2005 Chrysler Crossfire Factory Service Manual – PDF DOWNLOAD
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2005 Chrysler Crossfire Factory Service Manual – PDF DOWNLOAD
Language : English
Pages : 4120
Downloadable : Yes
File Type : PDF
Size: 76.9 MB
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DESCRIPTION:
2005 Chrysler Crossfire Factory Service Manual – PDF DOWNLOAD
FOREWORD:
- The information contained in this service manual has been prepared for the professional automotive technician
involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner’s Manual provided with the vehicle. - Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components. - To assist in locating a group title page, use the Group Tab Locator by clicking to the following page. The
solid bar after the group title is aligned to a solid tab on the first page of each group. The first page of the
group has a contents section that lists major topics within the group. If you are not sure which Group contains
the information you need, look up the Component/System in the alphabetical index located in the rear of this
manual. - A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions. - Tightening torques are provided as a specific value throughout this manual. This value represents the midpoint
of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed. - DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
TABLE OF CONTENTS:
2005 Chrysler Crossfire Factory Service Manual – PDF DOWNLOAD
sm-front pdf 1
2005-zh-sm pdf 5
MAIN WELCOME PAGE 0
ZH Crossfire Service Manual 5
FOREWORD 0
GROUP TAB LOCATOR 5
in-INTRODUCTION 7
VEHICLE IDENTIFICATION NUMBER 7
DESCRIPTION 7
VEHICLE SAFETY CERTIFICATION LABEL 8
DESCRIPTION 8
VECI LABEL 8
DESCRIPTION 8
INTERNATIONAL SYMBOLS 9
DESCRIPTION 9
FASTENER IDENTIFICATION 9
DESCRIPTION 9
FASTENER USAGE 12
DESCRIPTION 12
FASTENER USAGE 12
THREADED HOLE REPAIR 12
METRIC SYSTEM 12
DESCRIPTION 12
TORQUE REFERENCES 14
DESCRIPTION 14
0-LUBRICATION & MAINTENANCE 15
INTERNATIONAL SYMBOLS 15
DESCRIPTION 15
PARTS & LUBRICANT RECOMMENDATION 16
STANDARD PROCEDURE – PARTS AND LUBRICANT RECOMMENDATIONS 16
FLUID TYPES 16
DESCRIPTION 16
DESCRIPTION – ENGINE OIL AND LUBRICANTS 16
ENERGY CONSERVING OIL 17
LUBRICANTS AND GREASES 17
SPECIALIZED LUBRICANTS AND OILS 17
DESCRIPTION – COOLANT 17
COOLANT PERFORMANCE 18
COOLANT SELECTION AND ADDITIVES 18
DESCRIPTION – TRANSMISSION FLUID 18
Automatic Transmission Fluid 18
Manual Transmission Fluid 19
DESCRIPTION – DIFFERENTIAL LUBRICANT 19
DESCRIPTION – BRAKE FLUID 19
DESCRIPTION – POWER STEERING FLUID 19
DESCRIPTION – FUEL REQUIREMENTS 19
FLUID CAPACITIES 19
SPECIFICATIONS – FLUID CAPACITIES 19
FLUID FILL/CHECK LOCATIONS 19
DESCRIPTION 19
LUBRICATION POINTS 20
DESCRIPTION 20
MAINTENANCE SCHEDULES 20
DESCRIPTION 20
DESCRIPTION – FLEXIBLE SERVICE SYSTEM (FSS) 20
TRIP ODOMETER, FSS INDICATOR 20
MAIN ODOMETER 20
DESCRIPTION – MAINTENANCE SCHEDULES 22
22
23
HOISTING 24
STANDARD PROCEDURE – HOISTING 24
FLOOR JACK 24
JUMP STARTING 25
STANDARD PROCEDURE – JUMP STARTING 25
TO JUMP START A DISABLED VEHICLE: 25
DISCONNECT JUMPER CABLES AS FOLLOWS: 26
EMERGENCY TOW HOOKS 26
DESCRIPTION 26
TOWING 26
STANDARD PROCEDURE – TOWING 26
WARNINGS AND PRECAUTIONS 26
TOWING RECOMMENDATIONS 27
GROUND CLEARANCE 27
2-SUSPENSION 29
SUSPENSION 29
DIAGNOSIS AND TESTING – SUSPENSION AND STEERING SYSTEM 29
WHEEL ALIGNMENT 31
DESCRIPTION 31
OPERATION 32
CASTER 32
CAMBER 32
WHEEL TOE POSITION 33
TOE-OUT ON TURNS 33
STEERING AXIS INCLINATION ANGLE 33
STANDARD PROCEDURE 33
STANDARD PROCEDURE – WHEEL ALIGNMENT INSPECTION 33
STANDARD PROCEDURE – CHASSIS ALIGNMENT INSPECTION 34
INSPECTING AND ADJUSTING VEHICLE LEVEL AT FRONT AND REAR AXLES 35
INSPECTING AND ADJUSTING VEHICLE LEVEL AT FRONT AND REAR AXLES WITH AN ELECTRONIC INCLINOMETER 35
CHECKING AND ADJUSTING FRONT AXLE CAMBER AND CASTER 35
CHECKING 35
ADJUSTING 36
STANDARD PROCEDURE – CHECKING AND ADJUSTING FRONT TOE-IN 37
STANDARD PROCEDURE – CHECKING TOE-OUT ON TURNS 38
STANDARD PROCEDURE – CHECKING REAR AXLE CAMBER 38
STANDARD PROCEDURE – CHECKING AND ADJUSTING REAR AXLE TOE 39
SPECIFICATIONS 40
SPECIFICATIONS – WHEEL ALIGNMENT 40
SPECIFICATIONS – TORQUE 40
FRONT SUSPENSION 41
STANDARD PROCEDURE – ADJUSTING FRONT WHEEL BEARINGS 41
SPECIFICATIONS – TORQUE 42
SPECIAL TOOLS 43
KNUCKLE 44
DESCRIPTION 44
REMOVAL 44
INSPECTION 47
INSTALLATION 48
HUB / BEARING 50
DESCRIPTION 50
REMOVAL 51
INSPECTING HUB AND BEARINGS 52
INSTALLATION 53
LOWER BALL JOINT 55
REMOVAL 55
INSTALLATION 58
LOWER CONTROL ARM 60
REMOVAL 60
INSTALLATION 62
UPPER CONTROL ARM 64
REMOVAL 64
INSTALLATION 65
SHOCK 65
REMOVAL 65
INSTALLATION 66
SPRING 67
REMOVAL 67
INSTALLATION 68
STABILIZER BAR 70
REMOVAL 70
INSTALLATION 71
3-DIFFERENTIAL & DRIVELINE 121
HALFSHAFTS 121
DESCRIPTION 122
OPERATION 123
DIAGNOSIS AND TESTING – DRIVELINE 123
HALFSHAFT VISUAL INSPECTION 123
NOISE AND/OR VIBRATION IN TURNS 123
CLUNKING NOISE DURING ACCELERATION 123
SHUDDER OR VIBRATION DURING ACCELERATION 123
VIBRATION AT HIGHWAY SPEEDS 124
REMOVAL 124
INSTALLATION 125
SPECIFICATIONS – TORQUE 126
CV BOOT – INNER 126
REMOVAL 126
INSTALLATION 128
CV BOOT – OUTER 132
REMOVAL 132
INSTALLATION 134
CV JOINT 138
REMOVAL 138
INSPECTION 140
DISASSEMBLING 140
ASSEMBLING 142
INSTALLATION 143
PROPELLER SHAFT 146
DESCRIPTION 146
WARNING 146
DIAGNOSIS AND TESTING – PROPELLER SHAFT 147
VIBRATION 147
BALANCE 147
RUNOUT 149
REMOVAL 149
INSTALLATION 151
SPECIFICATIONS 153
SPECIFICATIONS – CENTERING SLEEVES 153
SPECIFICATION – RUNOUT 153
SPECIFICATIONS – TORQUE 153
CENTER BEARING 154
REMOVAL 154
INSTALLATION 155
SINGLE CARDAN UNIVERSAL JOINTS 155
DISASSEMBLY 155
ASSEMBLY 157
CENTERING AND FITTED SLEEVES 158
REMOVAL 158
REMOVAL – CENTERING SLEEVES 158
REMOVAL – FITTED SLEEVES 159
INSTALLATION 159
INSTALLATION – CENTERING SLEEVES 159
INSTALLATION – FITTED SLEEVES 159
REAR DIFFERENTIAL 160
DESCRIPTION 160
OPERATION 160
DIAGNOSIS AND TESTING – REAR DIFFERENTIAL NOISE 160
GEAR NOISE 160
BEARING NOISE 160
LOW SPEED KNOCK 161
VIBRATION 161
DRIVELINE SNAP 161
STANDARD PROCEDURE – DRAIN AND REFILL 163
SPECIFICATIONS 163
SPECIFICATIONS – DIFFERENTIAL LUBRICANT 163
SPECIFICATIONS – TORQUE 163
SPECIAL TOOLS 164
REAR DIFFERENTIAL HOUSING 165
REMOVAL 165
INSTALLATION 166
PINION FLANGE SEAL 167
REMOVAL 167
INSTALLATION 168
AXLE SHAFT SEALS 169
REMOVAL 169
INSTALLATION 170
5-BRAKES 171
BRAKES – BASE 171
DESCRIPTION 173
WARNING 174
DIAGNOSIS AND TESTING – BASE BRAKE SYSTEM 175
PRELIMINARY BRAKE CHECK 175
ROAD TESTING 175
PEDAL FALLS AWAY 176
LOW PEDAL 176
SPONGY PEDAL 176
HARD PEDAL OR HIGH PEDAL EFFORT 176
PEDAL PULSATION 176
BRAKE DRAG 176
BRAKE FADE 177
BRAKE PULL 177
REAR BRAKE DRAG OR PULL 177
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP WATER PUDDLES 177
BRAKE LINING CONTAMINATION 177
WHEEL AND TIRE PROBLEMS 177
BRAKE NOISES 178
BRAKE SQUEAK/SQUEAL 178
BRAKE CHATTER 178
THUMP/CLUNK NOISE 178
STANDARD PROCEDURE 178
STANDARD PROCEDURE – MANUAL BLEEDING 178
STANDARD PROCEDURE – PRESSURE BLEEDING 179
SPECIFICATIONS 180
BRAKE COMPONENTS 180
BRAKE LINES 182
DESCRIPTION 182
DIAGNOSIS AND TESTING – BRAKE HOSES AND LINES 182
STANDARD PROCEDURE 182
STANDARD PROCEDURE – DOUBLE INVERTED FLARING 182
STANDARD PROCEDURE – ISO FLARING 183
REMOVAL 184
FRONT BRAKE HOSE 184
REAR BRAKE HOSE 185
INSTALLATION 186
FRONT BRAKE HOSE 186
INSTALLATION – REAR BRAKE HOSE 187
BRAKE PADS/SHOES 188
REMOVAL 188
FRONT DISC BRAKE PADS 188
REMOVAL – REAR DISC BRAKE PADS 190
INSTALLATION 192
FRONT DISC BRAKE PADS 192
INSTALLATION – REAR DISC BRAKE PADS 194
DISC BRAKE CALIPERS 195
DESCRIPTION 195
OPERATION 195
REMOVAL 196
FRONT DISC BRAKE CALIPER 196
REMOVAL – REAR BRAKE CALIPER 199
DISASSEMBLY – FRONT DISC BRAKE CALIPER 200
CLEANING – DISC BRAKE CALIPER 201
INSPECTION – DISC BRAKE CALIPER 201
ASSEMBLY – FRONT DISC BRAKE CALIPER 201
INSTALLATION 202
FRONT DISC BRAKE CALIPER 202
INSTALLATION – REAR DISC BRAKE CALIPER 205
ROTORS 207
DIAGNOSIS AND TESTING 207
DISC BRAKE ROTORS 207
REAR ROTOR MINIMUM THICKNESS 207
REAR ROTOR THICKNESS VARIATION 207
REAR ROTOR LATERAL RUNOUT 207
FRONT ROTOR MINIMUM THICKNESS 208
FRONT ROTOR THICKNESS VARIATION 208
FRONT ROTOR LATERAL RUNOUT 208
STANDARD PROCEDURE 209
