2003 Jeep Liberty KJ Service Manual – PDF DOWNLOAD
DESCRIPTION:
2003 Jeep Liberty KJ Service Manual – PDF DOWNLOAD
INTRODUCTION:
FASTENER IDENTIFICATION
DESCRIPTION:
The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face.
DESCRIPTION – FASTENER USAGE:
WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL INJURY.
Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used.
DESCRIPTION – THREADED HOLE REPAIR: Most stripped threaded holes can be repaired using a Helicoilt. Follow the vehicle or Helicoilt recommendations for application and repair procedures.
INTERNATIONAL SYMBOLS DESCRIPTION : The graphic symbols illustrated in the following International Control and Display Symbols Chart (Fig. 3) are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.
TABLE OF CONTENTS:
2003 Jeep Liberty KJ Service Manual – PDF DOWNLOAD
KJ Service Manual.........................................................................................2144 FOREWORD.............................................................................................. 0 GROUP TAB LOCATOR..................................................................................... 1 in-INTRODUCTION....................................................................................... 2 FASTENER IDENTIFICATION........................................................................... 2 DESCRIPTION................................................................................... 2 FASTENER USAGE.................................................................................... 5 DESCRIPTION................................................................................... 5 DESCRIPTION - FASTENER USAGE.............................................................. 5 DESCRIPTION - THREADED HOLE REPAIR........................................................ 5 INTERNATIONAL SYMBOLS............................................................................. 5 DESCRIPTION................................................................................... 5 METRIC SYSTEM..................................................................................... 6 DESCRIPTION................................................................................... 6 TORQUE REFERENCES................................................................................. 8 DESCRIPTION................................................................................... 8 VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL................................................. 9 DESCRIPTION................................................................................... 9 VEHICLE IDENTIFICATION NUMBER..................................................................... 9 DESCRIPTION................................................................................... 9 VEHICLE SAFETY CERTIFICATION LABEL................................................................ 10 DESCRIPTION................................................................................... 10 0-LUBRICATION & MAINTENANCE........................................................................... 12 INTERNATIONAL SYMBOLS............................................................................. 12 DESCRIPTION................................................................................... 12 PARTS & LUBRICANT RECOMMENDATION.................................................................. 12 DESCRIPTION................................................................................... 12 DESCRIPTION - FLUID TYPES................................................................. 12 SAE VISCOSITY RATING.................................................................. 12 API QUALITY CLASSIFICATION............................................................ 13 GEAR LUBRICANTS....................................................................... 13 LUBRICANTS AND GREASES................................................................ 13 SPECIALIZED LUBRICANTS AND OILS....................................................... 13 DESCRIPTION - LUBRICANT RECOMMENDATIONS................................................... 13 Chassis............................................................................... 13 Body.................................................................................. 13 FLUID TYPES....................................................................................... 14 DESCRIPTION................................................................................... 14 DESCRIPTION - FLUID TYPES................................................................. 14 SAE VISCOSITY RATING.................................................................. 14 API QUALITY CLASSIFICATION............................................................ 14 GEAR LUBRICANTS....................................................................... 14 LUBRICANTS AND GREASES................................................................ 14 SPECIALIZED LUBRICANTS AND OILS....................................................... 14 DESCRIPTION - AXLE........................................................................ 14 DESCRIPTION - MANUAL TRANSMISSION......................................................... 15 DESCRIPTION - AUTOMATIC TRANSMISSION FLUID................................................ 15 FLUID ADDITIVES....................................................................... 15 DESCRIPTION - TRANSFER CASE - NV231....................................................... 15 DESCRIPTION - TRANSFER CASE - NV242....................................................... 15 DESCRIPTION - ENGINE COOLANT.............................................................. 15 COOLANT PERFORMANCE................................................................... 16 DESCRIPTION - ENGINE OIL - DIESEL ENGINES................................................. 16 SAE VISCOSITY GRADE................................................................... 16 DESCRIPTION - POWER STEERING FLUID........................................................ 16 OPERATION - AUTOMATIC TRANSMISSION FLUID...................................................... 16 FLUID CAPACITIES.................................................................................. 17 SPECIFICATIONS - FLUID CAPACITIES............................................................. 17 FLUID FILL/CHECK LOCATIONS........................................................................ 17 DESCRIPTION................................................................................... 17 MAINTENANCE SCHEDULES............................................................................. 17 DESCRIPTION................................................................................... 17 Schedule “B”.............................................................................. 18 Schedule “A”.............................................................................. 23 HOISTING.......................................................................................... 25 STANDARD PROCEDURE - HOISTING RECOMMENDATIONS................................................. 25 HOIST..................................................................................... 25 JUMP STARTING..................................................................................... 25 STANDARD PROCEDURE - JUMP STARTING PROCEDURE.................................................. 25 TO JUMP START A DISABLED VEHICLE:......................................................... 26 DISCONNECT CABLE CLAMPS AS FOLLOWS:....................................................... 26 TOWING............................................................................................ 26 STANDARD PROCEDURE - TOWING................................................................... 26 SAFETY PRECAUTIONS........................................................................ 27 TWO-WHEEL-DRIVE VEHICLE TOWING............................................................ 27 TWO WHEEL DRIVE TOWING-REAR END LIFTED.................................................... 27 TWO WHEEL DRIVE TOWING-FRONT END LIFTED................................................... 27 FOUR-WHEEL-DRIVE VEHICLE TOWING........................................................... 27 FOUR WHEEL DRIVE TOWING—REAR END LIFTED................................................... 27 FOUR WHEEL DRIVE TOWING—FRONT END LIFTED.................................................. 28 2-SUSPENSION.......................................................................................... 30 SUSPENSION........................................................................................ 30 DIAGNOSIS AND TESTING - SUSPENSION AND STEERING SYSTEM........................................ 30 WHEEL ALIGNMENT................................................................................... 32 WHEEL ALIGNMENT............................................................................... 32 DESCRIPTION............................................................................... 32 OPERATION................................................................................. 32 STANDARD PROCEDURE........................................................................ 33 STANDARD PROCEDURE - HEIGHT MEASUREMENT............................................... 33 RIDE HEIGHT....................................................................... 33 STANDARD PROCEDURE - CAMBER AND CASTER ADJUSTMENT..................................... 34 STANDARD PROCEDURE - TOE ADJUSTMENT................................................... 34 STANDARD PROCEDURE - CAMBER, CASTER AND TOE ADJUSTMENT................................ 34 CASTER............................................................................ 34 CAMBER............................................................................ 34 TOE ADJUSTMENT.................................................................... 34 SPECIFICATIONS............................................................................ 35 ALIGNMENT............................................................................. 35 FRONT............................................................................. 35 REAR.............................................................................. 35 FRONT............................................................................................. 36 FRONT......................................................................................... 36 DESCRIPTION............................................................................... 36 WARNING................................................................................... 37 SPECIFICATIONS............................................................................ 37 TORQUE CHART.......................................................................... 37 SPECIAL TOOLS............................................................................. 38 FRONT SUSPENSION...................................................................... 38 BUSHINGS...................................................................................... 39 REMOVAL................................................................................... 39 REMOVAL - STABILIZER BAR BUSHINGS..................................................... 39 REMOVAL - LOWER CONTROL ARM BUSHING................................................... 39 REMOVAL - CLEVIS BRACKET BUSHING...................................................... 39 REMOVAL - UPPER CONTROL ARM BUSHINGS.................................................. 39 INSTALLATION.............................................................................. 39 INSTALLATION - STABILIZER BAR BUSHINGS................................................ 39 INSTALLATION - LOWER CONTROL ARM BUSHING.............................................. 40 INSTALLATION - CLEVIS BRACKET BUSHING................................................. 40 INSTALLATION - UPPER CONTROL ARM BUSHINGS............................................. 41 HUB / BEARING................................................................................. 41 REMOVAL................................................................................... 41 INSTALLATION.............................................................................. 41 KNUCKLE....................................................................................... 42 REMOVAL................................................................................... 42 INSTALLATION.............................................................................. 42 LOWER BALL JOINT.............................................................................. 42 DIAGNOSIS AND TESTING - LOWER BALL JOINT.................................................. 42 REMOVAL................................................................................... 43 INSTALLATION.............................................................................. 43 LOWER CONTROL ARM............................................................................. 44 REMOVAL................................................................................... 44 INSTALLATION.............................................................................. 44 SHOCK......................................................................................... 44 REMOVAL................................................................................... 44 REMOVAL - LEFT SIDE................................................................... 44 REMOVAL - RIGHT SIDE.................................................................. 45 INSTALLATION.............................................................................. 45 INSTALLATION - LEFT SIDE.............................................................. 45 INSTALLATION - RIGHT SIDE............................................................. 46 SPRING........................................................................................ 46 REMOVAL................................................................................... 46 INSTALLATION.............................................................................. 46 CLEVIS BRACKET................................................................................ 47 REMOVAL................................................................................... 47 INSTALLATION.............................................................................. 47 STABILIZER BAR................................................................................ 47 REMOVAL................................................................................... 47 INSTALLATION.............................................................................. 47 STABILIZER LINK............................................................................... 48 REMOVAL................................................................................... 48 INSTALLATION.............................................................................. 48 UPPER CONTROL ARM............................................................................. 48 REMOVAL................................................................................... 48 REMOVAL - RIGHT SIDE.................................................................. 48 REMOVAL - LEFT SIDE................................................................... 48 INSTALLATION.............................................................................. 49 INSTALLATION - RIGHT SIDE............................................................. 49 INSTALLATION - LEFT SIDE.............................................................. 49 REAR.............................................................................................. 50 REAR.......................................................................................... 50 DESCRIPTION............................................................................... 50 WARNING................................................................................... 51 DIAGNOSIS AND TESTING - REAR SUSPENSION................................................... 51 SPECIFICATIONS............................................................................ 51 TORQUE CHART.......................................................................... 51 SPECIAL TOOLS............................................................................. 52 REAR SUSPENSION....................................................................... 52 SHOCK......................................................................................... 52 REMOVAL................................................................................... 52 INSTALLATION.............................................................................. 52 SPRING........................................................................................ 53 REMOVAL................................................................................... 53 INSTALLATION.............................................................................. 53 JOUNCE BUMPER................................................................................. 53 REMOVAL................................................................................... 53 INSTALLATION.............................................................................. 53 STABILIZER BAR................................................................................ 53 REMOVAL................................................................................... 53 INSTALLATION.............................................................................. 54 UPPER BALL JOINT.............................................................................. 54 REMOVAL................................................................................... 54 INSTALLATION.............................................................................. 54 UPPER CONTROL ARM............................................................................. 55 DESCRIPTION - UPPER SUSPENSION ARM, BUSHINGS, AND BALL JOINT.............................. 55 OPERATION - UPPER SUSPENSION ARM, BUSHINGS, AND BALL JOINT................................ 55 REMOVAL................................................................................... 55 INSTALLATION.............................................................................. 55 LOWER CONTROL ARM............................................................................. 56 DESCRIPTION............................................................................... 56 OPERATION................................................................................. 56 REMOVAL................................................................................... 56 INSTALLATION.............................................................................. 56 BUSHINGS...................................................................................... 56 REMOVAL................................................................................... 56 REMOVAL - LOWER SUSPENSION ARM BUSHING................................................ 56 REMOVAL - UPPER SUSPENSION ARM BUSHING................................................ 57 INSTALLATION.............................................................................. 57 INSTALLATION - LOWER SUSPENSION ARM BUSHING........................................... 57 INSTALLATION - UPPER SUSPENSION ARM BUSHING........................................... 58 3-DIFFERENTIAL & DRIVELINE............................................................................ 60 PROPELLER SHAFT................................................................................... 60 PROPELLER SHAFT............................................................................... 60 DIAGNOSIS AND TESTING..................................................................... 60 VIBRATION............................................................................. 60 BALANCE............................................................................... 61 RUNOUT................................................................................ 62 STANDARD PROCEDURE........................................................................ 62 STANDARD PROCEDURES................................................................... 62 PROPELLER SHAFT ANGLE............................................................. 62 SPECIFICATIONS............................................................................ 64 SPECIAL TOOLS............................................................................. 65 PROPELLER SHAFT - FRONT....................................................................... 65 REMOVAL................................................................................... 65 REMOVAL - 2.5L DIESEL................................................................. 65 REMOVAL............................................................................... 65 INSTALLATION.............................................................................. 66 INSTALLATION - 2.5L DIESEL............................................................ 66 INSTALLATION.......................................................................... 66 PROPELLER SHAFT - REAR........................................................................ 66 REMOVAL................................................................................... 66 INSTALLATION.............................................................................. 66 SINGLE CARDAN UNIVERSAL JOINTS................................................................ 67 DISASSEMBLY............................................................................... 67 ASSEMBLY.................................................................................. 68 HALF SHAFT........................................................................................ 69 HALF SHAFT.................................................................................... 69 CAUTION................................................................................... 69 DIAGNOSIS AND TESTING..................................................................... 69 NOISE/VIBRATION IN TURNS.............................................................. 69 CLUNKING NOISE DURING ACCELERATION.................................................... 69 SHUDDER/VIBRATION DURING ACCELERATION................................................. 69 VIBRATION AT HIGHWAY SPEEDS........................................................... 69 REMOVAL................................................................................... 69 INSTALLATION.............................................................................. 70 SPECIFICATIONS............................................................................ 70 SPECIAL TOOLS............................................................................. 71 CV JOINT/BOOT-OUTER........................................................................... 71 REMOVAL................................................................................... 71 INSTALLATION.............................................................................. 72 CV JOINT/BOOT-INNER........................................................................... 74 REMOVAL................................................................................... 74 INSTALLATION.............................................................................. 75 FRONT AXLE - 186FIA............................................................................... 77 FRONT AXLE - 186FIA........................................................................... 77 DESCRIPTION............................................................................... 77 OPERATION................................................................................. 77 DIAGNOSIS AND TESTING..................................................................... 78 GEAR NOISE............................................................................ 78 BEARING NOISE......................................................................... 78 LOW SPEED KNOCK....................................................................... 78 VIBRATION............................................................................. 78 DRIVELINE SNAP........................................................................ 78 REMOVAL................................................................................... 81 INSTALLATION.............................................................................. 83 ADJUSTMENTS............................................................................... 83 PINION DEPTH MEASUREMENT.............................................................. 84 DIFFERENTIAL.......................................................................... 85 SHIM SELECTION........................................................................ 85 GEAR CONTACT PATTERN.................................................................. 88 DIFFERENTIAL BEARING PRELOAD CHECK.................................................... 90 SPECIFICATIONS............................................................................ 90 SPECIAL TOOLS............................................................................. 90 AXLE SHAFTS................................................................................... 93 REMOVAL................................................................................... 93 INSTALLATION.............................................................................. 93 AXLE SHAFT SEALS.............................................................................. 94 REMOVAL................................................................................... 94 INSTALLATION.............................................................................. 94 AXLE BEARINGS................................................................................. 94 REMOVAL................................................................................... 94 INSTALLATION.............................................................................. 95 PINION SEAL................................................................................... 95 REMOVAL................................................................................... 95 INSTALLATION.............................................................................. 95 DIFFERENTIAL.................................................................................. 96 REMOVAL................................................................................... 96 DISASSEMBLY............................................................................... 97 ASSEMBLY.................................................................................. 98 INSTALLATION.............................................................................. 98 DIFFERENTIAL CASE BEARINGS.................................................................... 99 REMOVAL................................................................................... 99 INSTALLATION.............................................................................. 99 PINION GEAR/RING GEAR......................................................................... 100 REMOVAL................................................................................... 100 INSTALLATION.............................................................................. 102 REAR AXLE - 8 1/4................................................................................. 105 REAR AXLE - 8 1/4............................................................................. 105 DESCRIPTION............................................................................... 105 OPERATION................................................................................. 105 DIAGNOSIS AND TESTING..................................................................... 105 GEAR NOISE............................................................................ 105 BEARING NOISE......................................................................... 105 LOW SPEED KNOCK....................................................................... 106 VIBRATION............................................................................. 106 DRIVELINE SNAP........................................................................ 106 REMOVAL................................................................................... 108 INSTALLATION.............................................................................. 108 ADJUSTMENTS............................................................................... 109 PINION DEPTH MEASUREMENT.............................................................. 111 DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH........................................ 112 GEAR CONTACT PATTERN.................................................................. 113 SIDE GEAR CLEARANCE................................................................... 114 SPECIFICATIONS............................................................................ 115 SPECIAL TOOLS............................................................................. 115 AXLE SHAFTS................................................................................... 118 REMOVAL................................................................................... 118 INSTALLATION.............................................................................. 119 AXLE SHAFT SEALS.............................................................................. 119 REMOVAL................................................................................... 119 INSTALLATION.............................................................................. 119 AXLE BEARINGS................................................................................. 119 REMOVAL................................................................................... 119 INSTALLATION.............................................................................. 119 PINION SEAL................................................................................... 119 REMOVAL................................................................................... 119 INSTALLATION.............................................................................. 120 DIFFERENTIAL.................................................................................. 121 DESCRIPTION............................................................................... 121 OPERATION................................................................................. 121 REMOVAL................................................................................... 121 DISASSEMBLY............................................................................... 122 ASSEMBLY.................................................................................. 122 INSTALLATION.............................................................................. 123 DIFFERENTIAL - TRAC-LOK....................................................................... 123 DESCRIPTION............................................................................... 123 OPERATION................................................................................. 124 DIAGNOSIS AND TESTING..................................................................... 124 DIFFERENTIAL TEST..................................................................... 124 DISASSEMBLY............................................................................... 124 ASSEMBLY.................................................................................. 126 DIFFERENTIAL CASE BEARINGS.................................................................... 127 REMOVAL................................................................................... 127 INSTALLATION.............................................................................. 128 PINION GEAR/RING GEAR/TONE RING............................................................... 128 REMOVAL................................................................................... 128 INSTALLATION.............................................................................. 130 5-BRAKES.............................................................................................. 134 BRAKES - BASE..................................................................................... 134 BRAKES - BASE................................................................................. 135 DESCRIPTION............................................................................... 135 WARNING................................................................................... 136 DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM................................................. 136 PRELIMINARY BRAKE CHECK............................................................... 136 ROAD TESTING.......................................................................... 136 BRAKE NOISES.......................................................................... 138 STANDARD PROCEDURE........................................................................ 138 STANDARD PROCEDURE - PRESSURE BLEEDING................................................ 138 STANDARD PROCEDURE - MANUAL BLEEDING.................................................. 139 SPECIFICATIONS............................................................................ 139 BRAKE COMPONENTS...................................................................... 139 TORQUE................................................................................ 140 SPECIAL TOOLS............................................................................. 140 BASE BRAKES........................................................................... 140 BRAKE LINES................................................................................... 141 DESCRIPTION............................................................................... 141 DIAGNOSIS AND TESTING - BRAKE LINE AND HOSES.............................................. 141 STANDARD PROCEDURE - DOUBLE INVERTED FLARING.............................................. 141 REMOVAL................................................................................... 142 REMOVAL - FRONT HOSE.................................................................. 142 REMOVAL - REAR BRAKE HOSE............................................................. 142 INSTALLATION.............................................................................. 143 INSTALLATION - FRONT OR REAR BRAKE CALIPER HOSE....................................... 143 INSTALLATION - REAR BRAKE HOSE........................................................ 143 BRAKE PADS / SHOES............................................................................ 143 REMOVAL................................................................................... 143 REMOVAL - FRONT BRAKE PADS............................................................ 143 REMOVAL - REAR DISC BRAKE PADS........................................................ 143 INSTALLATION.............................................................................. 143 INSTALLATION - FRONT BRAKE PADS....................................................... 143 INSTALLATION - REAR DISC BRAKE PADS................................................... 143 DISC BRAKE CALIPERS........................................................................... 144 DESCRIPTION............................................................................... 144 OPERATION................................................................................. 144 REMOVAL................................................................................... 145 REMOVAL - FRONT....................................................................... 145 REMOVAL - REAR........................................................................ 145 DISASSEMBLY............................................................................... 145 CLEANING.................................................................................. 146 INSPECTION................................................................................ 146 ASSEMBLY.................................................................................. 147 INSTALLATION.............................................................................. 148 INSTALLATION - FRONT.................................................................. 148 INSTALLATION - REAR................................................................... 148 DISC BRAKE CALIPER ADAPTER.................................................................... 149 REMOVAL................................................................................... 149 INSTALLATION.............................................................................. 149 ROTORS........................................................................................ 149 DIAGNOSIS AND TESTING..................................................................... 149 DIAGNOSIS AND TESTING - DISC BRAKE ROTOR.............................................. 149 ROTOR MINIMUM THICKNESS........................................................... 149 ROTOR RUNOUT...................................................................... 149 ROTOR THICKNESS VARIATION......................................................... 150 DIAGNOSIS AND TESTING - BRAKE DRUM IN HAT ROTOR....................................... 150 BRAKE DRUM RUNOUT................................................................. 150 STANDARD PROCEDURE........................................................................ 150 STANDARD PROCEDURE - DISC BRAKE ROTOR................................................. 150 STANDARD PROCEDURE - BRAKE DRUM IN HAT ROTOR MACHINING................................ 150 REMOVAL................................................................................... 151 REMOVAL - FRONT....................................................................... 151 REMOVAL - REAR........................................................................ 151 INSTALLATION.............................................................................. 151 INSTALLATION - FRONT.................................................................. 151 INSTALLATION - REAR................................................................... 151 BRAKE JUNCTION BLOCK.......................................................................... 152 DESCRIPTION............................................................................... 152 OPERATION................................................................................. 152 PROPORTIONING VALVE................................................................... 152 DIAGNOSIS AND TESTING - PROPORTIONING VALVE............................................... 152 REMOVAL................................................................................... 152 INSTALLATION.............................................................................. 152 PEDAL......................................................................................... 152 DESCRIPTION............................................................................... 152 OPERATION................................................................................. 152 REMOVAL................................................................................... 152 INSTALLATION.............................................................................. 152 POWER BRAKE BOOSTER........................................................................... 153 DESCRIPTION............................................................................... 153 OPERATION................................................................................. 153 DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER..................................... 154 POWER BOOSTER VACUUM TEST............................................................. 154 POWER BOOSTER CHECK VALVE TEST........................................................ 154 REMOVAL................................................................................... 155 REMOVAL - LHD......................................................................... 155 REMOVAL - RHD......................................................................... 155 INSTALLATION.............................................................................. 156 INSTALLATION - LHD.................................................................... 156 INSTALLATION - RHD.................................................................... 156 MASTER CYLINDER............................................................................... 157 DESCRIPTION............................................................................... 157 OPERATION................................................................................. 157 DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER..................................... 157 POWER BOOSTER VACUUM TEST............................................................. 157 POWER BOOSTER CHECK VALVE TEST........................................................ 158 STANDARD PROCEDURE - MASTER CYLINDER BLEEDING............................................. 158 REMOVAL................................................................................... 158 INSTALLATION.............................................................................. 158 FLUID RESERVOIR............................................................................... 159 REMOVAL................................................................................... 159 INSTALLATION.............................................................................. 159 FLUID......................................................................................... 159 DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION......................................... 159 STANDARD PROCEDURE - MASTER CYLINDER FLUID LEVEL.......................................... 159 SPECIFICATIONS............................................................................ 159 BRAKE FLUID........................................................................... 159 SUPPORT PLATE................................................................................. 160 REMOVAL................................................................................... 160 INSTALLATION.............................................................................. 160 PARKING BRAKE................................................................................. 160 DESCRIPTION............................................................................... 160 OPERATION................................................................................. 161 ADJUSTMENTS............................................................................... 161 ADJUSTMENT - LOCK OUT................................................................. 161 CABLES........................................................................................ 161 REMOVAL................................................................................... 161 INSTALLATION.............................................................................. 162 LEVER......................................................................................... 162 REMOVAL................................................................................... 162 INSTALLATION.............................................................................. 162 SHOES......................................................................................... 163 DESCRIPTION............................................................................... 163 OPERATION................................................................................. 163 REMOVAL................................................................................... 163 CLEANING - REAR DRUM IN HAT BRAKE......................................................... 163 INSPECTION - REAR DRUM IN HAT BRAKE....................................................... 164 INSTALLATION.............................................................................. 164 ADJUSTMENTS............................................................................... 165 ADJUSTMENT - REAR DRUM IN HAT PARK BRAKE (ROTOR REMOVED).............................. 165 ADJUSTMENT - WITH ADJUSTING TOOL...................................................... 166 ADJUSTMENT - REAR DRUM IN HAT PARK BRAKE (ROTOR REMOVED).............................. 166 BRAKES - ABS...................................................................................... 169 BRAKES - ABS.................................................................................. 169 DESCRIPTION............................................................................... 169 ANTILOCK BRAKING SYSTEM............................................................... 169 ELECTRONIC BRAKE DISTRIBUTION......................................................... 169 OPERATION................................................................................. 169 ANTILOCK BRAKING SYSTEM............................................................... 169 ELECTRONIC BRAKE DISTRIBUTION......................................................... 169 DIAGNOSIS AND TESTING - ANTILOCK BRAKING SYSTEM........................................... 170 STANDARD PROCEDURE - ABS BRAKE BLEEDING................................................... 170 SPECIFICATIONS............................................................................ 170 ELECTRICAL.................................................................................... 171 DESCRIPTION............................................................................... 171 OPERATION................................................................................. 171 FRONT WHEEL SPEED SENSOR...................................................................... 171 REMOVAL................................................................................... 171 INSTALLATION.............................................................................. 171 REAR WHEEL SPEED SENSOR....................................................................... 172 REMOVAL................................................................................... 172 INSTALLATION.............................................................................. 172 HCU (HYDRAULIC CONTROL UNIT).................................................................. 172 DESCRIPTION............................................................................... 172 OPERATION................................................................................. 172 PRESSURE DECREASE..................................................................... 172 PRESSURE HOLD......................................................................... 172 PRESSURE INCREASE..................................................................... 172 REMOVAL................................................................................... 172 INSTALLATION.............................................................................. 173 6-CLUTCH.............................................................................................. 174 CLUTCH............................................................................................ 174 DESCRIPTION................................................................................... 174 OPERATION..................................................................................... 174 WARNING....................................................................................... 175 DIAGNOSIS AND TESTING - CLUTCH................................................................ 175 CLUTCH CONTAMINATION...................................................................... 175 IMPROPER RELEASE OR CLUTCH ENGAGEMENT..................................................... 175 CLUTCH MISALIGNMENT....................................................................... 175 PRESSURE PLATE AND DISC RUNOUT............................................................ 175 FLYWHEEL RUNOUT........................................................................... 175 DIAGNOSIS CHART........................................................................... 176 SPECIFICATIONS................................................................................ 178 SPECIFICATIONS............................................................................ 178 SPECIFICATIONS - 2.5L DIESEL.............................................................. 179 CLUTCH DISC....................................................................................... 179 REMOVAL....................................................................................... 179 INSTALLATION.................................................................................. 179 INSTALLATION.............................................................................. 179 INSTALLATION - 2.5L DIESEL................................................................ 180 CLUTCH RELEASE BEARING............................................................................ 180 REMOVAL....................................................................................... 180 INSTALLATION.................................................................................. 180 FLYWHEEL.......................................................................................... 181 DESCRIPTION................................................................................... 181 STANDARD FLYWHEEL......................................................................... 