAFT 452
DISASSEMBLY 452
ASSEMBLY 455
TRANSMISSION VALVE BODY 456
CLEANING AND INSPECTION 459
TRANSMISSION PARTS CLEANING AND INSPECTION 459
ADJUSTMENTS 459
GEARSHIFT CABLE 459
Gearshift Adjustment Procedure 459
BRAKE TRANSMISSION SHIFT INTERLOCK CABLE ADJUSTMENT 459
TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT 460
Checking Throttle Valve Cable Adjustment 460
Throttle Valve Cable Adjustment Procedure 460
SPECIFICATIONS 461
AW-4 AUTOMATIC TRANSMISSION 461
AW-4 GENERAL SPECIFICATIONS 462
AW-4 OIL PUMP WEAR LIMITS 463
AW-4 CLUTCH DISC AND PLATE THICKNESS 463
AW-4 BUSHING AND PISTON CLEARANCE 464
AW-4 RETAINER AND PISTON SPECIFICATIONS 465
AW-4 VALVE BODY BALL DIMENSIONS 466
AW-4 CLUTCH AND BRAKE PACK REQUIREMENTS 466
AW-4 VALVE AND SPRING IDENTIFICATION 467
AW-4 ACCUMULATOR COMPONENT IDENTIFICATION 468
AW-4 TORQUE SPECIFICATIONS 469
SPECIAL TOOLS 470
AW-4 470
NV231 TRANSFER CASE 472
GENERAL INFORMATION 472
NV231 TRANSFER CASE 472
OPERATING RANGES 472
SHIFT MECHANISM 472
TRANSFER CASE IDENTIFICATION 472
RECOMMENDED LUBRICANT AND FILL LEVEL 473
DIAGNOSIS AND TESTING 473
NV231 DIAGNOSIS 473
REMOVAL AND INSTALLATION 474
TRANSFER CASE 474
REMOVAL 474
INSTALLATION 474
SHIFT LEVER 474
REMOVAL 474
INSTALLATION 474
SPEEDOMETER 474
REMOVAL 474
INSTALLATION AND INDEXING 475
FRONT OUTPUT SHAFT SEAL 475
REMOVAL 475
INSTALLATION 476
DISASSEMBLY AND ASSEMBLY 477
NV231 TRANSFER CASE 477
DISASSEMBLY 477
ASSEMBLY 482
CLEANING AND INSPECTION 491
NV231 TRANSFER CASE 491
MAINSHAFT/SPROCKET/HUB INSPECTION 491
INPUT GEAR AND PLANETARY CARRIER 491
SHIFT FORKS/HUBS/SLEEVES 492
REAR RETAINER/BEARING/SEAL/SLINGER/BOOT 493
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN 493
LOW RANGE ANNULUS GEAR 493
FRONT-REAR CASES AND FRONT RETAINER 493
OIL PUMP/OIL PICKUP 493
ADJUSTMENTS 495
SHIFT LINKAGE ADJUSTMENT 495
SPECIFICATIONS 495
TORQUE 495
SPECIAL TOOLS 495
NV231 495
NV242 TRANSFER CASE 498
GENERAL INFORMATION 498
NV242 TRANSFER CASE 498
OPERATING RANGES 498
SHIFT MECHANISM 498
TRANSFER CASE IDENTIFICATION 498
RECOMMENDED LUBRICANT AND FILL LEVEL 499
DIAGNOSIS AND TESTING 499
NV242 DIAGNOSIS 499
REMOVAL AND INSTALLATION 500
TRANSFER CASE 500
REMOVAL 500
INSTALLATION 500
SHIFT LEVER 500
REMOVAL 500
INSTALLATION 500
SPEEDOMETER 500
REMOVAL 500
INSTALLATION AND INDEXING 501
FRONT OUTPUT SHAFT SEAL 501
REMOVAL 501
INSTALLATION 502
DISASSEMBLY AND ASSEMBLY 503
NV242 TRANSFER CASE 503
DISASSEMBLY 503
ASSEMBLY 511
CLEANING AND INSPECTION 522
NV242 TRANSFER CASE 522
MAINSHAFT/SPROCKET/HUB INSPECTION 522
INPUT GEAR AND PLANETARY CARRIER 522
SHIFT FORKS/HUBS/SLEEVES 523
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT 523
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN 523
LOW RANGE ANNULUS GEAR 524
FRONT-REAR CASES AND FRONT RETAINER 524
OIL PUMP/OIL PICKUP 525
ADJUSTMENTS 525
SHIFT LINKAGE ADJUSTMENT 525
SPECIFICATIONS 526