DISC BRAKE ROTOR MACHINING 209
REMOVAL 209
FRONT DISC BRAKE ROTOR 209
REMOVAL – REAR DISC BRAKE ROTOR 210
INSTALLATION 211
FRONT DISC BRAKE ROTOR 211
INSTALLATION – REAR DISC BRAKE ROTOR 213
FLUID 213
DIAGNOSIS AND TESTING 213
BRAKE FLUID CONTAMINATION 213
STANDARD PROCEDURE 214
MASTER CYLINDER FLUID LEVEL 214
SPECIFICATIONS 214
BRAKE FLUID 214
MASTER CYLINDER 215
DESCRIPTION 215
MASTER CYLINDER 215
OPERATION 215
MASTER CYLINDER 215
DIAGNOSIS AND TESTING 215
MASTER CYLINDER/POWER BOOSTER 215
POWER BOOSTER VACUUM TEST 216
POWER BOOSTER CHECK VALVE TEST 216
DIAGNOSIS AND TESTING – MASTER CYLINDER FLUID LOSS 216
STANDARD PROCEDURE 217
MASTER CYLINDER BLEEDING PROCEDURE 217
REMOVAL 218
REMOVAL – RHD 219
INSTALLATION 220
INSTALLATION – RHD 221
POWER BRAKE BOOSTER 222
DESCRIPTION 222
OPERATION 223
REMOVAL 224
REMOVAL – RHD 225
INSTALLATION 227
INSTALLATION – RHD 228
PEDAL 230
DESCRIPTION 230
OPERATION 230
REMOVAL 231
REMOVAL – RHD 232
INSTALLATION 234
INSTALLATION – RHD 235
PARKING BRAKE 237
OPERATION 237
DIAGNOSIS AND TESTING 238
PARKING BRAKE 238
ADJUSTMENTS 239
ADJUSTMENT 239
CABLES 241
REMOVAL 241
INSTALLATION 243
LEVER 245
REMOVAL 245
INSTALLATION 247
SHOES 249
REMOVAL 249
INSTALLATION 251
BRAKE FLUID LEVEL SENSOR 253
REMOVAL 253
INSTALLATION 254
BRAKE PRESSURE SENSOR 254
REMOVAL 254
INSTALLATION 255
TRAVEL SENSOR 256
REMOVAL 256
INSTALLATION 256
BRAKES – ABS ELECTRICAL DIAGNOSTICS 257
ELECTRICAL – ESP ELECTRICAL DIAGNOSTICS 257
DIAGNOSIS AND TESTING 257
CAB INTERNAL FAILURE 258
CAB SYSTEM UNDERVOLTAGE 260
CAB SYSTEM OVERVOLTAGE 263
CAN BUS COMMUNICATION GENERAL MALFUNCTION 266
NO CAN COMMUNICATIONS WITH PCM 269
NO CAN COMMUNICATIONS WITH TCM 272
PCM NOT IDENTIFIED OR INCORRECT 275
LEFT FRONT WHEEL SPEED SENSOR CIRCUIT 277
RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT 285
LEFT REAR WHEEL SPEED SENSOR CIRCUIT 293
RIGHT REAR WHEEL SPEED SENSOR CIRCUIT 301
ESP YAW RATE SENSOR CIRCUIT 309
STEERING ANGLE SENSOR CIRCUIT0 – 2 ZH 316
ESP BRAKE PRESSURE SENSOR 1 CIRCUIT 321
ESP BRAKE PRESSURE SENSOR 2 CIRCUIT 328
ESP LATERAL ACCELERATION SENSOR CIRCUIT 335
BRAKE LAMP SWITCH CIRCUIT 342
ABS VERIFICATION TEST 356
SCHEMATICS AND DIAGRAMS 357
ELECTRICAL – BAS ELECTRICAL DIAGNOSTICS 360
DIAGNOSIS AND TESTING 360
CAB INTERNAL FAILURE 361
CAB SYSTEM UNDERVOLTAGE 363
CAB SYSTEM OVERVOLTAGE 366
PCM NOT IDENTIFIED OR INCORRECT 369
CAN BUS COMMUNICATION GENERAL MALFUNCTION 371
NO CAN COMMUNICATIONS WITH PCM 374
BAS RELEASE SWITCH CIRCUIT 377
BAS TRAVEL SENSOR CIRCUIT 385
BRAKE LAMP SWITCH CIRCUIT 392
BAS SOLENOID VALVE CIRCUIT 406
ABS VERIFICATION TEST 412
SCHEMATICS AND DIAGRAMS 413
BRAKES – ABS SERVICE INFORMATION 414
BRAKES – ESP SERVICE INFORMATION 415
DESCRIPTION 415
OPERATION – ELECTRONIC STABILITY PROGRAM (ESP) 416
NORMAL BRAKING 416
ABS BRAKING 416
NOISE AND BRAKE PEDAL FEEL 416
TIRE NOISE AND MARKS 417
START-UP CYCLE 417
DRIVE MODE 417
PREMATURE ABS CYCLING 418
DIAGNOSIS AND TESTING – INSPECTION AND ROAD TEST 418
SPECIFICATIONS – TORQUE CHART 419
FRONT WHEEL SPEED SENSOR 420
DESCRIPTION 420
OPERATION 420
REMOVAL 421
INSTALLATION 422
REAR WHEEL SPEED SENSOR 423
DESCRIPTION 423
OPERATION 423
REMOVAL 424
INSTALLATION 425
STEERING ANGLE SENSOR 427
DESCRIPTION 427
OPERATION 427
REMOVAL 428
INSTALLATION 429
LATERAL ACCELERATION SENSOR 430
DESCRIPTION 430
OPERATION 431
REMOVAL 431
INSTALLATION 431
YAW RATE SENSOR 432
DESCRIPTION 432
OPERATION 432
REMOVAL 433
INSTALLATION 433
YAW RATE/LATERAL ACCELERATION SENSOR 434
DESCRIPTION 434
OPERATION 434
REMOVAL 435
INSTALLATION 435
BRAKE PRESSURE SENSOR 436
DESCRIPTION 436
OPERATION 436
REMOVAL 436
INSTALLATION 436
TRAVEL SENSOR 437
DESCRIPTION 437
OPERATION 437
REMOVAL 438
INSTALLATION 438
SOLENOID VALVE 438
DESCRIPTION 438
OPERATION 438
REMOVAL 438
INSTALLATION 439
RELEASE SWITCH 439
DESCRIPTION 439
OPERATION 439
REMOVAL 439
INSTALLATION 439
HYDRAULIC/MECHANICAL 440
STANDARD PROCEDURE – BLEEDING ABS BRAKE SYSTEM 440
HCU (HYDRAULIC CONTROL UNIT) 440
DESCRIPTION 440
OPERATION 440
NORMAL BRAKING FUNCTION 440
ABS BRAKING FUNCTION 440
ABS TRACTION CONTROL FUNCTION 441
REMOVAL 441
INSTALLATION 442
6-CLUTCH 443
CLUTCH 443
DESCRIPTION 443
OPERATION 444
WARNING 444
DIAGNOSIS AND TESTING 444
CLUTCH SYSTEM 444
CLUTCH CONTAMINATION 444
IMPROPER RELEASE OR IMPROPER CLUTCH ENGAGEMENT 444
CLUTCH MISALIGNMENT 445
CLUTCH COVER AND DISC RUNOUT 445
FLYWHEEL RUNOUT 445
DIAGNOSIS CHART 446
STANDARD PROCEDURE 448
MASTER CYLINDER BLEEDING 448
SPECIFICATIONS – TORQUE 449
SPECIAL TOOLS 450
CLUTCH DISC 451
REMOVAL 451
INSTALLATION 452
CLUTCH COVER 454
DESCRIPTION 454
OPERATION 454
REMOVAL 454
INSTALLATION 456
MASTER CYLINDER – CLUTCH 458
REMOVAL 458
INSTALLATION 459
RELEASE BEARING/SLAVE CYLINDER 461
DESCRIPTION 461
OPERATION 461
REMOVAL 462
INSTALLATION 462
FLYWHEEL 462
DESCRIPTION 462
OPERATION 462
DIAGNOSIS AND TESTING 463
REMOVAL 463
INSTALLATION 464
PILOT BEARING 464
REMOVAL 464
INSTALLATION 464
CLUTCH PEDAL 465
REMOVAL 465
INSTALLATION 466
7-COOLING 469
COOLING – ELECTRICAL DIAGNOSTICS 469
DESCRIPTION 469
OPERATION 469
DIAGNOSIS AND TESTING 469
*RADIATOR COOLING FAN INOPERATIVE 470
*RADIATOR COOLING FAN ALWAYS ON 475
478
SCHEMATICS AND DIAGRAMS 479
COOLING – SERVICE INFORMATION 480
DESCRIPTION 480
OPERATION 481
DIAGNOSIS AND TESTING 483
PRELIMINARY CHECKS 483
COOLING SYSTEM LEAK 484
CLEANING 484
INSPECTION 484
SPECIFICATIONS 485
SPECIAL TOOLS 486
ENGINE 487
COOLANT 488
DESCRIPTION 488
COOLANT PERFORMANCE 488
COOLANT SELECTION AND ADDITIVES 489
OPERATION 489
DIAGNOSIS AND TESTING 489
COOLANT CONCENTRATION 489
STANDARD PROCEDURE 490
DRAINING 490
REFILLING 490
REVERSE FLUSHING 491
CHEMICAL CLEANING 491
REVERSE FLUSHING RADIATOR 491
COOLANT LEVEL SENSOR 492
REMOVAL 492
INSTALLATION 492
ENGINE COOLANT THERMOSTAT 492
DESCRIPTION 492
OPERATION 493
DIAGNOSIS AND TESTING 494
THERMOSTAT 494
REMOVAL 495
INSTALLATION 495
COOLANT RECOVERY RESERVOIR 496
OPERATION 496
REMOVAL 496
REMOVAL – SRT 497
INSTALLATION 498
INSTALLATION – SRT 499
RADIATOR FAN 501
REMOVAL 501
INSTALLATION 503
RADIATOR FAN CONTROL MODULE 505
REMOVAL 505
REMOVAL – SRT 505
INSTALLATION 506
INSTALLATION – SRT 506
ENGINE COOLANT TEMPERATURE SENSOR 507
OPERATION 507
REMOVAL 507
REMOVAL – SRT 508
INSTALLATION 511
INSTALLATION – SRT 513
RADIATOR 516
DESCRIPTION 516
REMOVAL 517
CLEANING 519
INSPECTION 519
INSTALLATION 520
RADIATOR PRESSURE CAP 523
DESCRIPTION 523
OPERATION 523
WARNING 523
CLEANING 524
WATER PUMP 524
DESCRIPTION 524
OPERATION 524
REMOVAL 524
REMOVAL – SRT 527
INSPECTION 531
INSTALLATION 532
INSTALLATION – SRT 535
RADIATOR – CHARGE AIR COOLER 538
DESCRIPTION 538
OPERATION 539
REMOVAL 539
INSTALLATION 541
CHARGE AIR COOLER 543
DESCRIPTION 543
OPERATION 543
REMOVAL 544
INSTALLATION 545
CHARGE AIR COOLER CIRCULATION PUMP 547
DESCRIPTION 547
OPERATION 547
REMOVAL 548
INSTALLATION 549
ACCESSORY DRIVE 550
DESCRIPTION 550
OPERATION 550
OPERATION – SRT 551
DIAGNOSIS AND TESTING 551
ACCESSORY DRIVE 551
SPECIFICATIONS 551
BELT TENSIONER 552
REMOVAL 552
REMOVAL – SRT 553
INSTALLATION 555
INSTALLATION – SRT 557
DRIVE BELT 559
REMOVAL 559
REMOVAL – SRT 560
CLEANING 561
INSPECTION 562
INSTALLATION 562
INSTALLATION – SRT 564
IDLER PULLEY 566
REMOVAL 566
REMOVAL – IDLER PULLEY (SRT) 568
REMOVAL – SUPERCHARGER IDLER (SRT) 569
INSTALLATION 571
INSTALLATION – IDLER PULLEY (SRT) 573
INSTALLATION – SUPERCHARGER IDLER (SRT) 574
TRANSMISSION 576
TRANSMISSION COOLER LINES 576
REMOVAL 576
INSTALLATION 577
8a-AUDIO/VIDEO 579
AUDIO – ELECTRICAL DIAGNOSTICS 579
DIAGNOSIS AND TESTING 579
*RADIO INOPERATIVE 580
*NO SOUND FROM ALL SPEAKERS 583
*NO SOUND FROM LEFT DOOR SPEAKERS 586
*NO SOUND FROM RIGHT DOOR SPEAKERS 588
*NO SOUND FROM LEFT REAR SPEAKER 590
*NO SOUND FROM RIGHT REAR SPEAKER 593
BODY VERIFICATION TEST 596
SCHEMATICS AND DIAGRAMS 597
AUDIO – SERVICE INFORMATION 598
DESCRIPTION 599
OPERATION 599
DIAGNOSIS AND TESTING – AUDIO SYSTEM 599
SPECIAL TOOLS 600
AMPLIFIER 601
REMOVAL 601
REMOVAL – RHD 602
INSTALLATION 604
INSTALLATION – RHD 605
ANTENNA BODY & CABLE – CONVERTIBLE 606
DESCRIPTION 606
OPERATION 607
DIAGNOSIS AND TESTING – ANTENNA BODY AND CABLE 607
TEST 1 607
TEST 2 608
TEST 3 608
TEST 4 608
REMOVAL 609
INSTALLATION 609
REAR WINDOW ANTENNA MODULE 610