181 DUAL MASS FLYWHEEL........................................................................ 181 OPERATION..................................................................................... 181 DIAGNOSIS AND TESTING - FLYWHEEL.............................................................. 182 PILOT BEARING..................................................................................... 182 REMOVAL....................................................................................... 182 INSTALLATION.................................................................................. 182 LINKAGE........................................................................................... 182 REMOVAL....................................................................................... 182 INSTALLATION.................................................................................. 183 MASTER CYLINDER................................................................................... 183 INSPECTION.................................................................................... 183 CLUTCH PEDAL...................................................................................... 184 REMOVAL....................................................................................... 184 INSTALLATION.................................................................................. 184 CLUTCH SWITCH OVERRIDE RELAY...................................................................... 184 DESCRIPTION................................................................................... 184 OPERATION..................................................................................... 184 REMOVAL....................................................................................... 184 INSTALLATION.................................................................................. 184 CLUTCH PEDAL POSITION SWITCH...................................................................... 185 DESCRIPTION................................................................................... 185 OPERATION..................................................................................... 185 DIAGNOSIS AND TESTING - CLUTCH PEDAL POSITION SWITCH.......................................... 185 REMOVAL....................................................................................... 185 INSTALLATION.................................................................................. 185 7-COOLING............................................................................................. 186 COOLING........................................................................................... 186 DESCRIPTION................................................................................... 186 DESCRIPTION - COOLING SYSTEM 2.4L ENGINE.................................................. 186 DESCRIPTION - COOLING SYSTEM 3.7L ENGINE.................................................. 186 DESCRIPTION - COOLING SYSTEM ROUTING 3.7L ENGINE.......................................... 186 DESCRIPTION - HOSE CLAMPS................................................................. 187 OPERATION..................................................................................... 188 OPERATION - COOLING SYSTEM................................................................ 188 OPERATION - HOSE CLAMPS................................................................... 188 DIAGNOSIS AND TESTING......................................................................... 188 DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTICS (OBD)........................................ 188 COOLING SYSTEM RELATED DIAGNOSTICS.................................................... 188 ACCESSING DIAGNOSTIC TROUBLE CODES.................................................... 188 ERASING TROUBLE CODES................................................................. 188 DIAGNOSIS AND TESTING - PRELIMINARY CHECKS................................................ 188 ENGINE COOLING SYSTEM OVERHEATING..................................................... 188 DIAGNOSIS AND TESTING - COOLING SYSTEM LEAKS.............................................. 189 ULTRAVIOLET LIGHT METHOD.............................................................. 189 PRESSURE TESTER METHOD................................................................ 189 INTERNAL LEAKAGE INSPECTION........................................................... 190 COMBUSTION LEAKAGE TEST - WITHOUT PRESSURE TESTER..................................... 190 DIAGNOSIS AND TESTING - COOLING SYSTEM DIAGNOSIS CHART.................................... 191 STANDARD PROCEDURE............................................................................ 197 STANDARD PROCEDURE - DRAINING COOLING SYSTEM.............................................. 197 STANDARD PROCEDURE - REFILLING COOLING SYSTEM............................................. 197 STANDARD PROCEDURE - COOLING SYSTEM - REVERSE FLUSHING.................................... 197 CHEMICAL CLEANING..................................................................... 198 REVERSE FLUSHING RADIATOR............................................................. 198 REVERSE FLUSHING ENGINE............................................................... 198 SPECIFICATIONS................................................................................ 198 TORQUE.................................................................................... 198 SPECIAL TOOLS................................................................................. 199 COOLING................................................................................... 199 ACCESSORY DRIVE................................................................................... 200 ACCESSORY DRIVE............................................................................... 200 DIAGNOSIS AND TESTING - SERPENTINE DRIVE BELT DIAGNOSIS................................... 200 BELT TENSIONERS............................................................................... 202 REMOVAL................................................................................... 202 REMOVAL - 3.7L ENGINE................................................................. 202 REMOVAL - 2.4L ENGINE................................................................. 202 INSTALLATION.............................................................................. 203 INSTALLATION - 3.7L ENGINE............................................................ 203 INSTALLATION - 2.4L ENGINE............................................................ 203 DRIVE BELTS -2.4L............................................................................. 203 REMOVAL - 2.4L ENGINE..................................................................... 203 INSTALLATION - 2.4L ENGINE................................................................ 203 DRIVE BELTS - 3.7L............................................................................ 204 REMOVAL - 3.7L ENGINE..................................................................... 204 INSTALLATION - 3.7L ENGINE................................................................ 205 ENGINE............................................................................................ 206 COOLANT....................................................................................... 207 DESCRIPTION............................................................................... 207 DESCRIPTION - HOAT COOLANT............................................................ 207 COOLANT PERFORMANCE............................................................... 207 COOLANT SELECTION AND ADDITIVES................................................... 207 DESCRIPTION - ENGINE COOLANT.......................................................... 208 ETHYLENE-GLYCOL MIXTURES.......................................................... 208 PROPYLENE-GLYCOL MIXTURES......................................................... 208 OPERATION................................................................................. 208 COOLANT RECOVERY PRESS CONTAINER.............................................................. 208 DESCRIPTION............................................................................... 208 OPERATION................................................................................. 208 REMOVAL................................................................................... 209 INSTALLATION.............................................................................. 209 ENGINE BLOCK HEATER........................................................................... 209 DESCRIPTION............................................................................... 209 OPERATION................................................................................. 209 REMOVAL................................................................................... 209 REMOVAL - 2.4L........................................................................ 209 REMOVAL - 3.7L........................................................................ 209 INSTALLATION.............................................................................. 209 INSTALLATION - 2.4L................................................................... 209 INSTALLATION - 3.7L................................................................... 210 ENGINE COOLANT TEMPERATURE SENSOR............................................................. 210 DESCRIPTION............................................................................... 210 OPERATION................................................................................. 210 REMOVAL................................................................................... 211 2.4L.................................................................................. 211 3.7L.................................................................................. 211 INSTALLATION.............................................................................. 211 ENGINE COOLANT THERMOSTAT..................................................................... 211 DESCRIPTION - 3.7L ENGINE................................................................. 211 OPERATION................................................................................. 212 DIAGNOSIS AND TESTING - THERMOSTAT........................................................ 212 ON-BOARD DIAGNOSTICS.................................................................. 212 REMOVAL................................................................................... 212 REMOVAL - 3.7L ENGINE................................................................. 212 REMOVAL............................................................................... 212 INSTALLATION.............................................................................. 212 INSTALLATION - 3.7L ENGINE............................................................ 212 INSTALLATION.......................................................................... 213 FAN DRIVE VISCOUS CLUTCH...................................................................... 213 DESCRIPTION............................................................................... 213 OPERATION................................................................................. 213 DIAGNOSIS AND TESTING..................................................................... 214 VISCOUS FAN DRIVE..................................................................... 214 NOISE............................................................................. 214 LEAKS............................................................................. 215 TESTING........................................................................... 215 REMOVAL................................................................................... 215 INSTALLATION.............................................................................. 216 RADIATOR...................................................................................... 216 DESCRIPTION............................................................................... 216 REMOVAL................................................................................... 217 REMOVAL............................................................................... 217 REMOVAL............................................................................... 218 CLEANING.................................................................................. 220 INSPECTION................................................................................ 220 INSTALLATION.............................................................................. 220 INSTALLATION.......................................................................... 220 INSTALLATION.......................................................................... 220 RADIATOR PRESSURE CAP......................................................................... 221 DESCRIPTION............................................................................... 221 OPERATION................................................................................. 221 DIAGNOSIS AND TESTING - RADIATOR PRESSURE CAP............................................. 221 CLEANING.................................................................................. 221 INSPECTION................................................................................ 221 RADIATOR FAN - ELECTRIC....................................................................... 222 DESCRIPTION............................................................................... 222 OPERATION................................................................................. 222 REMOVAL................................................................................... 222 REMOVAL............................................................................... 222 REMOVAL............................................................................... 223 INSTALLATION.............................................................................. 223 INSTALLATION.......................................................................... 223 INSTALLATION.......................................................................... 223 RADIATOR - FAN - VISCOUS...................................................................... 223 DESCRIPTION............................................................................... 223 OPERATION................................................................................. 224 DIAGNOSIS AND TESTING - VISCOUS FAN DRIVE................................................. 224 REMOVAL................................................................................... 224 CLEANING0 - 2 KJ (Continued).......................................................... 225 INSPECTION................................................................................ 225 INSTALLATION.............................................................................. 225 THERMOSTAT HOUSING............................................................................ 225 REMOVAL................................................................................... 225 INSTALLATION.............................................................................. 226 WATER PUMP - 2.4L............................................................................. 226 DESCRIPTION............................................................................... 226 OPERATION................................................................................. 226 REMOVAL - 2.4L ENGINE..................................................................... 226 INSPECTION................................................................................ 227 INSTALLATION - 2.4L ENGINE................................................................ 227 WATER PUMP - 3.7L............................................................................. 228 DESCRIPTION............................................................................... 228 DESCRIPTION - WATER PUMP.............................................................. 228 DESCRIPTION - WATER PUMP BYPASS....................................................... 228 OPERATION - WATER PUMP.................................................................... 228 REMOVAL................................................................................... 228 REMOVAL............................................................................... 228 REMOVAL — 2.4L........................................................................ 229 CLEANING.................................................................................. 230 INSPECTION................................................................................ 230 INSTALLATION.............................................................................. 230 INSTALLATION.......................................................................... 230 INSTALLATION.......................................................................... 231 TRANSMISSION...................................................................................... 232 TRANS COOLER.................................................................................. 232 DESCRIPTION............................................................................... 232 8a-AUDIO.............................................................................................. 234 AUDIO............................................................................................. 234 DESCRIPTION................................................................................... 234 OPERATION..................................................................................... 235 DIAGNOSIS AND TESTING - AUDIO................................................................. 235 AMPLIFIER CHOKE AND RELAY......................................................................... 237 DESCRIPTION................................................................................... 237 OPERATION..................................................................................... 237 DIAGNOSIS AND TESTING - AMPLIFIER CHOKE AND RELAY............................................. 237 REMOVAL....................................................................................... 238 INSTALLATION.................................................................................. 238 ANTENNA BODY & CABLE.............................................................................. 238 DESCRIPTION................................................................................... 238 DOMESTIC.................................................................................. 238 EXPORT.................................................................................... 238 OPERATION..................................................................................... 238 DIAGNOSIS AND TESTING - ANTENNA BODY AND CABLE................................................ 239 TEST 1.................................................................................... 239 TEST 2.................................................................................... 239 TEST 3.................................................................................... 239 TEST 4.................................................................................... 240 REMOVAL....................................................................................... 240 DOMESTIC.................................................................................. 240 EXPORT.................................................................................... 240 INSTALLATION.................................................................................. 241 DOMESTIC.................................................................................. 241 EXPORT.................................................................................... 241 ANTENNA MODULE.................................................................................... 242 DESCRIPTION................................................................................... 242 OPERATION..................................................................................... 242 DIAGNOSIS AND TESTING - ANTENNA MODULE........................................................ 242 REMOVAL....................................................................................... 243 INSTALLATION.................................................................................. 243 CD CHANGER........................................................................................ 243 DESCRIPTION................................................................................... 243 OPERATION..................................................................................... 243 REMOVAL....................................................................................... 244 INSTALLATION.................................................................................. 244 INSTRUMENT PANEL ANTENNA CABLE.................................................................... 244 REMOVAL....................................................................................... 244 DOMESTIC.................................................................................. 244 EXPORT.................................................................................... 245 INSTALLATION.................................................................................. 245 DOMESTIC.................................................................................. 245 EXPORT.................................................................................... 246 QUARTER GLASS INTEGRAL ANTENNA.................................................................... 246 DESCRIPTION................................................................................... 246 OPERATION..................................................................................... 246 DIAGNOSIS AND TESTING - QUARTER GLASS INTEGRAL ANTENNA........................................ 246 RADIO............................................................................................. 246 DESCRIPTION................................................................................... 246 OPERATION..................................................................................... 247 REMOVAL....................................................................................... 247 INSTALLATION.................................................................................. 247 RADIO NOISE SUPPRESSION GROUND STRAP.............................................................. 247 DESCRIPTION................................................................................... 247 OPERATION..................................................................................... 248 REMOVAL....................................................................................... 248 2.4L ENGINE............................................................................... 248 2.5L ENGINE............................................................................... 249 3.7L ENGINE............................................................................... 249 INSTALLATION.................................................................................. 249 2.4L ENGINE............................................................................... 249 2.5L ENGINE............................................................................... 249 3.7L ENGINE............................................................................... 249 REMOTE SWITCHES................................................................................... 250 DESCRIPTION................................................................................... 250 OPERATION..................................................................................... 250 DIAGNOSIS AND TESTING - REMOTE SWITCHES....................................................... 250 REMOVAL....................................................................................... 251 INSTALLATION.................................................................................. 252 SPEAKER........................................................................................... 252 DESCRIPTION................................................................................... 252 STANDARD.................................................................................. 252 PREMIUM................................................................................... 252 OPERATION..................................................................................... 252 DIAGNOSIS AND TESTING - SPEAKER............................................................... 253 REMOVAL....................................................................................... 253 FRONT DOOR................................................................................ 253 INSTRUMENT PANEL.......................................................................... 254 REAR DOOR................................................................................. 254 INSTALLATION.................................................................................. 254 FRONT DOOR................................................................................ 254 INSTRUMENT PANEL.......................................................................... 254 REAR DOOR................................................................................. 254 8b-CHIME/BUZZER....................................................................................... 256 CHIME WARNING SYSTEM.............................................................................. 256 DESCRIPTION................................................................................... 256 OPERATION..................................................................................... 256 DIAGNOSIS AND TESTING - CHIME WARNING SYSTEM.................................................. 260 8e-ELECTRONIC CONTROL MODULES......................................................................... 262 ELECTRONIC CONTROL MODULES........................................................................ 262 STANDARD PROCEDURE - PCM/SKIM PROGRAMMING..................................................... 262 PROGRAMMING THE PCM (JTEC)................................................................ 262 PROGRAMMING THE SKIM...................................................................... 263 PROGRAMMING IGNITION KEYS TO THE SKIM..................................................... 263 BODY CONTROL MODULE............................................................................... 263 DESCRIPTION................................................................................... 263 OPERATION..................................................................................... 266 DIAGNOSIS AND TESTING - BODY CONTROL MODULE................................................... 268 REMOVAL....................................................................................... 268 INSTALLATION.................................................................................. 269 COMMUNICATION..................................................................................... 269 DESCRIPTION................................................................................... 269 OPERATION..................................................................................... 270 CONTROLLER ANTILOCK BRAKE......................................................................... 271 DESCRIPTION................................................................................... 271 OPERATION..................................................................................... 271 REMOVAL....................................................................................... 271 INSTALLATION.................................................................................. 271 DATA LINK CONNECTOR............................................................................... 272 DESCRIPTION - DATA LINK CONNECTOR............................................................. 272 OPERATION - DATA LINK CONNECTOR............................................................... 272 POWERTRAIN CONTROL MODULE......................................................................... 272 DESCRIPTION................................................................................... 272 DESCRIPTION - PCM......................................................................... 272 DESCRIPTION - MODES OF OPERATION.......................................................... 272 ...................................................................................... 274 DESCRIPTION - 5 VOLT SUPPLIES............................................................. 275 DESCRIPTION - IGNITION CIRCUIT SENSE...................................................... 275 DESCRIPTION - POWER GROUNDS............................................................... 275 DESCRIPTION - SENSOR RETURN............................................................... 275 OPERATION..................................................................................... 275 OPERATION - PCM........................................................................... 275 OPERATION - 5 VOLT SUPPLIES............................................................... 276 OPERATION - IGNITION CIRCUIT SENSE........................................................ 276 REMOVAL....................................................................................... 276 INSTALLATION.................................................................................. 277 SENTRY KEY IMMOBILIZER MODULE..................................................................... 277 DESCRIPTION................................................................................... 277 OPERATION..................................................................................... 277 REMOVAL....................................................................................... 278 INSTALLATION.................................................................................. 279 TRANSMISSION CONTROL MODULE....................................................................... 279 DESCRIPTION................................................................................... 279 OPERATION..................................................................................... 280 BATTERY FEED.............................................................................. 280 CLUTCH VOLUME INDEXES (CVI)............................................................... 280 SHIFT SCHEDULES........................................................................... 281 STANDARD PROCEDURE............................................................................ 283 STANDARD PROCEDURE - TCM QUICK LEARN...................................................... 283 STANDARD PROCEDURE - DRIVE LEARN - RFE TRANSMISSIONS ONLY................................. 284 LEARN A SMOOTH 1ST NEUTRAL TO DRIVE SHIFT............................................. 284 LEARN A SMOOTH NEUTRAL TO DRIVE GARAGE SHIFT.......................................... 284 LEARN THE 1ST 2-3 SHIFT AFTER A RESTART OR SHIFT TO REVERSE........................... 284 LEARN A SMOOTH 2-3 AND 3-4 UPSHIFT.................................................... 284 LEARN A SMOOTH 4-3 COASTDOWN AND PART THROTTLE 4-3 KICKDOWN........................... 285 LEARN A SMOOTH 1-2 UPSHIFT AND 3-2 KICKDOWN........................................... 285 LEARN A SMOOTH MANUAL 2-1 PULLDOWN SHIFT AS WELL AS A NEUTRAL TO REVERSE SHIFT........ 285 LEARN A SMOOTH NEUTRAL TO REVERSE SHIFT............................................... 285 HEATED SEAT MODULE................................................................................ 285 DESCRIPTION................................................................................... 285 OPERATION..................................................................................... 286 DIAGNOSIS AND TESTING - HEATED SEAT MODULE.................................................... 286 RIGHT SEAT HEATER INOPERATIVE............................................................. 286 LEFT SEAT HEATER INOPERATIVE.............................................................. 287 BOTH SEATS INOPERATIVE.................................................................... 288 REMOVAL....................................................................................... 288 INSTALLATION.................................................................................. 288 8f-ENGINE SYSTEMS..................................................................................... 290 BATTERY SYSTEM.................................................................................... 290 BATTERY SYSTEM................................................................................ 290 DESCRIPTION............................................................................... 290 OPERATION................................................................................. 291 DIAGNOSIS AND TESTING - BATTERY SYSTEM.................................................... 291 MICRO 420 BATTERY TESTER.............................................................. 291 ABNORMAL BATTERY DISCHARGING.......................................................... 293 CLEANING.................................................................................. 294 INSPECTION................................................................................ 294 SPECIFICATIONS............................................................................ 295 BATTERY....................................................................................... 296 DESCRIPTION............................................................................... 296 OPERATION................................................................................. 296 DIAGNOSIS AND TESTING - BATTERY........................................................... 297 STANDARD PROCEDURE........................................................................ 298 STANDARD PROCEDURE - BATTERY CHARGING................................................. 298 CHARGING A COMPLETELY DISCHARGED BATTERY.......................................... 298 CHARGING TIME REQUIRED............................................................ 299 STANDARD PROCEDURE - BUILT-IN INDICATOR TEST.......................................... 299 STANDARD PROCEDURE - HYDROMETER TEST.................................................. 300 STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST........................................ 301 STANDARD PROCEDURE - IGNITION-OFF DRAW TEST........................................... 302 STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER................................... 303 BATTERY TESTING................................................................... 303 REMOVAL................................................................................... 304 INSTALLATION.............................................................................. 304 BATTERY HOLDDOWN.............................................................................. 305 DESCRIPTION............................................................................... 305 OPERATION................................................................................. 305 REMOVAL................................................................................... 305 INSTALLATION.............................................................................. 305 BATTERY CABLES................................................................................ 306 DESCRIPTION............................................................................... 306 OPERATION................................................................................. 306 DIAGNOSIS AND TESTING - BATTERY CABLES.................................................... 306 VOLTAGE DROP TEST..................................................................... 307 THERMAL GUARD................................................................................. 308 DESCRIPTION............................................................................... 308 OPERATION................................................................................. 308 REMOVAL................................................................................... 308 INSTALLATION.............................................................................. 309 BATTERY TRAY.................................................................................. 309 DESCRIPTION............................................................................... 309 OPERATION................................................................................. 309 REMOVAL................................................................................... 309 INSTALLATION.............................................................................. 309 CHARGING SYSTEM................................................................................... 310 CHARGING SYSTEM............................................................................... 310 DESCRIPTION............................................................................... 310 OPERATION................................................................................. 310 DIAGNOSIS AND TESTING - CHARGING SYSTEM................................................... 311 SPECIFICATIONS............................................................................ 311 TORQUE - EXCEPT DIESEL................................................................ 311 GENERATOR RATINGS - GAS ENGINES....................................................... 312 SPECIAL TOOLS............................................................................. 312 BATTERY TEMPERATURE SENSOR.................................................................... 312 DESCRIPTION............................................................................... 312 OPERATION................................................................................. 312 REMOVAL................................................................................... 312 INSTALLATION.............................................................................. 312 GENERATOR..................................................................................... 313 DESCRIPTION............................................................................... 313 OPERATION................................................................................. 313 REMOVAL................................................................................... 313 INSTALLATION.............................................................................. 313 GENERATOR DECOUPLER PULLEY.................................................................... 315 DESCRIPTION............................................................................... 315 OPERATION................................................................................. 315 DIAGNOSIS AND TESTING - GENERATOR DECOUPLER............................................... 315 REMOVAL................................................................................... 315 INSTALLATION.............................................................................. 317 VOLTAGE REGULATOR............................................................................. 319 DESCRIPTION............................................................................... 319 OPERATION................................................................................. 319 STARTING SYSTEM................................................................................... 320 STARTING SYSTEM............................................................................... 320 DESCRIPTION............................................................................... 320 OPERATION................................................................................. 320 DIAGNOSIS AND TESTING - STARTING SYSTEM................................................... 321 INSPECTION............................................................................ 322 TESTING............................................................................... 323 INSPECTION - STARTING SYSTEM.............................................................. 325 SPECIFICATIONS............................................................................ 326 TORQUE - GAS POWERED.................................................................. 326 STARTER MOTOR - GAS POWERED........................................................... 327 STARTER MOTOR................................................................................. 327 DIAGNOSIS AND TESTING - STARTER MOTOR..................................................... 327 REMOVAL................................................................................... 328 2.4L 4–Cylinder....................................................................... 328 3.7L V-6.............................................................................. 328 INSTALLATION.............................................................................. 329 2.4L 4–Cylinder....................................................................... 329 3.7L V-6.............................................................................. 329 STARTER MOTOR RELAY........................................................................... 329 DESCRIPTION............................................................................... 329 OPERATION................................................................................. 330 DIAGNOSIS AND TESTING - STARTER RELAY..................................................... 330 RELAY TEST............................................................................ 330 RELAY CIRCUIT TEST.................................................................... 330 REMOVAL................................................................................... 331 INSTALLATION.............................................................................. 331 8g-HEATED SYSTEMS..................................................................................... 332 HEATED MIRRORS.................................................................................... 332 HEATED MIRRORS................................................................................ 332 DESCRIPTION............................................................................... 332 OPERATION................................................................................. 332 DIAGNOSIS AND TESTING - HEATED MIRRORS.................................................... 332 WINDOW DEFOGGER................................................................................... 334 WINDOW DEFOGGER............................................................................... 334 DESCRIPTION - REAR WINDOW DEFOGGER........................................................ 334 OPERATION - REAR WINDOW DEFOGGER.......................................................... 334 DIAGNOSIS AND TESTING - REAR WINDOW DEFOGGER SYSTEM....................................... 334 STANDARD PROCEDURE - REAR GLASS HEATING GRID REPAIR....................................... 335 REAR WINDOW DEFOGGER GRID..................................................................... 336 DESCRIPTION............................................................................... 336 OPERATION................................................................................. 336 DIAGNOSIS AND TESTING - REAR WINDOW DEFOGGER GRID......................................... 336 REAR WINDOW DEFOGGER RELAY.................................................................... 337 DESCRIPTION............................................................................... 337 OPERATION................................................................................. 337 DIAGNOSIS AND TESTING - REAR WINDOW DEFOGGER RELAY........................................ 337 RELAY TEST............................................................................ 337 RELAY CIRCUIT TEST.................................................................... 338 REMOVAL................................................................................... 338 INSTALLATION.............................................................................. 338 REAR WINDOW DEFOGGER SWITCH................................................................... 339 DESCRIPTION............................................................................... 339 OPERATION................................................................................. 339 DIAGNOSIS AND TESTING..................................................................... 339 DIAGNOSIS AND TESTING - REAR WINDOW DEFOGGER SWITCH................................... 339 DIAGNOSIS AND TESTING - REAR HVAC CONTROL ASSEMBLY WINDOW DEFOGGER FUNCTION........... 340 REMOVAL................................................................................... 340 INSTALLATION.............................................................................. 340 HEATED SEAT SYSTEM................................................................................ 341 HEATED SEAT SYSTEM............................................................................ 341 DESCRIPTION............................................................................... 341 OPERATION................................................................................. 341 DIAGNOSIS AND TESTING - HEATED SEAT SYSTEM................................................ 342 HEATED SEAT SYSTEM SELF-DIAGNOSIS..................................................... 342 HEATED SEAT SYSTEM TESTING............................................................ 342 DRIVER HEATED SEAT SWITCH..................................................................... 343 DESCRIPTION............................................................................... 343 OPERATION................................................................................. 343 DIAGNOSIS AND TESTING - DRIVER HEATED SEAT SWITCH......................................... 343 REMOVAL................................................................................... 344 INSTALLATION.............................................................................. 344 PASSENGER HEATED SEAT SWITCH.................................................................. 344 DESCRIPTION............................................................................... 344 OPERATION................................................................................. 344 DIAGNOSIS AND TESTING - PASSENGER HEATED SEAT SWITCH...................................... 344 REMOVAL................................................................................... 345 INSTALLATION.............................................................................. 345 HEATED SEAT ELEMENT........................................................................... 345 DESCRIPTION............................................................................... 345 OPERATION................................................................................. 345 DIAGNOSIS AND TESTING - HEATED SEAT ELEMENT............................................... 346 SEAT CUSHION ELEMENT.................................................................. 346 SEAT BACK ELEMENT..................................................................... 346 HEATED SEAT SENSOR............................................................................ 346 DESCRIPTION............................................................................... 346 OPERATION................................................................................. 346 DIAGNOSIS AND TESTING - HEATED SEAT SENSOR................................................ 346 REMOVAL................................................................................... 347 8h-HORN............................................................................................... 348 HORN SYSTEM....................................................................................... 348 DESCRIPTION................................................................................... 348 OPERATION..................................................................................... 348 DIAGNOSIS AND TESTING - HORN SYSTEM........................................................... 348 HORN.............................................................................................. 349 DIAGNOSIS AND TESTING - HORN.................................................................. 349 REMOVAL....................................................................................... 350 INSTALLATION.................................................................................. 350 HORN RELAY........................................................................................ 350 DIAGNOSIS AND TESTING - HORN RELAY............................................................ 350 REMOVAL....................................................................................... 350 INSTALLATION.................................................................................. 351 HORN SWITCH....................................................................................... 351 DESCRIPTION................................................................................... 