TORQUE 526
SPECIAL TOOLS 526
NV242 526
TIRES AND WHEELS 541
TIRES 541
DESCRIPTION AND OPERATION 541
TIRE INFORMATION 541
TIRE IDENTIFICATION 541
TIRE CHAINS 541
RADIAL-PLY TIRES 542
SPARE TIRE-TEMPORARY 542
TIRE INFLATION PRESSURES 542
TIRE PRESSURE FOR HIGH SPEED OPERATION 543
REPLACEMENT TIRES 543
DIAGNOSIS AND TESTING 543
PRESSURE GAUGES 543
TREAD WEAR INDICATORS 543
TIRE WEAR PATTERNS 543
TIRE NOISE OR VIBRATION 544
SERVICE PROCEDURES 544
ROTATION 544
MATCH MOUNTING 544
REPAIRING LEAKS 545
CLEANING AND INSPECTION 546
CLEANING TIRES 546
SPECIFICATIONS 546
TIRE SIZE 546
WHEELS 547
DESCRIPTION AND OPERATION 547
WHEEL 547
DIAGNOSIS AND TESTING 547
WHEEL INSPECTION 547
TIRE AND WHEEL RUNOUT 547
METHOD 1 (RELOCATE WHEEL ON HUB) 548
METHOD 2 (RELOCATE TIRE ON WHEEL) 548
SERVICE PROCEDURES 548
WHEEL INSTALLATION 548
WHEEL REPLACEMENT 549
TIRE AND WHEEL BALANCE 549
SPECIFICATIONS 550
TORQUE CHART 550
BODY 551
GENERAL SERVICE INFORMATION 551
GENERAL INFORMATION 551
SAFETY PRECAUTIONS AND WARNINGS 551
PAINT 552
GENERAL INFORMATION 552
PAINT CODE 552
BASE COAT/CLEAR COAT FINISH 552
WET SANDING, BUFFING, AND POLISHING 552
PAINTED SURFACE TOUCH-UP 552
TOUCH-UP PROCEDURE 552
SPECIFICATIONS 553
AFTERMARKET PAINT REPAIR PRODUCTS 553
EXTERIOR COLOR 553
INTERIOR COLOR 553
STATIONARY GLASS 554
DESCRIPTION AND OPERATION 554
SAFETY PRECAUTIONS 554
REMOVAL AND INSTALLATION 554
WINDSHIELD 554
REMOVAL 554
INSTALLATION-SHORT METHOD 555
INSTALLATION-EXTENDED METHOD 556
REAR DOOR STATIONARY WINDOW GLASS 557
REMOVAL 557
INSTALLATION 558
REAR QUARTER WINDOW GLASS 558
REMOVAL 558
INSTALLATION 558
LIFTGATE GLASS 559
REMOVAL 559
INSTALLATION 559
SEATS 560
REMOVAL AND INSTALLATION 560
HEAD RESTRAINT SLEEVE 560
REMOVAL 560
INSTALLATION 560
HEAD RESTRAINT COVER 561
REMOVAL 561
INSTALLATION 561
BUCKET SEAT 561
REMOVAL 561
INSTALLATION 561
BUCKET SEAT TRACK 562
REMOVAL 562
INSTALLATION 562
BUCKET SEAT PLATFORM 562
BUCKET SEATBACK COVER 562
REMOVAL 562
INSTALLATION 562
BUCKET SEATBACK 563
REMOVAL 563
INSTALLATION 563
BUCKET SEAT CUSHION COVER 563
REMOVAL 563
INSTALLATION 563
BUCKET SEAT RECLINER 564
REMOVAL 564
INSTALLATION 564
REAR SEAT CUSHION 564
REMOVAL 564
INSTALLATION 565
REAR SEATBACK 565
REMOVAL 565
INSTALLATION 565
REAR SEAT CUSHION COVER 565
REMOVAL 565
INSTALLATION 565
REAR SEATBACK LATCH STRIKER AND BUMPER 565
REMOVAL 565
INSTALLATION 565
REAR SEATBACK COVER 566
REMOVAL 566
INSTALLATION 566
SPECIAL TOOLS 566
SEATS 566
BODY COMPONENT SERVICE 567
DIAGNOSIS AND TESTING 568
WATER LEAKS 568
VISUAL INSPECTION BEFORE WATER LEAK TESTS 568
WATER LEAK TESTS 568
WATER LEAK DETECTION 568
WIND NOISE 569
VISUAL INSPECTION BEFORE TESTS 569
SERVICE PROCEDURES 569
BODY LUBRICATION 569
REMOVAL AND INSTALLATION 570
GRILLE 570
REMOVAL 570
INSTALLATION 570
GRILLE OPENING PANEL (GOP) 570
REMOVAL 570
INSTALLATION 570
HOOD 570
REMOVAL 570