REMOVAL 610
INSTALLATION 610
REAR WINDOW ANTENNA 611
DESCRIPTION 611
STANDARD PROCEDURE – ANTENNA GRID REPAIR 611
REMOVAL 612
INSTALLATION 613
RADIO 613
REMOVAL 613
INSTALLATION 614
SPEAKER 614
REMOVAL 614
LOWER DOOR SPEAKER 614
REMOVAL – REAR PANEL SPEAKER 615
REMOVAL – TWEETER SPEAKER 616
INSTALLATION 617
LOWER DOOR SPEAKER 617
INSTALLATION – REAR PANEL SPEAKER 618
INSTALLATION – TWEETER SPEAKER 618
8b-CHIME/BUZZER 621
CHIME/BUZZER – ELECTRICAL DIAGNOSTICS 621
DESCRIPTION 621
SCHEMATICS AND DIAGRAMS 622
CHIME/BUZZER – SERVICE INFORMATION 623
CHIME TONE GENERATOR 623
DESCRIPTION 623
DIAGNOSIS AND TESTING – CHIME WARNING SYSTEM 624
OPERATION 625
8e-ELECTRONIC CONTROL MODULES 627
ELECTRONIC CONTROL MODULES – ELECTRICAL DIAGNOSTICS 627
DIAGNOSIS AND TESTING 627
*DRB III DOES NOT POWER UP 628
*NO RESPONSE FROM ALL MODULES 630
*NO RESPONSE FROM POWERTRAIN CONTROL MODULE 634
*NO RESPONSE FROM OCCUPANT RESTRAINT CONTROLLER 640
*NO RESPONSE FROM INSTRUMENT CLUSTER 644
*NO RESPONSE FROM UNIVERSAL GARAGE DOOR OPENER/TIRE PRESSURE MONITOR 650
*NO RESPONSE FROM A/C HEATER CONTROL MODULE 655
*NO RESPONSE FROM POWER TOP CONTROL MODULE 661
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE 665
*NO RESPONSE FROM SHIFT LEVER ASSEMBLY 671
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE 676
*NO RESPONSE FROM BODY CONTROL MODULE 680
*NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE 686
BODY VERIFICATION TEST 692
SCHEMATICS AND DIAGRAMS 693
ELECTRONIC CONTROL MODULES – SERVICE INFORMATION 700
COMMUNICATION 700
DESCRIPTION 700
OPERATION 701
DATA LINK CONNECTOR 701
DESCRIPTION 701
OPERATION 701
POWERTRAIN CONTROL MODULE 702
DESCRIPTION 702
DESCRIPTION – RHD 703
OPERATION0 – 4 ZH 703
STANDARD PROCEDURE – PCM/SKREEM PROGRAMMING 703
PROGRAMMING THE PCM 704
PROGRAMMING THE SENTRY KEY REMOTE ENTRY MODULE 704
PROGRAMMING IGNITION KEYS TO THE SENTRY KEY REMOTE ENTRY MODULE 704
REMOVAL 704
REMOVAL – RHD 706
INSTALLATION 707
INSTALLATION – RHD 708
TRANSMISSION CONTROL MODULE 709
DESCRIPTION 709
OPERATION 709
BATTERY FEED 710
LIMP-HOME MODE 710
STANDARD PROCEDURE – TCM QUICK LEARN 710
REMOVAL 711
INSTALLATION 714
CONTROLLER ANTILOCK BRAKE 717
DESCRIPTION 717
OPERATION 717
CAB INPUTS 718
CAB OUTPUTS 718
REMOVAL 718
INSTALLATION 719
SECURITY SYSTEM MODULE 720
DESCRIPTION 720
OPERATION 721
VEHICLE LOCKING / UNLOCKING 721
AUTOMATIC LOCKING / UNLOCKING 721
EMERGENCY UNLOCKING 721
VEHICLE RELOCKING 721
ANTI-THEFT SYSTEM 721
SIREN 722
ANTI-THEFT SWITCH / ANTI-THEFT TOW SENSOR 722
REMOVAL 722
INSTALLATION 723
SENTRY KEY REMOTE ENTRY MODULE 724
DESCRIPTION 724
OPERATION 725
REMOVAL 726
INSTALLATION 726
BODY CONTROL MODULE 727
DESCRIPTION 727
BODY CONTROL MODULE 727
CONTROL MODULE COOLING FAN 727
DESCRIPTION – RHD 728
BODY CONTROL MODULE 728
CONTROL MODULE COOLING FAN 728
OPERATION 728
REMOVAL 729
REMOVAL – RHD 730
INSTALLATION 731
INSTALLATION – RHD 732
POWER TOP CONTROL MODULE 733
DESCRIPTION 733
OPERATION 733
STANDARD PROCEDURE – POWER TOP CONTROL MODULE INITIALIZATION 733
REMOVAL 734
INSTALLATION 735
8f-ENGINE SYSTEMS 737
BATTERY SYSTEM 737
DESCRIPTION 737
OPERATION 738
DIAGNOSIS AND TESTING – BATTERY SYSTEM 738
MICRO 420 ELECTRICAL SYSTEM TESTER 738
ABNORMAL BATTERY DISCHARGING 740
CLEANING 741
INSPECTION 742
SPECIFICATIONS 742
SPECIAL TOOLS 743
BATTERY 744
DESCRIPTION 744
OPERATION 744
DIAGNOSIS AND TESTING – BATTERY 745
MICRO 420 BATTERY TESTER 745
STANDARD PROCEDURE 745
CHARGING BATTERY 745
CHARGING A COMPLETELY DISCHARGED BATTERY 746
CHARGING TIME REQUIRED 747
STANDARD PROCEDURE – USING MICRO 420 BATTERY TESTER 748
BATTERY TESTING 748
STANDARD PROCEDURE – OPEN-CIRCUIT VOLTAGE TEST 749
STANDARD PROCEDURE – IGNITION-OFF DRAW TEST 749
STANDARD PROCEDURE – CHECKING BATTERY ELECTROLYTE LEVEL 751
REMOVAL 753
REMOVAL – BATTERY 753
REMOVAL – RHD 754
INSTALLATION 755
INSTALLATION – BATTERY 755
INSTALLATION – RHD 756
CABLES 756
DESCRIPTION 756
OPERATION 757
DIAGNOSIS AND TESTING – BATTERY CABLES 757
VOLTAGE DROP TEST 757
TRAY 759
DESCRIPTION 759
DESCRIPTION – RHD 760
OPERATION 760
REMOVAL 761
REMOVAL – RHD 761
INSTALLATION 762
INSTALLATION – RHD 762
CHARGING SYSTEM 763
DESCRIPTION 763
OPERATION 763
DIAGNOSIS AND TESTING – CHARGING SYSTEM 763
SCHEMATICS AND DIAGRAMS 765
SPECIFICATIONS 766
SPECIFICATIONS – GENERATOR 766
SPECIFICATIONS – TORQUE 766
GENERATOR 766
DESCRIPTION 766
OPERATION 766
REMOVAL 767
INSTALLATION 768
VOLTAGE REGULATOR 769
DESCRIPTION 769
OPERATION 769
REMOVAL 770
INSTALLATION 770
STARTING SYSTEM 771
DESCRIPTION 771
OPERATION 772
DIAGNOSIS AND TESTING – STARTING SYSTEM 772
TESTING 774
SCHEMATICS AND DIAGRAMS 778
SPECIFICATIONS 779
STARTER MOTOR 779
TORQUE SPECIFICATIONS 779
STARTER MOTOR 779
DESCRIPTION 779
OPERATION 780
DIAGNOSIS AND TESTING – STARTER MOTOR 780
STARTER SOLENOID 780
REMOVAL 782
INSTALLATION 783
8g-HEATED SYSTEMS 785
HEATED GLASS – ELECTRICAL DIAGNOSTICS 785
DIAGNOSIS AND TESTING 785
REAR DEFOGGER SWITCH SENSE CIRCUIT 786
*REAR WINDOW DEFOGGER INOPERATIVE 790
BODY VERIFICATION TEST 794
SCHEMATICS AND DIAGRAMS 795
HEATED GLASS – SERVICE INFORMATION 796
DESCRIPTION 796
OPERATION 797
DIAGNOSIS AND TESTING – REAR WINDOW DEFOGGER SYSTEM 798
REAR WINDOW DEFOGGER SWITCH 799
REMOVAL 799
INSTALLATION 799
REAR WINDOW DEFOGGER GRID 799
DIAGNOSIS AND TESTING – REAR WINDOW DEFOGGER GRID 799
STANDARD PROCEDURE – REAR GLASS HEATING GRID REPAIR 800
HEATED MIRRORS – ELECTRICAL DIAGNOSTICS 802
DIAGNOSIS AND TESTING 802
*LEFT HEATED MIRROR INOPERATIVE 803
*RIGHT HEATED MIRROR INOPERATIVE 805
BODY VERIFICATION TEST 807
SCHEMATICS AND DIAGRAMS 808
HEATED MIRRORS – SERVICE INFORMATION 809
DESCRIPTION 809
OPERATION 809
DIAGNOSIS AND TESTING 810
HEATED MIRROR GRID 810
DESCRIPTION 810
HEATED SEATS – ELECTRICAL DIAGNOSTICS 812
DIAGNOSIS AND TESTING 812
*LEFT HEATED SEAT INOPERATIVE 813
*RIGHT HEATED SEAT INOPERATIVE 816
*BOTH HEATED SEATS INOPERATIVE 819
BODY VERIFICATION TEST 821
SCHEMATICS AND DIAGRAMS 822
HEATED SEATS – SERVICE INFORMATION 823
DESCRIPTION 823
OPERATION 824
DIAGNOSIS AND TESTING 824
HEATED SEAT SWITCH 824
REMOVAL 824
INSTALLATION 825
HEATED SEAT ELEMENT 826
DESCRIPTION 826
REMOVAL 827
HEATED SEAT CUSHION ELEMENT 827
REMOVAL – HEATED SEAT BACK ELEMENT 827
INSTALLATION 828
HEATED SEAT CUSHION ELEMENT 828
INSTALLATION – HEATED SEAT BACK ELEMENT 828
HEATED SEAT MODULE 828
REMOVAL 828
INSTALLATION 829
8h-HORN 831
HORN – ELECTRICAL DIAGNOSTICS 831
DIAGNOSIS AND TESTING 831
*HORNS INOPERATIVE 832
*HORNS ALWAYS ON 835
BODY VERIFICATION TEST 837
SCHEMATICS AND DIAGRAMS 838
HORN – SERVICE INFORMATION 839
DESCRIPTION 839
OPERATION 840
SPECIFICATIONS – HORN 840
HORN 841
REMOVAL 841
INSTALLATION 842
HORN SWITCH 843
DIAGNOSIS AND TESTING 843
REMOVAL 844
INSTALLATION 844
HORN RELAY 846
DESCRIPTION 846
REMOVAL 847
INSTALLATION 847
8i-IGNITION CONTROL 849
IGNITION SYSTEM – ELECTRICAL DIAGNOSTICS 849
DESCRIPTION 849
SCHEMATICS AND DIAGRAMS 850
IGNITION SYSTEM – SERVICE INFORMATION 851
DESCRIPTION 852
OPERATION 852
Spark Plugs 853
Ignition Coil Packs 853
Spark Plug Cables 853
Camshaft Position Sensor 853
Crankshaft Position Sensor 853
Knock Sensors 853
Powertrain Control Module 853
SPECIFICATIONS 853
SPECIFICATIONS – SPARK PLUGS 853
SPECIFICATIONS – TORQUE 853
CAMSHAFT POSITION SENSOR 854
DESCRIPTION 854
OPERATION 854
REMOVAL 855
INSTALLATION 855
IGNITION COIL 856
DESCRIPTION 856
OPERATION 857
REMOVAL 858
REMOVAL – SRT 859
INSTALLATION 861
INSTALLATION – SRT 863
KNOCK SENSOR 866
DESCRIPTION 866
OPERATION 866
REMOVAL 867
INSTALLATION 867
SPARK PLUG 868
DESCRIPTION 868
OPERATION 869
DIAGNOSIS AND TESTING – SPARK PLUG CONDITIONS 870
REMOVAL 874
INSTALLATION 875
SPARK PLUG CABLE 876
DESCRIPTION 876
OPERATION 877
REMOVAL 877
INSTALLATION 877
8j-INSTRUMENT CLUSTER 879
INSTRUMENT CLUSTER – ELECTRICAL DIAGNOSTICS 879
DIAGNOSIS AND TESTING 879
COOLANT LEVEL SENSOR/WASHER FLUID LEVEL SWITCH CIRCUIT 880
LAMP OUTAGE INDICATOR CIRCUIT 883
FUEL LEVEL SENSOR CIRCUIT 886
AMBIENT TEMPERATURE SENSOR CIRCUIT 889
NO COMMUNICATION FROM INSTRUMENT CLUSTER 895
NO COMMUNICATION TO INSTRUMENT CLUSTER 897
NO CAN COMMUNICATIONS WITH PCM 899
NO CAN COMMUNICATIONS WITH CAB 906
NO CAN COMMUNICATIONS WITH TCM 913
CAN BUS COMMUNICATION GENERAL MALFUNCTION 920