351 DIAGNOSIS AND TESTING - HORN SWITCH........................................................... 351 8i-IGNITION CONTROL................................................................................... 352 IGNITION CONTROL.................................................................................. 352 DESCRIPTION................................................................................... 352 OPERATION..................................................................................... 352 2.4L...................................................................................... 352 3.7L...................................................................................... 353 SPECIFICATIONS................................................................................ 353 SPECIFICATIONS - IGNITION TIMING.......................................................... 353 ENGINE FIRING ORDER - 2.4L 4-CYLINDER..................................................... 353 ENGINE FIRING ORDER - 3.7L V-6............................................................ 353 IGNITION COIL RESISTANCE - 2.4L........................................................... 353 IGNITION COIL RESISTANCE - 3.7L V-6....................................................... 353 SPARK PLUGS............................................................................... 354 SPARK PLUG CABLE RESISTANCE - 2.4L........................................................ 354 TORQUE - IGNITION SYSTEM.................................................................. 354 AUTO SHUT DOWN RELAY.............................................................................. 355 DESCRIPTION - PCM OUTPUT...................................................................... 355 OPERATION..................................................................................... 355 OPERATION - ASD SENSE - PCM INPUT......................................................... 355 OPERATION - PCM OUTPUT.................................................................... 355 DIAGNOSIS AND TESTING - ASD AND FUEL PUMP RELAYS.............................................. 355 REMOVAL....................................................................................... 356 INSTALLATION.................................................................................. 356 CAMSHAFT POSITION SENSOR.......................................................................... 356 DESCRIPTION................................................................................... 356 DESCRIPTION - 2.4L........................................................................ 356 DESCRIPTION-3.7L.......................................................................... 356 OPERATION..................................................................................... 356 OPERATION - 2.4L.......................................................................... 356 OPERATION - 3.7L.......................................................................... 357 REMOVAL....................................................................................... 357 2.4L...................................................................................... 357 3.7L...................................................................................... 358 INSTALLATION.................................................................................. 358 2.4L...................................................................................... 358 3.7L...................................................................................... 359 IGNITION COIL..................................................................................... 360 DESCRIPTION................................................................................... 360 2.4L...................................................................................... 360 3.7L...................................................................................... 360 OPERATION..................................................................................... 360 2.4L...................................................................................... 360 3.7L...................................................................................... 361 REMOVAL....................................................................................... 361 2.4L...................................................................................... 361 3.7L...................................................................................... 361 INSTALLATION.................................................................................. 362 2.4L...................................................................................... 362 3.7L...................................................................................... 362 KNOCK SENSOR...................................................................................... 362 DESCRIPTION................................................................................... 362 OPERATION..................................................................................... 362 REMOVAL....................................................................................... 362 INSTALLATION.................................................................................. 363 SPARK PLUG........................................................................................ 363 DESCRIPTION................................................................................... 363 OPERATION..................................................................................... 363 DIAGNOSIS AND TESTING - SPARK PLUG CONDITIONS................................................. 364 REMOVAL....................................................................................... 366 2.4L...................................................................................... 366 3.7L...................................................................................... 366 CLEANING...................................................................................... 366 CLEANING SPARK PLUGS...................................................................... 366 INSTALLATION.................................................................................. 366 2.4L...................................................................................... 366 3.7L...................................................................................... 366 IGNITION COIL CAPACITOR........................................................................... 367 DESCRIPTION................................................................................... 367 OPERATION..................................................................................... 367 REMOVAL....................................................................................... 367 INSTALLATION.................................................................................. 367 8j-INSTRUMENT CLUSTER................................................................................. 368 INSTRUMENT CLUSTER................................................................................ 369 DESCRIPTION................................................................................... 369 OPERATION..................................................................................... 372 INPUT AND OUTPUT CIRCUITS................................................................. 375 DIAGNOSIS AND TESTING - INSTRUMENT CLUSTER.................................................... 375 REMOVAL....................................................................................... 377 DISASSEMBLY................................................................................... 377 ASSEMBLY...................................................................................... 379 INSTALLATION.................................................................................. 379 ABS INDICATOR..................................................................................... 380 DESCRIPTION................................................................................... 380 OPERATION..................................................................................... 380 AIRBAG INDICATOR.................................................................................. 380 DESCRIPTION................................................................................... 380 OPERATION..................................................................................... 381 BRAKE/PARK BRAKE INDICATOR........................................................................ 381 DESCRIPTION................................................................................... 381 OPERATION..................................................................................... 381 DIAGNOSIS AND TESTING - BRAKE INDICATOR....................................................... 382 CHARGING INDICATOR................................................................................ 383 DESCRIPTION................................................................................... 383 OPERATION..................................................................................... 383 COOLANT LOW INDICATOR............................................................................. 384 DESCRIPTION................................................................................... 384 OPERATION..................................................................................... 384 CRUISE INDICATOR.................................................................................. 385 DESCRIPTION................................................................................... 385 OPERATION..................................................................................... 385 DOOR AJAR INDICATOR............................................................................... 385 DESCRIPTION................................................................................... 385 OPERATION..................................................................................... 386 ENGINE TEMPERATURE GAUGE.......................................................................... 386 DESCRIPTION................................................................................... 386 OPERATION..................................................................................... 386 FRONT FOG LAMP INDICATOR.......................................................................... 387 DESCRIPTION................................................................................... 387 OPERATION..................................................................................... 387 FUEL GAUGE........................................................................................ 388 DESCRIPTION................................................................................... 388 OPERATION..................................................................................... 388 GATE AJAR INDICATOR............................................................................... 389 DESCRIPTION................................................................................... 389 OPERATION..................................................................................... 389 GLASS AJAR INDICATOR.............................................................................. 389 DESCRIPTION................................................................................... 389 OPERATION..................................................................................... 390 HIGH BEAM INDICATOR............................................................................... 390 DESCRIPTION................................................................................... 390 OPERATION..................................................................................... 390 LIGHT BAR LAMP INDICATOR.......................................................................... 391 DESCRIPTION................................................................................... 391 OPERATION..................................................................................... 391 LOW FUEL INDICATOR................................................................................ 392 DESCRIPTION................................................................................... 392 OPERATION..................................................................................... 392 LOW OIL PRESSURE INDICATOR........................................................................ 393 DESCRIPTION................................................................................... 393 OPERATION..................................................................................... 393 MALFUNCTION INDICATOR LAMP (MIL).................................................................. 393 DESCRIPTION................................................................................... 393 OPERATION..................................................................................... 394 ODOMETER.......................................................................................... 394 DESCRIPTION................................................................................... 394 OPERATION..................................................................................... 395 OVERDRIVE OFF INDICATOR........................................................................... 395 DESCRIPTION................................................................................... 395 OPERATION..................................................................................... 396 REAR FOG LAMP INDICATOR........................................................................... 396 DESCRIPTION................................................................................... 396 OPERATION..................................................................................... 396 SEATBELT INDICATOR................................................................................ 397 DESCRIPTION................................................................................... 397 OPERATION..................................................................................... 397 SECURITY INDICATOR................................................................................ 398 DESCRIPTION................................................................................... 398 OPERATION..................................................................................... 398 SHIFT INDICATOR (TRANSFER CASE)................................................................... 398 DESCRIPTION................................................................................... 398 DESCRIPTION - PART TIME INDICATOR......................................................... 398 DESCRIPTION - FULL TIME INDICATOR......................................................... 398 DESCRIPTION - FOUR LOW MODE INDICATOR..................................................... 399 OPERATION..................................................................................... 399 OPERATION - PART TIME INDICATOR........................................................... 399 OPERATION - FULL TIME INDICATOR........................................................... 399 OPERATION - FOUR LOW MODE INDICATOR....................................................... 400 SKIS INDICATOR.................................................................................... 400 DESCRIPTION................................................................................... 400 OPERATION..................................................................................... 401 SPEEDOMETER....................................................................................... 401 DESCRIPTION................................................................................... 401 OPERATION..................................................................................... 402 TACHOMETER........................................................................................ 402 DESCRIPTION................................................................................... 402 OPERATION..................................................................................... 402 TRANS TEMP INDICATOR.............................................................................. 403 DESCRIPTION................................................................................... 403 OPERATION..................................................................................... 403 TURN SIGNAL INDICATOR............................................................................. 404 DESCRIPTION................................................................................... 404 OPERATION..................................................................................... 404 WAIT-TO-START INDICATOR........................................................................... 404 DESCRIPTION................................................................................... 404 OPERATION..................................................................................... 404 WASHER FLUID INDICATOR............................................................................ 405 DESCRIPTION................................................................................... 405 OPERATION..................................................................................... 405 DIAGNOSIS AND TESTING - WASHER FLUID INDICATOR................................................ 406 WATER-IN-FUEL INDICATOR........................................................................... 406 DESCRIPTION................................................................................... 406 OPERATION..................................................................................... 407 8l-LAMPS.............................................................................................. 408 LAMPS/LIGHTING - EXTERIOR......................................................................... 408 LAMPS/LIGHTING - EXTERIOR..................................................................... 409 DESCRIPTION............................................................................... 409 OPERATION................................................................................. 412 DIAGNOSIS AND TESTING - LAMPS/LIGHTING - EXTERIOR......................................... 414 SPECIFICATIONS - LAMPS/LIGHTING - EXTERIOR................................................ 421 BACKUP LAMP SWITCH............................................................................ 421 DESCRIPTION............................................................................... 421 OPERATION................................................................................. 422 DIAGNOSIS AND TESTING - BACKUP LAMP SWITCH................................................ 422 BRAKE LAMP SWITCH............................................................................. 422 DESCRIPTION............................................................................... 422 OPERATION................................................................................. 422 DIAGNOSIS AND TESTING - BRAKE LAMP SWITCH................................................. 423 REMOVAL................................................................................... 423 INSTALLATION.............................................................................. 424 CENTER HIGH MOUNTED STOP LAMP BULB............................................................ 424 REMOVAL................................................................................... 424 INSTALLATION.............................................................................. 425 CENTER HIGH MOUNTED STOP LAMP UNIT............................................................ 425 REMOVAL................................................................................... 425 INSTALLATION.............................................................................. 425 COMBINATION FLASHER........................................................................... 425 DESCRIPTION............................................................................... 425 OPERATION................................................................................. 425 DAYTIME RUNNING LAMP RELAY.................................................................... 426 DESCRIPTION............................................................................... 426 OPERATION................................................................................. 426 REMOVAL................................................................................... 426 INSTALLATION.............................................................................. 427 FRONT FOG LAMP BULB........................................................................... 427 REMOVAL................................................................................... 427 INSTALLATION.............................................................................. 427 FRONT FOG LAMP RELAY.......................................................................... 428 DESCRIPTION............................................................................... 428 OPERATION................................................................................. 428 DIAGNOSIS AND TESTING - FRONT FOG LAMP RELAY.............................................. 428 REMOVAL................................................................................... 429 INSTALLATION.............................................................................. 429 FRONT FOG LAMP UNIT........................................................................... 430 REMOVAL................................................................................... 430 INSTALLATION.............................................................................. 430 ADJUSTMENTS............................................................................... 431 ADJUSTMENT - FRONT FOG LAMP UNIT...................................................... 431 FRONT LAMP BULB............................................................................... 431 REMOVAL................................................................................... 431 INSTALLATION.............................................................................. 431 FRONT LAMP UNIT............................................................................... 431 REMOVAL................................................................................... 431 INSTALLATION.............................................................................. 433 FRONT POSITION LAMP BULB...................................................................... 433 REMOVAL................................................................................... 433 INSTALLATION.............................................................................. 433 HAZARD SWITCH................................................................................. 434 DESCRIPTION............................................................................... 434 OPERATION................................................................................. 434 REMOVAL................................................................................... 434 INSTALLATION.............................................................................. 435 HEADLAMP BULB................................................................................. 435 REMOVAL................................................................................... 435 INSTALLATION.............................................................................. 437 HEADLAMP HIGH BEAM RELAY...................................................................... 437 DESCRIPTION............................................................................... 437 OPERATION................................................................................. 438 DIAGNOSIS AND TESTING - HEADLAMP HIGH BEAM RELAY.......................................... 438 REMOVAL................................................................................... 439 INSTALLATION.............................................................................. 439 HEADLAMP LEVELING MOTOR....................................................................... 439 DESCRIPTION............................................................................... 439 OPERATION................................................................................. 440 REMOVAL................................................................................... 440 INSTALLATION.............................................................................. 440 HEADLAMP LEVELING SWITCH...................................................................... 441 DESCRIPTION............................................................................... 441 OPERATION................................................................................. 441 DIAGNOSIS AND TESTING - HEADLAMP LEVELING SWITCH.......................................... 442 REMOVAL................................................................................... 442 INSTALLATION.............................................................................. 443 HEADLAMP LOW BEAM RELAY....................................................................... 443 DESCRIPTION............................................................................... 443 OPERATION................................................................................. 443 DIAGNOSIS AND TESTING - HEADLAMP LOW BEAM RELAY........................................... 444 REMOVAL................................................................................... 444 INSTALLATION.............................................................................. 445 HEADLAMP UNIT................................................................................. 445 REMOVAL................................................................................... 445 INSTALLATION.............................................................................. 446 ADJUSTMENTS............................................................................... 446 ADJUSTMENT - HEADLAMP UNIT............................................................ 446 LAMP BAR...................................................................................... 448 DESCRIPTION............................................................................... 448 OPERATION................................................................................. 448 DIAGNOSIS AND TESTING - LAMP BAR.......................................................... 448 STANDARD PROCEDURE - LAMP BAR AIMING...................................................... 449 REMOVAL................................................................................... 449 REMOVAL - LAMP BAR.................................................................... 449 REMOVAL - LAMP........................................................................ 449 INSTALLATION.............................................................................. 449 INSTALLATION - LAMP BAR............................................................... 449 INSTALLATION - LAMP................................................................... 449 LAMP BAR SWITCH............................................................................... 450 DESCRIPTION............................................................................... 450 REMOVAL................................................................................... 450 INSTALLATION.............................................................................. 450 LICENSE PLATE LAMP BULB....................................................................... 450 REMOVAL................................................................................... 450 INSTALLATION.............................................................................. 451 LICENSE PLATE LAMP UNIT....................................................................... 452 REMOVAL................................................................................... 452 INSTALLATION.............................................................................. 452 MULTI-FUNCTION SWITCH......................................................................... 453 DESCRIPTION............................................................................... 453 OPERATION................................................................................. 454 DIAGNOSIS AND TESTING - MULTI-FUNCTION SWITCH............................................. 456 REMOVAL................................................................................... 458 INSTALLATION.............................................................................. 459 PARK LAMP RELAY............................................................................... 459 DESCRIPTION............................................................................... 459 OPERATION................................................................................. 460 DIAGNOSIS AND TESTING - PARK LAMP RELAY................................................... 460 REMOVAL................................................................................... 461 INSTALLATION.............................................................................. 461 REAR FOG LAMP RELAY........................................................................... 461 DESCRIPTION............................................................................... 461 OPERATION................................................................................. 462 DIAGNOSIS AND TESTING - REAR FOG LAMP RELAY............................................... 462 REMOVAL................................................................................... 463 INSTALLATION.............................................................................. 463 REAR LAMP BULB................................................................................ 464 REMOVAL0 - 4 KJ (Continued)........................................................... 464 INSTALLATION.............................................................................. 464 REAR LAMP UNIT................................................................................ 464 REMOVAL................................................................................... 464 INSTALLATION.............................................................................. 465 REPEATER LAMP BULB............................................................................ 465 REMOVAL................................................................................... 465 INSTALLATION.............................................................................. 465 REPEATER LAMP UNIT............................................................................ 465 REMOVAL................................................................................... 465 INSTALLATION.............................................................................. 465 TRAILER TOW CONNECTOR......................................................................... 466 REMOVAL................................................................................... 466 INSTALLATION.............................................................................. 466 TRAILER TOW RELAY............................................................................. 466 DESCRIPTION............................................................................... 466 OPERATION................................................................................. 467 DIAGNOSIS AND TESTING - TRAILER TOW RELAY................................................. 467 REMOVAL................................................................................... 467 INSTALLATION.............................................................................. 468 TRAILER TOW WIRING............................................................................ 469 DESCRIPTION............................................................................... 469 LAMPS/LIGHTING - INTERIOR......................................................................... 470 LAMPS/LIGHTING - INTERIOR..................................................................... 470 DESCRIPTION............................................................................... 470 OPERATION................................................................................. 472 DIAGNOSIS AND TESTING - LAMPS/LIGHTING - INTERIOR......................................... 473 SPECIFICATIONS - LAMPS/LIGHTING - INTERIOR................................................ 475 ASH RECEIVER LAMP BULB........................................................................ 475 REMOVAL................................................................................... 475 INSTALLATION.............................................................................. 476 ASH RECEIVER LAMP UNIT........................................................................ 476 REMOVAL................................................................................... 476 INSTALLATION.............................................................................. 477 CARGO LAMP BULB............................................................................... 477 REMOVAL................................................................................... 477 INSTALLATION.............................................................................. 477 CARGO LAMP SWITCH............................................................................. 478 REMOVAL................................................................................... 478 INSTALLATION.............................................................................. 478 CARGO LAMP UNIT............................................................................... 478 REMOVAL................................................................................... 478 INSTALLATION.............................................................................. 478 COMPASS MINI-TRIP ILLUMINATION BULB........................................................... 479 REMOVAL................................................................................... 479 INSTALLATION.............................................................................. 479 COURTESY LAMP BULB............................................................................ 480 REMOVAL................................................................................... 480 INSTALLATION.............................................................................. 480 COURTESY LAMP UNIT............................................................................ 481 REMOVAL................................................................................... 481 INSTALLATION.............................................................................. 481 DOOR AJAR SWITCH.............................................................................. 482 DESCRIPTION............................................................................... 482 OPERATION................................................................................. 482 FLIP-UP GLASS AJAR SWITCH..................................................................... 482 DESCRIPTION............................................................................... 482 OPERATION................................................................................. 482 HEATER-A/C CONTROL ILLUMINATION BULB.......................................................... 482 REMOVAL................................................................................... 482 INSTALLATION.............................................................................. 483 READING LAMP BULB............................................................................. 483 REMOVAL................................................................................... 483 INSTALLATION.............................................................................. 484 READING LAMP SWITCH........................................................................... 484 REMOVAL................................................................................... 484 INSTALLATION.............................................................................. 485 READING LAMP UNIT............................................................................. 485 REMOVAL................................................................................... 485 INSTALLATION.............................................................................. 486 TAILGATE AJAR SWITCH.......................................................................... 486 DESCRIPTION............................................................................... 486 OPERATION................................................................................. 486 TRANSMISSION RANGE INDICATOR ILLUMINATION BULB................................................ 487 REMOVAL................................................................................... 487 INSTALLATION.............................................................................. 487 VANITY LAMP BULB.............................................................................. 488 REMOVAL................................................................................... 488 INSTALLATION.............................................................................. 488 8m-MESSAGE SYSTEMS.................................................................................... 490 OVERHEAD CONSOLE.................................................................................. 490 DESCRIPTION................................................................................... 490 OPERATION..................................................................................... 490 STANDARD PROCEDURE............................................................................ 490 STANDARD PROCEDURE - MODULE LENS REPLACEMENT.............................................. 490 STANDARD PROCEDURE - MODULE LAMP REPLACEMENT.............................................. 491 STANDARD PROCEDURE - COURTESY LAMP REPLACEMENT............................................ 491 STANDARD PROCEDURE - COMPASS CALIBRATION.................................................. 491 STANDARD PROCEDURE - COMPASS DEMAGNETIZING................................................ 492 STANDARD PROCEDURE - COMPASS VARIATION ADJUSTMENT......................................... 493 STANDARD PROCEDURE - ELECTRONIC VEHICLE INFORMATION CENTER PROGRAMMING.................... 493 EVIC PROGRAMMING MODE................................................................. 493 PROGRAMMABLE FEATURES................................................................. 493 REMOVAL....................................................................................... 495 OVERHEAD CONSOLE - REMOVAL................................................................ 495 INSTALLATION.................................................................................. 495 COMPASS MINI/TRIP COMPUTER........................................................................ 495 DESCRIPTION................................................................................... 495 DESCRIPTION - COMPASS..................................................................... 496 DESCRIPTION - THERMOMETER................................................................. 496 OPERATION..................................................................................... 496 DIAGNOSIS AND TESTING - COMPASS MINI-TRIP COMPUTER............................................ 497 TEMPERATURE............................................................................... 497 TRIP ODOMETER............................................................................. 497 COMPASS DISPLAY........................................................................... 497 COMPASS MINI-TRIP COMPUTER - SELF DIAGNOSTIC TEST......................................... 497 REMOVAL....................................................................................... 498 INSTALLATION.................................................................................. 498 ELECTRONIC VEHICLE INFO CENTER.................................................................... 498 DESCRIPTION - ELECTRONIC VEHICLE INFORMATION CENTER (EVIC).................................... 498 DESCRIPTION - COMPASS..................................................................... 499 DESCRIPTION - TEMPERATURE................................................................. 499 OPERATION..................................................................................... 499 DIAGNOSIS AND TESTING - ELECTRONIC VEHICLE INFORMATION CENTER................................. 500 SELF-DIAGNOSTIC TEST...................................................................... 500 REMOVAL....................................................................................... 501 INSTALLATION.................................................................................. 501 UNIVERSAL TRANSMITTER............................................................................. 501 DESCRIPTION................................................................................... 501 OPERATION..................................................................................... 502 DIAGNOSIS AND TESTING - UNIVERSAL TRANSMITTER................................................. 502 STANDARD PROCEDURE............................................................................ 502 STANDARD PROCEDURE - ERASING TRANSMITTER CODES............................................ 502 STANDARD PROCEDURE - SETTING TRANSMITTER CODES............................................ 502 AMBIENT TEMP SENSOR............................................................................... 503 DESCRIPTION................................................................................... 503 OPERATION..................................................................................... 503 DIAGNOSIS AND TESTING......................................................................... 503 DIAGNOSIS AND TESTING - AMBIENT TEMPERATURE SENSOR........................................ 503 DIAGNOSIS AND TESTING - AMBIENT TEMPERATURE SENSOR CIRCUIT................................ 503 REMOVAL....................................................................................... 504 INSTALLATION.................................................................................. 504 8n-POWER SYSTEMS...................................................................................... 506 POWER LOCKS....................................................................................... 506 POWER LOCKS................................................................................... 506 DESCRIPTION............................................................................... 506 POWER LOCKS........................................................................... 506 REMOTE KEYLESS ENTRY.................................................................. 507 TAILGATE / FLIP-UP GLASS POWER RELEASE SYSTEM......................................... 507 COMBINATION FLASHER................................................................... 508 HORN RELAY............................................................................ 508 LOW BEAM HEADLAMP RELAY............................................................... 508 OPERATION................................................................................. 508 POWER LOCKS........................................................................... 508 AUTOMATIC DOOR LOCKS.................................................................. 508 DOOR LOCK INHIBIT..................................................................... 508 DOOR LOCK CIRCUIT PROTECTION.......................................................... 508 REMOTE KEYLESS ENTRY.................................................................. 508 DIAGNOSIS AND TESTING - POWER LOCKS....................................................... 509 PRELIMINARY DIAGNOSIS................................................................. 509 DOOR LOCK / UNLOCK SWITCH..................................................................... 509 DIAGNOSIS AND TESTING - DOOR LOCK/UNLOCK SWITCH........................................... 509 REMOVAL................................................................................... 510 INSTALLATION.............................................................................. 510 DOOR LOCK MOTOR............................................................................... 510 DESCRIPTION............................................................................... 510 OPERATION................................................................................. 510 DIAGNOSIS AND TESTING - DOOR LOCK MOTOR................................................... 510 FLIP-UP GLASS RELEASE SWITCH.................................................................. 511 DIAGNOSIS AND TESTING - FLIP-UP GLASS RELEASE SWITCH...................................... 511 DOOR LOCK RELAY............................................................................... 511 DESCRIPTION............................................................................... 511 OPERATION................................................................................. 511 DIAGNOSIS AND TESTING - DOOR LOCK RELAY................................................... 511 REMOVAL................................................................................... 512 INSTALLATION.............................................................................. 512 REMOTE KEYLESS ENTRY MODULE................................................................... 512 DESCRIPTION............................................................................... 512 OPERATION................................................................................. 512 DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY MODULE....................................... 512 REMOVAL................................................................................... 512 INSTALLATION.............................................................................. 512 REMOTE KEYLESS ENTRY TRANSMITTER.............................................................. 513 DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY TRANSMITTER.................................. 513 STANDARD PROCEDURE........................................................................ 513 STANDARD PROCEDURE - RKE TRANSMITTER CUSTOMER PREFERENCES............................. 513 AUTOMATIC (ROLLING) LOCKS......................................................... 513 HORN CHIRP DISABLING / ENABLING................................................... 513 OPTICAL CHIRP (FLASH) DISABLING / ENABLING........................................ 513 TAIL GATE RELEASE DELAY........................................................... 513 UNLOCK SEQUENCE................................................................... 514 STANDARD PROCEDURE - RKE TRANSMITTER PROGRAMING....................................... 514 STANDARD PROCEDURE - RKE TRANSMITTER BATTERIES........................................ 514 SPECIFICATIONS - REMOTE KEYLESS ENTRY TRANSMITTER......................................... 514 RANGE................................................................................. 514 TAILGATE CYLINDER LOCK SWITCH................................................................. 514 DESCRIPTION............................................................................... 514 OPERATION................................................................................. 514 DIAGNOSIS AND TESTING - TAILGATE CYLINDER LOCK SWITCH..................................... 515 REMOVAL................................................................................... 515 INSTALLATION.............................................................................. 515 POWER MIRRORS..................................................................................... 516 POWER MIRRORS................................................................................. 516 DESCRIPTION............................................................................... 516 OPERATION................................................................................. 516 DIAGNOSIS AND TESTING - POWER MIRRORS..................................................... 516 WIRING VOLTAGE TEST................................................................... 516 POWER MIRROR MOTOR TEST............................................................... 517 AUTOMATIC DAY / NIGHT MIRROR.................................................................. 517 DESCRIPTION............................................................................... 517 DESCRIPTION - REAR VIEW MIRROR........................................................ 517 DESCRIPTION - OUTSIDE REAR VIEW MIRROR................................................ 517 OPERATION................................................................................. 518 OPERATION - REAR VIEW MIRROR.......................................................... 518 OPERATION - OUTSIDE REAR VIEW MIRROR.................................................. 518 DIAGNOSIS AND TESTING - AUTOMATIC DAY / NIGHT MIRROR...................................... 