INSTALLATION 570
HOOD HINGE 570
REMOVAL 570
INSTALLATION 572
HOOD LATCH 572
REMOVAL 572
INSTALLATION 572
HOOD LATCH STRIKER 572
REMOVAL 572
INSTALLATION 572
HOOD RELEASE CABLE 572
REMOVAL 572
INSTALLATION 572
HOOD SAFETY LATCH 573
REMOVAL 573
INSTALLATION 573
SAFETY LATCH STRIKER 573
REMOVAL 573
INSTALLATION 573
HOOD SILENCER PAD 573
REMOVAL 573
INSTALLATION 574
COWL WEATHERSTRIP 574
REMOVAL 574
INSTALLATION 574
COWL GRILLE 574
REMOVAL 574
INSTALLATION 574
BODY DECALS 574
REMOVAL 575
INSTALLATION 575
EXTERIOR NAMEPLATES 575
REMOVAL 575
INSTALLATION 576
SIDE VIEW MIRROR 576
REMOVAL 576
INSTALLATION 576
FRONT FENDER FLARE 576
REMOVAL 576
INSTALLATION 577
FRONT WHEELHOUSE LINER 577
REMOVAL 577
INSTALLATION 577
RIGHT FRONT FENDER 577
REMOVAL 577
INSTALLATION 577
LEFT FRONT FENDER 577
REMOVAL 577
INSTALLATION 578
FRONT DOOR TRIM PANEL 578
REMOVAL 578
INSTALLATION 578
FRONT DOOR WATERDAM 579
REMOVAL 579
INSTALLATION 580
FRONT DOOR 580
REMOVAL 580
INSTALLATION 580
FRONT DOOR HINGE 580
REMOVAL 580
INSTALLATION 580
FRONT DOOR RESTRAINT 580
REMOVAL 580
INSTALLATION 581
FRONT DOOR OUTSIDE HANDLE 581
REMOVAL 581
INSTALLATION 581
FRONT DOOR LOCK CYLINDER 581
REMOVAL 581
INSTALLATION 581
FRONT DOOR LATCH 581
REMOVAL 581
INSTALLATION 581
FRONT DOOR LATCH STRIKER 582
REMOVAL 582
INSTALLATION 582
FRONT DOOR INSIDE HANDLE ACTUATOR 582
REMOVAL 582
INSTALLATION 582
FRONT DOOR INNER BELT WEATHERSTRIP 582
REMOVAL 582
INSTALLATION 582
FRONT DOOR OUTER BELT WEATHERSTRIP 582
REMOVAL 582
INSTALLATION 582
FRONT DOOR GLASS RUN CHANNEL WEATHERSTRIP 583
REMOVAL 583
INSTALLATION 583
FRONT DOOR OPENING WEATHERSTRIP 583
REMOVAL 583
INSTALLATION 583
FRONT DOOR OPENING SECONDARY WEATHERSTRIP 583
REMOVAL 583
INSTALLATION 584
FRONT DOOR GLASS EXTERIOR MOLDING 584
REMOVAL 584
INSTALLATION 584
FRONT DOOR WINDOW REGULATOR 584
REMOVAL 584
INSTALLATION 584
FRONT DOOR SPACER BLOCKS-TWO-DOOR VEHICLES 584
REMOVAL 584
INSTALLATION 584
FRONT DOOR GLASS 585
REMOVAL 585
INSTALLATION 585
REAR DOOR TRIM PANEL 586
REMOVAL 586
INSTALLATION 587
REAR DOOR WATERDAM 587
REMOVAL 587
INSTALLATION 587
REAR DOOR 587
REMOVAL 587
INSTALLATION 587
REAR DOOR RESTRAINT 587
REMOVAL 587
INSTALLATION 588
REAR DOOR HINGE 588
REMOVAL 588
INSTALLATION 588
REAR DOOR OUTSIDE HANDLE 588
REMOVAL 588
INSTALLATION 588
REAR DOOR LATCH 588
REMOVAL 588
INSTALLATION 589
REAR DOOR LATCH STRIKER 589
REMOVAL 589
INSTALLATION 589
REAR DOOR INSIDE HANDLE ACTUATOR 589
REMOVAL 589
INSTALLATION 589
REAR DOOR INNER BELT WEATHERSTRIP 589
REMOVAL 589
INSTALLATION 589
REAR DOOR OUTER BELT WEATHERSTRIP 589
REMOVAL 589
INSTALLATION 589
REAR DOOR GLASS RUN CHANNEL WEATHERSTRIP 589
REMOVAL 589
INSTALLATION 590
REAR DOOR GLASS EXTERIOR MOLDING 590
REMOVAL 590
INSTALLATION 590
REAR DOOR WEATHERSTRIP 590
REMOVAL 590
INSTALLATION 590
REAR DOOR WINDOW REGULATOR 590
REMOVAL 590
INSTALLATION 591
REAR DOOR WINDOW GLASS 591