*LEFT TURN SIGNAL INDICATOR INOPERATIVE 923
*RIGHT TURN SIGNAL INDICATOR INOPERATIVE 925
*HIGH BEAM INDICATOR INOPERATIVE 927
*BRAKE WARNING INDICATOR INOPERATIVE 930
*BATTERY VOLTAGE INDICATOR INOPERATIVE 933
*SEAT BELT INDICATOR INOPERATIVE 936
*TELESCOPING WHEEL INDICATOR INOPERATIVE 938
BODY VERIFICATION TEST 940
SCHEMATICS AND DIAGRAMS 941
INSTRUMENT CLUSTER – SERVICE INFORMATION 944
DESCRIPTION 944
HARD WIRE ACTUATED INDICATOR LAMPS 945
CAN BUS ACTUATED INDICATOR LAMPS 945
HARD WIRE ACTUATED AUDIBLE TONES AND INDICATOR LAMPS 945
CAN BUS ACTUATED AUDIBLE TONES 945
CAN BUS FUNCTIONAL DIAGRAM 946
FLEXIBLE SERVICE SYSTEM (FSS) INDICATOR 946
DESCRIPTION – RHD 947
HARD WIRE ACTUATED INDICATOR LAMPS 947
CAN BUS ACTUATED INDICATOR LAMPS 947
HARD WIRE ACTUATED AUDIBLE TONES AND INDICATOR LAMPS 947
CAN BUS ACTUATED AUDIBLE TONES 947
FLEXIBLE SERVICE SYSTEM (FSS) INDICATOR 948
OPERATION 948
INSTRUMENT CLUSTER GAUGES 948
INSTRUMENT CLUSTER DIGITAL DISPLAYS 950
WARNING INDICATORS 951
INSTRUMENT CLUSTER CHIME FUNCTION 957
HARD WIRE ACTUATED INDICATOR LAMPS AND AUDIBLE TONES 958
CAN DATA BUS ACTUATED INDICATOR LAMPS AND AUDIBLE TONES 958
CAN DATA BUS ACTUATED INSTRUMENTS 958
APPEARANCE AND LIGHTING 959
CONTROL BUTTONS 959
OUTSIDE AMBIENT AIR TEMPERATURE 960
FLEXIBLE SERVICE SYSTEM (FSS) MAINTENANCE INDICATOR 960
ACKNOWLEDGING THE FSS MAINTENANCE INDICATOR 961
OPERATION – RHD 962
INSTRUMENT CLUSTER GAUGES 962
INSTRUMENT CLUSTER DIGITAL DISPLAYS 964
WARNING INDICATORS 965
INDICATOR LAMPS AND AUDIBLE TONES TRIGGERED OVER DIRECT LINES 972
INDICATOR LAMPS AND AUDIBLE TONES TRIGGERED BY THE CAN DATA BUS 972
INSTRUMENTS ACTUATED BY THE CAN DATA BUS 972
APPEARANCE AND LIGHTING 973
CONTROL BUTTONS 973
OUTSIDE AMBIENT AIR TEMPERATURE 974
FLEXIBLE SERVICE SYSTEM (FSS) MAINTENANCE INDICATOR 974
ACKNOWLEDGING THE FSS MAINTENANCE INDICATOR 975
DIAGNOSIS AND TESTING – FUNCTION CHECK 976
INSTRUMENT CLUSTER BULBS 976
DISPLAY INSTRUMENTS 977
WARNING CHIME OPERATIONAL CHECK 977
MAINTENANCE DISPLAY 978
STANDARD PROCEDURE 978
DISPLAY OF REMAINING FSS MILEAGE AT DRIVER’S REQUEST 978
RESETTING THE FSS MAINTENANCE INDICATOR 979
RESETTING THE FSS MAINTENANCE INDICATOR AFTER AN OIL CHANGE 981
STANDARD PROCEDURE – INSTRUMENT CLUSTER BULBS 984
INSTRUMENT CLUSTER BULB REMOVAL 984
INSTRUMENT CLUSTER BULB INSTALLATION 985
REMOVAL 985
REMOVAL – INSTRUMENT CLUSTER 985
REMOVAL – RHD 987
INSTALLATION 988
INSTALLATION – INSTRUMENT CLUSTER 988
INSTALLATION – RHD 989
8l-LAMPS 991
LAMPS/LIGHTING – EXTERIOR – ELECTRICAL DIAGNOSTICS 991
DIAGNOSIS AND TESTING 991
*LEFT FOG LAMP INOPERATIVE 992
*RIGHT FOG LAMP INOPERATIVE 995
*LEFT PARK LAMP INOPERATIVE 998
*LEFT FRONT TURN LAMP INOPERATIVE 1001
*RIGHT PARK LAMP INOPERATIVE 1004
*RIGHT FRONT TURN LAMP INOPERATIVE 1007
*LEFT LOW BEAM HEADLAMP INOPERATIVE 1010
*LEFT HIGH BEAM HEADLAMP INOPERATIVE 1013
*RIGHT LOW BEAM HEADLAMP INOPERATIVE 1016
*RIGHT HIGH BEAM HEADLAMP INOPERATIVE 1019
*LEFT FRONT SIDE MARKER LAMP INOPERATIVE 1022
*RIGHT FRONT SIDE MARKER LAMP INOPERATIVE 1025
*LEFT REAR SIDE MARKER LAMP INOPERATIVE 1028
*RIGHT REAR SIDE MARKER LAMP INOPERATIVE 1031
*LEFT TAIL LAMP INOPERATIVE0 – 6 ZH 1034
*LEFT STOP LAMP INOPERATIVE 1037
*LEFT BACK UP LAMP INOPERATIVE 1040
*LEFT REAR TURN LAMP INOPERATIVE 1043
*RIGHT TAIL LAMP INOPERATIVE 1046
*RIGHT STOP LAMP INOPERATIVE 1049
*RIGHT BACK UP LAMP INOPERATIVE 1052
*RIGHT REAR TURN LAMP INOPERATIVE 1055
*CENTER HIGH MOUNTED STOP LAMP INOPERATIVE 1058
*LICENSE LAMP NO 1 INOPERATIVE 1061
*LICENSE LAMP NO 2 INOPERATIVE 1064
BODY VERIFICATION TEST 1067
SCHEMATICS AND DIAGRAMS 1068
LAMPS/LIGHTING – EXTERIOR – SERVICE INFORMATION 1074
DESCRIPTION 1075
OPERATION 1075
DIAGNOSIS AND TESTING 1076
LAMPS/LIGHTING – EXTERIOR 1076
EXTERIOR LAMPS 1076
HEADLAMPS 1076
SPECIFICATIONS – EXTERIOR LAMPS 1077
BACKUP LAMP 1078
REMOVAL 1078
INSTALLATION 1078
BACKUP LAMP SWITCH 1079
DESCRIPTION 1079
BACKUP LAMP SWITCH (Manual Transmission) 1079
BACKUP LAMP SWITCH (Automatic Transmission) 1079
BRAKE LAMP RELAY 1080
DESCRIPTION 1080
OPERATION 1080
REMOVAL 1080
INSTALLATION 1080
BRAKE LAMP SWITCH 1081
DESCRIPTION 1081
OPERATION 1081
REMOVAL 1081
INSTALLATION 1081
CENTER HIGH MOUNTED STOP LAMP 1082
DESCRIPTION 1082
REMOVAL 1082
REMOVAL – COUPE 1082
REMOVAL – ROADSTER 1082
INSTALLATION 1084
INSTALLATION – COUPE 1084
INSTALLATION – ROADSTER 1084
FOG LAMP 1085
REMOVAL 1085
INSTALLATION 1086
FOG LAMP UNIT 1087
REMOVAL 1087
INSTALLATION 1088
FRONT POSITION LAMP 1089
DESCRIPTION 1089
OPERATION 1089
REMOVAL 1089
INSTALLATION 1090
FRONT TURN SIGNAL LAMP 1090
REMOVAL 1090
INSTALLATION 1091
HAZARD FLASHER 1091
DESCRIPTION 1091
HAZARD SWITCH 1092
DESCRIPTION 1092
OPERATION 1092
REMOVAL 1092
INSTALLATION 1093
HEADLAMP 1094
DESCRIPTION 1094
OPERATION 1094
REMOVAL 1094
LOW BEAM BULB 1094
REMOVAL – HIGH BEAM BULB 1095
INSTALLATION 1096
LOW BEAM BULB 1096
INSTALLATION – HIGH BEAM BULB 1096
HEADLAMP LEVELING MOTOR – EXPORT 1096
DESCRIPTION 1096
HEADLAMP LEVELING SYSTEM 1096
HEADLAMP LEVELING MOTOR 1097
OPERATION 1097
HEADLAMP LEVELING SYSTEM 1097
HEADLAMP LEVELING MOTOR 1097
DIAGNOSIS AND TESTING 1097
HEADLAMP LEVELING MOTOR – EXPORT 1097
HEADLAMP LEVELING SYSTEM 1098
REMOVAL 1098
INSTALLATION 1098
HEADLAMP LEVELING SWITCH – EXPORT 1099
DESCRIPTION 1099
OPERATION 1099
DIAGNOSIS AND TESTING 1099
HEADLAMP LEVELING SWITCH 1099
REMOVAL 1099
INSTALLATION 1100
HEADLAMP SWITCH 1100
DESCRIPTION 1100
OPERATION 1100
REMOVAL 1100
INSTALLATION 1101
HEADLAMP UNIT 1102
DESCRIPTION 1102
STANDARD PROCEDURE 1102
STANDARD PROCEDURE – HEADLAMP UNIT ALIGNMENT 1102
HEADLAMP ALIGNMENT PREPARATION 1102
ALIGNMENT SCREEN PREPARATION 1103
HEADLAMP ADJUSTMENT 1103
STANDARD PROCEDURE – HEADLAMP UNIT ALIGNMENT 1103
HEADLAMP ALIGNMENT PREPARATION 1103
ALIGNMENT SCREEN PREPARATION 1104
HEADLAMP ADJUSTMENT 1104
REMOVAL 1105
INSTALLATION 1105
LICENSE PLATE LAMP 1106
REMOVAL 1106
INSTALLATION 1107
MARKER LAMP 1107
REMOVAL 1107
REMOVAL – REAR MARKER LAMP 1107
REMOVAL – FRONT MARKER LAMP 1108
INSTALLATION 1108
INSTALLATION – REAR MARKER LAMP 1108
INSTALLATION – FRONT MARKER LAMP 1109
MULTI-FUNCTION SWITCH 1109
REMOVAL 1109
INSTALLATION 1110
TAIL LAMP UNIT 1110
REMOVAL 1110
REMOVAL – TAIL LAMP UNIT 1110
REMOVAL – TAIL/STOP LAMP 1111
REMOVAL – TURN SIGNAL LAMP 1111
INSTALLATION 1112
INSTALLATION – TAIL LAMP UNIT 1112
INSTALLATION – TAIL/STOP LAMP 1112
INSTALLATION – TURN SIGNAL LAMP 1113
LAMPS/LIGHTING – INTERIOR – ELECTRICAL DIAGNOSTICS 1114
DIAGNOSIS AND TESTING 1114
HAZARD SWITCH CIRCUIT 1115
DOME LAMP CIRCUIT 1118
*CARGO LAMP INOPERATIVE 1121
*GLOVE BOX LAMP INOPERATIVE 1124
*ASH RECEIVER LAMP INOPERATIVE 1127
BODY VERIFICATION TEST 1130
SCHEMATICS AND DIAGRAMS 1131
LAMPS/LIGHTING – INTERIOR – SERVICE INFORMATION 1133
DIAGNOSIS AND TESTING – LAMPS/LIGHTING-INTERIOR 1133
SPECIFICATIONS – INTERIOR LAMPS 1134
CARGO LAMP 1134
REMOVAL 1134
INSTALLATION 1135
CARGO LAMP UNIT 1136
REMOVAL 1136
INSTALLATION 1137
COURTESY LAMP 1137
REMOVAL 1137
INSTALLATION 1138
COURTESY LAMP DEFEAT SWITCH 1138
DESCRIPTION 1138
COURTESY LAMP SWITCH/UNIT 1139
DESCRIPTION 1139
OPERATION 1139
REMOVAL 1139
INSTALLATION 1140
DIMMER SWITCH 1141
DESCRIPTION 1141
DOOR AJAR SWITCH 1141
DESCRIPTION 1141
OPERATION 1141
REMOVAL 1142
DOOR AJAR SWITCH 1142
REMOVAL – LIFTGATE AJAR SWITCH 1142
INSTALLATION 1143
DOOR AJAR SWITCH 1143
INSTALLATION – LIFTGATE AJAR SWITCH 1143
GLOVE BOX LAMP 1143
REMOVAL 1143
INSTALLATION 1144
GLOVE BOX LAMP/SWITCH 1145
DESCRIPTION 1145
OPERATION 1145
REMOVAL 1145
INSTALLATION 1146
HEATER SWITCH ILLUMINATION 1146
DESCRIPTION 1146
TRANS RANGE INDICATOR ILLUMINATION 1147
DESCRIPTION 1147
ASH RECEIVER LAMP 1147
REMOVAL 1147
INSTALLATION 1149
8m-MESSAGE SYSTEMS 1151
UNIVERSAL TRANSMITTER 1151
DESCRIPTION 1151
OPERATION 1152
DIAGNOSIS AND TESTING – UNIVERSAL TRANSMITTER 1152
STANDARD PROCEDURE – UNIVERSAL TRANSMITTER PROGRAMMING 1152
ERASING CODES 1152
PROGRAMMING CODES 1152
REMOVAL 1153
INSTALLATION 1153
8n-POWER SYSTEMS 1155
POWER LOCKS – ELECTRICAL DIAGNOSTICS 1155
DIAGNOSIS AND TESTING 1155
DRIVER DOOR LOCK ACTUATOR SLOW RESPONSE 1156
FUEL DOOR LOCK ACTUATOR SLOW RESPONSE 1158
PASSENGER DOOR/LIFTGATE LOCK ACTUATOR SLOW RESPONSE 1160
BODY CONTROL MODULE INTERNAL FAILURE 1162