518 POWER FOLDAWAY MIRROR SWITCH - EXPORT......................................................... 519 DESCRIPTION............................................................................... 519 OPERATION................................................................................. 519 DIAGNOSIS AND TESTING - POWER FOLDAWAY MIRROR SWITCH - EXPORT............................. 519 REMOVAL................................................................................... 520 POWER MIRROR SWITCH........................................................................... 520 DIAGNOSIS AND TESTING - POWER MIRROR SWITCH............................................... 520 REMOVAL................................................................................... 521 INSTALLATION.............................................................................. 521 SIDEVIEW MIRROR............................................................................... 521 REMOVAL................................................................................... 521 POWER SEATS....................................................................................... 522 POWER SEATS................................................................................... 522 DESCRIPTION............................................................................... 522 OPERATION................................................................................. 523 DIAGNOSIS AND TESTING - POWER SEATS....................................................... 523 LEFT POWER SEAT SWITCH........................................................................ 523 DESCRIPTION............................................................................... 523 OPERATION................................................................................. 524 DIAGNOSIS AND TESTING - LEFT POWER SEAT SWITCH............................................ 524 REMOVAL................................................................................... 525 INSTALLATION.............................................................................. 525 RIGHT POWER SEAT SWITCH....................................................................... 525 DESCRIPTION............................................................................... 525 OPERATION................................................................................. 525 DIAGNOSIS AND TESTING - RIGHT POWER SEAT SWITCH........................................... 526 REMOVAL................................................................................... 527 INSTALLATION.............................................................................. 527 POWER SEAT TRACK.............................................................................. 527 DESCRIPTION............................................................................... 527 OPERATION................................................................................. 528 DIAGNOSIS AND TESTING - POWER SEAT TRACK.................................................. 528 REMOVAL................................................................................... 528 INSTALLATION.............................................................................. 528 POWER WINDOWS..................................................................................... 529 POWER WINDOWS................................................................................. 529 DESCRIPTION............................................................................... 529 OPERATION................................................................................. 529 WINDOW SWITCH......................................................................... 529 WINDOW MOTOR.......................................................................... 529 DIAGNOSIS AND TESTING - POWER WINDOWS..................................................... 529 WIRING VOLTAGE TEST................................................................... 529 POWER WINDOW MOTOR TEST............................................................... 529 WINDOW MOTOR.................................................................................. 530 REMOVAL................................................................................... 530 WINDOW SWITCH................................................................................. 530 DIAGNOSIS AND TESTING - WINDOW SWITCH..................................................... 530 REMOVAL................................................................................... 531 FRONT................................................................................. 531 REAR.................................................................................. 531 INSTALLATION.............................................................................. 531 FRONT................................................................................. 531 REAR.................................................................................. 531 8o-RESTRAINTS......................................................................................... 556 RESTRAINTS........................................................................................ 557 DESCRIPTION................................................................................... 557 ACTIVE RESTRAINTS......................................................................... 558 PASSIVE RESTRAINTS........................................................................ 558 OPERATION..................................................................................... 559 ACTIVE RESTRAINTS......................................................................... 559 PASSIVE RESTRAINTS........................................................................ 559 WARNING....................................................................................... 560 WARNINGS - RESTRAINT SYSTEM............................................................... 560 DIAGNOSIS AND TESTING - SUPPLEMENTAL RESTRAINT SYSTEM......................................... 561 STANDARD PROCEDURE............................................................................ 561 STANDARD PROCEDURE - HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS........................ 561 SUPPLEMENTAL RESTRAINT STORAGE........................................................ 561 STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT.................... 562 AIRBAG SQUIB STATUS................................................................... 562 CLEANUP PROCEDURE..................................................................... 563 STANDARD PROCEDURE - VERIFICATION TEST.................................................... 564 AIRBAG CONTROL MODULE............................................................................. 565 DESCRIPTION................................................................................... 565 OPERATION..................................................................................... 565 REMOVAL....................................................................................... 567 INSTALLATION.................................................................................. 568 CHILD RESTRAINT ANCHOR............................................................................ 568 DESCRIPTION................................................................................... 568 OPERATION..................................................................................... 570 CLOCKSPRING....................................................................................... 570 DESCRIPTION................................................................................... 570 OPERATION..................................................................................... 571 STANDARD PROCEDURE - CLOCKSPRING CENTERING.................................................... 572 REMOVAL....................................................................................... 572 INSTALLATION.................................................................................. 573 DRIVER AIRBAG..................................................................................... 574 DESCRIPTION................................................................................... 574 OPERATION..................................................................................... 575 REMOVAL....................................................................................... 576 INSTALLATION.................................................................................. 576 FRONT IMPACT SENSOR............................................................................... 578 DESCRIPTION................................................................................... 578 OPERATION..................................................................................... 578 REMOVAL....................................................................................... 579 INSTALLATION.................................................................................. 579 FRONT SEAT BELT & RETRACTOR....................................................................... 580 REMOVAL....................................................................................... 580 INSTALLATION.................................................................................. 581 FRONT SEAT BELT BUCKLE............................................................................ 582 REMOVAL....................................................................................... 582 INSTALLATION.................................................................................. 584 PASSENGER AIRBAG.................................................................................. 584 DESCRIPTION................................................................................... 584 OPERATION..................................................................................... 585 REMOVAL....................................................................................... 586 INSTALLATION.................................................................................. 586 PASSENGER AIRBAG DOOR............................................................................. 587 REMOVAL....................................................................................... 587 INSTALLATION.................................................................................. 588 PASSENGER AIRBAG MOUNTING BRACKET................................................................. 589 REMOVAL....................................................................................... 589 INSTALLATION.................................................................................. 589 REAR CENTER SEAT BELT & RETRACTOR................................................................. 590 REMOVAL....................................................................................... 590 INSTALLATION.................................................................................. 591 REAR OUTBOARD SEAT BELT & RETRACTOR............................................................... 591 REMOVAL....................................................................................... 591 INSTALLATION.................................................................................. 592 REAR SEAT BELT BUCKLE............................................................................. 593 REMOVAL....................................................................................... 593 INSTALLATION.................................................................................. 593 SEAT BELT SWITCH.................................................................................. 593 DESCRIPTION................................................................................... 593 OPERATION..................................................................................... 594 SEAT BELT TENSIONER............................................................................... 594 DESCRIPTION................................................................................... 594 OPERATION..................................................................................... 595 SEAT BELT TURNING LOOP ADJUSTER................................................................... 595 REMOVAL....................................................................................... 595 INSTALLATION.................................................................................. 596 SIDE CURTAIN AIRBAG............................................................................... 597 DESCRIPTION................................................................................... 597 OPERATION..................................................................................... 597 REMOVAL....................................................................................... 597 INSTALLATION.................................................................................. 600 SIDE IMPACT AIRBAG CONTROL MODULE................................................................. 601 DESCRIPTION................................................................................... 601 OPERATION..................................................................................... 601 REMOVAL....................................................................................... 602 INSTALLATION.................................................................................. 603 8p-SPEED CONTROL...................................................................................... 604 SPEED CONTROL..................................................................................... 604 DESCRIPTION................................................................................... 604 OPERATION..................................................................................... 604 DIAGNOSIS AND TESTING - ROAD TEST............................................................. 605 SPECIFICATIONS................................................................................ 605 TORQUE - SPEED CONTROL.................................................................... 605 CABLE............................................................................................. 606 DESCRIPTION................................................................................... 606 OPERATION..................................................................................... 606 REMOVAL - 3.7L................................................................................ 606 INSTALLATION - 3.7L........................................................................... 607 SERVO............................................................................................. 607 DESCRIPTION................................................................................... 607 OPERATION..................................................................................... 607 REMOVAL....................................................................................... 608 INSTALLATION.................................................................................. 608 SWITCH............................................................................................ 608 DESCRIPTION................................................................................... 608 OPERATION..................................................................................... 608 Multiplexing.............................................................................. 609 REMOVAL....................................................................................... 609 INSTALLATION.................................................................................. 609 VACUUM RESERVOIR.................................................................................. 610 DESCRIPTION................................................................................... 610 OPERATION..................................................................................... 610 DIAGNOSIS AND TESTING - VACUUM RESERVOIR...................................................... 610 REMOVAL....................................................................................... 610 INSTALLATION.................................................................................. 611 8q-VEHICLE THEFT SECURITY............................................................................. 612 VEHICLE THEFT SECURITY............................................................................ 612 DESCRIPTION................................................................................... 612 OPERATION..................................................................................... 614 DIAGNOSIS AND TESTING - VEHICLE THEFT SECURITY SYSTEM......................................... 616 VEHICLE THEFT ALARM....................................................................... 617 SENTRY KEY IMMOBILIZER SYSTEM............................................................. 617 STANDARD PROCEDURE............................................................................ 618 STANDARD PROCEDURE - SKIS INITIALIZATION.................................................. 618 STANDARD PROCEDURE - SENTRY KEY TRANSPONDER PROGRAMMING................................... 619 DOOR CYLINDER LOCK SWITCH......................................................................... 620 DESCRIPTION................................................................................... 620 OPERATION..................................................................................... 620 DIAGNOSIS AND TESTING - DOOR CYLINDER LOCK SWITCH............................................. 620 REMOVAL....................................................................................... 620 INSTALLATION.................................................................................. 621 HOOD AJAR SWITCH.................................................................................. 621 DESCRIPTION................................................................................... 621 OPERATION..................................................................................... 621 DIAGNOSIS AND TESTING - HOOD AJAR SWITCH...................................................... 622 REMOVAL....................................................................................... 622 INSTALLATION.................................................................................. 622 HOOD AJAR SWITCH BRACKET.......................................................................... 622 REMOVAL....................................................................................... 622 INSTALLATION.................................................................................. 623 HOOD AJAR SWITCH STRIKER.......................................................................... 623 REMOVAL....................................................................................... 623 INSTALLATION.................................................................................. 623 INTRUSION TRANSCEIVER MODULE...................................................................... 624 DESCRIPTION................................................................................... 624 OPERATION..................................................................................... 624 REMOVAL....................................................................................... 625 INSTALLATION.................................................................................. 626 SIREN............................................................................................. 626 DESCRIPTION................................................................................... 626 OPERATION..................................................................................... 626 REMOVAL....................................................................................... 627 INSTALLATION.................................................................................. 627 TRANSPONDER KEY................................................................................... 628 DESCRIPTION................................................................................... 628 OPERATION..................................................................................... 628 8r-WIPERS/WASHERS..................................................................................... 630 FRONT WIPERS/WASHERS.............................................................................. 630 FRONT WIPERS/WASHERS.......................................................................... 631 DESCRIPTION............................................................................... 631 OPERATING MODES....................................................................... 632 OPERATION................................................................................. 633 OPERATING MODES....................................................................... 633 DIAGNOSIS AND TESTING - FRONT WIPER & WASHER SYSTEM....................................... 635 WIPER SYSTEM.......................................................................... 635 WASHER SYSTEM......................................................................... 635 CLEANING - FRONT WIPER & WASHER SYSTEM.................................................... 636 WIPER SYSTEM.......................................................................... 636 WASHER SYSTEM......................................................................... 636 INSPECTION - FRONT WIPER & WASHER SYSTEM.................................................. 636 WIPER SYSTEM.......................................................................... 636 WASHER SYSTEM......................................................................... 637 FRONT CHECK VALVE............................................................................. 637 DESCRIPTION............................................................................... 637 OPERATION................................................................................. 638 REMOVAL................................................................................... 638 INSTALLATION.............................................................................. 639 FRONT WASHER HOSES/TUBES...................................................................... 639 DESCRIPTION............................................................................... 639 OPERATION................................................................................. 640 FRONT WASHER NOZZLE........................................................................... 640 DESCRIPTION............................................................................... 640 OPERATION................................................................................. 640 REMOVAL................................................................................... 640 INSTALLATION.............................................................................. 640 FRONT WIPER ARM............................................................................... 641 DESCRIPTION............................................................................... 641 OPERATION................................................................................. 641 REMOVAL................................................................................... 641 INSTALLATION.............................................................................. 642 FRONT WIPER BLADE............................................................................. 642 DESCRIPTION............................................................................... 642 OPERATION................................................................................. 643 REMOVAL................................................................................... 643 INSTALLATION.............................................................................. 643 FRONT WIPER MODULE............................................................................ 644 DESCRIPTION............................................................................... 644 OPERATION................................................................................. 644 REMOVAL................................................................................... 645 INSTALLATION.............................................................................. 645 FRONT WIPER/WASHER SWITCH..................................................................... 645 DESCRIPTION............................................................................... 645 OPERATION................................................................................. 645 WASHER FLUID LEVEL SWITCH..................................................................... 646 DESCRIPTION............................................................................... 646 OPERATION................................................................................. 646 REMOVAL................................................................................... 646 INSTALLATION.............................................................................. 647 WASHER PUMP/MOTOR............................................................................. 647 DESCRIPTION............................................................................... 647 OPERATION................................................................................. 648 REMOVAL................................................................................... 648 INSTALLATION.............................................................................. 649 WASHER RESERVOIR.............................................................................. 650 DESCRIPTION............................................................................... 650 OPERATION................................................................................. 650 REMOVAL................................................................................... 650 INSTALLATION.............................................................................. 651 WIPER HIGH/LOW RELAY.......................................................................... 652 DESCRIPTION............................................................................... 652 OPERATION................................................................................. 652 DIAGNOSIS AND TESTING - WIPER HIGH/LOW RELAY.............................................. 653 REMOVAL................................................................................... 653 INSTALLATION.............................................................................. 654 WIPER ON/OFF RELAY............................................................................ 654 DESCRIPTION............................................................................... 654 OPERATION................................................................................. 654 DIAGNOSIS AND TESTING - WIPER ON/OFF RELAY................................................ 655 REMOVAL................................................................................... 655 INSTALLATION.............................................................................. 655 REAR WIPERS/WASHERS............................................................................... 656 REAR WIPERS/WASHERS........................................................................... 656 DESCRIPTION............................................................................... 656 OPERATING MODES....................................................................... 658 OPERATION................................................................................. 658 OPERATING MODES....................................................................... 659 DIAGNOSIS AND TESTING - REAR WIPER & WASHER SYSTEM........................................ 659 WIPER SYSTEM.......................................................................... 659 WASHER SYSTEM......................................................................... 661 CLEANING - REAR WIPER & WASHER SYSTEM..................................................... 661 WIPER SYSTEM.......................................................................... 661 WASHER SYSTEM......................................................................... 661 INSPECTION - REAR WIPER & WASHER SYSTEM................................................... 662 WIPER SYSTEM.......................................................................... 662 WASHER SYSTEM......................................................................... 662 REAR WASHER HOSES/TUBES....................................................................... 663 DESCRIPTION............................................................................... 663 OPERATION................................................................................. 663 REAR WASHER NOZZLE............................................................................ 664 DESCRIPTION............................................................................... 664 OPERATION................................................................................. 664 REMOVAL................................................................................... 664 INSTALLATION.............................................................................. 664 REAR WIPER ARM................................................................................ 665 DESCRIPTION............................................................................... 665 OPERATION................................................................................. 665 REMOVAL................................................................................... 665 INSTALLATION.............................................................................. 666 REAR WIPER BLADE.............................................................................. 667 DESCRIPTION............................................................................... 667 OPERATION................................................................................. 667 REMOVAL................................................................................... 667 INSTALLATION.............................................................................. 668 REAR WIPER MOTOR.............................................................................. 668 DESCRIPTION............................................................................... 668 OPERATION................................................................................. 669 REMOVAL................................................................................... 669 INSTALLATION.............................................................................. 670 REAR WIPER/WASHER SWITCH...................................................................... 670 DESCRIPTION............................................................................... 670 OPERATION................................................................................. 670 WIPER ARM PARK RAMP........................................................................... 671 REMOVAL................................................................................... 671 INSTALLATION.............................................................................. 671 8w-WIRING............................................................................................. 672 8W-01 WIRING DIAGRAM INFORMATION.................................................................. 674 WIRING DIAGRAM INFORMATION.................................................................... 674 DESCRIPTION............................................................................... 674 DESCRIPTION - HOW TO USE WIRING DIAGRAMS.............................................. 674 SYMBOLS........................................................................... 674 TERMINOLOGY....................................................................... 678 DESCRIPTION - CIRCUIT INFORMATION..................................................... 678 DESCRIPTION - CIRCUIT FUNCTIONS....................................................... 679 DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION.................................. 679 DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION................................ 680 IDENTIFICATION.................................................................... 680 LOCATIONS......................................................................... 680 WARNING................................................................................... 680 WARNINGS - GENERAL.................................................................... 680 DIAGNOSIS AND TESTING - WIRING HARNESS.................................................... 680 TROUBLESHOOTING TOOLS................................................................. 680 INTERMITTENT AND POOR CONNECTIONS..................................................... 681 TROUBLESHOOTING WIRING PROBLEMS....................................................... 681 STANDARD PROCEDURE........................................................................ 681 STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES.................. 681 STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL..................................... 682 STANDARD PROCEDURE - TESTING FOR CONTINUITY........................................... 682 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND.................................... 682 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS.... 683 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP....................................... 683 SPECIAL TOOLS............................................................................. 683 WIRING/TERMINAL....................................................................... 683 CONNECTOR..................................................................................... 684 REMOVAL................................................................................... 684 INSTALLATION.............................................................................. 684 DIODE......................................................................................... 687 REMOVAL................................................................................... 687 INSTALLATION.............................................................................. 687 TERMINAL...................................................................................... 687 REMOVAL................................................................................... 687 INSTALLATION.............................................................................. 687 WIRE.......................................................................................... 688 STANDARD PROCEDURE - WIRE SPLICING........................................................ 688 8W-02 COMPONENT INDEX............................................................................. 690 8W-10 POWER DISTRIBUTION.......................................................................... 692 8W-12 JUNCTION BLOCK.............................................................................. 722 8W-15 GROUND DISTRIBUTION......................................................................... 756 8W-18 BUS COMMUNICATIONS.......................................................................... 776 8W-20 CHARGING SYSTEM............................................................................. 782 8W-21 STARTING SYSTEM............................................................................. 786 8W-30 FUEL/IGNITION SYSTEM........................................................................ 794 8W-31 TRANSMISSION CONTROL SYSTEM................................................................. 832 8W-33 VEHICLE SPEED CONTROL....................................................................... 848 8W-35 ANTILOCK BRAKES............................................................................. 854 8W-39 VEHICLE THEFT SECURITY SYSTEM............................................................... 858 8W-40 INSTRUMENT CLUSTER.......................................................................... 870 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET............................................................. 878 8W-42 AIR CONDITIONING-HEATER..................................................................... 882 8W-43 AIRBAG SYSTEM............................................................................... 890 8W-44 INTERIOR LIGHTING........................................................................... 894 8W-45 BODY CONTROL MODULE......................................................................... 898 8W-47 AUDIO SYSTEM................................................................................ 910 8W-48 REAR WINDOW DEFOGGER........................................................................ 920 8W-49 OVERHEAD CONSOLE............................................................................ 922 8W-50 FRONT LIGHTING.............................................................................. 928 8W-51 REAR LIGHTING............................................................................... 946 8W-52 TURN SIGNALS................................................................................ 952 8W-53 WIPERS...................................................................................... 960 8W-54 TRAILER TOW................................................................................. 966 8W-60 POWER WINDOWS............................................................................... 972 8W-61 POWER DOOR LOCKS............................................................................ 976 8W-62 POWER MIRRORS............................................................................... 984 8W-63 POWER SEAT.................................................................................. 990 8W-64 POWER SUNROOF............................................................................... 996 8W-70 SPLICE INFORMATION.......................................................................... 998 8W-80 CONNECTOR PIN-OUTS..........................................................................1006 8W-91 CONNECTOR/GROUND/SPLICE LOCATION............................................................1112 CONNECTOR/GROUND/SPLICE LOCATION..............................................................1112 DESCRIPTION...............................................................................1112 8W-97 POWER DISTRIBUTION..........................................................................1174 POWER DISTRIBUTION............................................................................1174 DESCRIPTION...............................................................................1174 OPERATION.................................................................................1174 SPECIAL TOOLS.............................................................................1175 POWER DISTRIBUTION SYSTEMS............................................................1175 CIGAR LIGHTER OUTLET..........................................................................1175 DESCRIPTION...............................................................................1175 OPERATION.................................................................................1175 DIAGNOSIS AND TESTING - CIGAR LIGHTER OUTLET..............................................1175 IOD FUSE......................................................................................1176 DESCRIPTION...............................................................................1176 CIRCUITS INCLUDED WITH IOD FUSE.......................................................1176 OPERATION.................................................................................1176 REMOVAL...................................................................................1176 INSTALLATION..............................................................................1176 JUNCTION BLOCK................................................................................1177 DESCRIPTION...............................................................................1177 OPERATION.................................................................................1177 DIAGNOSIS AND TESTING - JUNCTION BLOCK....................................................1177 REMOVAL...................................................................................1178 REMOVAL - LHD.........................................................................1178 REMOVAL - RHD.........................................................................1178 INSTALLATION..............................................................................1179 INSTALLATION - LHD....................................................................1179 INSTALLATION - RHD....................................................................1179 POWER DISTRIBUTION CENTER.....................................................................1179 DESCRIPTION...............................................................................1179 OPERATION.................................................................................1179 REMOVAL...................................................................................1180 DISASSEMBLY...............................................................................1180 POWER DISTRIBUTION CENTER DISASSEMBLY.................................................1180 PDC HOUSING LOWER COVER...........................................................1180 PDC B+ TERMINAL MODULE............................................................1181 PDC RELAY WEDGE...................................................................1181 PDC RELAY CASSETTE................................................................1181 ASSEMBLY..................................................................................1182 POWER DISTRIBUTION CENTER ASSEMBLY....................................................1182 PDC B(+) TERMINAL MODULE..........................................................1182 RELAY WEDGE.......................................................................1182 RELAY CASSETTE....................................................................1183 PDC LOWER COVER...................................................................1183 INSTALLATION..............................................................................1183 POWER OUTLET..................................................................................1184 DESCRIPTION...............................................................................1184 OPERATION.................................................................................1184 DIAGNOSIS AND TESTING - POWER OUTLET......................................................1184 REMOVAL...................................................................................1184 INSTALLATION..............................................................................1185 RELAY.........................................................................................1185 DESCRIPTION...............................................................................1185 OPERATION.................................................................................1186 DIAGNOSIS AND TESTING - RELAY.............................................................1186 DIAGNOSIS & TESTING - RELAY CIRCUIT TEST..............................................1186 REMOVAL...................................................................................1186 INSTALLATION..............................................................................1186 MICRO-RELAY...................................................................................1186 DESCRIPTION...............................................................................1186 OPERATION.................................................................................1187 DIAGNOSIS AND TESTING - MICRO-RELAY.......................................................1187 REMOVAL...................................................................................1187 INSTALLATION..............................................................................1187 9-ENGINE..............................................................................................1188 ENGINE - 2.4L.....................................................................................1188 ENGINE - 2.4L.................................................................................1190 DESCRIPTION...............................................................................1190 DIAGNOSIS AND TESTING.....................................................................1190 DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST.....................1190 DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST............................1191 DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION0 - 6 KJ (Continued)............1191 INSPECTION FOR REAR SEAL AREA LEAKS...............................................1192 DIAGNOSIS AND TESTING - ENGINE........................................................1192 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE................................1193 DIAGNOSIS AND TESTING - ENGINE MECHANICAL.............................................1195 STANDARD PROCEDURE........................................................................1197 STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS................................1197 STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS................................1197 STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE........................................1197 STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS................................1198 SEALER APPLICATION................................................................1198 STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION................................1199 STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE.....................1199 REMOVAL - ENGINE ASSEMBLY.................................................................1200 INSTALLATION - ENGINE ASSEMBLY............................................................1200 SPECIFICATIONS............................................................................1201 SPECIFICATIONS - 2.4L ENGINE..........................................................1201 SPECIFICATIONS - TORQUE...............................................................1204 SPECIAL TOOLS.............................................................................1205 2.4L ENGINE...........................................................................1205 AIR CLEANER ELEMENT...........................................................................1207 REMOVAL - 2.4L............................................................................1207 INSTALLATION - 2.4L.......................................................................1207 CYLINDER HEAD.................................................................................1207 DESCRIPTION...............................................................................1207 OPERATION.................................................................................1207 DIAGNOSIS AND TESTING - CYLINDER HEAD GASKET..............................................1207 CYLINDER-TO-CYLINDER LEAKAGE TEST.....................................................1208 CYLINDER-TO-WATER JACKET LEAKAGE TEST.................................................1208 REMOVAL - CYLINDER HEAD...................................................................1208 CLEANING..................................................................................1208 INSPECTION................................................................................1209 INSTALLATION - CYLINDER HEAD..............................................................1209 CAMSHAFT OIL SEAL(S)..........................................................................1210 REMOVAL...................................................................................1210 INSTALLATION..............................................................................1210 CAMSHAFT(S)...................................................................................1211 DESCRIPTION...............................................................................1211 OPERATION.................................................................................1211 STANDARD PROCEDURE - CAMSHAFT END-PLAY....................................................1211 REMOVAL...................................................................................1211 CLEANING..................................................................................1212 INSPECTION................................................................................1212 INSTALLATION..............................................................................1213 CYLINDER HEAD COVER...........................................................................1213 REMOVAL...................................................................................1213 CLEANING..................................................................................1214 INSPECTION................................................................................1214 INSTALLATION..............................................................................1214 INTAKE/EXHAUST