REMOVAL 591
INSTALLATION 591
BODY SIDE MOLDING 592
REMOVAL 592
INSTALLATION 592
REAR FENDER FLARE 592
REMOVAL 592
INSTALLATION 592
QUARTER WINDOW APPLIQUE 592
REMOVAL 592
INSTALLATION 592
DRIP RAIL MOLDING 592
REMOVAL 592
INSTALLATION 592
LUGGAGE RACK 593
REMOVAL 593
INSTALLATION 593
AIR EXHAUST GRILLE 593
REMOVAL 593
INSTALLATION 593
A-PILLAR TRIM 594
REMOVAL 594
INSTALLATION 594
LOWER A-PILLAR COWL TRIM 594
REMOVAL 594
INSTALLATION 594
FRONT INNER SCUFF PLATE 595
REMOVAL 595
INSTALLATION 595
DOOR SILL SCUFF PLATE 595
REMOVAL 595
INSTALLATION 595
ASSIST HANDLE 595
REMOVAL 595
INSTALLATION 595
B-PILLAR TRIM 595
REMOVAL 595
INSTALLATION 595
C-PILLAR TRIM 595
REMOVAL 595
INSTALLATION 596
QUARTER PANEL TRIM EXTENSION 596
REMOVAL 596
INSTALLATION 596
QUARTER PANEL TRIM AND WHEELHOUSE COVER 596
REMOVAL 596
INSTALLATION 596
LIFTGATE PILLAR TRIM 597
REMOVAL 597
INSTALLATION 597
LIFTGATE OPENING UPPER TRIM 597
REMOVAL 597
INSTALLATION 597
LIFTGATE SCUFF PLATE 598
REMOVAL 598
INSTALLATION 598
FRONT SHOULDER BELT/BUCKLE 598
REMOVAL 598
INSTALLATION 598
REAR SHOULDER/LAP BELT/BUCKLE 599
REMOVAL 599
INSTALLATION 599
FULL FLOOR CONSOLE 600
REMOVAL 600
INSTALLATION 600
FRONT CARPET/MAT 600
REMOVAL 600
INSTALLATION 600
REAR CARPET/MAT 600
REMOVAL 600
INSTALLATION 600
REARVIEW MIRROR 601
REMOVAL 601
INSTALLATION 601
REARVIEW MIRROR SUPPORT BRACKET 601
INSTALLATION 601
SUNVISORS 602
REMOVAL 602
INSTALLATION 602
HEADLINER 602
REMOVAL 602
INSTALLATION 602
LIFTGATE TRIM PANEL 603
REMOVAL 603
INSTALLATION 603
LIFTGATE 604
REMOVAL 604
INSTALLATION 604
LIFTGATE HINGE 604
REMOVAL 604
INSTALLATION 604
LIFTGATE SUPPORT ROD CYLINDER 604
REMOVAL 604
INSTALLATION 604
LIFTGATE SUPPORT ROD BALL STUD 605
REMOVAL 605
INSTALLATION 605
LIFTGATE OUTSIDE HANDLE 605
REMOVAL 605
INSTALLATION 605
LIFTGATE LOCK CYLINDER 605
LIFTGATE LATCH 605
REMOVAL 605
INSTALLATION 605
LIFTGATE LATCH STRIKER 606
REMOVAL 606
INSTALLATION 606
LIFTGATE WEATHERSTRIP 606
REMOVAL 606
INSTALLATION 606
ADJUSTMENTS 607
HOOD 607
DOOR 607
IN AND OUT-MINOR ADJUSTMENT 607
UP AND DOWN-MINOR ADJUSTMENT 607
ALIGNMENT MAJOR-ADJUSTMENT 607
DOOR LATCH ADJUSTMENT 607
LIFTGATE 608
REAR SEATBACK 608
SPECIFICATIONS 608
BODY LUBRICANTS 608
WELD LOCATIONS 609
UPPER COWL 609
UPPER COWL 610
COWL 611
A-PILLAR 612
A-PILLAR 613
A-PILLAR 614
A-PILLAR 615
B-PILLAR 616
D-PILLAR 617
FUEL FILLER OPENING 618
CARGO AREA FLOOR PAN 619
ROOF AND D-PILLAR 620
LIFTGATE OPENING 621
ROOF 622
ROOF 623
FRAME RAIL 624
FRAME RAIL 625
FRAME RAIL 626
FRAME RAIL 627
REINFORCEMENT 628
FRONT INNER FENDER 629
FRONT INNER FENDER AND RADIATOR CLOSURE PANEL 630
REINFORCEMENT 631
FRONT FENDER 631
BODY SIDE 632
REAR WHEELHOUSE 633
REAR INNER WHEELHOUSE 634
BODY SIDE 635
BODY SIDE 636
BODY SIDE 637
BODY SIDE 638
BODY SIDE 639
BODY SIDE 640
UNDERBODY 641
UNDERBODY 642
UNDERBODY 643
UNDERBODY 644
UNDERBODY 645