CLP/SSM SYSTEM UNDERVOLTAGE 1165
CLP/SSM SYSTEM OVERVOLTAGE 1168
NO COMMUNICATION WITH BODY CONTROL MODULE AND CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE 1171
DOOR LOCK/DOOR UNLOCK SWITCH SENSE CIRCUIT 1174
CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE INTERNAL FAILURE 1179
BODY VERIFICATION TEST 1181
SCHEMATICS AND DIAGRAMS 1182
POWER LOCKS – SERVICE INFORMATION 1183
DESCRIPTION 1183
Central Locking 1184
Door Lock Inhibit 1184
Sentry Key Remote Entry 1184
OPERATION 1184
Central Locking 1184
Remote Keyless Entry 1185
Automatic Relocking Function 1185
Automatic Locking 1185
Emergency Unlocking 1185
DIAGNOSIS AND TESTING – POWER LOCKS 1185
PNEUMATIC SUPPLY LINES 1186
SUPPLY LINE/ACTUATOR TESTING 1186
Entire System 1186
Pneumatic Actuator Test 1187
Pneumatic Line Test 1187
STANDARD PROCEDURE – TOGGLING CUSTOMER PREFERENCES 1187
Automatic Locking 1187
Global/Selective Central Locking 1187
SPECIFICATIONS – POWER LOCKS 1188
CENTRAL LOCKING PUMP 1188
DESCRIPTION 1188
DIAGNOSIS AND TESTING 1188
KEYLESS ENTRY TRANSMITTER 1189
DIAGNOSIS AND TESTING 1189
STANDARD PROCEDURE – TRANSMITTER PROGRAMMING 1189
PROGRAMMING PROCEDURE 1189
SPECIFICATIONS 1189
TRANSMITTER 1189
BATTERY TESTING 1189
BATTERY REPLACEMENT 1190
TRANSMITTER RANGE 1190
POWER LOCK SWITCH 1190
DESCRIPTION 1190
REMOVAL 1190
INSTALLATION 1191
DOOR LATCH ASSEMBLY 1192
REMOVAL 1192
INSTALLATION 1194
DRIVER DOOR LOCK SWITCH 1194
REMOVAL 1194
INSTALLATION 1195
FUEL DOOR LOCK ACTUATOR 1196
REMOVAL 1196
INSTALLATION 1197
LIFTGATE LOCK SWITCH 1199
REMOVAL 1199
INSTALLATION 1199
LIFTGATE LOCK ACTUATOR 1199
REMOVAL 1199
INSTALLATION 1200
SENTRY KEY REMOTE ENTRY MODULE 1200
DESCRIPTION 1200
DIAGNOSIS AND TESTING 1200
REMOVAL 1201
REMOVAL – REMOTE KEYLESS ENTRY RELAY 1201
INSTALLATION 1203
INSTALLATION – REMOTE KEYLESS ENTRY RELAY 1203
POWER MIRRORS – ELECTRICAL DIAGNOSTICS 1205
DIAGNOSIS AND TESTING 1205
*LEFT POWER MIRROR INOPERATIVE 1206
*RIGHT POWER MIRROR INOPERATIVE 1209
*BOTH POWER MIRRORS INOPERATIVE 1212
*AUTOMATIC DAY/NIGHT MIRROR INOPERATIVE 1214
BODY VERIFICATION TEST 1217
SCHEMATICS AND DIAGRAMS 1218
POWER MIRRORS – SERVICE INFORMATION 1220
DESCRIPTION 1220
OPERATION 1220
DIAGNOSIS AND TESTING 1221
AUTOMATIC DAY / NIGHT MIRROR 1222
DESCRIPTION 1222
OPERATION 1222
REMOVAL 1222
INSTALLATION 1223
INSTALLATION – REARVIEW MIRROR 1223
INSTALLATION – WINDSHIELD MOUNTING BRACKET 1224
POWER MIRROR SWITCH 1225
REMOVAL 1225
INSTALLATION 1225
SIDEVIEW MIRROR 1225
REMOVAL 1225
INSTALLATION 1226
POWER SEATS – ELECTRICAL DIAGNOSTICS 1227
DIAGNOSIS AND TESTING 1227
*DRIVER POWER SEAT INOPERATIVE 1228
*PASSENGER POWER SEAT INOPERATIVE 1230
*BOTH POWER SEATS INOPERATIVE 1232
*DRIVER POWER SEAT RECLINER MOTOR INOPERATIVE 1235
*DRIVER POWER SEAT HORIZONTAL MOTOR INOPERATIVE 1237
*DRIVER POWER SEAT FRONT RISER MOTOR INOPERATIVE 1239
*DRIVER POWER SEAT REAR RISER MOTOR INOPERATIVE 1241
*PASSENGER POWER SEAT RECLINER MOTOR INOPERATIVE 1243
*PASSENGER POWER SEAT HORIZONTAL MOTOR INOPERATIVE 1245
BODY VERIFICATION TEST 1247
SCHEMATICS AND DIAGRAMS 1248
POWER SEATS – SERVICE INFORMATION 1249
DESCRIPTION 1249
OPERATION 1249
DIAGNOSIS AND TESTING 1250
SPECIFICATIONS 1250
POWER SEAT SWITCH 1250
DIAGNOSIS AND TESTING 1250
REMOVAL 1250
INSTALLATION 1252
REAR RISER MOTOR 1253
REMOVAL 1253
INSTALLATION 1254
HORIZONTAL AND FRONT RISER MOTORS 1255
REMOVAL 1255
REMOVAL – HORIZONTAL MOTOR 1255
REMOVAL – FRONT RISER MOTOR 1256
INSTALLATION 1257
INSTALLATION – HORIZONTAL MOTOR 1257
INSTALLATION – FRONT RISER MOTOR 1258
RECLINER MOTOR 1258
REMOVAL 1258
INSTALLATION 1259
POWER SEAT TRACK 1260
REMOVAL 1260
INSTALLATION 1261
POWER WINDOWS – ELECTRICAL DIAGNOSTICS 1263
DIAGNOSIS AND TESTING 1263
*LEFT FRONT POWER WINDOW INOPERATIVE 1264
*RIGHT FRONT POWER WINDOW INOPERATIVE 1268
*BOTH POWER WINDOWS INOPERATIVE 1272
BODY VERIFICATION TEST 1274
SCHEMATICS AND DIAGRAMS 1275
POWER WINDOWS – SERVICE INFORMATION 1276
DESCRIPTION 1276
OPERATION 1276
DIAGNOSIS AND TESTING 1276
WINDOW MOTOR 1276
REMOVAL 1276
INSTALLATION 1278
POWER WINDOW SWITCH 1278
REMOVAL 1278
INSTALLATION 1279
8o-RESTRAINTS 1281
RESTRAINTS – ELECTRICAL DIAGNOSTICS 1281
DIAGNOSIS AND TESTING0 – 8 ZH 1281
ORC INTERNAL FAILURE 1282
DRIVER AIRBAG SQUIB CIRCUIT 1284
DRIVER SEAT BELT TENSIONER SQUIB CIRCUIT 1291
PASSENGER SEAT BELT TENSIONER SQUIB CIRCUIT 1297
PASSENGER AIRBAG SQUIB CIRCUIT 1303
LEFT SIDE AIRBAG SQUIB CIRCUIT 1309
RIGHT SIDE AIRBAG SQUIB CIRCUIT 1315
PROGRAMMING DOES NOT CORRESPOND TO THE VEHICLE EQUIPMENT 1321
ORC SYSTEM UNDERVOLTAGE 1323
AIRBAG WARNING INDICATOR CIRCUIT 1326
PASSENGER AIRBAG ON/OFF SWITCH SIGNAL CIRCUIT 1329
DRIVER SEAT BELT SWITCH CIRCUIT 1333
PASSENGER SEAT BELT SWITCH CIRCUIT 1337
LEFT SIDE IMPACT SENSOR SIGNAL CIRCUIT 1341
RIGHT SIDE IMPACT SENSOR SIGNAL CIRCUIT 1345
AIRBAG VERIFICATION TEST 1349
SCHEMATICS AND DIAGRAMS 1350
RESTRAINTS – SERVICE INFORMATION 1352
DESCRIPTION 1352
ACTIVE RESTRAINTS 1352
PASSIVE RESTRAINTS 1353
OPERATION 1357
ACTIVE RESTRAINTS 1357
PASSIVE RESTRAINTS 1358
SRS – AIRBAG WARNING INDICATOR 1358
PASSENGER AIRBAG OFF INDICATOR LAMP 1359
FRONT END MEDIUM-SEVERE HEAD ON COLLISION SRS OPERATION 1359
FRONT END SEVERE HEAD-ON COLLISION SRS OPERATION 1360
REAR-END COLLISION SRS OPERATION 1361
SIDE IMPACT COLLISION SRS OPERATION 1362
WARNING 1363
DIAGNOSIS AND TESTING – SUPPLEMENTAL RESTRAINT SYSTEM 1364
STANDARD PROCEDURE 1364
STANDARD PROCEDURE – HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS 1364
STANDARD PROCEDURE – SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT 1364
AIRBAG SQUIB STATUS 1365
CLEANUP PROCEDURE 1366
STANDARD PROCEDURE – SUPPLEMENTAL RESTRAINT SYSTEM (SRS) – VERIFICATION TEST 1366
SPECIFICATIONS 1367
TORQUE CHART – RESTRAINTS 1367
OCCUPANT RESTRAINT CONTROLLER 1368
DESCRIPTION 1368
OPERATION 1368
STANDARD PROCEDURE – ORC PROGRAMMING 1369
REMOVAL 1370
INSTALLATION 1371
CLOCKSPRING 1372
DESCRIPTION 1372
OPERATION 1372
STANDARD PROCEDURE – CLOCKSPRING CENTERING 1373
REMOVAL 1374
INSTALLATION 1376
DRIVER AIRBAG 1378
DESCRIPTION 1378
OPERATION 1378
AIRBAG DEPLOYMENT SEQUENCE 1379
REMOVAL 1380
INSTALLATION 1382
PASSENGER AIRBAG 1383
DESCRIPTION 1383
OPERATION 1383
AIRBAG DEPLOYMENT SEQUENCE 1383
REMOVAL 1384
INSTALLATION 1386
ON / OFF SWITCH INDICATOR MODULE 1387
DESCRIPTION 1387
OPERATION 1387
REMOVAL 1388
INSTALLATION 1390
SIDE IMPACT SENSOR 1392
DESCRIPTION 1392
OPERATION 1392
REMOVAL 1393
1393
1395
INSTALLATION 1398
1398
1400
SIDE IMPACT AIRBAG 1403
DESCRIPTION 1403
OPERATION 1404
REMOVAL 1405
INSTALLATION 1405
SEAT BELT BUCKLE 1407
DESCRIPTION 1407
REMOVAL 1407
INSTALLATION 1409
SEAT BELT & SEAT BELT TENSIONER 1410
DESCRIPTION 1410
OPERATION 1410
1411
FORCE LIMITATION 1412
REMOVAL 1413
INSPECTION 1416
INSTALLATION 1416
8p-SPEED CONTROL 1419
SPEED CONTROL – ELECTRICAL DIAGNOSTICS 1419
DIAGNOSIS AND TESTING 1419
(P0575) SPEED CONTROL SWITCH INPUT CIRCUIT 1420
1425
SCHEMATICS AND DIAGRAMS 1426
SPEED CONTROL – SERVICE INFORMATION 1427
DESCRIPTION 1427
OPERATION 1427
SWITCH 1428
REMOVAL 1428
INSTALLATION 1429
8q-VEHICLE THEFT SECURITY 1431
VEHICLE THEFT SECURITY – ELECTRICAL DIAGNOSTICS 1431
DIAGNOSIS AND TESTING 1431
CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE SYSTEM UNDERVOLTAGE 1432
CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE SYSTEM OVERVOLTAGE 1435
NO COMMUNICATION WITH BCM AND CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE 1438
CAN B BUS (-) CIRCUIT FAILURE 1441
CAN B BUS (+) CIRCUIT FAILURE 1444
DOOR LOCK SWITCH SENSE CIRCUIT 1447
DOOR UNLOCK SWITCH SENSE CIRCUIT 1450
ANTI-THEFT TOW SENSOR SIGNAL CIRCUIT 1453
NO CAN COMMUNICATIONS WITH PCM 1456
SIREN SIGNAL OUTPUT CIRCUIT 1459
CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE INTERNAL FAILURE 1462
*ALARM TRIPS ON ITS OWN 1464
VTSS VERIFICATION TEST 1465
SENTRY KEY REMOTE ENTRY MODULE INTERNAL FAILURE 1466
INVALID TRANSMITTER 1468
SENTRY KEY ANTENNA CIRCUIT 1470
REMOTE KEYLESS ENTRY RELAY CONTROL CIRCUIT 1472
SENTRY KEY VERIFICATION TEST 1475
SCHEMATICS AND DIAGRAMS 1476
VEHICLE THEFT SECURITY – SERVICE INFORMATION 1478
DESCRIPTION 1479
OPERATION 1479
VEHICLE LOCKING / UNLOCKING 1479
AUTOMATIC LOCKING / UNLOCKING 1480
EMERGENCY UNLOCKING 1480
VEHICLE RELOCKING 1480