VALVES & SEATS.................................................................1215 DESCRIPTION...............................................................................1215 CLEANING..................................................................................1215 VALVE SPRINGS.................................................................................1215 REMOVAL...................................................................................1215 REMOVAL - CYLINDER HEAD ON............................................................1215 REMOVAL - CYLINDER HEAD OFF...........................................................1215 INSPECTION................................................................................1215 INSTALLATION..............................................................................1215 INSTALLATION - CYLINDER HEAD ON.......................................................1215 INSTALLATION - CYLINDER HEAD OFF......................................................1216 HYDRAULIC LIFTERS.............................................................................1216 DIAGNOSIS AND TESTING - LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS............................1216 REMOVAL...................................................................................1217 INSTALLATION..............................................................................1217 ROCKER ARMS...................................................................................1217 REMOVAL...................................................................................1217 INSPECTION................................................................................1217 INSTALLATION..............................................................................1218 ENGINE BLOCK..................................................................................1218 DESCRIPTION...............................................................................1218 STANDARD PROCEDURE........................................................................1218 STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING..................................1218 STANDARD PROCEDURE - CYLINDER BORE HONING.............................................1218 CLEANING..................................................................................1219 INSPECTION................................................................................1219 ENGINE BLOCK..........................................................................1219 CYLINDER BORE.........................................................................1220 CONNECTING ROD BEARINGS.......................................................................1220 STANDARD PROCEDURE........................................................................1220 CONNECTING ROD - FITTING..............................................................1220 CRANKSHAFT....................................................................................1220 DESCRIPTION...............................................................................1220 OPERATION.................................................................................1220 STANDARD PROCEDURE - CRANKSHAFT END PLAY..................................................1220 REMOVAL...................................................................................1221 INSPECTION................................................................................1221 INSTALLATION..............................................................................1222 CRANKSHAFT MAIN BEARINGS......................................................................1223 STANDARD PROCEDURE - MAIN BEARING - FITTING...............................................1223 CRANKSHAFT MAIN BEARINGS..............................................................1223 MAIN BEARING INSTALLATION.............................................................1223 CRANKSHAFT OIL SEAL - FRONT...................................................................1224 REMOVAL...................................................................................1224 INSTALLATION..............................................................................1225 CRANKSHAFT OIL SEAL - REAR....................................................................1226 REMOVAL...................................................................................1226 INSTALLATION..............................................................................1226 PISTON & CONNECTING ROD.......................................................................1227 DESCRIPTION...............................................................................1227 OPERATION.................................................................................1227 REMOVAL...................................................................................1228 INSTALLATION..............................................................................1228 PISTON RINGS..................................................................................1229 STANDARD PROCEDURE........................................................................1229 PISTON RING - FITTING.................................................................1229 PISTON RINGS - INSTALLATION.......................................................1229 VIBRATION DAMPER..............................................................................1230 REMOVAL...................................................................................1230 INSTALLATION..............................................................................1230 STRUCTURAL COLLAR.............................................................................1231 REMOVAL...................................................................................1231 INSTALLATION..............................................................................1231 ENGINE MOUNTING...............................................................................1231 DESCRIPTION...............................................................................1231 FRONT MOUNT...................................................................................1231 REMOVAL...................................................................................1231 INSTALLATION..............................................................................1231 REAR MOUNT....................................................................................1232 REMOVAL...................................................................................1232 MANUAL TRANSMISSION...................................................................1232 AUTOMATIC TRANSMISSION................................................................1232 INSTALLATION..............................................................................1232 MANUAL TRANSMISSION:..................................................................1232 AUTOMATIC TRANSMISSION:...............................................................1232 LUBRICATION...................................................................................1233 DESCRIPTION...............................................................................1233 OPERATION.................................................................................1233 DIAGNOSIS AND TESTING - ENGINE OIL PRESSURE CHECKING......................................1234 OIL...........................................................................................1234 STANDARD PROCEDURE........................................................................1234 ENGINE OIL LEVEL CHECK................................................................1234 STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE.....................................1234 OIL FILTER....................................................................................1235 DESCRIPTION...............................................................................1235 REMOVAL...................................................................................1235 INSTALLATION..............................................................................1235 OIL PAN.......................................................................................1235 REMOVAL...................................................................................1235 INSTALLATION..............................................................................1235 OIL PRESSURE SENSOR/SWITCH....................................................................1236 DESCRIPTION...............................................................................1236 OPERATION.................................................................................1236 OIL PUMP......................................................................................1236 REMOVAL...................................................................................1236 DISASSEMBLY...............................................................................1237 CLEANING..................................................................................1237 INSPECTION................................................................................1237 ASSEMBLY..................................................................................1237 INSTALLATION..............................................................................1238 INTAKE MANIFOLD...............................................................................1239 DESCRIPTION...............................................................................1239 OPERATION.................................................................................1240 DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS.............................................1240 REMOVAL...................................................................................1240 REMOVAL — UPPER.......................................................................1240 REMOVAL — LOWER.......................................................................1240 INSPECTION................................................................................1240 INSTALLATION..............................................................................1240 INSTALLATION — UPPER..................................................................1240 INSTALLATION — LOWER..................................................................1241 EXHAUST MANIFOLD..............................................................................1241 DESCRIPTION...............................................................................1241 OPERATION.................................................................................1241 REMOVAL...................................................................................1241 CLEANING..................................................................................1242 INSPECTION................................................................................1242 INSTALLATION..............................................................................1242 TIMING BELT COVER(S)..........................................................................1242 REMOVAL...................................................................................1242 FRONT COVER...........................................................................1242 REAR COVER............................................................................1242 INSTALLATION..............................................................................1242 REAR COVER............................................................................1242 FRONT COVER...........................................................................1242 TIMING BELT AND SPROCKET(S)...................................................................1243 REMOVAL...................................................................................1243 REMOVAL - TIMING BELT.................................................................1243 REMOVAL - CRANKSHAFT SPROCKET.........................................................1243 CLEANING..................................................................................1243 INSTALLATION..............................................................................1244 INSTALLATION - CRANKSHAFT SPROCKET....................................................1244 INSTALLATION - TIMING BELT............................................................1245 TIMING BELT TENSIONER & PULLEY................................................................1247 REMOVAL...................................................................................1247 INSTALLATION..............................................................................1247 BALANCE SHAFT.................................................................................1247 DESCRIPTION...............................................................................1247 OPERATION.................................................................................1247 REMOVAL...................................................................................1248 BALANCE SHAFTS........................................................................1248 BALANCE SHAFT CARRIER.................................................................1248 INSTALLATION..............................................................................1250 BALANCE SHAFT TIMING..................................................................1250 BALANCE SHAFT INSTALLATION........................................................1250 BALANCE SHAFT CARRIER.........................................................................1251 REMOVAL...................................................................................1251 INSTALLATION..............................................................................1251 BALANCE SHAFT CHAIN...........................................................................1251 REMOVAL...................................................................................1251 INSTALLATION..............................................................................1251 ENGINE - 3.7L.....................................................................................1252 ENGINE - 3.7L.................................................................................1254 DESCRIPTION...............................................................................1254 DIAGNOSIS AND TESTING.....................................................................1255 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION...............................1255 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE................................1255 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL.................................1257 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION................................1258 DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE.................................1259 DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE..........................1259 STANDARD PROCEDURE........................................................................1260 STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION................................1260 STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS...................................1260 STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS................................1261 REMOVAL...................................................................................1261 INSTALLATION..............................................................................1262 SPECIFICATIONS............................................................................1263 TORQUE................................................................................1263 SPECIFICATIONS – 3.7L ENGINE..........................................................1263 SPECIAL TOOLS.............................................................................1266 3.7L ENGINE...........................................................................1266 AIR CLEANER ELEMENT...........................................................................1270 REMOVAL - 3.7L............................................................................1270 INSTALLATION - 3.7L.......................................................................1270 CYLINDER HEAD - LEFT..........................................................................1270 DESCRIPTION - VALVE GUIDES................................................................1270 DIAGNOSIS AND TESTING.....................................................................1270 DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER.......................................1270 DIAGNOSIS AND TESTING - CYLINDER HEAD GASKET..........................................1270 CYLINDER-TO-CYLINDER LEAKAGE TEST.................................................1271 CYLINDER-TO-WATER JACKET LEAKAGE TEST.............................................1271 REMOVAL...................................................................................1271 CLEANING..................................................................................1273 INSTALLATION..............................................................................1273 CAMSHAFT(S)...................................................................................1274 DESCRIPTION...............................................................................1274 REMOVAL...................................................................................1274 INSTALLATION..............................................................................1275 CYLINDER HEAD COVER(S)........................................................................1276 DESCRIPTION...............................................................................1276 REMOVAL...................................................................................1276 INSTALLATION..............................................................................1277 INTAKE/EXHAUST VALVES & SEATS.................................................................1277 DESCRIPTION...............................................................................1277 STANDARD PROCEDURE - REFACING.............................................................1277 REMOVAL...................................................................................1277 TESTING VALVE SPRINGS.................................................................1278 INSTALLATION..............................................................................1278 ROCKER ARM....................................................................................1279 DESCRIPTION...............................................................................1279 REMOVAL...................................................................................1279 VALVE GUIDE SEALS.............................................................................1280 DESCRIPTION...............................................................................1280 VALVE SPRINGS.................................................................................1280 DESCRIPTION...............................................................................1280 REMOVAL...................................................................................1280 INSTALLATION..............................................................................1280 CYLINDER HEAD - RIGHT.........................................................................1281 DESCRIPTION...............................................................................1281 DESCRIPTION - CYLINDER HEAD...........................................................1281 DESCRIPTION - VALVE GUIDES............................................................1281 DESCRIPTION...........................................................................1281 DIAGNOSIS AND TESTING.....................................................................1281 DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER.......................................1281 DIAGNOSIS AND TESTING - CYLINDER HEAD GASKET..........................................1281 CYLINDER-TO-CYLINDER LEAKAGE TEST.................................................1281 CYLINDER-TO-WATER JACKET LEAKAGE TEST.............................................1282 REMOVAL...................................................................................1282 CLEANING..................................................................................1283 INSPECTION................................................................................1283 INSTALLATION..............................................................................1283 CAMSHAFT(S)...................................................................................1284 DESCRIPTION...............................................................................1284 REMOVAL...................................................................................1284 INSTALLATION..............................................................................1285 CYLINDER HEAD COVER(S)........................................................................1286 REMOVAL...................................................................................1286 INSTALLATION..............................................................................1286 INTAKE/EXHAUST VALVES & SEATS.................................................................1286 STANDARD PROCEDURE - REFACING.............................................................1286 REMOVAL...................................................................................1286 TESTING VALVE SPRINGS.................................................................1287 INSTALLATION..............................................................................1287 ROCKER ARM....................................................................................1288 DESCRIPTION...............................................................................1288 REMOVAL...................................................................................1288 INSTALLATION..............................................................................1289 VALVE GUIDE SEALS.............................................................................1289 DESCRIPTION...............................................................................1289 VALVE SPRINGS.................................................................................1289 DESCRIPTION...............................................................................1289 REMOVAL...................................................................................1289 INSTALLATION..............................................................................1290 ENGINE BLOCK..................................................................................1290 DESCRIPTION...............................................................................1290 STANDARD PROCEDURE - CYLINDER BORE HONING.................................................1290 CLEANING..................................................................................1291 INSPECTION................................................................................1291 CRANKSHAFT....................................................................................1292 DESCRIPTION...............................................................................1292 REMOVAL...................................................................................1292 INSPECTION................................................................................1293 INSTALLATION..............................................................................1293 CRANKSHAFT MAIN BEARINGS......................................................................1294 STANDARD PROCEDURE........................................................................1294 MAIN BEARING - FITTING................................................................1294 SELECT FIT IDENTIFICATION.........................................................1294 INSPECTION........................................................................1294 MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)................................1294 CRANKSHAFT MAIN BEARING SELECTION.................................................1296 CRANKSHAFT OIL SEAL - FRONT...................................................................1296 REMOVAL...................................................................................1296 INSTALLATION..............................................................................1297 CRANKSHAFT OIL SEAL - REAR....................................................................1298 REMOVAL...................................................................................1298 INSTALLATION..............................................................................1298 FLEX PLATE....................................................................................1299 REMOVAL...................................................................................1299 INSTALLATION..............................................................................1299 PISTON & CONNECTING ROD.......................................................................1299 DESCRIPTION...............................................................................1299 STANDARD PROCEDURE........................................................................1299 CONNECTING ROD BEARING FITTING........................................................1299 STANDARD PROCEDURE - PISTON FITTING...................................................1302 REMOVAL...................................................................................1302 CLEANING..................................................................................1303 INSPECTION................................................................................1303 INSTALLATION..............................................................................1303 PISTON RINGS..................................................................................1304 STANDARD PROCEDURE - PISTON RING FITTING..................................................1304 VIBRATION DAMPER..............................................................................1306 REMOVAL...................................................................................1306 INSTALLATION..............................................................................1306 STRUCTURAL COVER..............................................................................1307 DESCRIPTION...............................................................................1307 OPERATION.................................................................................1307 REMOVAL...................................................................................1307 INSTALLATION..............................................................................1307 FRONT MOUNT...................................................................................1308 REMOVAL...................................................................................1308 INSTALLATION..............................................................................1308 REAR MOUNT....................................................................................1309 REMOVAL...................................................................................1309 MANUAL TRANSMISSION...................................................................1309 AUTOMATIC TRANSMISSION................................................................1309 INSTALLATION..............................................................................1309 MANUAL TRANSMISSION:..................................................................1309 AUTOMATIC TRANSMISSION:...............................................................1309 LUBRICATION...................................................................................1310 DESCRIPTION...............................................................................1310 OPERATION.................................................................................1310 DIAGNOSIS AND TESTING.....................................................................1311 DIAGNOSIS AND TESTING - ENGINE OIL LEAK...............................................1311 Air Leak Detection Test Method....................................................1311 INSPECTION FOR REAR SEAL AREA LEAKS...............................................1313 DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE..................................1313 DIAGNOSIS AND TESTING - REAR SEAL AREA LEAKS..........................................1313 OIL...........................................................................................1314 STANDARD PROCEDURE - ENGINE OIL...........................................................1314 ENGINE OIL SPECIFICATION..............................................................1314 API SERVICE GRADE CERTIFIED...........................................................1314 SAE VISCOSITY.........................................................................1314 ENERGY CONSERVING OIL.................................................................1314 CONTAINER IDENTIFICATION..............................................................1314 OIL LEVEL INDICATOR (DIPSTICK)........................................................1314 CRANKCASE OIL LEVEL INSPECTION........................................................1315 ENGINE OIL CHANGE.....................................................................1315 USED ENGINE OIL DISPOSAL..............................................................1315 OIL FILTER....................................................................................1315 REMOVAL...................................................................................1315 INSTALLATION..............................................................................1316 OIL PAN.......................................................................................1316 DESCRIPTION...............................................................................1316 REMOVAL...................................................................................1316 REMOVAL...............................................................................1316 REMOVAL - 4x4.........................................................................1317 CLEANING..................................................................................1317 INSPECTION................................................................................1317 INSTALLATION..............................................................................1318 INSTALLATION..........................................................................1318 INSTALLATION - 4x4....................................................................1318 OIL PRESSURE SENSOR/SWITCH....................................................................1318 DESCRIPTION...............................................................................1318 OPERATION.................................................................................1319 REMOVAL...................................................................................1319 INSTALLATION..............................................................................1319 OIL PUMP......................................................................................1319 REMOVAL...................................................................................1319 DISASSEMBLY...............................................................................1319 INSPECTION................................................................................1319 ASSEMBLY..................................................................................1320 INSTALLATION..............................................................................1320 INTAKE MANIFOLD...............................................................................1322 DESCRIPTION...............................................................................1322 DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS.............................................1322 REMOVAL...................................................................................1322 INSTALLATION..............................................................................1322 EXHAUST MANIFOLD..............................................................................1323 DESCRIPTION...............................................................................1323 REMOVAL...................................................................................1323 RIGHT EXHAUST MANIFOLD................................................................1323 LEFT EXHAUST MANIFOLD.................................................................1324 INSTALLATION..............................................................................1325 RIGHT EXHAUST MANIFOLD................................................................1325 LEFT EXHAUST MANIFOLD.................................................................1325 VALVE TIMING..................................................................................1325 DESCRIPTION...............................................................................1325 OPERATION.................................................................................1325 STANDARD PROCEDURE........................................................................1327 MEASURING TIMING CHAIN WEAR...........................................................1327 SERVICE PROCEDURE - TIMING VERIFICATION...............................................1327 COUNTER BALANCE SHAFT TIMING......................................................1327 TIMING - SINGLE CAMSHAFT..........................................................1327 BALANCE SHAFT.................................................................................1329 REMOVAL...................................................................................1329 INSTALLATION..............................................................................1329 TIMING BELT / CHAIN COVER(S)..................................................................1330 REMOVAL...................................................................................1330 INSTALLATION..............................................................................1330 IDLER SHAFT...................................................................................1331 REMOVAL...................................................................................1331 INSTALLATION..............................................................................1332 TIMING BELT/CHAIN AND SPROCKET(S).............................................................1332 REMOVAL...................................................................................1332 INSPECTION................................................................................1334 INSTALLATION..............................................................................1334 11-EXHAUST SYSTEM.....................................................................................1338 EXHAUST SYSTEM....................................................................................1338 DESCRIPTION...................................................................................1338 DIAGNOSIS AND TESTING - EXHAUST SYSTEM........................................................1339 CATALYTIC CONVERTER...............................................................................1339 DESCRIPTION - CATALYTIC CONVERTER.............................................................1339 REMOVAL.......................................................................................1339 2.4L ENGINES..............................................................................1339 3.7L ENGINES..............................................................................1340 INSPECTION....................................................................................1340 INSTALLATION..................................................................................1340 CROSS-OVER PIPE...................................................................................1341 REMOVAL.......................................................................................1341 INSTALLATION..................................................................................1341 EXHAUST PIPE-2.4L.................................................................................1341 REMOVAL.......................................................................................1341 INSTALLATION..................................................................................1342 HEAT SHIELDS......................................................................................1342 DESCRIPTION...................................................................................1342 MUFFLER...........................................................................................1342 DESCRIPTION...................................................................................1342 REMOVAL.......................................................................................1342 INSTALLATION..................................................................................1343 13-FRAMES & BUMPERS...................................................................................1346 FRONT FASCIA......................................................................................1346 REMOVAL.......................................................................................1346 INSTALLATION..................................................................................1347 REAR FASCIA.......................................................................................1347 REMOVAL.......................................................................................1347 INSTALLATION..................................................................................1347 REAR FASCIA SUPPORT...............................................................................1347 REMOVAL.......................................................................................1347 INSTALLATION..................................................................................1348 REAR FASCIA - STEP PAD............................................................................1348 REMOVAL.......................................................................................1348 INSTALLATION..................................................................................1348 REAR FASCIA - RAIN DIVERTER.......................................................................1348 REMOVAL.......................................................................................1348 INSTALLATION..................................................................................1348 FRAME.............................................................................................1348 SPECIFICATIONS................................................................................1348 SPECIFICATIONS - FRAME DIMENSIONS.........................................................1348 VEHICLE PREPARATION...................................................................1348 DIMENSION ILLUSTRATIONS...............................................................1348 SPECIFICATIONS - TORQUE...................................................................1350 FRONT SKID PLATE..................................................................................1351 REMOVAL.......................................................................................1351 INSTALLATION..................................................................................1351 ENGINE CRADLE CROSSMEMBER.........................................................................1351 REMOVAL.......................................................................................1351 INSTALLATION..................................................................................1351 TRANSFER CASE SKID PLATE..........................................................................1351 REMOVAL.......................................................................................1351 INSTALLATION..................................................................................1351 REAR CROSSMEMBER..................................................................................1352 REMOVAL.......................................................................................1352 INSTALLATION..................................................................................1352 FRONT TOW HOOK....................................................................................1352 REMOVAL.......................................................................................1352 INSTALLATION..................................................................................1352 REAR TOW HOOK.....................................................................................1353 REMOVAL.......................................................................................1353 INSTALLATION..................................................................................1353 TRAILER HITCH.....................................................................................1353 REMOVAL.......................................................................................1353 INSTALLATION..................................................................................1353 FUEL TANK SKID PLATE..............................................................................1353 REMOVAL.......................................................................................1353 INSTALLATION..................................................................................1353 14-FUEL SYSTEM........................................................................................1354 FUEL DELIVERY.....................................................................................1354 FUEL DELIVERY.................................................................................1355 DESCRIPTION...............................................................................1355 OPERATION.................................................................................1355 STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE.........................................1355 SPECIFICATIONS............................................................................1355 FUEL SYSTEM PRESSURE..................................................................1355 TORQUE................................................................................1357 SPECIAL TOOLS.............................................................................1358 FUEL SYSTEM...........................................................................1358 FLOW MANAGEMENT VALVE.........................................................................1358 DESCRIPTION...............................................................................1358 OPERATION.................................................................................1358 REMOVAL...................................................................................1359 INSTALLATION..............................................................................1359 FUEL FILTER...................................................................................1359 DESCRIPTION...............................................................................1359 REMOVAL...................................................................................1359 INSTALLATION..............................................................................1360 FUEL LEVEL SENDING UNIT / SENSOR..............................................................1361 DESCRIPTION...............................................................................1361 OPERATION.................................................................................1361 REMOVAL...................................................................................1361 INSTALLATION..............................................................................1362 FUEL LINES....................................................................................1362 DESCRIPTION...............................................................................1362 QUICK CONNECT FITTING.........................................................................1362 DESCRIPTION...............................................................................1362 STANDARD PROCEDURE - QUICK-CONNECT FITTINGS...............................................1363 DISCONNECTING.........................................................................1363 CONNECTING............................................................................1366 FUEL PRESSURE REGULATOR.......................................................................1366 DESCRIPTION...............................................................................1366 OPERATION.................................................................................1366 REMOVAL...................................................................................1366 INSTALLATION..............................................................................1367 FUEL PUMP.....................................................................................1367 DESCRIPTION...............................................................................1367 OPERATION.................................................................................1367 FUEL PUMP MODULE..............................................................................1367 DESCRIPTION...............................................................................1367 OPERATION.................................................................................1367 REMOVAL...................................................................................1367 INSTALLATION..............................................................................1368 FUEL RAIL.....................................................................................1370 DESCRIPTION...............................................................................1370 OPERATION.................................................................................1371 REMOVAL...................................................................................1371 INSTALLATION..............................................................................1373 FUEL TANK.....................................................................................1374 DESCRIPTION...............................................................................1374 OPERATION.................................................................................1374 REMOVAL...................................................................................1374 Fuel Tank Draining....................................................................1374 Tank Removal..........................................................................1375 INSTALLATION..............................................................................1376 FUEL TANK CHECK VALVE.........................................................................1377 DESCRIPTION...............................................................................1377 OPERATION.................................................................................1377 REMOVAL...................................................................................1377 INSTALLATION..............................................................................1377 INLET FILTER..................................................................................1378 REMOVAL...................................................................................1378 INSTALLATION..............................................................................1378 FUEL INJECTION....................................................................................1379 FUEL INJECTION................................................................................1379 DESCRIPTION...............................................................................1379 ACCELERATOR PEDAL.............................................................................1379 REMOVAL...................................................................................1379 INSTALLATION..............................................................................1379 CRANKSHAFT POSITION SENSOR....................................................................1380 DESCRIPTION...............................................................................1380 2.4L..................................................................................1380 3.7L..................................................................................1380 OPERATION.................................................................................1380 2.4L..................................................................................1380 3.7L..................................................................................1381 REMOVAL...................................................................................1381 2.4L..................................................................................1381 3.7L..................................................................................1382 