UNDERBODY 646
UNDERBODY 647
UNDERBODY 648
UNDERBODY 649
UNDERBODY 650
UNDERBODY 651
BODY SEALING LOCATIONS 652
APPLICATION METHODS 652
COWL AND DASH PANEL 653
DASH PANEL AND FLOOR PAN 654
FLOOR PAN 655
REAR INNER WHEELHOUSE 656
FRONT INNER WHEELHOUSE 657
BODY SIDE 658
BODY SIDE 659
BODY SIDE 660
ROOF PANEL 661
FUEL FILLER HOUSING 662
LIFTGATE OPENING 663
STRUCTURAL ADHESIVE LOCATIONS 664
LEFT QUARTER PANEL 664
REAR WHEELHOUSE 665
ROOF BOWS 666
BODY GAP AND FLUSH MEASUREMENTS 667
BODY OPENING DIMENSIONS 668
WINDSHIELD OPENING 668
FRONT DOOR OPENING 2-DOOR 669
FRONT DOOR OPENING 4-DOOR 670
REAR DOOR OPENING 671
QUARTER WINDOW OPENING 2-DOOR 672
QUARTER WINDOW OPENING 4-DOOR 673
ENGINE COMPARTMENT 674
LIFTGATE OPENING 675
TORQUE SPECIFICATIONS 675
SPECIAL TOOLS 676
BODY 676
HEATING AND AIR CONDITIONING 677
GENERAL INFORMATION 678
HEATER AND AIR CONDITIONER 678
HEATER AND AIR CONDITIONER CONTROL 678
SERVICE WARNINGS AND PRECAUTIONS 679
COOLING SYSTEM REQUIREMENTS 679
COOLANT PRECAUTIONS 680
REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS 680
DESCRIPTION AND OPERATION 680
ACCUMULATOR 680
BLOWER MOTOR 680
BLOWER MOTOR RESISTOR 681
BLOWER MOTOR SWITCH 681
COMPRESSOR 681
BLOWER MOTOR RELAY 681
COMPRESSOR CLUTCH 682
CONDENSER 682
EVAPORATOR COIL 682
FIXED ORIFICE TUBE 682
COMPRESSOR CLUTCH RELAY 682
HEATER CORE 682
HIGH PRESSURE CUT-OFF SWITCH 683
REFRIGERANT 683
HIGH PRESSURE RELIEF VALVE REFRIGERANT LINE 683
LOW PRESSURE CYCLING CLUTCH SWITCH 683
REFRIGERANT LINE COUPLER 684
REFRIGERANT OIL 684
MANIFOLD GAUGE SET CONNECTIONS 684
REFRIGERANT SYSTEM SERVICE EQUIPMENT 684
REFRIGERANT SYSTEM SERVICE PORT 684
VACUUM CHECK VALVE 685
VACUUM RESERVOIR 685
DIAGNOSIS AND TESTING 685
A/C PERFORMANCE 685
HEATER PERFORMANCE 689
PREPARATIONS 689
MAXIMUM HEATER OUTPUT 689
TEMPERATURE CONTROL 689
VACUUM SYSTEM 690
HEATER-A/C CONTROLS 690
LOCATING VACUUM LEAKS 690
VACUUM CHECK VALVE 690
VIBRATION 691
NOISE 691
BLOWER MOTOR RELAY 691
BLOWER MOTOR 691
RELAY TEST 691
BLOWER MOTOR RESISTOR 694
CIRCUIT TEST 694
BLOWER MOTOR SWITCH 694
COMPRESSOR 695
COMPRESSOR CLUTCH RELAY 695
RELAY TEST 695
COMPRESSOR CLUTCH COIL 695
LOW PRESSURE CYCLING CLUTCH SWITCH 696
RELAY CIRCUIT TEST 696
REFRIGERANT SYSTEM LEAKS 696
HIGH PRESSURE CUT-OFF SWITCH 696
SYSTEM EMPTY 697
REFRIGERANT SYSTEM EVACUATE 697
SYSTEM LOW 697
REFRIGERANT SYSTEM CHARGE 697
SERVICE PROCEDURES 697
REFRIGERANT RECOVERY 697
REFRIGERANT CHARGE CAPACITY 697
REFRIGERANT OIL LEVEL 697
INSTALLATION 698
REMOVAL AND INSTALLATION 698
REFRIGERANT LINE COUPLER 698
REMOVAL 698
HIGH PRESSURE CUT-OFF SWITCH 699
REMOVAL 699
L ENGINE 699
INSTALLATION 699
SUCTION AND DISCHARGE LINE 699
LEFT-HAND DRIVE 4 0L ENGINE 700
COMPRESSOR 701
RIGHT-HAND DRIVE 4 0L ENGINE 701
REMOVAL 701
COMPRESSOR CLUTCH 702
REMOVAL 702
INSTALLATION 702
INSPECTION 703
INSTALLATION 704
LIQUID LINE 705
CLUTCH BREAK-IN 705