ANTI-THEFT SYSTEM 1480
SIREN 1480
ANTI-THEFT SWITCH / ANTI-THEFT TOW SENSOR 1480
SECURITY SYSTEM MODULE 1481
REMOVAL 1481
INSTALLATION 1482
HOOD AJAR SWITCH 1483
REMOVAL 1483
INSTALLATION 1483
SIREN 1483
REMOVAL 1483
INSTALLATION 1484
SENTRY KEY REMOTE ENTRY MODULE 1485
DESCRIPTION 1485
OPERATION 1486
REMOVAL 1487
REMOVAL – SENTRY KEY REMOTE ENTRY MODULE 1487
REMOVAL – SENTRY KEY ANTENNA RING 1487
INSTALLATION 1488
INSTALLATION – SENTRY KEY REMOTE ENTRY MODULE 1488
INSTALLATION – SENTRY KEY ANTENNA RING 1489
DOOR CYLINDER LOCK SWITCH 1490
REMOVAL 1490
INSTALLATION – DRIVER CYLINDER LOCK SWITCH 1490
ANTI-THEFT TOW SENSOR 1490
REMOVAL 1490
INSTALLATION 1491
TOW-AWAY ALARM SWITCH 1492
REMOVAL 1492
INSTALLATION 1493
UK SECURITY SYSTEM MODULE 1493
DESCRIPTION 1493
OPERATION 1493
8r-WIPERS/WASHERS 1495
WIPERS/WASHERS – ELECTRICAL DIAGNOSTICS 1495
DIAGNOSIS AND TESTING 1495
VOLTAGE SUPPLY CIRCUIT OPEN 1496
*HEATED WASHER NOZZLES INOPERATIVE 1498
*WASHERS INOPERATIVE 1501
*WASHERS RUN CONTINUOUSLY WITH IGNITION ON 1504
*WIPERS INOPERATIVE 1507
*WIPERS HIGH SPEED INOPERATIVE 1511
*WIPERS LOW SPEED INOPERATIVE 1514
*WIPERS INTERMITTENT SPEED INOPERATIVE 1517
*WIPERS RUN CONTINUOUSLY WITH IGNITION ON 1519
BODY VERIFICATION TEST 1521
SCHEMATICS AND DIAGRAMS 1522
WIPERS/WASHERS – SERVICE INFORMATION 1524
DESCRIPTION 1525
OPERATION 1526
WINDSHIELD WIPER SYSTEM 1526
WASHER SYSTEM 1526
DIAGNOSIS AND TESTING 1527
WINDSHIELD WIPER/WASHER SYSTEM 1527
Windshield Wiper System 1527
Windshield Washer System 1528
SPECIFICATIONS 1528
MULTI-FUNCTION SWITCH 1529
DESCRIPTION 1529
WASHER FLUID LEVEL SWITCH 1530
REMOVAL 1530
INSTALLATION 1530
WASHER HOSES / TUBES 1531
REMOVAL 1531
INSTALLATION 1532
WASHER NOZZLE 1532
DESCRIPTION 1532
OPERATION 1532
STANDARD PROCEDURE – WASHER NOZZLE AIMING 1533
REMOVAL 1534
INSTALLATION 1536
WASHER PUMP MOTOR 1538
REMOVAL 1538
INSTALLATION 1538
WASHER RESERVOIR 1539
REMOVAL 1539
INSTALLATION 1540
WIPER ARMS 1540
DESCRIPTION 1540
REMOVAL 1541
INSTALLATION 1542
WIPER BLADES 1543
STANDARD PROCEDURE 1543
WINDSHIELD WIPER BLADE ALIGNMENT 1543
REMOVAL 1545
CLEANING 1547
INSTALLATION 1547
WIPER LINKAGE 1549
DESCRIPTION 1549
WIPER MODULE 1550
DESCRIPTION 1550
REMOVAL 1550
INSTALLATION 1553
WIPER MOTOR 1555
STANDARD PROCEDURE 1555
REPLACEMENT WIPER MOTOR SYNCHRONIZATION 1555
REMOVAL 1555
INSTALLATION 1557
8w-WIRING 1559
8W-01 WIRING DIAGRAM INFORMATION 1561
WIRING DIAGRAM INFORMATION 1561
DESCRIPTION 1561
HOW TO USE WIRING DIAGRAMS 1561
SYMBOLS 1561
TERMINOLOGY 1565
CIRCUIT INFORMATION 1565
SECTION IDENTIFICATION AND INFORMATION 1565
CONNECTOR, GROUND AND SPLICE INFORMATION 1566
IDENTIFICATION 1566
LOCATIONS 1566
WARNING 1567
GENERAL 1567
DIAGNOSIS AND TESTING 1567
WIRING HARNESS 1567
TROUBLESHOOTING TOOLS 1567
INTERMITTENT AND POOR CONNECTIONS 1568
TROUBLESHOOTING WIRING PROBLEMS 1568
STANDARD PROCEDURE 1569
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES 1569
TESTING OF VOLTAGE POTENTIAL 1569
TESTING FOR CONTINUITY 1570
TESTING FOR A SHORT TO GROUND 1570
TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1570
TESTING FOR A VOLTAGE DROP 1571
CONNECTOR 1571
REMOVAL 1571
INSTALLATION 1571
DIODE 1572
REMOVAL 1572
INSTALLATION 1572
TERMINAL 1572
REMOVAL 1572
INSTALLATION 1572
WIRE 1573
STANDARD PROCEDURE 1573
WIRE SPLICING 1573
8W-02 COMPONENT INDEX 1575
8W-10 POWER DISTRIBUTION 1577
8W-15 GROUND DISTRIBUTION 1601
8W-18 BUS COMMUNICATIONS 1615
8W-20 CHARGING SYSTEM 1623
8W-21 STARTING SYSTEM 1625
8W-30 FUEL/IGNITION SYSTEM 1627
8W-31 TRANSMISSION CONTROL SYSTEM 1639
8W-33 VEHICLE SPEED CONTROL 1643
8W-35 ANTILOCK BRAKES 1645
8W-39 VEHICLE THEFT SECURITY SYSTEM 1655
8W-40 INSTRUMENT CLUSTER 1659
8W-41 HORN/CIGAR LIGHTER 1663
8W-42 AIR CONDITIONING-HEATER 1665
8W-43 OCCUPANT RESTRAINT SYSTEM 1669
8W-44 INTERIOR LIGHTING 1673
8W-45 BODY CONTROL MODULE 1677
8W-46 MESSAGE CENTER 1683
8W-47 AUDIO SYSTEM 1687
8W-48 REAR WINDOW DEFOGGER 1693
8W-49 TIRE PRESSURE MONITOR 1695
8W-50 FRONT LIGHTING 1697
8W-51 REAR LIGHTING 1703
8W-52 TURN SIGNALS 1709
8W-53 WIPERS 1713
8W-60 POWER WINDOWS 1717
8W-61 POWER DOOR LOCKS 1721
8W-62 POWER MIRRORS 1727
8W-63 POWER SEATS 1731
8W-66 POWER TOP 1737
8W-68 POWER REAR SPOILER 1743
8W-70 SPLICE INFORMATION 1745
8W-80 CONNECTOR PIN-OUTS 1747
8W-91 CONNECTOR/GROUND/SPLICE LOCATION 1823
CONNECTOR/GROUND/SPLICE LOCATION 1823
DESCRIPTION 1823
8W-97 POWER DISTRIBUTION 1851
POWER DISTRIBUTION 1851
DESCRIPTION 1851
OPERATION 1851
ENGINE FUSE BLOCK 1852
DESCRIPTION 1852
OPERATION 1852
REMOVAL 1852
INSTALLATION 1853
RELAY CONTROL MODULE 1853
DESCRIPTION 1853
OPERATION 1853
REMOVAL 1854
INSTALLATION 1855
UNDERHOOD ACCESSORY FUSE BLOCK 1855
DESCRIPTION 1855
OPERATION 1855
REMOVAL 1856
INSTALLATION 1857
FUSE BLOCK 1857
DESCRIPTION 1857
OPERATION 1857
9-ENGINE 1859
ENGINE – ELECTRICAL DIAGNOSTICS 1859
DIAGNOSIS AND TESTING 1862
(P0040) 1/1 AND 2/1 O2 SENSOR HARNESS CONNECTORS REVERSED 1863
(P0101) MAF SENSOR PERFORMANCE 1866
(P0102) MASS AIR FLOW CIRCUIT 1868
(P0103) MAF SENSOR CIRCUIT LOW 1877
(P0104) MAF SENSOR THROTTLE ANGLE AND SPEED 1879
(P0106) MAP SENSOR PERFORMANCE 1881
(P0107) MAP SENSOR CIRCUIT LOW 1892
(P0108) MAP SENSOR CIRCUIT HIGH 1895
(P0111) INTAKE AIR TEMPERATURE SENSOR CIRCUIT PERFORMANCE (SRT) 1898
(P0112) INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW (SRT) 1900
(P0112) INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW (EXCEPT SRT) 1902
(P0113) INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH (SRT) 1906
(P0113) INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH (EXCEPT SRT) 1913
(P0116) ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE 1920
(P0116) ENGINE COOLANT TEMPERATURE SENSOR SHORT CIRCUIT 1927
(P0117) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW 1929
(P0118) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH 1931
(P0120) ELECTRONIC THROTTLE CONTROL MOTOR PERFORMANCE 1933
(P0120) THROTTLE POSITION SENSOR 1/2 CORRELATION 1947
(P0121) APPS 5-VOLT SUPPLY CIRCUIT 1950
(P0122) APPS SIGNAL 1 CIRCUIT LOW 1957
(P0123) APPS SIGNAL 1 CIRCUIT HIGH 1963
(P0128) FORCED LIMITED POWER EXCESSIVE HIGH COOLANT TEMP 1969
(P0128) THERMOSTAT RATIONALITY 1973
(P0131) O2 SENSOR 1/1 CIRCUIT LOW 1981
(P0132) O2 SENSOR 1/1 CIRCUIT HIGH 1989
(P0133) O2 SENSOR 1/1 SHORT DELAY TIME 1991
(P0133) O2 SENSOR 1/1 LONG PERFORMANCE 1995
(P0133) O2 SENSOR 1/1 LONG DELAY TIME 1997
(P0133) O2 SENSOR 1/1 SHORT PERFORMANCE 1999
(P0134) O2 SENSOR 1/1 CIRCUIT OPEN 2001
(P0135) O2 SENSOR 1/1 HEATER CIRCUIT LOW 2003
(P0135) O2 SENSOR 1/1 HEATER PERFORMANCE 2006
(P0135) O2 SENSOR 1/1 HEATER CIRCUIT HIGH 2011
(P0135) O2 SENSOR 1/1 HEATER CIRCUIT OPEN 2016
(P0137) O2 SENSOR 1/2 BELOW THRESHOLD 2018
(P0137) O2 SENSOR 1/2 ABOVE THRESHOLD 2020
(P0137) O2 SENSOR 2/2 ABOVE THRESHOLD 2022
(P0137) O2 SENSOR 2/2 BELOW THRESHOLD 2026
(P0138) O2 SENSOR 1/2 CIRCUIT HIGH 2028
(P0138) O2 SENSOR 1/2 CIRCUIT OPEN 2030
(P0138) O2 SENSOR 2/2 CIRCUIT LOW 2032
(P0138) O2 SENSOR 2/2 CIRCUIT OPEN 2034
(P0140) O2 SENSOR 1/2 CIRCUIT LOW 2036
(P0140) O2 SENSOR 2/2 CIRCUIT HIGH 2038
(P0141) O2 SENSOR 1/2 HEATER CIRCUIT LOW 2040
(P0141) O2 SENSOR 1/2 HEATER CIRCUIT OPEN 2042
(P0141) O2 SENSOR 1/2 HEATER CIRCUIT HIGH 2044
(P0141) O2 SENSOR 1/2 HEATER PERFORMANCE 2046
(P0151) O2 SENSOR 2/1 CIRCUIT LOW 2048
(P0152) O2 SENSOR 2/1 CIRCUIT HIGH 2050
(P0153) O2 SENSOR 2/1 LONG PERFORMANCE 2052
(P0153) O2 SENSOR 2/1 LONG DELAY TIME 2054
(P0153) O2 SENSOR 2/1 SHORT DELAY TIME 2056
(P0153) O2 SENSOR 2/1 SHORT PERFORMANCE 2058
(P0154) O2 SENSOR 2/1 CIRCUIT OPEN 2060
(P0155) O2 SENSOR 2/1 HEATER CIRCUIT LOW 2062
(P0155) O2 SENSOR 2/1 HEATER CIRCUIT HIGH 2064
(P0155) O2 SENSOR 2/1 HEATER CIRCUIT OPEN 2066
(P0155) O2 SENSOR 2/1 HEATER PERFORMANCE 2068
(P0161) O2 SENSOR 2/2 HEATER PERFORMANCE 2070
(P0161) O2 SENSOR 2/2 HEATER CIRCUIT LOW 2072
(P0161) O2 SENSOR 2/2 HEATER CIRCUIT OPEN 2074
(P0161) O2 SENSOR 2/2 HEATER CIRCUIT HIGH 2076
(P0171) FUEL SYSTEM 1/1 UNDERCORRECTION OF FUEL MIXTURE (OFF IDLE) 2078
(P0171) FUEL SYSTEM 1/1 RICH CONTROL OVER LIMIT (AT IDLE) 2082
(P0171) FUEL SYSTEM 1/1 RICH CONTROL OVER LIMIT (AT LOAD) 2086
(P0172) FUEL SYSTEM 1/1 OVERCORRECTION OF FUEL MIXTURE (AT IDLE) 2094