INSTALLATION..............................................................................1382 2.4L..................................................................................1382 3.7L..................................................................................1382 FUEL INJECTOR.................................................................................1382 DESCRIPTION...............................................................................1382 OPERATION.................................................................................1382 OPERATION - FUEL INJECTOR.............................................................1382 OPERATION - PCM OUTPUT................................................................1383 REMOVAL...................................................................................1383 INSTALLATION..............................................................................1383 FUEL PUMP RELAY...............................................................................1384 DESCRIPTION...............................................................................1384 OPERATION.................................................................................1384 REMOVAL...................................................................................1384 INSTALLATION..............................................................................1384 IDLE AIR CONTROL MOTOR........................................................................1384 DESCRIPTION...............................................................................1384 OPERATION.................................................................................1384 REMOVAL...................................................................................1385 2.4L..................................................................................1385 3.7L..................................................................................1385 INSTALLATION..............................................................................1386 2.4L..................................................................................1386 3.7L..................................................................................1386 INTAKE AIR TEMPERATURE SENSOR.................................................................1386 DESCRIPTION...............................................................................1386 OPERATION.................................................................................1386 REMOVAL...................................................................................1386 2.4L..................................................................................1386 3.7L..................................................................................1387 INSTALLATION..............................................................................1387 2.4L..................................................................................1387 3.7L..................................................................................1387 MAP SENSOR....................................................................................1387 DESCRIPTION...............................................................................1387 2.4L..................................................................................1387 3.7L..................................................................................1387 OPERATION.................................................................................1387 REMOVAL...................................................................................1388 2.4L..................................................................................1388 3.7L..................................................................................1388 INSTALLATION..............................................................................1389 2.4L..................................................................................1389 3.7L..................................................................................1389 OXYGEN SENSOR.................................................................................1389 DESCRIPTION...............................................................................1389 OPERATION.................................................................................1390 REMOVAL...................................................................................1391 INSTALLATION..............................................................................1392 THROTTLE BODY.................................................................................1392 DESCRIPTION...............................................................................1392 OPERATION.................................................................................1392 REMOVAL...................................................................................1393 2.4L..................................................................................1393 3.7L..................................................................................1393 INSTALLATION..............................................................................1393 2.4L..................................................................................1393 3.7L..................................................................................1393 THROTTLE CONTROL CABLE........................................................................1394 REMOVAL...................................................................................1394 2.4L..................................................................................1394 3.7L..................................................................................1395 INSTALLATION..............................................................................1396 THROTTLE POSITION SENSOR......................................................................1396 DESCRIPTION...............................................................................1396 OPERATION.................................................................................1396 REMOVAL...................................................................................1396 2.4L..................................................................................1396 3.7L..................................................................................1397 INSTALLATION..............................................................................1397 2.4L..................................................................................1397 3.7L..................................................................................1397 19-STEERING...........................................................................................1398 STEERING..........................................................................................1398 DESCRIPTION...................................................................................1398 OPERATION.....................................................................................1398 DIAGNOSIS AND TESTING.........................................................................1398 DIAGNOSIS AND TESTING - POWER STEERING SYSTEM.............................................1398 DIAGNOSIS AND TESTING - POWER STEERING FLOW AND PRESSURE..................................1401 FLOW AND PRESSURE TEST................................................................1401 COLUMN............................................................................................1402 COLUMN........................................................................................1402 DESCRIPTION...............................................................................1402 OPERATION - SERVICE PRECAUTIONS...........................................................1402 REMOVAL...................................................................................1402 INSTALLATION..............................................................................1404 SPECIFICATIONS............................................................................1405 TORQUE CHART..........................................................................1405 SPECIAL TOOLS.............................................................................1405 STEERING COLUMN.......................................................................1405 IGNITION SWITCH...............................................................................1405 DESCRIPTION...............................................................................1405 DIAGNOSIS AND TESTING - IGNITION SWITCH...................................................1405 ELECTRICAL DIAGNOSIS..................................................................1405 MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE)........................................1405 REMOVAL...................................................................................1406 IGNITION SWITCH REMOVAL...............................................................1406 INSTALLATION..............................................................................1406 IGNITION SWITCH INSTALLATION..........................................................1406 KEY-IN IGNITION SWITCH........................................................................1407 DESCRIPTION...............................................................................1407 DIAGNOSIS AND TESTING - KEY-IN IGNITION SWITCH............................................1407 KEY CYLINDER0 - 8 KJ (Continued)..........................................................1407 REMOVAL...................................................................................1407 INSTALLATION..............................................................................1408 INTERMEDIATE SHAFT............................................................................1408 REMOVAL...................................................................................1408 INSTALLATION..............................................................................1408 STEERING WHEEL................................................................................1409 REMOVAL...................................................................................1409 INSTALLATION..............................................................................1409 GEAR..............................................................................................1410 GEAR..........................................................................................1410 DESCRIPTION...............................................................................1410 OPERATION.................................................................................1410 REMOVAL...................................................................................1410 REMOVAL - 4WD.........................................................................1410 REMOVAL - 2WD.........................................................................1411 REMOVAL - 2.5L DIESEL.................................................................1411 REMOVAL - RHD - 4X2 & 4X4.............................................................1412 INSTALLATION..............................................................................1412 INSTALLATION - 4WD....................................................................1412 INSTALLATION - 2WD....................................................................1413 INSTALLATION - 2.5L DIESEL............................................................1413 INSTALLATION - RHD - 4X2 & 4X4........................................................1413 SPECIFICATIONS............................................................................1414 TORQUE CHART..........................................................................1414 SPECIAL TOOLS.............................................................................1414 OUTER TIE ROD END REMOVAL TOOL........................................................1414 LINKAGE...........................................................................................1415 LINKAGE.......................................................................................1415 STANDARD PROCEDURE - STEERING LINKAGE.....................................................1415 TIE ROD END...................................................................................1415 REMOVAL...................................................................................1415 INSTALLATION..............................................................................1415 PUMP..............................................................................................1416 PUMP..........................................................................................1416 DESCRIPTION...............................................................................1416 DESCRIPTION...........................................................................1416 DESCRIPTION...........................................................................1416 OPERATION.................................................................................1416 STANDARD PROCEDURE - POWER STEERING PUMP - INITIAL OPERATION..............................1417 REMOVAL...................................................................................1417 REMOVAL...............................................................................1417 REMOVAL - 3.7L........................................................................1418 REMOVAL - 2.4L........................................................................1418 INSTALLATION..............................................................................1418 INSTALLATION..........................................................................1418 INSTALLATION - 3.7L...................................................................1419 INSTALLATION - 2.4L...................................................................1419 SPECIFICATIONS............................................................................1419 TORQUE CHART..........................................................................1419 SPECIAL TOOLS.............................................................................1420 POWER STEERING PUMP...................................................................1420 FLUID COOLER..................................................................................1420 DESCRIPTION...............................................................................1420 OPERATION.................................................................................1420 REMOVAL...................................................................................1420 INSTALLATION..............................................................................1420 HOSES.........................................................................................1421 REMOVAL...................................................................................1421 REMOVAL...............................................................................1421 REMOVAL - PRESSURE HOSE...............................................................1421 REMOVAL - RETURN HOSE (GEAR TO THE COOLER)............................................1421 REMOVAL - RETURN HOSE (RESERVOIR TO THE COOLER).......................................1421 INSTALLATION..............................................................................1421 INSTALLATION..........................................................................1421 INSTALLATION - PRESSURE HOSE..........................................................1422 INSTALLATION - RETURN HOSE (GEAR TO THE COOLER).......................................1422 INSTALLATION - RETURN HOSE (RESERVOIR TO THE COOLER)..................................1423 POWER STEERING PRESSURE SWITCH................................................................1423 DESCRIPTION...............................................................................1423 OPERATION.................................................................................1423 REMOVAL...................................................................................1423 INSTALLATION..............................................................................1423 PULLEY........................................................................................1423 REMOVAL...................................................................................1423 REMOVAL - DIESEL......................................................................1423 REMOVAL...............................................................................1423 INSTALLATION..............................................................................1424 INSTALLATION - DIESEL.................................................................1424 INSTALLATION..........................................................................1424 RESERVOIR.....................................................................................1424 REMOVAL...................................................................................1424 REMOVAL - DIESEL......................................................................1424 REMOVAL - 3.7L........................................................................1425 REMOVAL - 2.4L........................................................................1425 INSTALLATION..............................................................................1425 INSTALLATION - DIESEL.................................................................1425 INSTALLATION - 3.7L...................................................................1425 INSTALLATION - 2.4L...................................................................1425 21-TRANSMISSION AND TRANSFER CASE.....................................................................1426 MANUAL - NV1500...................................................................................1426 MANUAL - NV1500...............................................................................1426 DESCRIPTION...............................................................................1426 OPERATION.................................................................................1426 DIAGNOSIS AND TESTING.....................................................................1427 LOW LUBRICANT LEVEL...................................................................1427 HARD SHIFTING.........................................................................1427 TRANSMISSION NOISE....................................................................1428 REMOVAL...................................................................................1428 DISASSEMBLY...............................................................................1429 CLEANING..................................................................................1436 INSPECTION................................................................................1436 SHIFT LEVER ASSEMBLY..................................................................1436 SHIFT SHAFT AND FORKS.................................................................1436 FRONT/REAR HOUSINGS AND BEARING RETAINERS.............................................1436 COUNTERSHAFT BEARINGS AND RACES.......................................................1437 REVERSE IDLER COMPONENTS..............................................................1437 Shift Socket..........................................................................1438 Output Shaft And Geartrain............................................................1438 ASSEMBLY..................................................................................1438 INSTALLATION..............................................................................1455 SPECIFICATIONS............................................................................1456 SPECIAL TOOLS.............................................................................1456 EXTENSION HOUSING SEAL........................................................................1458 REMOVAL...................................................................................1458 INSTALLATION..............................................................................1458 MANUAL - NV3550...................................................................................1459 MANUAL - NV3550...............................................................................1459 DESCRIPTION...............................................................................1459 OPERATION.................................................................................1459 DIAGNOSIS AND TESTING.....................................................................1459 LOW LUBRICANT LEVEL...................................................................1459 HARD SHIFTING.........................................................................1460 TRANSMISSION NOISE....................................................................1460 REMOVAL...................................................................................1460 DISASSEMBLY...............................................................................1461 FRONT HOUSING.........................................................................1461 SHIFT/FORK SHAFTS AND REVERSE IDLER SEGMENT...........................................1464 REAR HOUSING - 2WD....................................................................1467 REAR ADAPTER HOUSING - 4WD............................................................1469 GEARTRAIN FROM FIXTURE................................................................1470 OUTPUT SHAFT..........................................................................1470 REVERSE IDLER.........................................................................1473 CLEANING..................................................................................1473 INSPECTION................................................................................1474 SHIFT LEVER ASSEMBLY..................................................................1474 SHIFT SHAFT AND FORKS.................................................................1474 FRONT/REAR HOUSINGS AND BEARING RETAINERS.............................................1474 COUNTERSHAFT BEARINGS AND RACES.......................................................1475 REVERSE IDLER COMPONENTS..............................................................1475 Shift Socket..........................................................................1475 Output Shaft And Geartrain............................................................1475 ASSEMBLY..................................................................................1475 SYNCHRONIZER..........................................................................1475 OUTPUT SHAFT..........................................................................1476 REVERSE IDLER ASSEMBLY................................................................1483 SHIFT SHAFT AND BUSHINGS/BEARINGS.....................................................1484 DETENT PLUNGER BUSHING................................................................1484 GEARTRAIN ASSEMBLY....................................................................1485 REAR HOUSING - 2WD....................................................................1487 ADAPTER HOUSING - 4WD.................................................................1489 SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET.................................1490 FRONT HOUSING AND INPUT SHAFT BEARING RETAINER........................................1493 SHIFT TOWER AND LEVER.................................................................1496 INSTALLATION..............................................................................1496 SPECIFICATIONS............................................................................1497 SPECIAL TOOLS.............................................................................1498 EXTENSION HOUSING BUSHING.....................................................................1500 REMOVAL...................................................................................1500 INSTALLATION..............................................................................1500 EXTENSION HOUSING SEAL........................................................................1500 REMOVAL...................................................................................1500 INSTALLATION..............................................................................1500 AUTOMATIC TRANSMISSION - 42RLE....................................................................1501 AUTOMATIC TRANSMISSION - 42RLE................................................................1502 DESCRIPTION...............................................................................1502 TRANSMISSION IDENTIFICATION...........................................................1504 OPERATION.................................................................................1504 FIRST GEAR POWERFLOW..................................................................1505 SECOND GEAR POWERFLOW.................................................................1506 THIRD GEAR POWERFLOW..................................................................1507 FOURTH GEAR POWERFLOW.................................................................1508 REVERSE GEAR POWERFLOW................................................................1509 DIAGNOSIS AND TESTING.....................................................................1509 DIAGNOSIS AND TESTING - AUTOMATIC TRANSMISSION........................................1509 DIAGNOSIS AND TESTING - ROAD TEST.....................................................1510 DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TESTS......................................1511 TEST ONE-SELECTOR IN L (1st Gear).................................................1511 TEST TWO-SELECTOR IN DRIVE (Second Gear)..........................................1511 TEST TWO A–SELECTOR IN OD (Fourth Gear)...........................................1511 TEST THREE-SELECTOR IN OVERDRIVE (Third and Second Gear)..........................1511 TEST FOUR-SELECTOR IN OD (Fourth Gear)............................................1511 TEST FIVE-SELECTOR IN OVERDRIVE (Fourth Gear, CC on)..............................1512 TEST SIX-SELECTOR IN REVERSE......................................................1512 TEST RESULT INDICATIONS...........................................................1512 DIAGNOSIS AND TESTING - CLUTCH AIR PRESSURE TESTS.....................................1513 OVERDRIVE CLUTCH..................................................................1513 UNDERDRIVE CLUTCH.................................................................1513 REVERSE CLUTCH....................................................................1513 2/4 CLUTCH........................................................................1513 LOW/REVERSE CLUTCH................................................................1513 DIAGNOSIS AND TESTING - FLUID LEAKAGE.................................................1513 FLUID LEAKAGE - TORQUE CONVERTER HOUSING AREA.....................................1513 TORQUE CONVERTER LEAKAGE..........................................................1514 STANDARD PROCEDURE - ALUMINUM THREAD REPAIR...............................................1514 REMOVAL...................................................................................1514 DISASSEMBLY...............................................................................1516 ASSEMBLY..................................................................................1533 INSTALLATION..............................................................................1550 SCHEMATICS AND DIAGRAMS - 42RLE TRANSMISSION..............................................1552 SPECIFICATIONS............................................................................1565 42RLE AUTOMATIC TRANSMISSION..........................................................1565 SPECIAL TOOLS.............................................................................1567 42RLE AUTOMATIC TRANSMISSION..........................................................1567 ACCUMULATOR...................................................................................1570 DESCRIPTION...............................................................................1570 OPERATION.................................................................................1570 ADAPTER HOUSING SEAL..........................................................................1570 REMOVAL...................................................................................1570 INSTALLATION..............................................................................1570 BEARINGS......................................................................................1571 ADJUSTMENTS...............................................................................1571 BEARING ADJUSTMENT PROCEDURES.........................................................1571 BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM..................................................1571 DESCRIPTION...............................................................................1571 OPERATION.................................................................................1571 DIAGNOSIS AND TESTING - BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM.........................1571 DRIVING CLUTCHES..............................................................................1571 DESCRIPTION...............................................................................1571 OPERATION.................................................................................1571 UNDERDRIVE CLUTCH.....................................................................1572 OVERDRIVE CLUTCH......................................................................1572 REVERSE CLUTCH........................................................................1572 EXTENSION HOUSING SEAL........................................................................1572 REMOVAL...................................................................................1572 INSTALLATION..............................................................................1572 FLUID AND FILTER..............................................................................1573 DIAGNOSIS AND TESTING.....................................................................1573 DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID.........................................1573 DIAGNOSIS AND TESTING - EFFECTS OF INCORRECT FLUID LEVEL..............................1573 DIAGNOSIS AND TESTING - FLUID CONTAMINATION...........................................1573 STANDARD PROCEDURE........................................................................1573 STANDARD PROCEDURE - FLUID LEVEL CHECK................................................1573 FLUID LEVEL CHECK.................................................................1573 FLUID LEVEL CHECK USING DRB.......................................................1573 STANDARD PROCEDURE - FLUID/FILTER SERVICE.............................................1574 STANDARD PROCEDURE - TRANSMISSION FILL................................................1574 GEARSHIFT CABLE...............................................................................1575 DIAGNOSIS AND TESTING - GEARSHIFT CABLE...................................................1575 REMOVAL...................................................................................1575 INSTALLATION..............................................................................1576 ADJUSTMENTS - GEARSHIFT CABLE.............................................................1577 Gearshift Adjustment Procedure........................................................1577 HOLDING CLUTCHES..............................................................................1577 DESCRIPTION...............................................................................1577 OPERATION.................................................................................1577 2/4 CLUTCH............................................................................1577 LOW/REVERSE CLUTCH....................................................................1578 INPUT CLUTCH ASSEMBLY.........................................................................1578 DISASSEMBLY...............................................................................1578 ASSEMBLY..................................................................................1585 INPUT SPEED SENSOR............................................................................1595 DESCRIPTION...............................................................................1595 OPERATION.................................................................................1595 REMOVAL...................................................................................1596 INSTALLATION..............................................................................1596 OIL PUMP......................................................................................1596 DESCRIPTION...............................................................................1596 OPERATION.................................................................................1596 DISASSEMBLY...............................................................................1596 ASSEMBLY..................................................................................1597 OUTPUT SPEED SENSOR...........................................................................1598 DESCRIPTION...............................................................................1598 OPERATION.................................................................................1598 REMOVAL...................................................................................1598 INSTALLATION..............................................................................1598 OVERDRIVE SWITCH..............................................................................1598 DESCRIPTION...............................................................................1598 OPERATION.................................................................................1598 PARK - INTERLOCK CABLE........................................................................1599 REMOVAL...................................................................................1599 INSTALLATION..............................................................................1599 ADJUSTMENTS - PARK-INTERLOCK CABLE........................................................1600 PLANETARY GEARTRAIN...........................................................................1601 DESCRIPTION...............................................................................1601 OPERATION.................................................................................1601 SEAL - OIL PUMP...............................................................................1601 REMOVAL...................................................................................1601 INSTALLATION..............................................................................1601 SHIFT MECHANISM...............................................................................1601 DESCRIPTION...............................................................................1601 OPERATION.................................................................................1601 REMOVAL...................................................................................1602 INSTALLATION..............................................................................1602 SOLENOID......................................................................................1602 DESCRIPTION...............................................................................1602 OPERATION.................................................................................1603 SOLENOID/PRESSURE SWITCH ASSY.................................................................1604 DESCRIPTION...............................................................................1604 OPERATION.................................................................................1604 SOLENOIDS.............................................................................1604 PRESSURE SWITCHES.....................................................................1604 REMOVAL...................................................................................1605 INSTALLATION..............................................................................1605 TORQUE CONVERTER..............................................................................1606 DESCRIPTION...............................................................................1606 IMPELLER..............................................................................1607 TURBINE...............................................................................1608 STATOR................................................................................1609 TORQUE CONVERTER CLUTCH (TCC).........................................................1609 OPERATION.................................................................................1610 TURBINE...............................................................................1610 STATOR................................................................................1611 TORQUE CONVERTER CLUTCH (TCC).........................................................1611 REMOVAL...................................................................................1611 INSTALLATION..............................................................................1611 TRANSMISSION CONTROL RELAY....................................................................1612 DESCRIPTION...............................................................................1612 OPERATION.................................................................................1612 TRANSMISSION RANGE SENSOR.....................................................................1612 DESCRIPTION...............................................................................1612 OPERATION.................................................................................1612 REMOVAL...................................................................................1613 INSTALLATION..............................................................................1613 TRANSMISSION TEMPERATURE SENSOR...............................................................1613 DESCRIPTION...............................................................................1613 OPERATION.................................................................................1614 CALCULATED TEMPERATURE................................................................1614 VALVE BODY....................................................................................1614 DESCRIPTION...............................................................................1614 OPERATION.................................................................................1614 THERMAL VALVE.........................................................................1614 REGULATOR VALVE.......................................................................1614 SOLENOID SWITCH VALVE.................................................................1616 MANUAL VALVE..........................................................................1616 CONVERTER CLUTCH SWITCH VALVE.........................................................1616 CONVERTER CLUTCH CONTROL VALVE........................................................1616 T/C REGULATOR VALVE...................................................................1616 LOW/REVERSE SWITCH VALVE..............................................................1616 REMOVAL...................................................................................1617 DISASSEMBLY...............................................................................1619 ASSEMBLY..................................................................................1625 INSTALLATION..............................................................................1630 AUTOMATIC TRANSMISSION - 45RFE....................................................................1631 AUTOMATIC TRANSMISSION - 45RFE................................................................1632 DESCRIPTION...............................................................................1632 TRANSMISSION IDENTIFICATION...........................................................1633 GEAR RATIOS...........................................................................1633 OPERATION.................................................................................1633 DIAGNOSIS AND TESTING.....................................................................1633 DIAGNOSIS AND TESTING - AUTOMATIC TRANSMISSION........................................1633 DIAGNOSIS AND TESTING - PRELIMINARY...................................................1634 VEHICLE IS DRIVABLE...............................................................1634 VEHICLE IS DISABLED...............................................................1634 DIAGNOSIS AND TESTING - ROAD TESTING..................................................1634 DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TEST.......................................1635 Pressure Test Port Locations......................................................1635 TEST PROCEDURE....................................................................1635 DIAGNOSIS AND TESTING - AIR CHECKING TRANSMISSION CLUTCH OPERATION....................1636 DIAGNOSIS AND TESTING - CONVERTER HOUSING FLUID LEAK..................................1636 TORQUE CONVERTER LEAK POINTS......................................................1636 STANDARD PROCEDURE - ALUMINUM THREAD REPAIR...............................................1637 REMOVAL...................................................................................1637 DISASSEMBLY...............................................................................1639 CLEANING..................................................................................1645 INSPECTION................................................................................1645 ASSEMBLY..................................................................................1646 INSTALLATION..............................................................................1652 SCHEMATICS AND DIAGRAMS...................................................................1656 HYDRAULIC SCHEMATICS..................................................................1656 SPECIFICATIONS............................................................................1675 TRANSMISSION..........................................................................1675 SPECIAL TOOLS.............................................................................1676 RFE TRANSMISSION......................................................................1676 4C RETAINER/BULKHEAD..........................................................................1679 DISASSEMBLY...............................................................................1679 ASSEMBLY..................................................................................1679 ADAPTER HOUSING SEAL..........................................................................1680 REMOVAL...................................................................................1680 INSTALLATION..............................................................................1680 BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM.....................................................1681 DESCRIPTION...............................................................................1681 OPERATION.................................................................................1681 DIAGNOSIS AND TESTING - BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM.........................1681 FLUID AND FILTER..............................................................................1681 DIAGNOSIS AND TESTING.....................................................................1681 DIAGNOSIS AND TESTING - EFFECTS OF INCORRECT FLUID LEVEL..............................1681 DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID.........................................1681 DIAGNOSIS AND TESTING - FLUID CONTAMINATION...........................................1681 STANDARD PROCEDURE........................................................................1682 STANDARD PROCEDURE - FLUID LEVEL CHECK................................................1682 STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT.....................................1682 REMOVAL...........................................................................1682 INSPECTION........................................................................1683 CLEANING..........................................................................1683 INSTALLATION......................................................................1684 STANDARD PROCEDURE - TRANSMISSION FILL................................................1684 GEARSHIFT CABLE...............................................................................1684 DIAGNOSIS AND TESTING - GEARSHIFT CABLE...................................................1684 REMOVAL...................................................................................1684 INSTALLATION..............................................................................1685 ADJUSTMENTS - GEARSHIFT CABLE.............................................................1686 Gearshift Adjustment Procedure........................................................1686 HOLDING CLUTCHES..............................................................................1687 DESCRIPTION...............................................................................1687 OPERATION.................................................................................1688 2C CLUTCH.............................................................................1688 4C CLUTCH.............................................................................1688 LOW/REVERSE CLUTCH....................................................................1688 INPUT CLUTCH ASSEMBLY.........................................................................1689 DESCRIPTION...............................................................................1689 OPERATION.................................................................................1689 UNDERDRIVE CLUTCH.....................................................................1689 OVERDRIVE CLUTCH......................................................................1691 REVERSE CLUTCH........................................................................1691 DISASSEMBLY...............................................................................1691 ASSEMBLY..................................................................................1693 INPUT SPEED SENSOR............................................................................1698 DESCRIPTION...............................................................................1698 OPERATION.................................................................................1698 REMOVAL...................................................................................1698 INSTALLATION..............................................................................1699 LINE PRESSURE (LP) SENSOR.....................................................................1699 DESCRIPTION...............................................................................1699 OPERATION.................................................................................1699 REMOVAL...................................................................................1699 INSTALLATION..............................................................................1699 LOW/REVERSE CLUTCH............................................................................1700 DISASSEMBLY...............................................................................1700 CLEANING..................................................................................1701 INSPECTION................................................................................1701 ASSEMBLY..................................................................................1701 OIL PUMP......................................................................................1702 DESCRIPTION...............................................................................1702 OPERATION.................................................................................1702 CONVERTER CLUTCH SWITCH VALVE.........................................................1702 CONVERTER CLUTCH REGULATOR VALVE......................................................1703 TORQUE CONVERTER LIMIT VALVE..........................................................1703 STANDARD PROCEDURE - OIL PUMP VOLUME CHECK................................................1703 DISASSEMBLY...............................................................................1704 CLEANING..................................................................................1705 INSPECTION................................................................................1705 ASSEMBLY..................................................................................1706 OIL