COMPRESSOR CLUTCH RELAY 705
L ENGINE 705
L ENGINE 706
FIXED ORIFICE TUBE 707
LOW PRESSURE CYCLING CLUTCH SWITCH 707
ACCUMULATOR 708
REMOVAL 708
INSTALLATION 708
CONDENSER 708
L ENGINE 708
L ENGINE 709
VACUUM CHECK VALVE 710
VACUUM RESERVOIR 710
BLOWER MOTOR 711
REMOVAL 711
HEATER-A/C CONTROL 711
REMOVAL 711
INSTALLATION 711
INSTALLATION 712
TEMPERATURE CONTROL CABLE 712
REMOVAL 712
INSTALLATION 713
KICK COVER 713
REMOVAL 713
BLOWER MOTOR RELAY 713
INSTALLATION 714
MODE DOOR VACUUM ACTUATOR 714
BLOWER MOTOR RESISTOR 714
DEFROST DOOR ACTUATOR 714
FLOOR DOOR ACTUATOR 714
PANEL/DEMIST DOOR ACTUATOR 715
RECIRCULATION AIR DOOR ACTUATOR 715
HEATER-A/C HOUSING 715
REMOVAL 716
DISASSEMBLY 716
INSTALLATION 717
ASSEMBLY 717
HEATER-A/C HOUSING DOOR 718
BLEND-AIR DOOR 718
DEFROST DOOR AND CRANK ARM PANEL/DEMIST DOOR AND CRANK ARM 718
RECIRCULATION AIR DOOR 719
FLOOR DOOR AND CRANK ARM 719
EVAPORATOR COIL 719
PANEL OUTLET DUCTS 720
HEATER CORE 720
PANEL OUTLET BARRELS 720
DUCTS AND OUTLETS 720
DEMISTER OUTLETS 721
DEFROST DUCT/DEMISTER ADAPTER 721
CONSOLE REAR DUCT 721
DEMISTER HOSES 721
DEMISTER DUCTS 721
FLOOR DUCT AND ADAPTER 722
EMISSION CONTROL SYSTEMS 723
GENERAL INFORMATION 723
SYSTEM DESCRIPTION 723
DESCRIPTION AND OPERATION 723
MALFUNCTION INDICATOR LAMP (MIL) 723
CIRCUIT ACTUATION TEST MODE 724
DIAGNOSTIC TROUBLE CODES 724
STATE DISPLAY TEST MODE 724
BULB CHECK 724
OBTAINING DTC’S USING DRB SCAN TOOL 724
OBTAINING DTC’S USING VEHICLE ODOMETER 725
OBTAINING DTC’S USING MIL LAMP 725
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS 725
MIL 21—OXYGEN SENSOR (O2S) MONITOR 729
MONITORED SYSTEMS 729
MIL 21—OXYGEN SENSOR HEATER MONITOR 730
MIL 64—CATALYST MONITOR 730
MIL 43—MISFIRE MONITOR 730
MIL 51/52—FUEL SYSTEM MONITOR 730
COMPONENT MONITORS 731
TRIP DEFINITION 731
NON-MONITORED CIRCUITS 731
FUEL PRESSURE 731
SECONDARY IGNITION CIRCUIT 731
CYLINDER COMPRESSION 732
EXHAUST SYSTEM PCM SYSTEM GROUND 732
FUEL INJECTOR MECHANICAL MALFUNCTIONS PCM CONNECTOR ENGAGEMENT 732
HIGH AND LOW LIMITS 732
EXCESSIVE OIL CONSUMPTION 732
THROTTLE BODY AIR FLOW 732
VACUUM ASSIST 732
LOAD VALUE 732
DESCRIPTION AND OPERATION 733
EVAPORATION (EVAP) CONTROL SYSTEM 733
ROLLOVER VALVE 733
DUTY CYCLE EVAP CANISTER PURGE SOLENOID EVAP CANISTER 733
CRANKCASE VENTILATION SYSTEM 734
DIAGNOSIS AND TESTING 735
VACUUM SCHEMATICS 735
REMOVAL AND INSTALLATION 735
EVAP CANISTER 735
VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL 735
REMOVAL 735
INSTALLATION 736
INSTALLATION 736
ROLLOVER VALVE(S) 736
DUTY CYCLE EVAP CANISTER PURGE SOLENOID 736
REMOVAL 736
SPECIFICATIONS 736
TORQUE CHART 736
DIESEL SUPPLEMENT 13
FUEL SYSTEM-2 5L DIESEL ENGINE 95
GENERAL INFORMATION 95
GENERAL INFORMATION 95
FUEL SHUTDOWN SOLENOID 95
FUEL REQUIREMENTS-2 5L DIESEL 95
FUEL DELIVERY SYSTEM-2 5L DIESEL ENGINE 96
DESCRIPTION AND OPERATION 96
INTRODUCTION 96