(P0172) FUEL SYSTEM 1/1 LEAN CONTROL BELOW LIMIT (AT LOAD) 2098
(P0172) FUEL SYSTEM 1/1 LEAN CONTROL BELOW LIMIT (AT IDLE) 2106
(P0173) FUEL SYSTEM 2/1 RICH CONTROL OVER LIMIT (AT LOAD) 2110
(P0174) FUEL SYSTEM 2/1 RICH CONTROL OVER LIMIT (AT IDLE) 2117
(P0174) FUEL SYSTEM 2/1 RICH CONTROL OVER LIMIT (AT LOAD) 2120
(P0174) FUEL SYSTEM 2/1 LEAN CONTROL BELOW LIMIT (AT LOAD) 2123
(P0174) FUEL SYSTEM 2/1 UNDERCORRECTION OF FUEL MIXTURE (OFF IDLE) 2126
(P0175) FUEL SYSTEM 2/1 OVERCORRECTION OF FUEL MIXTURE (OFF IDLE) 2129
(P0175) FUEL SYSTEM 2/1 LEAN CONTROL BELOW LIMIT (AT IDLE) 2132
(P0200) FUEL INJECTOR CIRCUIT 2135
(P0201) FUEL INJECTOR #1 CIRCUIT 2137
(P0202) FUEL INJECTOR #2 CIRCUIT 2142
(P0203) FUEL INJECTOR #3 CIRCUIT 2144
(P0204) FUEL INJECTOR #4 CIRCUIT 2146
(P0205) FUEL INJECTOR #5 CIRCUIT 2148
(P0206) FUEL INJECTOR #6 CIRCUIT 2150
(P0211) THROTTLE ACTUATOR STUCK 2152
(P0211) THROTTLE ACTUATOR STUCK 2158
(P0221) APPS SENSOR 1 AND 2 VOLTAGE CORRELATION 2164
(P0221) IDLE SPEED PERFORMANCE 2168
(P0221) ELECTRONIC THROTTLE CONTROL MODULE PERFORMANCE 2172
(P0221) ELECTRONIC THROTTLE CONTROL MODULE PROCESSOR 2174
(P0222) APPS SIGNAL 2 CIRCUIT LOW 2176
(P0223) APPS SIGNAL 2 CIRCUIT HIGH 2181
(P023A) CHARGE AIR COOLER CIRCULATION PUMP CONTROL CIRCUIT 2187
(P023B) CHARGE AIR COOLER CIRCULATION PUMP CIRCUIT LOW 2193
(P023C) CHARGE AIR COOLER CIRCULATION PUMP CIRCUIT HIGH 2195
(P0300) MULTIPLE CYLINDER MISFIRE 2197
(P0301) CYLINDER #1 MISFIRE 2209
(P0302) CYLINDER #2 MISFIRE 2220
(P0303) CYLINDER #3 MISFIRE 2224
(P0304) CYLINDER #4 MISFIRE 2228
(P0305) CYLINDER #5 MISFIRE 2232
(P0306) CYLINDER #6 MISFIRE 2236
(P0325) KNOCK SENSOR 1 CIRCUIT LOW 2240
(P0325) KNOCK SENSOR 1 CIRCUIT HIGH 2247
(P0330) KNOCK SENSOR 2 CIRCUIT HIGH 2249
(P0330) KNOCK SENSOR 2 CIRCUIT LOW 2251
(P0335) CRANKSHAFT POSITION SENSOR CIRCUIT 2253
(P0341) CAMSHAFT POSITION TIMING OVER-RETARDED 2260
(P0341) CAMSHAFT POSITION TIMING OVER-ADVANCED 2265
(P0341) CAMSHAFT POSITION SENSOR PERFORMANCE 2267
(P0400) EGR SYSTEM PERFORMANCE 2274
(P0403) EGR CONTROL CIRCUIT 2280
(P0410) SECONDARY AIR INJECTION SYSTEM 2282
(P0412) SECONDARY AIR INJECTION SWITCHOVER SOLENOID CIRCUIT 2289
(P0418) SECONDARY AIR INJECTION SYSTEM CONTROL CIRCUIT 2294
(P0422) CATALYTIC 1/1 EFFICIENCY0 – 10 ZH 2299
(P0432) CATALYTIC 2/1 EFFICIENCY 2302
(P0440) GENERAL EVAP SYSTEM FAILURE 2304
(P0441) EVAP PURGE VALVE 2306
(P0442) EVAP SYSTEM SMALL LEAK 2308
(P0445) EVAP PURGE SOLENOID CIRCUIT 2310
(P0446) CHARCOAL CANISTER SHUTOFF VALVE 2315
(P0446) EVAP PURGE SOLENOID STUCK OPEN 2321
(P0451) FUEL TANK PRESSURE SENSOR PERFORMANCE 2324
(P0452) FUEL TANK PRESSURE SENSOR CIRCUIT LOW 2334
(P0453) FUEL TANK PRESSURE SENSOR CIRCUIT HIGH 2336
(P0455) EVAP SYSTEM LARGE LEAK 2338
(P0456) EVAP SYSTEM: SMALL LEAK 2344
(P0457) EVAP PURGE VALVE LEAKING 2346
(P0460) FUEL LEVEL SENSOR CIRCUIT 2348
(P0480) COOLING FAN CONTROL CIRCUIT 2350
(P0480) COOLING FAN CONTROL CIRCUIT HIGH 2355
(P0480) COOLING FAN CONTROL CIRCUIT LOW 2357
(P0500) NO VEHICLE SPEED SIGNAL (CAB CAN MESSAGE) 2359
(P0500) VEHICLE SPEED PERFORMANCE ESP MIL REQUEST 2361
(P0521) ENGINE OIL SENSOR LEVEL PERFORMANCE 2363
(P0521) ENGINE OIL SENSOR OVER TEMPERATURE 2375
(P0521) ENGINE OIL SENSOR PERFORMANCE 2387
(P0521) ENGINE OIL SENSOR QUALITY PERFORMANCE 2390
(P0521) ENGINE OIL SENSOR WATER CONTAMINATION 2402
(P0561) BATTERY SYSTEM VOLTAGE 2405
(P0562) BATTERY SYSTEM LOW 2408
(P0563) BATTERY SYSTEM HIGH 2410
(P0571) STOP LAMP SWITCH CAN SIGNAL LOST TO TRANS PERFORMANCE 2412
(P0571) STOP LAMP SWITCH SIGNAL PERFORMANCE 2414
(P0575) SPEED CONTROL SWITCH INPUT CIRCUIT 2416
(P0600) NO CAN MESSAGE FROM CAB MODULE 2421
(P0600) NO TRANSMISSION BUS MESSAGE 2428
(P0600) LOST COMM WITH ELECTRIC GEAR SHIFT MODULE (SLA) 2435
(P0600) NO CLUSTER BUS MESSAGE 2442
(P0602) PCM PROGRAMMED INCORRECT TRANS/NO COMM FROM TCM 2449
(P0606) INTERNAL PCM PROCESSOR 2451
(P0700) TRANSMISSION CONTROL SYSTEM (MIL REQUEST) 2453
(P0702) TRANSMISSION CONTROL MODULE LOW VOLTAGE 2455
(P0702) TRANSMISSION CONTROL SYSTEM (MIL REQUEST) 2457
(P0702) LOSS OF TORQUE MANAGEMENT SIGNAL 2459
(P0702) TCM TORQUE MANAGEMENT REQUEST PERFORMANCE 2461
(P0705) SLA CONTROL SYSTEM (MIL REQUEST) 2463
(P0705) TRANSMISSION CONTROL SYSTEM (MIL REQUEST) 2465
(P0715) TRANSMISSION CONTROL SYSTEM (MIL REQUEST) 2467
(P0720) TRANSMISSION INCORRECT TORQUE REQUEST FROM ESP 2469
(P0720) TRANSMISSION CONTROL SYSTEM (MIL REQUEST) 2476
(P0730) TRANSMISSION CONTROL SYSTEM (MIL REQUEST) 2478
(P0740) TRANSMISSION CONTROL SYSTEM (MIL REQUEST) 2480
(P0743) TRANSMISSION CONTROL SYSTEM (MIL REQUEST) 2482
(P0748) TRANSMISSION CONTROL SYSTEM (MIL REQUEST) 2484
(P0753) TRANSMISSION CONTROL SYSTEM (MIL REQUEST) 2486
(P0758) TRANSMISSION CONTROL SYSTEM (MIL REQUEST) 2488
(P0763) TRANSMISSION CONTROL SYSTEM (MIL REQUEST) 2490
(P1386) KNOCK SENSOR SYSTEM FAILURE 2492
(P1600) ROUGH ROAD DETECTED 2494
(P1612) MAXIMUM GOVERNOR SPEED DEVIATION – FUEL LIMITING 2501
(P2008) SHORT RUNNER SOLENOID CIRCUIT 2506
(P2009) SHORT RUNNER SOLENOID CIRCUIT LOW 2511
(P2010) SHORT RUNNER SOLENOID CIRCUIT HIGH 2513
(P2263) SUPERCHARGER CLUTCH CONTROL CIRCUIT 2515
(P2513) ENHANCED ACCIDENT REPORT DRIVER CIRCUIT HIGH 2520
(P2513) ENHANCED ACCIDENT REPORT DRIVER CIRCUIT LOW 2525
(P2545) ESP TORQUE MANAGEMENT REQUEST PERFORMANCE 2527
(P2561) HVAC CONTROL MODULE REQUESTED MIL ILLUMINATION 2534
*CHECKING FUEL DELIVERY 2536
*CHECKING HARD START (FUEL SYSTEM) 2541
*ENGINE CRANKS BUT DOES NOT START 2544
*CHARGE AIR COOLER CIRCULATION PUMP INOPERATIVE 2547
2552
2553
2554
2555
2556
SCHEMATICS AND DIAGRAMS 2557
ENGINE – 3 2L SERVICE INFORMATION 2566
DESCRIPTION 2568
DIAGNOSIS AND TESTING 2568
ENGINE DIAGNOSIS – INTRODUCTION 2568
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – MECHANICAL 2569
ENGINE DIAGNOSIS – PERFORMANCE 2571
DIAGNOSIS AND TESTING – CYLINDER COMPRESSION PRESSURE TEST 2572
DIAGNOSIS AND TESTING – CYLINDER COMBUSTION PRESSURE LEAKAGE TEST 2573
STANDARD PROCEDURE 2573
HYDROSTATIC LOCKED ENGINE 2573
STANDARD PROCEDURE – REPAIR OF DAMAGED OR WORN THREADS 2574
STANDARD PROCEDURE – FORM-IN-PLACE GASKETS AND SEALERS 2574
SEALER APPLICATION 2574
STANDARD PROCEDURE – ENGINE GASKET SURFACE PREPARATION 2574
STANDARD PROCEDURE – ENGINE CORE AND OIL GALLERY PLUGS 2575
STANDARD PROCEDURE – MEASURING BEARING CLEARANCE USING PLASTIGAGE 2576
REMOVAL 2576
INSTALLATION 2581
SPECIFICATIONS 2584
SPECIFICATIONS – ENGINE 2584
SPECIFICATIONS – TORQUE 2586
SPECIAL TOOLS 2588
AIR CLEANER HOUSING 2590
REMOVAL 2590
INSTALLATION 2590
AIR CLEANER ELEMENT 2591
REMOVAL 2591
INSTALLATION 2591
CYLINDER HEAD 2591
DESCRIPTION 2591
OPERATION 2592
DIAGNOSIS AND TESTING – CYLINDER HEAD GASKET 2592
CYLINDER-TO-CYLINDER LEAKAGE TEST 2592
CYLINDER-TO-WATER JACKET LEAKAGE TEST 2592
REMOVAL 2593
CLEANING 2596
INSPECTION 2596
INSTALLATION 2597
CYLINDER HEAD COVER 2600
DESCRIPTION 2600
REMOVAL 2600
INSTALLATION 2601
CAMSHAFT BEARING BRIDGE 2602
REMOVAL 2602
INSTALLATION 2605
ROCKER ARM / ADJUSTER ASSY 2608
DISASSEMBLY 2608
REMOVAL 2608
ASSEMBLY 2609
INSTALLATION 2609
CAMSHAFT 2609
DESCRIPTION 2609
OPERATION 2609
REMOVAL 2610
CLEANING 2610
INSPECTION 2610
INSTALLATION 2610
VALVE STEM SEAL 2611
REMOVAL 2611
INSTALLATION 2612
INTAKE/EXHAUST VALVES AND SEALS 2614
DESCRIPTION 2614
OPERATION 2614
REMOVAL 2615
CLEANING 2616
INSTALLATION 2616
VALVE SPRINGS 2617
DESCRIPTION 2617
OPERATION 2617
ENGINE BLOCK 2617
DESCRIPTION 2617
CLEANING 2618
INSPECTION 2618
ENGINE BLOCK 2618
CYLINDER BORE 2618
CRANKSHAFT OIL SEAL – REAR 2618
REMOVAL 2618
INSTALLATION 2619
CRANKSHAFT OIL SEAL – FRONT 2620
REMOVAL 2620
INSTALLATION 2620
CONNECTING ROD BEARINGS 2621
DESCRIPTION 2621
STANDARD PROCEDURE – CONNECTING RODS AND BEARINGS 2621
CONNECTING ROD BEARINGS 2621
CONNECTING ROD BOLTS 2621
PISTON AND CONNECTING ROD 2622
DESCRIPTION 2622
STANDARD PROCEDURE 2623
PISTON FITTING 2623
REMOVAL 2624
INSPECTION 2625
CONNECTING ROD 2625
PISTON PIN 2626
PISTON 2626
INSTALLATION 2626
PISTON RINGS 2629
REMOVAL 2629
INSTALLATION 2629
CRANKSHAFT AND MAIN BEARINGS 2631
DESCRIPTION 2631
OPERATION 2632
REMOVAL 2632
INSTALLATION 2635
VIBRATION DAMPER 2637
REMOVAL 2637
INSTALLATION 2638
FLEX PLATE / FLYWHEEL 2639
REMOVAL 2639
INSTALLATION 2640
ENGINE MOUNT BRACKETS 2641