PUMP FRONT SEAL...........................................................................1707 REMOVAL...................................................................................1707 INSTALLATION..............................................................................1707 OUTPUT SPEED SENSOR...........................................................................1707 DESCRIPTION...............................................................................1707 OPERATION.................................................................................1707 REMOVAL...................................................................................1707 INSTALLATION..............................................................................1707 OVERDRIVE SWITCH..............................................................................1708 DESCRIPTION...............................................................................1708 OPERATION.................................................................................1708 PARK - INTERLOCK CABLE........................................................................1708 REMOVAL...................................................................................1708 INSTALLATION..............................................................................1708 ADJUSTMENTS - PARK-INTERLOCK CABLE........................................................1709 PISTONS.......................................................................................1710 DESCRIPTION...............................................................................1710 OPERATION.................................................................................1710 PRESSURE..............................................................................1710 PRESSURE ON A CONFINED FLUID..........................................................1710 FORCE MULTIPLICATION..................................................................1711 PISTON TRAVEL.........................................................................1711 PLANETARY GEARTRAIN...........................................................................1712 DESCRIPTION...............................................................................1712 OPERATION.................................................................................1712 REACTION PLANETARY GEARTRAIN..........................................................1712 REVERSE PLANETARY GEARTRAIN...........................................................1712 INPUT PLANETARY GEARTRAIN.............................................................1713 DISASSEMBLY...............................................................................1713 CLEANING..................................................................................1713 INSPECTION................................................................................1713 ASSEMBLY..................................................................................1714 SHIFT MECHANISM...............................................................................1715 DESCRIPTION...............................................................................1715 OPERATION.................................................................................1715 REMOVAL...................................................................................1715 INSTALLATION..............................................................................1716 SOLENOID SWITCH VALVE.........................................................................1716 DESCRIPTION...............................................................................1716 OPERATION.................................................................................1716 SOLENOIDS.....................................................................................1716 DESCRIPTION...............................................................................1716 OPERATION.................................................................................1717 TORQUE CONVERTER..............................................................................1717 DESCRIPTION...............................................................................1717 IMPELLER..............................................................................1718 TURBINE...............................................................................1719 STATOR................................................................................1720 TORQUE CONVERTER CLUTCH (TCC).........................................................1720 OPERATION.................................................................................1721 TURBINE...............................................................................1721 STATOR................................................................................1721 TORQUE CONVERTER CLUTCH (TCC).........................................................1721 REMOVAL...................................................................................1722 INSTALLATION..............................................................................1722 TRANSMISSION CONTROL RELAY....................................................................1723 DESCRIPTION...............................................................................1723 OPERATION.................................................................................1723 TRANSMISSION RANGE SENSOR.....................................................................1723 DESCRIPTION...............................................................................1723 OPERATION.................................................................................1723 TRANSMISSION SOLENOID/TRS ASSEMBLY............................................................1724 DESCRIPTION...............................................................................1724 OPERATION.................................................................................1724 SOLENOIDS.............................................................................1724 PRESSURE SWITCHES.....................................................................1724 REMOVAL...................................................................................1725 INSTALLATION..............................................................................1725 TRANSMISSION TEMPERATURE SENSOR...............................................................1725 DESCRIPTION...............................................................................1725 OPERATION.................................................................................1725 Calculated Temperature................................................................1725 VALVE BODY....................................................................................1726 DESCRIPTION...............................................................................1726 OPERATION.................................................................................1726 SOLENOID SWITCH VALVE.................................................................1726 MANUAL VALVE..........................................................................1727 LOW/REVERSE SWITCH VALVE..............................................................1727 REMOVAL...................................................................................1727 DISASSEMBLY...............................................................................1728 CLEANING..................................................................................1730 INSPECTION................................................................................1731 ASSEMBLY..................................................................................1732 INSTALLATION..............................................................................1732 TRANSFER CASE - NV231.............................................................................1733 TRANSFER CASE - NV231.........................................................................1733 DESCRIPTION...............................................................................1733 OPERATING RANGES......................................................................1733 SHIFT MECHANISM.......................................................................1734 IDENTIFICATION........................................................................1734 OPERATION.................................................................................1734 DIAGNOSIS AND TESTING - TRANSFER CASE - NV231.............................................1735 REMOVAL...................................................................................1736 DISASSEMBLY...............................................................................1737 REAR RETAINER AND OIL PUMP............................................................1737 COMPANION FLANGE AND RANGE LEVER......................................................1738 FRONT OUTPUT SHAFT AND DRIVE CHAIN....................................................1739 SHIFT FORKS AND MAINSHAFT.............................................................1740 MAINSHAFT.............................................................................1742 INPUT GEAR AND LOW RANGE GEAR.........................................................1742 INPUT AND LOW RANGE GEAR..............................................................1743 CLEANING..................................................................................1745 INSPECTION................................................................................1745 MAINSHAFT/SPROCKET/HUB................................................................1745 INPUT GEAR AND PLANETARY CARRIER......................................................1746 SHIFT FORKS/HUBS/SLEEVES..............................................................1746 REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT..............................................1747 REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN....................................................1748 LOW RANGE ANNULUS GEAR................................................................1748 FRONT/REAR CASES AND FRONT RETAINER...................................................1748 OIL PUMP/OIL PICKUP...................................................................1748 ASSEMBLY..................................................................................1748 BEARINGS AND SEALS....................................................................1748 INPUT AND LOW RANGE GEAR..............................................................1752 MAINSHAFT.............................................................................1753 SHIFT FORKS, SECTOR, AND MAINSHAFT....................................................1753 FRONT OUTPUT SHAFT AND DRIVE CHAIN....................................................1755 OIL PUMP AND REAR CASE................................................................1756 COMPANION FLANGE AND RANGE LEVER......................................................1757 REAR RETAINER.........................................................................1757 INSTALLATION..............................................................................1758 SPECIFICATIONS............................................................................1758 TRANSFER CASE - NV231.................................................................1758 SPECIAL TOOLS.............................................................................1759 TRANSFER CASE - NV231.................................................................1759 FLUID.........................................................................................1761 STANDARD PROCEDURE - FLUID DRAIN AND FILL.................................................1761 FRONT OUTPUT SHAFT SEAL.......................................................................1761 REMOVAL...................................................................................1761 INSTALLATION..............................................................................1761 POSITION SENSOR...............................................................................1761 DESCRIPTION...............................................................................1761 OPERATION.................................................................................1762 REMOVAL...................................................................................1763 INSTALLATION..............................................................................1763 REAR OUTPUT SHAFT SEAL........................................................................1763 REMOVAL...................................................................................1763 INSTALLATION..............................................................................1764 SHIFT LEVER...................................................................................1765 REMOVAL...................................................................................1765 INSTALLATION..............................................................................1765 TRANSFER CASE - NV242.............................................................................1766 TRANSFER CASE - NV242.........................................................................1766 DESCRIPTION...............................................................................1766 TRANSFER CASE IDENTIFICATION..........................................................1766 OPERATING RANGES......................................................................1766 SHIFT MECHANISM.......................................................................1766 OPERATION.................................................................................1767 DIAGNOSIS AND TESTING - TRANSFER CASE - NV242.............................................1767 REMOVAL...................................................................................1768 DISASSEMBLY...............................................................................1769 REAR RETAINER.........................................................................1769 COMPANION FLANGE AND RANGE LEVER......................................................1771 FRONT OUTPUT SHAFT AND DRIVE CHAIN....................................................1772 SHIFT FORKS AND MAINSHAFT.............................................................1773 INPUT GEAR/LOW RANGE ASSEMBLY.........................................................1776 DIFFERENTIAL..........................................................................1778 CLEANING..................................................................................1779 INSPECTION................................................................................1779 MAINSHAFT/SPROCKET/HUB................................................................1779 INPUT GEAR AND PLANETARY CARRIER......................................................1779 SHIFT FORKS/HUBS/SLEEVES..............................................................1780 REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT..............................................1780 REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN....................................................1780 LOW RANGE ANNULUS GEAR................................................................1780 FRONT-REAR CASES AND FRONT RETAINER...................................................1780 OIL PUMP/OIL PICKUP...................................................................1780 ASSEMBLY..................................................................................1782 BEARINGS AND SEALS....................................................................1782 DIFFERENTIAL..........................................................................1785 INPUT GEAR/LOW RANGE ASSEMBLY.........................................................1786 SHIFT FORKS, SECTOR, AND MAINSHAFT....................................................1787 FRONT OUTPUT SHAFT AND DRIVE CHAIN....................................................1792 OIL PUMP AND REAR CASE................................................................1792 REAR RETAINER.........................................................................1793 COMPANION FLANGE AND RANGE LEVER......................................................1794 INSTALLATION..............................................................................1795 SPECIFICATIONS............................................................................1795 NV242 TRANSFER CASE...................................................................1795 SPECIAL TOOLS.............................................................................1796 TRANSFER CASE - NV242.................................................................1796 FLUID.........................................................................................1798 STANDARD PROCEDURE - FLUID DRAIN AND FILL.................................................1798 FRONT OUTPUT SHAFT SEAL.......................................................................1798 REMOVAL...................................................................................1798 INSTALLATION..............................................................................1798 POSITION SENSOR...............................................................................1798 DESCRIPTION...............................................................................1798 OPERATION.................................................................................1799 REMOVAL...................................................................................1800 INSTALLATION..............................................................................1800 REAR OUTPUT SHAFT SEAL........................................................................1800 REMOVAL...................................................................................1800 INSTALLATION..............................................................................1801 SHIFT LEVER...................................................................................1801 REMOVAL...................................................................................1801 INSTALLATION..............................................................................1802 22-TIRES/WHEELS.......................................................................................1804 TIRES/WHEELS......................................................................................1804 DIAGNOSIS AND TESTING - TIRE AND WHEEL RUNOUT.................................................1804 METHOD 1 (RELOCATE WHEEL ON HUB)..........................................................1804 METHOD 2 (RELOCATE TIRE ON WHEEL).........................................................1804 STANDARD PROCEDURE............................................................................1805 STANDARD PROCEDURE - TIRE ROTATION........................................................1805 STANDARD PROCEDURE - MATCH MOUNTING.......................................................1806 STANDARD PROCEDURE - WHEEL BALANCING......................................................1807 SPARE TIRE........................................................................................1808 DESCRIPTION...................................................................................1808 DESCRIPTION - SPARE / TEMPORARY TIRE......................................................1808 DESCRIPTION - FULL SIZE, SPARE WHEEL WITH MATCHING TIRE...................................1808 REMOVAL.......................................................................................1808 INSTALLATION..................................................................................1808 TIRES.............................................................................................1808 DESCRIPTION...................................................................................1808 DESCRIPTION - TIRES.......................................................................1808 TIRE IDENTIFICATION...................................................................1809 TIRE CHAINS...........................................................................1809 DESCRIPTION - RADIAL-PLY TIRES............................................................1809 DESCRIPTION - SPARE TIRE &TEMPORARY.......................................................1809 DESCRIPTION - TIRE PRESSURE FOR HIGH SPEED................................................1809 DESCRIPTION - REPLACEMENT TIRES...........................................................1810 DIAGNOSIS AND TESTING.........................................................................1810 DIAGNOSIS AND TESTING - TIRE INFLATION....................................................1810 DIAGNOSIS AND TESTING - TREAD WEAR INDICATORS.............................................1811 DIAGNOSIS AND TESTING - PRESSURE GAUGES...................................................1811 DIAGNOSIS AND TESTING - TIRE/VEHICLE LEAD.................................................1811 DIAGNOSIS AND TESTING - TIRE WEAR PATTERNS................................................1811 DIAGNOSIS AND TESTING - TIRE NOISE OR VIBRATION...........................................1811 STANDARD PROCEDURE - REPAIRING LEAKS..........................................................1811 CLEANING......................................................................................1811 SPECIFICATIONS................................................................................1813 WHEELS............................................................................................1813 DESCRIPTION...................................................................................1813 DIAGNOSIS AND TESTING - WHEELS................................................................1814 STANDARD PROCEDURE............................................................................1814 STANDARD PROCEDURE - WHEEL REPLACEMENT....................................................1814 STANDARD PROCEDURE - WHEEL MOUNTING.......................................................1814 SPECIFICATIONS................................................................................1815 SPECIFICATION.............................................................................1815 STUDS.............................................................................................1815 REMOVAL.......................................................................................1815 INSTALLATION..................................................................................1815 23-BODY...............................................................................................1824 BODY..............................................................................................1824 WARNING.......................................................................................1824 SAFETY PRECAUTIONS AND WARNINGS0 - 10 KJ (Continued)..................................1824 DIAGNOSIS AND TESTING.........................................................................1824 DIAGNOSIS AND TESTING - WATER LEAKS.......................................................1824 VISUAL INSPECTION BEFORE WATER LEAK TESTS.............................................1825 WATER LEAK TESTS......................................................................1825 WATER LEAK DETECTION..................................................................1825 DIAGNOSIS AND TESTING - WIND NOISE........................................................1825 VISUAL INSPECTION BEFORE TESTS........................................................1825 STANDARD PROCEDURE............................................................................1826 STANDARD PROCEDURE - BODY LUBRICATION.....................................................1826 STANDARD PROCEDURE - HEAT STAKING.........................................................1826 STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR............................................1826 Rigid Plastics:.......................................................................1826 Semi-Rigid Plastics:..................................................................1827 Flexible Plastics:....................................................................1827 Repair Procedure:.....................................................................1827 Adhesion Promoter/Surface Modifier:...................................................1827 SAFETY PRECAUTION AND WARNINGS........................................................1827 RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES...................................1827 PANEL SECTIONING......................................................................1829 PANEL REINFORCEMENT...................................................................1829 VISUAL INSPECTION.....................................................................1830 PANEL SURFACE PREPARATION.............................................................1830 PATCHING PANELS.......................................................................1831 PANEL PATCH FABRICATIONS..............................................................1831 PANEL PATCH INSTALLATION..............................................................1831 PATCHED PANEL SURFACING...............................................................1833 STANDARD PROCEDURE - BUZZ, SQUEAK & RATTLE................................................1833 SPECIFICATIONS................................................................................1835 SPECIAL TOOLS.................................................................................1836 BODY......................................................................................1836 HOOD..............................................................................................1837 HINGE.........................................................................................1837 REMOVAL...................................................................................1837 INSTALLATION..............................................................................1837 HOOD..........................................................................................1837 REMOVAL...................................................................................1837 INSTALLATION..............................................................................1837 ADJUSTMENTS...............................................................................1837 ADJUSTMENT............................................................................1837 LATCH.........................................................................................1837 REMOVAL...................................................................................1837 INSTALLATION..............................................................................1838 LATCH RELEASE CABLE...........................................................................1838 REMOVAL...................................................................................1838 INSTALLATION..............................................................................1838 SUPPORT CYLINDER..............................................................................1839 REMOVAL...................................................................................1839 INSTALLATION..............................................................................1839 LATCH RELEASE HANDLE..........................................................................1839 REMOVAL...................................................................................1839 INSTALLATION..............................................................................1839 DOOR - FRONT......................................................................................1840 CHECK STRAP...................................................................................1840 REMOVAL...................................................................................1840 INSTALLATION..............................................................................1840 DOOR..........................................................................................1841 REMOVAL...................................................................................1841 INSTALLATION..............................................................................1841 ADJUSTMENTS...............................................................................1841 ADJUSTMENT............................................................................1841 FORE/AFT..........................................................................1841 UP/DOWN...........................................................................1841 IN/OUT............................................................................1842 DOOR GLASS....................................................................................1842 REMOVAL...................................................................................1842 INSTALLATION..............................................................................1842 EXTERIOR HANDLE...............................................................................1843 REMOVAL...................................................................................1843 INSTALLATION..............................................................................1843 GLASS RUN CHANNEL.............................................................................1843 REMOVAL...................................................................................1843 INSTALLATION..............................................................................1843 HINGE.........................................................................................1843 REMOVAL...................................................................................1843 INSTALLATION..............................................................................1843 LATCH.........................................................................................1844 REMOVAL...................................................................................1844 INSTALLATION..............................................................................1844 LATCH STRIKER.................................................................................1844 REMOVAL...................................................................................1844 INSTALLATION..............................................................................1844 LOCK CYLINDER.................................................................................1845 REMOVAL...................................................................................1845 INSTALLATION..............................................................................1845 TRIM PANEL....................................................................................1845 REMOVAL...................................................................................1845 INSTALLATION..............................................................................1845 WATERDAM......................................................................................1846 REMOVAL...................................................................................1846 INSTALLATION..............................................................................1846 WINDOW REGULATOR - MANUAL.....................................................................1846 REMOVAL...................................................................................1846 INSTALLATION..............................................................................1847 WINDOW REGULATOR - POWER......................................................................1847 REMOVAL...................................................................................1847 INSTALLATION..............................................................................1848 DOORS - REAR......................................................................................1849 CHECK STRAP...................................................................................1849 REMOVAL...................................................................................1849 INSTALLATION..............................................................................1849 DOOR..........................................................................................1850 REMOVAL...................................................................................1850 INSTALLATION..............................................................................1850 ADJUSTMENTS...............................................................................1850 ADJUSTMENT............................................................................1850 FORE/AFT..........................................................................1850 UP/DOWN...........................................................................1850 IN/OUT............................................................................1851 DOOR GLASS....................................................................................1851 REMOVAL...................................................................................1851 INSTALLATION..............................................................................1852 EXTERIOR HANDLE...............................................................................1852 REMOVAL...................................................................................1852 INSTALLATION..............................................................................1852 GLASS RUN CHANNEL.............................................................................1853 REMOVAL...................................................................................1853 INSTALLATION..............................................................................1853 HINGE.........................................................................................1853 REMOVAL...................................................................................1853 INSTALLATION..............................................................................1853 LATCH.........................................................................................1853 REMOVAL...................................................................................1853 INSTALLATION..............................................................................1854 ADJUSTMENTS...............................................................................1854 ADJUSTMENT............................................................................1854 LATCH STRIKER.................................................................................1854 REMOVAL...................................................................................1854 INSTALLATION..............................................................................1854 TRIM PANEL....................................................................................1854 REMOVAL...................................................................................1854 INSTALLATION..............................................................................1855 WATERDAM......................................................................................1855 REMOVAL...................................................................................1855 INSTALLATION..............................................................................1855 WINDOW REGULATOR - MANUAL.....................................................................1856 REMOVAL...................................................................................1856 INSTALLATION..............................................................................1856 WINDOW REGULATOR - POWER......................................................................1856 REMOVAL...................................................................................1856 INSTALLATION..............................................................................1857 SWING GATE........................................................................................1858 FLIP-UP GLASS.................................................................................1858 REMOVAL...................................................................................1858 INSTALLATION..............................................................................1858 ADJUSTMENTS...............................................................................1858 ADJUSTMENT............................................................................1858 FLIP-UP GLASS LATCH...........................................................................1859 REMOVAL...................................................................................1859 INSTALLATION..............................................................................1859 FLIP-UP GLASS - HINGE.........................................................................1859 REMOVAL...................................................................................1859 INSTALLATION..............................................................................1860 FLIP-UP GLASS - HINGE COVER...................................................................1860 REMOVAL...................................................................................1860 INSTALLATION..............................................................................1860 FLIP-UP GLASS SUPPORT CYLINDER................................................................1861 REMOVAL...................................................................................1861 INSTALLATION..............................................................................1861 TRIM PANEL....................................................................................1862 REMOVAL...................................................................................1862 INSTALLATION..............................................................................1862 LATCH.........................................................................................1862 REMOVAL...................................................................................1862 INSTALLATION..............................................................................1862 LATCH STRIKER.................................................................................1862 REMOVAL...................................................................................1862 INSTALLATION..............................................................................1862 ADJUSTMENTS...............................................................................1862 ADJUSTMENT............................................................................1862 LATCH - ACCESS PANEL..........................................................................1863 DESCRIPTION...............................................................................1863 REMOVAL...................................................................................1863 INSTALLATION..............................................................................1863 EXTERIOR HANDLE...............................................................................1863 REMOVAL...................................................................................1863 INSTALLATION..............................................................................1863 LOCK CYLINDER.................................................................................1863 REMOVAL...................................................................................1863 INSTALLATION..............................................................................1863 CHECK STRAP...................................................................................1864 REMOVAL...................................................................................1864 INSTALLATION..............................................................................1864 STABILIZER WEDGE/INSERT.......................................................................1864 REMOVAL...................................................................................1864 INSTALLATION..............................................................................1864 ADJUSTMENTS...............................................................................1864 ADJUSTMENT............................................................................1864 HINGE.........................................................................................1865 REMOVAL...................................................................................1865 INSTALLATION..............................................................................1865 SWING GATE....................................................................................1866 REMOVAL...................................................................................1866 INSTALLATION..............................................................................1866 ADJUSTMENTS...............................................................................1867 ADJUSTMENT............................................................................1867 IN/OUT............................................................................1867 UP/DOWN...........................................................................1867 LEFT/RIGHT........................................................................1867 EXTERIOR..........................................................................................1868 BODY SIDE MOLDINGS............................................................................1868 REMOVAL...................................................................................1868 INSTALLATION..............................................................................1868 COWL GRILLE...................................................................................1868 REMOVAL...................................................................................1868 INSTALLATION..............................................................................1868 EXTERIOR NAME PLATES..........................................................................1869 REMOVAL...................................................................................1869 INSTALLATION..............................................................................1869 FRONT FENDER..................................................................................1869 REMOVAL...................................................................................1869 INSTALLATION..............................................................................1869 FUEL FILL DOOR/HOUSING........................................................................1870 REMOVAL...................................................................................1870 INSTALLATION..............................................................................1870 GRILLE........................................................................................1871 REMOVAL...................................................................................1871 INSTALLATION..............................................................................1871 GRILLE OPENING REINFORCEMENT..................................................................1871 REMOVAL...................................................................................1871 INSTALLATION..............................................................................1871 FRONT WHEELHOUSE SPLASH SHIELD................................................................1872 REMOVAL...................................................................................1872 INSTALLATION..............................................................................1872 LUGGAGE RACK..................................................................................1873 REMOVAL...................................................................................1873 INSTALLATION..............................................................................1873 REAR WHEELHOUSE SPLASH SHIELD.................................................................1873 REMOVAL...................................................................................1873 INSTALLATION..............................................................................1873 SIDE VIEW MIRROR..............................................................................1874 REMOVAL...................................................................................1874 INSTALLATION..............................................................................1874 FRONT WHEEL OPENING FLARE MOLDINGS............................................................1874 REMOVAL...................................................................................1874 INSTALLATION..............................................................................1874 REAR WHEEL OPENING FLARE MOLDINGS.............................................................1875 REMOVAL...................................................................................1875 INSTALLATION..............................................................................1875 RADIATOR CROSSMEMBER..........................................................................1875 REMOVAL...................................................................................1875 INSTALLATION..............................................................................1876 SIDE VIEW MIRROR GLASS........................................................................1876 REMOVAL...................................................................................1876 INSTALLATION..............................................................................1876 INSTRUMENT PANEL..................................................................................1877 CLUSTER BEZEL.................................................................................1877 REMOVAL...................................................................................1877 INSTALLATION..............................................................................1877 GLOVE BOX.....................................................................................1878 REMOVAL...................................................................................1878 INSTALLATION..............................................................................1878 GLOVE BOX LATCH...............................................................................1878 REMOVAL...................................................................................1878 INSTALLATION..............................................................................1878 GLOVE BOX LATCH STRIKER.......................................................................1878 REMOVAL...................................................................................1878 INSTALLATION..............................................................................1879 INSTRUMENT PANEL ASSEMBLY.....................................................................1879 REMOVAL...................................................................................1879 INSTALLATION..............................................................................1882 INSTRUMENT PANEL TOP COVER....................................................................1883 REMOVAL...................................................................................1883 INSTALLATION..............................................................................1884 INSTRUMENT PANEL END CAP......................................................................1884 REMOVAL...................................................................................1884 INSTALLATION..............................................................................1884 INSTRUMENT PANEL DRIVER SIDE BEZELS...........................................................1884 REMOVAL...................................................................................1884 INSTALLATION..............................................................................1885 INSTRUMENT PANEL CENTER BEZEL.................................................................1885 REMOVAL...................................................................................1885 INSTALLATION..............................................................................1885 INSTRUMENT PANEL PASSENGER SIDE BEZEL.........................................................1885 REMOVAL...................................................................................1885 INSTALLATION..............................................................................1886 KNEE BLOCKER..................................................................................1886 REMOVAL...................................................................................1886 INSTALLATION..............................................................................1886 INTERIOR..........................................................................................1887 4WD FLOOR SHIFT BOOT..........................................................................1887 REMOVAL...................................................................................1887 INSTALLATION..............................................................................1887 