FUEL SYSTEM PRESSURE WARNING 96
FUEL TANK 96
FUEL TANK MODULE 97
FUEL GAUGE SENDING UNIT 97
FUEL FILTER/WATER SEPARATOR 97
FUEL SHUTDOWN SOLENOID 97
FUEL INJECTION PUMP 98
FUEL INJECTORS 98
FUEL TUBES/LINES/HOSES AND CLAMPS-LOW-PRESSURE TYPE 99
QUICK-CONNECT FITTINGS-LOW PRESSURE TYPE 99
HIGH-PRESSURE FUEL LINES 100
FUEL DRAIN TUBES 100
FUEL HEATER 100
FUEL HEATER RELAY 101
DIAGNOSIS AND TESTING 101
GENERAL INFORMATION 101
VISUAL INSPECTION 101
AIR IN FUEL SYSTEM 104
FUEL HEATER RELAY TEST 104
FUEL INJECTOR TEST 104
FUEL INJECTOR / NEEDLE MOVEMENT SENSOR TEST 105
FUEL INJECTION PUMP TEST 105
FUEL SUPPLY RESTRICTIONS 105
LOW-PRESSURE LINES 105
HIGH-PRESSURE LINES 105
FUEL SHUTDOWN SOLENOID TEST 106
HIGH-PRESSURE FUEL LINE LEAK TEST 106
SERVICE PROCEDURES 106
AIR BLEED PROCEDURES 106
AIR BLEEDING AT FUEL FILTER 106
FUEL INJECTION PUMP BLEEDING 106
HIGH-PRESSURE FUEL LINE BLEEDING 107
FUEL INJECTION PUMP TIMING 107
REMOVAL AND INSTALLATION 107
ACCELERATOR PEDAL 107
REMOVAL 107
INSTALLATION 107
AIR CLEANER ELEMENT 107
REMOVAL 107
INSTALLATION 107
FUEL DRAIN TUBES 108
FUEL FILTER/WATER SEPARATOR 108
DRAINING WATER FROM FILTER BOWL 108
FUEL FILTER REMOVAL 109
FUEL FILTER INSTALLATION 109
FUEL HEATER 109
FUEL HEATER RELAY 109
FUEL LEVEL SENSOR 109
REMOVAL 109
FUEL INJECTION PUMP 109
REMOVAL 109
INSTALLATION/ADJUSTING PUMP TIMING 111
FUEL INJECTORS 113
REMOVAL 113
INSTALLATION 114
FUEL TANK 114
REMOVAL 114
INSTALLATION 115
FUEL RESERVOIR MODULE 115
REMOVAL 115
INSTALLATION 115
HIGH-PRESSURE LINES 116
REMOVAL 116
INSTALLATION 116
SPECIFICATIONS 116
FUEL TANK CAPACITY 116
IDLE SPEED 116
FUEL INJECTOR FIRING SEQUENCE 116
FUEL SYSTEM PRESSURE 116
FUEL INJECTION SYSTEM-2 5L DIESEL ENGINE 117
GENERAL INFORMATION 117
INTRODUCTION 117
DESCRIPTION AND OPERATION 118
POWERTRAIN CONTROL MODULE (PCM) 118
BOOST / PRESSURE SENSOR 119
VEHICLE THEFT ALARM 119
BATTERY VOLTAGE-PCM INPUT 119
SENSOR RETURN-ECM/PCM INPUT (ANALOG GROUND) 119
IGNITION CIRCUIT SENSE-MSA/PCM INPUT 119
IGNITION CIRCUIT SENSE-PCM INPUT 120
POWER GROUND 120
NEEDLE MOVEMENT OR INSTRUMENTED FIRST INJECTOR-ECM INPUT 120
FUEL INJECTOR SENSOR-GROUND 120
ENGINE COOLANT TEMPERATURE SENSOR-ECM/PCM INPUT 120
ENGINE SPEED/CRANK POSITION SENSOR-ECM INPUT 120
AIR CONDITIONING (A/C) CONTROLS-ECM INPUTS 121
BRAKE SWITCH-ECM INPUT 121
DATA LINK CONNECTOR-PCM AND ECM INPUT AND OUTPUT 121
VEHICLE SPEED SENSOR-ECM INPUT 121
SPEED CONTROL-ECM INPUT 122
ASD RELAY-ECM INPUT 122
FIVE VOLT POWER-ECM/PCM OUTPUT 122
ENGINE COOLANT GAUGE-PCM OUTPUT 122
ENGINE OIL PRESSURE GAUGE-PCM OUTPUT 122
GLOW PLUG LAMP-PCM OUTPUT 122
SPEED CONTROL-PCM OUTPUTS 122
AIR CONDITIONING RELAY-ECM OUTPUT 122
TIMING SOLENOID-ECM OUTPUT 123
TACHOMETER-PCM OUTPUT 123
GLOW PLUG RELAY-ECM OUTPUT 123
GLOW PLUGS 124
ELECTRIC VACUUM MODULATOR (EVM)-ECM OUTPUT 124
DIAGNOSIS AND TESTING 124
DIESEL DIAGNOSTICS 124