A-PILLAR TRIM AND GRAB HANDLE.................................................................1887 REMOVAL...................................................................................1887 INSTALLATION..............................................................................1887 COWL TRIM COVER...............................................................................1888 REMOVAL...................................................................................1888 INSTALLATION..............................................................................1888 DOOR SILL SCUFF PLATE.........................................................................1888 REMOVAL...................................................................................1888 INSTALLATION..............................................................................1888 ASSIST HANDLE.................................................................................1888 REMOVAL...................................................................................1888 INSTALLATION..............................................................................1888 B-PILLAR LOWER TRIM...........................................................................1888 REMOVAL...................................................................................1888 INSTALLATION..............................................................................1888 B-PILLAR UPPER TRIM...........................................................................1889 REMOVAL...................................................................................1889 INSTALLATION..............................................................................1889 CARPETS AND FLOOR MATS........................................................................1889 REMOVAL...................................................................................1889 Front Carpet..........................................................................1889 Rear Cargo Carpet.....................................................................1889 INSTALLATION..............................................................................1889 Front Carpet..........................................................................1889 Rear Cargo Carpet.....................................................................1889 SHIFT BEZEL...................................................................................1889 REMOVAL...................................................................................1889 INSTALLATION..............................................................................1889 FLOOR CONSOLE.................................................................................1889 REMOVAL...................................................................................1889 INSTALLATION..............................................................................1890 FLOOR CONSOLE LID LATCH.......................................................................1890 REMOVAL...................................................................................1890 INSTALLATION..............................................................................1890 HEADLINER.....................................................................................1890 REMOVAL...................................................................................1890 INSTALLATION..............................................................................1890 QUARTER TRIM PANEL............................................................................1891 REMOVAL...................................................................................1891 INSTALLATION..............................................................................1891 REAR DOOR SCUFF PLATE.........................................................................1891 REMOVAL...................................................................................1891 INSTALLATION..............................................................................1891 SUN VISOR.....................................................................................1891 REMOVAL...................................................................................1891 INSTALLATION..............................................................................1891 SUN VISOR SUPPORT.............................................................................1891 REMOVAL...................................................................................1891 INSTALLATION..............................................................................1891 REAR VIEW MIRROR..............................................................................1892 REMOVAL...................................................................................1892 INSTALLATION..............................................................................1892 INSTALLATION..........................................................................1892 INSTALLATION - REARVIEW MIRROR SUPPORT BRACKET........................................1892 PAINT.............................................................................................1893 PAINT.........................................................................................1893 SPECIFICATIONS - PAINT CODES..............................................................1893 PAINT CODE....................................................................................1893 DESCRIPTION...............................................................................1893 BASE COAT/CLEAR COAT FINISH...................................................................1894 DESCRIPTION...............................................................................1894 PAINT TOUCH-UP................................................................................1894 DESCRIPTION...............................................................................1894 OPERATION.............................................................................1894 FINESSE SANDING/BUFFING & POLISHING...........................................................1894 DESCRIPTION...............................................................................1894 SEATS.............................................................................................1895 HEADREST......................................................................................1895 REMOVAL0 - 12 KJ (Continued)..........................................................1895 INSTALLATION..............................................................................1895 HEADREST SLEEVE...............................................................................1895 REMOVAL...................................................................................1895 INSTALLATION..............................................................................1895 SEAT - FRONT..................................................................................1896 REMOVAL...................................................................................1896 INSTALLATION..............................................................................1896 SEAT BACK - FRONT.............................................................................1897 REMOVAL...................................................................................1897 INSTALLATION..............................................................................1897 SEAT BACK RECLINER - FRONT....................................................................1897 REMOVAL...................................................................................1897 INSTALLATION..............................................................................1897 SEAT BACK COVER - FRONT.......................................................................1897 REMOVAL...................................................................................1897 INSTALLATION..............................................................................1898 SEAT BACK CUSHION - FRONT.....................................................................1898 REMOVAL...................................................................................1898 INSTALLATION..............................................................................1898 SEAT CUSHION - FRONT..........................................................................1898 REMOVAL...................................................................................1898 INSTALLATION..............................................................................1898 SEAT CUSHION COVER - FRONT....................................................................1898 REMOVAL...................................................................................1898 INSTALLATION..............................................................................1898 SEAT CUSHION SIDE SHIELDS.....................................................................1898 REMOVAL...................................................................................1898 INSTALLATION..............................................................................1898 MANUAL SEAT RISER.............................................................................1898 REMOVAL...................................................................................1898 INSTALLATION..............................................................................1898 SEAT TRACK....................................................................................1899 REMOVAL...................................................................................1899 INSTALLATION..............................................................................1899 SEAT - REAR...................................................................................1899 REMOVAL...................................................................................1899 INSTALLATION..............................................................................1899 SEAT BACK - REAR..............................................................................1900 REMOVAL...................................................................................1900 60/40 Split Seat - Left...............................................................1900 60/40 Split Seat - Right..............................................................1900 INSTALLATION..............................................................................1900 60/40 Split Seat - Left...............................................................1900 60/40 Split Seat - Right..............................................................1900 SEAT BACK COVER - REAR........................................................................1901 REMOVAL...................................................................................1901 INSTALLATION..............................................................................1901 SEAT BACK CUSHION - REAR......................................................................1901 REMOVAL...................................................................................1901 INSTALLATION..............................................................................1901 FOLDING REAR SEAT BACK LATCH / LOCK...........................................................1901 REMOVAL...................................................................................1901 INSTALLATION..............................................................................1901 REAR SEAT BACK LATCH STRIKER..................................................................1902 REMOVAL...................................................................................1902 INSTALLATION..............................................................................1902 SEAT BACK FRAME - REAR........................................................................1903 REMOVAL...................................................................................1903 INSTALLATION..............................................................................1903 SEAT CUSHION - REAR...........................................................................1903 REMOVAL...................................................................................1903 INSTALLATION..............................................................................1903 STATIONARY GLASS..................................................................................1904 DOOR GLASS....................................................................................1904 REMOVAL...................................................................................1904 INSTALLATION..............................................................................1904 QUARTER WINDOW................................................................................1904 REMOVAL...................................................................................1904 INSTALLATION..............................................................................1904 WINDSHIELD....................................................................................1905 WARNING...................................................................................1905 WINDSHIELD SAFETY PRECAUTIONS.........................................................1905 REMOVAL...................................................................................1905 INSTALLATION..............................................................................1905 SUNROOF...........................................................................................1907 SUNROOF.......................................................................................1907 DESCRIPTION...............................................................................1907 SUNROOF OPERATION INSTRUCTIONS........................................................1908 DIAGNOSIS AND TESTING.....................................................................1908 WATER DRAINAGE AND WIND NOISE DIAGNOSIS...............................................1908 DIAGNOSTIC PROCEDURES.................................................................1908 GLASS PANEL...................................................................................1910 REMOVAL...................................................................................1910 INSTALLATION..............................................................................1910 ADJUSTMENTS...............................................................................1910 SUNROOF GLASS PANEL ADJUSTMENT........................................................1910 GLASS PANEL SEAL..............................................................................1910 REMOVAL...................................................................................1910 INSTALLATION..............................................................................1910 SUNSHADE......................................................................................1911 REMOVAL...................................................................................1911 INSTALLATION..............................................................................1911 GUIDE ASSEMBLY................................................................................1911 REMOVAL...................................................................................1911 INSTALLATION..............................................................................1911 WIND DEFLECTOR................................................................................1912 REMOVAL...................................................................................1912 INSTALLATION..............................................................................1912 OPENING TRIM LACE.............................................................................1912 REMOVAL...................................................................................1912 INSTALLATION..............................................................................1912 DRAIN TUBE....................................................................................1912 REMOVAL...................................................................................1912 FRONT DRAIN TUBES.....................................................................1912 REAR DRAIN TUBES......................................................................1913 INSTALLATION..............................................................................1913 FRONT DRAIN TUBES.....................................................................1913 REAR DRAIN TUBES......................................................................1913 MODULE ASSEMBLY...............................................................................1913 REMOVAL...................................................................................1913 INSTALLATION..............................................................................1913 DRIVE MOTOR...................................................................................1914 REMOVAL...................................................................................1914 INSTALLATION..............................................................................1914 CONTROL MODULE................................................................................1914 REMOVAL...................................................................................1914 INSTALLATION..............................................................................1914 CONTROL SWITCH................................................................................1915 DESCRIPTION...............................................................................1915 OPERATION.................................................................................1915 DIAGNOSIS AND TESTING - CONTROL SWITCH....................................................1916 REMOVAL...................................................................................1916 INSTALLATION..............................................................................1916 WEATHERSTRIP/SEALS................................................................................1917 A-PILLAR SEAL.................................................................................1917 REMOVAL...................................................................................1917 INSTALLATION..............................................................................1917 COWL WEATHERSTRIP.............................................................................1917 REMOVAL...................................................................................1917 INSTALLATION..............................................................................1917 DOOR PRIMARY WEATHERSTRIP.....................................................................1917 REMOVAL...................................................................................1917 INSTALLATION..............................................................................1917 DOOR LOWER WEATHERSTRIP.......................................................................1918 REMOVAL...................................................................................1918 INSTALLATION..............................................................................1918 FRONT DOOR OUTER BELT MOLDING.................................................................1918 REMOVAL...................................................................................1918 INSTALLATION..............................................................................1918 SWING GATE BELTLINE WEATHERSTRIP..............................................................1918 REMOVAL...................................................................................1918 INSTALLATION..............................................................................1918 SWING GATE OPENING WEATHERSTRIP...............................................................1918 REMOVAL...................................................................................1918 INSTALLATION..............................................................................1918 REAR DOOR OUTER BELT MOLDING..................................................................1919 REMOVAL...................................................................................1919 INSTALLATION..............................................................................1919 SIDE RAIL WEATHERSTRIP/RETAINER...............................................................1919 REMOVAL...................................................................................1919 INSTALLATION..............................................................................1919 WINDSHIELD A-PILLAR WEATHERSTRIP/RETAINER.....................................................1919 REMOVAL...................................................................................1919 INSTALLATION..............................................................................1919 COWL/PLENUM SEAL..............................................................................1919 REMOVAL...................................................................................1919 INSTALLATION..............................................................................1919 COWL/PLENUM WINDOW BAFFLE SEAL................................................................1920 REMOVAL...................................................................................1920 INSTALLATION..............................................................................1920 AIR INLET SEAL................................................................................1920 REMOVAL...................................................................................1920 INSTALLATION..............................................................................1920 FRONT DOOR INNER BELT WEATHERSTRIP............................................................1920 REMOVAL...................................................................................1920 INSTALLATION..............................................................................1920 REAR DOOR INNER BELT WEATHERSTRIP.............................................................1920 REMOVAL...................................................................................1920 INSTALLATION..............................................................................1920 BODY STRUCTURE....................................................................................1921 ASSEMBLY......................................................................................1921 SPECIFICATIONS............................................................................1921 SPECIFICATION.........................................................................1921 WELD AND STRUCTURAL ADHESIVE LOCATIONS........................................................1924 SPECIFICATIONS............................................................................1924 FRONT END ASSEMBLY....................................................................1928 FRONT END ASSEMBLY/UNDERBODY..........................................................1945 REAR FRAME RAILS......................................................................1950 REAR FLOOR PAN ASSEMBLY...............................................................1956 FULL FLOOR PAN ASSEMBLY...............................................................1963 BODY SIDE PANELS AND SUB ASSEMBLIES...................................................1969 BODY SIDE PANELS......................................................................1976 FENDER ASSEMBLIES.....................................................................1988 ROOF PANEL ASSEMBLIES.................................................................1992 BODY SIDE PANELS & FLOOR PAN ASSEMBLIES...............................................1996 SEALER LOCATIONS..............................................................................2002 SPECIFICATIONS............................................................................2002 OPENING DIMENSIONS............................................................................2026 SPECIFICATIONS............................................................................2026 GAP AND FLUSH.................................................................................2031 SPECIFICATIONS............................................................................2031 24-HEATING & AIR CONDITIONING.........................................................................2034 HEATING & AIR CONDITIONING........................................................................2034 DESCRIPTION...................................................................................2034 DESCRIPTION - HEATER AND AIR CONDITIONER..................................................2034 DESCRIPTION - COOLING SYSTEM REQUIREMENTS.................................................2034 DESCRIPTION - REFRIGERANT SYSTEM SERVICE PORT.............................................2035 OPERATION.....................................................................................2035 OPERATION - HEATER AND AIR CONDITIONER....................................................2035 OPERATION - REFRIGERANT SYSTEM SERVICE PORT...............................................2035 DIAGNOSIS AND TESTING.........................................................................2035 DIAGNOSIS AND TESTING - A/C PERFORMANCE...................................................2035 DIAGNOSIS AND TESTING - HEATER PERFORMANCE................................................2039 MAXIMUM HEATER OUTPUT.................................................................2039 TEMPERATURE CONTROL...................................................................2039 DIAGNOSIS AND TESTING - VACUUM SYSTEM.....................................................2039 VACUUM CHECK VALVE....................................................................2040 A/C HEATER CONTROLS...................................................................2040 LOCATING VACUUM LEAKS.................................................................2040 STANDARD PROCEDURE - DIODE REPLACEMENT........................................................2042 SPECIFICATIONS................................................................................2042 A/C APPLICATION TABLE.....................................................................2042 SPECIFICATIONS............................................................................2043 CONTROLS..........................................................................................2044 A/C COMPRESSOR CLUTCH.........................................................................2045 DESCRIPTION - 3.7L and 2.4L...............................................................2045 OPERATION - 3.7L and 2.4L.................................................................2045 DIAGNOSIS AND TESTING - A/C COMPRESSOR CLUTCH.............................................2045 STANDARD PROCEDURE - A/C COMPRESSOR CLUTCH BREAK-IN.......................................2046 REMOVAL...................................................................................2046 INSPECTION................................................................................2047 INSTALLATION..............................................................................2047 A/C COMPRESSOR CLUTCH RELAY...................................................................2048 DESCRIPTION...............................................................................2048 OPERATION.................................................................................2048 DIAGNOSIS AND TESTING - COMPRESSOR CLUTCH RELAY...........................................2048 RELAY TEST............................................................................2048 RELAY CIRCUIT TEST....................................................................2049 REMOVAL...................................................................................2049 INSTALLATION..............................................................................2049 A/C HEATER CONTROL............................................................................2049 DESCRIPTION...............................................................................2049 REMOVAL...................................................................................2050 INSTALLATION..............................................................................2050 A/C HIGH PRESSURE SWITCH......................................................................2050 DESCRIPTION...............................................................................2050 OPERATION.................................................................................2051 DIAGNOSIS AND TESTING - A/C HIGH PRESSURE SWITCH..........................................2051 REMOVAL...................................................................................2051 INSTALLATION..............................................................................2051 A/C LOW PRESSURE SWITCH.......................................................................2051 DESCRIPTION...............................................................................2051 OPERATION.................................................................................2051 DIAGNOSIS AND TESTING - A/C LOW PRESSURE SWITCH...........................................2052 REMOVAL...................................................................................2052 INSTALLATION..............................................................................2052 BLEND DOOR ACTUATOR...........................................................................2053 REMOVAL...................................................................................2053 INSTALLATION..............................................................................2053 BLOWER MOTOR RELAY............................................................................2053 DESCRIPTION...............................................................................2053 OPERATION.................................................................................2053 DIAGNOSIS AND TESTING - BLOWER MOTOR RELAY................................................2054 RELAY TEST............................................................................2054 RELAY CIRCUIT TEST....................................................................2054 REMOVAL...................................................................................2054 INSTALLATION..............................................................................2055 BLOWER MOTOR RESISTOR BLOCK...................................................................2055 DESCRIPTION...............................................................................2055 OPERATION.................................................................................2055 DIAGNOSIS AND TESTING - BLOWER MOTOR RESISTOR.............................................2055 REMOVAL...................................................................................2055 INSTALLATION..............................................................................2055 BLOWER MOTOR SWITCH...........................................................................2056 DESCRIPTION...............................................................................2056 OPERATION.................................................................................2056 DIAGNOSIS AND TESTING - BLOWER MOTOR SWITCH...............................................2056 REMOVAL...................................................................................2056 INSTALLATION..............................................................................2056 MODE DOOR ACTUATOR............................................................................2057 REMOVAL...................................................................................2057 REMOVAL - PANEL DOOR ACTUATOR.........................................................2057 REMOVAL - FLOOR - DEFROST DOOR ACTUATOR...............................................2057 INSTALLATION..............................................................................2058 INSTALLATION - PANEL DOOR ACTUATOR....................................................2058 INSTALLATION - FLOOR - DEFROST DOOR ACTUATOR..........................................2058 RECIRCULATION DOOR ACTUATOR...................................................................2059 REMOVAL...................................................................................2059 INSTALLATION..............................................................................2059 VACUUM CHECK VALVE............................................................................2060 DESCRIPTION...............................................................................2060 OPERATION.................................................................................2060 REMOVAL...................................................................................2061 INSTALLATION..............................................................................2061 DISTRIBUTION......................................................................................2062 AIR OUTLETS...................................................................................2062 DESCRIPTION - DEMISTER OUTLETS............................................................2062 REMOVAL - PANEL OUTLET BARRELS............................................................2062 INSTALLATION - PANEL OUTLET BARRELS.......................................................2062 BLEND DOOR....................................................................................2063 REMOVAL...................................................................................2063 INSTALLATION..............................................................................2063 BLOWER MOTOR..................................................................................2063 DESCRIPTION...............................................................................2063 OPERATION.................................................................................2063 DIAGNOSIS AND TESTING - BLOWER MOTOR......................................................2064 VIBRATION.............................................................................2064 NOISE.................................................................................2064 REMOVAL...................................................................................2064 INSTALLATION..............................................................................2064 DEFROST - DEMISTER DUCT.......................................................................2065 REMOVAL - DEFROST DUCT/DEMISTER ADAPTOR...................................................2065 INSTALLATION - DEFROST/DEMISTER DUCT......................................................2065 FLOOR CONSOLE DUCT............................................................................2066 REMOVAL...................................................................................2066 INSTALLATION..............................................................................2066 FLOOR DUCT....................................................................................2066 REMOVAL...................................................................................2066 INSTALLATION..............................................................................2066 HVAC HOUSING..................................................................................2066 REMOVAL...................................................................................2066 DISASSEMBLY...............................................................................2067 ASSEMBLY..................................................................................2068 INSTALLATION..............................................................................2068 MODE DOOR.....................................................................................2069 REMOVAL...................................................................................2069 REMOVAL - DEFROST DOOR................................................................2069 REMOVAL - FLOOR - DEFROST DOOR........................................................2069 INSTALLATION..............................................................................2070 INSTALLATION - PANEL DOOR.............................................................2070 INSTALLATION - FLOOR - DEFROST DOOR...................................................2070 RECIRCULATION DOOR............................................................................2070 REMOVAL...................................................................................2070 INSTALLATION..............................................................................2071 PLUMBING..........................................................................................2072 PLUMBING......................................................................................2072 DESCRIPTION - REFRIGERANT LINE............................................................2072 WARNING...................................................................................2073 SERVICE WARNINGS......................................................................2073 CAUTION...................................................................................2073 SERVICE CAUTIONS......................................................................2073 CAUTION - REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS...................................2074 STANDARD PROCEDURE........................................................................2074 STANDARD PROCEDURE - REFRIGERANT SYSTEM SERVICE EQUIPMENT.............................2074 MANIFOLD GAUGE SET CONNECTIONS....................................................2074 STANDARD PROCEDURE - REFRIGERANT RECOVERY.............................................2075 STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE......................................2075 STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE........................................2075 SPECIFICATIONS - CHARGE CAPACITY0 - 14 KJ (Continued).................................2076 A/C COMPRESSOR................................................................................2076 DESCRIPTION...............................................................................2076 DESCRIPTION...........................................................................2076 DESCRIPTION - HIGH PRESSURE RELIEF VALVE..............................................2076 OPERATION.................................................................................2076 OPERATION.............................................................................2076 OPERATION - HIGH PRESSURE RELIEF VALVE................................................2076 DIAGNOSIS AND TESTING - A/C COMPRESSOR NOISE..............................................2076 REMOVAL...................................................................................2077 INSTALLATION..............................................................................2078 A/C CONDENSER.................................................................................2079 DESCRIPTION...............................................................................2079 OPERATION.................................................................................2079 REMOVAL...................................................................................2079 INSTALLATION..............................................................................2080 A/C DISCHARGE LINE............................................................................2080 REMOVAL...................................................................................2080 INSTALLATION..............................................................................2081 A/C LIQUID LINE...............................................................................2081 REMOVAL...................................................................................2081 INSTALLATION..............................................................................2081 A/C SUCTION LINE..............................................................................2082 REMOVAL...................................................................................2082 INSTALLATION..............................................................................2083 A/C EVAPORATOR................................................................................2083 DESCRIPTION...............................................................................2083 OPERATION.................................................................................2083 REMOVAL...................................................................................2083 INSTALLATION..............................................................................2083 A/C ORIFICE TUBE..............................................................................2084 DESCRIPTION...............................................................................2084 OPERATION.................................................................................2084 REMOVAL...................................................................................2084 INSTALLATION..............................................................................2084 ACCUMULATOR...................................................................................2085 DESCRIPTION...............................................................................2085 OPERATION.................................................................................2085 REMOVAL...................................................................................2085 INSTALLATION..............................................................................2086 HEATER CORE...................................................................................2086 DESCRIPTION...............................................................................2086 OPERATION.................................................................................2086 REMOVAL...................................................................................2086 INSTALLATION..............................................................................2087 REFRIGERANT...................................................................................2087 DESCRIPTION...............................................................................2087 OPERATION.................................................................................2087 REFRIGERANT OIL...............................................................................2087 DESCRIPTION...............................................................................2087 OPERATION.................................................................................2088 STANDARD PROCEDURE - REFRIGERANT OIL LEVEL................................................2088 25-EMISSIONS CONTROL..................................................................................2090 EMISSIONS CONTROL.................................................................................2090 DESCRIPTION...................................................................................2090 DESCRIPTION - EMISSION CONTROL SYSTEM.....................................................2090 DESCRIPTION - STATE DISPLAY TEST MODE.....................................................2091 DESCRIPTION - CIRCUIT ACTUATION TEST MODE.................................................2091 DESCRIPTION - DIAGNOSTIC TROUBLE CODES....................................................2091 DESCRIPTION - TASK MANAGER................................................................2091 DESCRIPTION - MONITORED SYSTEMS...........................................................2091 OXYGEN SENSOR (O2S) MONITOR...........................................................2091 OXYGEN SENSOR HEATER MONITOR..........................................................2092 LEAK DETECTION PUMP MONITOR (IF EQUIPPED).............................................2092 MISFIRE MONITOR.......................................................................2093 FUEL SYSTEM MONITOR...................................................................2093 CATALYST MONITOR......................................................................2093 DESCRIPTION - TRIP DEFINITION.............................................................2093 DESCRIPTION - COMPONENT MONITORS..........................................................2094 DESCRIPTION - NON-MONITORED CIRCUITS......................................................2094 DESCRIPTION - HIGH AND LOW LIMITS.........................................................2095 DESCRIPTION - LOAD VALUE..................................................................2095 OPERATION - TASK MANAGER......................................................................2095 Test Sequence.............................................................................2095 MIL Illumination..........................................................................2096 Diagnostic Trouble Codes (DTCs)...........................................................2096 DTC Self Erasure..........................................................................2096 Trip Indicator............................................................................2096 Freeze Frame Data Storage.................................................................2097 Similar Conditions Window.................................................................2097 EVAPORATIVE EMISSIONS.............................................................................2099 EVAPORATIVE EMISSIONS.........................................................................2099 DESCRIPTION - EVAPORATION CONTROL SYSTEM..................................................2099 SPECIFICATIONS............................................................................2101 TORQUE................................................................................2101 EVAP/PURGE SOLENOID...........................................................................2102 DESCRIPTION...............................................................................2102 OPERATION.................................................................................2102 REMOVAL...................................................................................2102 INSTALLATION..............................................................................2102 FUEL FILLER CAP...............................................................................2102 DESCRIPTION...............................................................................2102 OPERATION.................................................................................2102 LEAK DETECTION PUMP...........................................................................2103 DESCRIPTION...............................................................................2103 OPERATION.................................................................................2103 REMOVAL...................................................................................2103 INSTALLATION..............................................................................2103 ORVR..........................................................................................2104 DESCRIPTION...............................................................................2104 OPERATION.................................................................................2104 PCV VALVE.....................................................................................2104 DESCRIPTION...............................................................................2104 2.4L..................................................................................2104 3.7L..................................................................................2105 OPERATION.................................................................................2105 DIAGNOSIS AND TESTING - PCV VALVE.........................................................2106 REMOVAL...................................................................................2107 INSTALLATION..............................................................................2107 VACUUM LINES..................................................................................2107 DESCRIPTION...............................................................................2107 VAPOR CANISTER................................................................................2108 DESCRIPTION...............................................................................2108 OPERATION.................................................................................2108 REMOVAL...................................................................................2108 INSTALLATION..............................................................................2108 INDEX.................................................................................................2110 COMMENTS..............................................................................................2144
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S.V
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Very good service !