ASD RELAY TEST 124
ENGINE SPEED SENSOR TEST 124
ENGINE COOLANT TEMPERATURE SENSOR TEST 124
GLOW PLUG TEST 125
GLOW PLUG RELAY TEST 126
RELAYS-OPERATION/TESTING 126
OPERATION 126
TESTING 127
BOOST / PRESSURE SENSOR 127
VEHICLE SPEED SENSOR TEST 128
DIAGNOSTIC TROUBLE CODES 128
REMOVAL AND INSTALLATION 128
ASD RELAY 128
A/C CLUTCH RELAY 128
ENGINE SPEED SENSOR 128
REMOVAL 128
INSTALLATION 128
ENGINE COOLANT TEMPERATURE SENSOR 128
REMOVAL 128
INSTALLATION 128
GLOW PLUGS 128
REMOVAL 128
INSTALLATION 129
GLOW PLUG RELAY 129
REMOVAL 129
INSTALLATION 129
POWERTRAIN CONTROL MODULE (PCM) 129
REMOVAL 129
INSTALLATION 130
VEHICLE SPEED SENSOR 130
REMOVAL 130
INSTALLATION 130
SPECIFICATIONS 131
GLOW PLUG CURRENT DRAW 131
TORQUE CHART-2 5L DIESEL 131
LUBRICATION AND MAINTENANCE 13
GENERAL INFORMATION 13
SPECIFICATIONS 13
ENGINE OIL-DIESEL ENGINES 13
SAE VISCOSITY GRADE 13
FLUID CAPACITIES 13
FUEL TANK 13
ENGINE OIL 13
COOLING SYSTEM 13
MANUAL TRANSMISSION 13
TRANSFER CASE 13
FRONT AXLE 13
REAR AXLE 13
MAINTENANCE SCHEDULE 14
GENERAL INFORMATION 14
MAINTENANCE SCHEDULE-DIESEL ENGINE 14
AT EACH STOP FOR FUEL OR SCHEDULED SERVICE STOP 14
SCHEDULE-A 14
SCHEDULE-B 15
EXHAUST SYSTEM AND TURBOCHARGER 23
GENERAL INFORMATION 23
EXHAUST SYSTEM 23
EXHAUST HEAT SHIELDS 23
REMOVAL AND INSTALLATION 24
EXHAUST PIPE 24
REMOVAL 24
INSTALLATION 24
MUFFLER AND EXHAUST TAILPIPE 24
REMOVAL 24
INSTALLATION 24
EXHAUST MANIFOLD AND TURBOCHARGER (LHD) 25
REMOVAL 25
Cleaning 26
INSTALLATION 26
EXHAUST MANIFOLD AND TURBOCHARGER (RHD) 27
REMOVAL 27
Cleaning 29
INSTALLATION 29
INTAKE MANIFOLD 32
REMOVAL 32
CLEANING 32
INSTALLATION 32
SPECIFICATIONS 32
TORQUE SPECIFICATIONS 32
STEERING 163
TRANSMISSION AND TRANSFER CASE 529
AX15 MANUAL TRANSMISSION 529
GENERAL INFORMATION 529
AX 15 MANUAL TRANSMISSION 529
TRANSMISSION IDENTIFICATION 530
TRANSMISSION SHIFT PATTERN 530
TRANSMISSION LUBRICANT 530
TRANSMISSION SWITCH AND PLUG LOCATIONS 530
TRANSMISSION GEAR RATIOS 531
TRANSMISSION ASSEMBLY INFORMATION 531
DIAGNOSIS AND TESTING 531
LOW LUBRICANT LEVEL 531
HARD SHIFTING 531
TRANSMISSION NOISE 531
REMOVAL AND INSTALLATION 531
TRANSMISSION 531
REMOVAL 531
INSTALLATION 532
SPECIFICATIONS 534
TORQUE 534
NV231 TRANSFER CASE 535
GENERAL INFORMATION 535
NV231 TRANSFER CASE 535
OPERATING RANGES 535
SHIFT MECHANISM 535
TRANSFER CASE IDENTIFICATION 535
RECOMMENDED LUBRICANT AND FILL LEVEL 535
DIAGNOSIS AND TESTING 536
NV231 DIAGNOSIS 536
REMOVAL AND INSTALLATION 537
TRANSFER CASE 537
REMOVAL 537
INSTALLATION 537
SHIFT LEVER 537
REMOVAL 537
INSTALLATION 537
SPEEDOMETER 537
REMOVAL 537
INSTALLATION AND INDEXING 538
FRONT OUTPUT SHAFT SEAL 539
REMOVAL 539
INSTALLATION 539
REAR RETAINER BUSHING AND SEAL 539
REMOVAL 539
INSTALLATION 540
SPECIFICATIONS 540
TORQUE 540
SPECIAL TOOLS 540
SPECIAL TOOLS-NV231 540
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
S.V