REMOVAL 2641
REMOVAL – LEFT 2641
REMOVAL – RIGHT 2641
INSTALLATION 2642
INSTALLATION – LEFT 2642
INSTALLATION – RIGHT 2642
FRONT MOUNT 2643
REMOVAL 2643
INSTALLATION 2644
REAR MOUNT 2645
REMOVAL 2645
INSTALLATION 2646
LUBRICATION 2646
DESCRIPTION 2646
DIAGNOSIS AND TESTING 2646
ENGINE OIL LEAK INSPECTION 2646
INSPECTION FOR REAR SEAL AREA LEAKS 2647
DIAGNOSIS AND TESTING – CHECKING ENGINE OIL PRESSURE 2648
OIL LEVEL INDICATOR TUBE 2649
REMOVAL 2649
INSTALLATION 2649
OIL 2649
DESCRIPTION 2649
STANDARD PROCEDURE 2650
ENGINE OIL LEVEL CHECK 2650
STANDARD PROCEDURE – ENGINE OIL AND FILTER CHANGE 2650
TO CHANGE ENGINE OIL 2650
USED ENGINE OIL DISPOSAL 2651
OIL FILTER 2652
DESCRIPTION 2652
REMOVAL 2652
INSTALLATION 2653
OIL PAN 2654
REMOVAL 2654
LOWER OIL PAN 2654
REMOVAL – UPPER OIL PAN 2655
INSTALLATION 2657
LOWER OIL PAN 2657
INSTALLATION – UPPER OIL PAN 2659
OIL LEVEL/TEMPERATURE SENSOR 2661
REMOVAL 2661
INSTALLATION 2662
OIL SPRAY NOZZLES 2663
REMOVAL 2663
INSTALLATION 2663
OIL PUMP 2663
DESCRIPTION 2663
REMOVAL 2663
CLEANING 2664
INSTALLATION 2665
OIL PUMP DRIVE CHAIN 2666
REMOVAL 2666
INSTALLATION 2666
OIL PRESSURE RELIEF VALVE 2666
DESCRIPTION 2666
INTAKE MANIFOLD 2667
DESCRIPTION 2667
OPERATION 2667
DIAGNOSIS AND TESTING – INTAKE MANIFOLD LEAKS 2667
REMOVAL 2667
INSTALLATION 2668
EXHAUST MANIFOLD 2669
DESCRIPTION 2669
REMOVAL 2670
LEFT SIDE 2670
REMOVAL- RIGHT SIDE 2671
INSTALLATION 2672
LEFT SIDE 2672
INSTALLATION – RIGHT SIDE 2673
TIMING CHAIN TENSIONER 2674
REMOVAL 2674
INSTALLATION 2674
TIMING CHAIN COVER 2674
REMOVAL 2674
INSTALLATION 2676
TIMING CHAIN 2679
REMOVAL 2679
INSTALLATION 2681
BALANCE SHAFT 2685
DESCRIPTION 2685
REMOVAL 2685
INSTALLATION 2688
TIMING CHAIN GUIDES 2690
REMOVAL 2690
INSTALLATION 2690
ENGINE TIMING 2691
OPERATION 2691
11-EXHAUST SYSTEM 2693
EXHAUST SYSTEM 2694
DESCRIPTION 2694
DESCRIPTION – SRT 2695
OPERATION 2696
DIAGNOSIS AND TESTING – EXHAUST SYSTEM 2697
INSPECTION 2697
ADJUSTMENTS 2697
EXHAUST SYSTEM ALIGNMENT 2697
SPECIFICATIONS – TORQUE 2697
CATALYTIC CONVERTER 2698
REMOVAL 2698
REMOVAL – FRONT EXHAUST PIPES 2698
REMOVAL – FRONT EXHAUST PIPES – SRT 2699
INSTALLATION 2701
INSTALLATION – FRONT EXHAUST PIPES 2701
INSTALLATION – FRONT EXHAUST PIPES – SRT 2702
HEAT SHIELDS 2703
REMOVAL 2703
REMOVAL – FRONT HEAT SHIELD 2703
REMOVAL – REAR HEAT SHIELD 2704
INSTALLATION 2704
INSTALLATION – FRONT HEAT SHIELD 2704
INSTALLATION – REAR HEAT SHIELD 2705
MUFFLER 2705
REMOVAL 2705
REMOVAL – MUFFLER (SRT) 2707
INSTALLATION 2709
INSTALLATION – MUFFLER (SRT) 2710
SUPPORT BRACKET AND ISOLATOR 2712
REMOVAL 2712
INSTALLATION 2712
13-FRAME & BUMPERS 2713
FRONT FASCIA 2713
REMOVAL 2713
INSTALLATION 2716
REAR FASCIA 2718
REMOVAL 2718
INSTALLATION 2719
FRAME 2720
SPECIFICATIONS – FRAME DIMENSIONS 2720
REAR SUPPORT BRACKET 2721
REMOVAL 2721
INSTALLATION 2722
14-FUEL SYSTEM 2723
FUEL DELIVERY 2723
DESCRIPTION 2724
OPERATION 2725
DIAGNOSIS AND TESTING – FUEL PRESSURE LEAK DOWN TEST 2726
CHECK VALVE OPERATION 2726
TESTING FOR FUEL INJECTOR OR FUEL RAIL LEAKAGE 2726
TESTING FOR FUEL PUMP CHECK VALVE, FILTER/REGULATOR CHECK VALVE, OR FUEL TUBE/LINE LEAKAGE 2726
STANDARD PROCEDURE 2727
STANDARD PROCEDURE – FUEL SYSTEM PRESSURE RELEASE PROCEDURE 2727
STANDARD PROCEDURE – DRAINING FUEL TANK 2728
SPECIFICATIONS 2729
FUEL DELIVERY 2729
FUEL SYSTEM 2729
FUEL CAPACITY 2729
SPECIAL TOOLS 2730
FUEL FILL CHECK VALVE 2731
DESCRIPTION 2731
OPERATION 2731
FUEL FILTER/PRESSURE REGULATOR 2731
DESCRIPTION 2731
FUEL FILTER 2731
FUEL PRESSURE REGULATOR 2732
OPERATION 2732
FUEL PRESSURE REGULATOR 2732
FUEL FILTER 2733
REMOVAL 2733
INSTALLATION 2734
FUEL LEVEL SENDING UNIT / SENSOR 2735
DESCRIPTION 2735
FUEL LEVEL SENDING UNIT/SENSOR 2735
OPERATION 2735
FUEL LEVEL SENDING UNIT/SENSOR 2735
DIAGNOSIS AND TESTING – FUEL LEVEL SENDING UNIT 2736
REMOVAL 2737
INSTALLATION 2737
FUEL LINES 2738
DESCRIPTION0 – 12 ZH 2738
FUEL PUMP 2738
DESCRIPTION 2738
OPERATION 2738
DIAGNOSIS AND TESTING 2739
FUEL PUMP TEST 2739
FUEL PUMP PRESSURE TEST 2739
FUEL PUMP CAPACITY TEST 2739
FUEL PUMP AMPERAGE TEST 2740
REMOVAL 2741
INSTALLATION 2742
FUEL RAIL 2742
DESCRIPTION 2742
OPERATION 2742
REMOVAL 2743
INSTALLATION 2744
FUEL TANK 2744
DESCRIPTION 2744
OPERATION 2744
REMOVAL 2745
INSTALLATION 2746
FUEL TANK FILLER TUBE 2747
DESCRIPTION 2747
FUEL INJECTION 2748
SPECIFICATIONS 2749
ACCELERATOR PEDAL 2749
DESCRIPTION 2749
REMOVAL 2750
REMOVAL – RHD 2751
INSTALLATION 2752
INSTALLATION – RHD 2753
ACCELERATOR PEDAL POSITION SENSOR 2754
DESCRIPTION 2754
OPERATION 2754
CRANKSHAFT POSITION SENSOR 2755
DESCRIPTION 2755
OPERATION 2755
REMOVAL 2756
INSTALLATION 2756
FUEL INJECTOR 2757
DESCRIPTION 2757
OPERATION 2757
REMOVAL 2758
INSTALLATION 2759
FUEL PUMP RELAY 2760
DESCRIPTION 2760
OPERATION 2760
INTAKE AIR TEMPERATURE SENSOR 2760
DESCRIPTION 2760
OPERATION 2761
REMOVAL 2761
REMOVAL – SRT 2761
INSTALLATION 2762
INSTALLATION – SRT 2763
MANIFOLD AIR FLOW (MAF) SENSOR 2764
DESCRIPTION 2764
OPERATION 2764
REMOVAL 2765
INSTALLATION 2766
MANIFOLD TUNE VALVE 2767
DESCRIPTION 2767
OPERATION 2767
REMOVAL 2767
INSTALLATION 2768
MAP SENSOR 2768
DESCRIPTION 2768
DESCRIPTION – SRT 2769
OPERATION 2769
OPERATION – SRT 2769
REMOVAL 2769
REMOVAL – SRT 2770
INSTALLATION 2773
INSTALLATION – SRT 2773
O2 SENSOR 2776
DESCRIPTION 2776
OPERATION 2776
UPSTREAM OXYGEN SENSOR 2777
DOWNSTREAM OXYGEN SENSOR 2777
REMOVAL 2778
UPSTREAM O2 SENSOR 2778
REMOVAL – DOWNSTREAM O2 2778
INSTALLATION 2779
UPSTREAM O2 2779
INSTALLATION – DOWNSTREAM O2 2779
THROTTLE BODY 2780
DESCRIPTION 2780
OPERATION 2780
REMOVAL 2780
REMOVAL – SRT 2781
INSTALLATION 2782
INSTALLATION – SRT 2782
THROTTLE POSITION SENSOR 2783
DESCRIPTION 2783
OPERATION 2784
19-STEERING 2785
STEERING 2785
DESCRIPTION 2785
STEERING SYSTEM 2785
OPERATION 2786
DIAGNOSIS AND TESTING 2786
POWER STEERING SYSTEM 2786
DIAGNOSIS AND TESTING – STEERING FLOW AND PRESSURE 2789
FLOW AND PRESSURE TEST 2789
SPECIFICATIONS 2790
SPECIFICATIONS – FLUID 2790
SPECIFICATIONS – TORQUE 2790
SPECIAL TOOLS 2791
STEERING 2791
COLUMN 2792
DESCRIPTION 2792
REMOVAL 2793
REMOVAL – RHD 2797
DISASSEMBLY 2800
ASSEMBLY 2801
INSTALLATION 2802
INSTALLATION – RHD 2806
IGNITION LOCK CABLE 2808
REMOVAL 2808
INSTALLATION 2810
IGNITION SWITCH 2812
REMOVAL 2812
INSTALLATION 2813
STEERING WHEEL 2814
REMOVAL 2814
INSTALLATION 2815
KEY/LOCK CYLINDER 2816
REMOVAL 2816
INSTALLATION 2817
GEAR 2819
DESCRIPTION 2819
OPERATION 2819
REMOVAL 2820
REMOVAL – RHD 2823
INSTALLATION 2825
INSTALLATION – RHD 2827
ADJUSTMENTS 2829
STEERING GEAR 2829
PITMAN SHAFT SEAL 2829
REMOVAL 2829
INSTALLATION 2830
LINKAGE 2832
IDLER ARM 2833
REMOVAL 2833
REMOVAL – RHD 2834
INSTALLATION 2835
INSTALLATION – RHD 2836
PITMAN ARM 2837
REMOVAL 2837
REMOVAL – RHD 2839
INSTALLATION 2841
INSTALLATION – RHD 2842
DAMPER 2843
REMOVAL 2843
REMOVAL – RHD 2844
INSTALLATION 2844
INSTALLATION – RHD 2845
DRAG LINK 2845
REMOVAL 2845
REMOVAL – RHD 2847
INSTALLATION 2848
INSTALLATION – RHD 2849
TIE ROD END 2849
REMOVAL 2849
INSTALLATION 2850
21-TRANSMISSION 2855
NAG1 – ELECTRICAL DIAGNOSTICS 2855
DIAGNOSIS AND TESTING 2856
(P0219) ENGINE OVERSPEED 2857
(P0562) SYSTEM UNDERVOLTAGE 2860
(PO563) SYSTEM OVERVOLTAGE 2863
(P0600) ABS BRAKE MESSAGE 2866
(P0600) ABS CAN MESSAGE INCORRECT 2869
(P0600) ABS CAN MESSAGE MISSING 2872
(P0600) ABS LEFT FRONT SENSOR MESSAGE 2876
(P0600) ABS LEFT REAR SENSOR MESSAGE 2879
(P0600) ABS RIGHT FRONT SENSOR MESSAGE 2882
(P0600) ABS RIGHT REAR SENSOR MESSAGE 2885
(P0600) ACCEL PEDAL SENSOR CAN MESSAGE INCORRECT 2888
(P0600) CAN MESSAGE FROM ECM FROM SLA 2892
(P0600) ENGINE CAN MESSAGE INCORRECT 2895
(P0600) ENGINE CAN MESSAGE MISSING 2898
(P0600) ENGINE RPM MESSAGE 2902
(P0600) ENGINE TEMPERATURE MESSAGE 2905
(P0600) ENGINE TORQUE MESSAGE INCORRECT 2908
(P0600) IC CAN MESSAGE INCORRECT 2911
(P0600) IC/HVAC CAN MESSAGE MISSING 2914
(P0600) SLA CAN MESSAGE INCORRECT 2919
(P0700) SENSOR SUPPLY VOLTAGE 2922
(P0700) TRANSMISSION SLIPPING 2926
(P0702) CONTROL MODULE TCM IS NOT CODED 2929
(P0702) INTERNAL CONTROLLER 2931
(P0702) INVALID CONTROL MODULE VERSION 2933
(P0702) SOLENOID SUPPLY/WATCHDOG 2935
(P0710) TRANS TEMP SENSOR SHORTED 2939
(P0714) TRANS TEMP SENSOR ERRATIC 2943
(P0715) INPUT SENSOR MISMATCH 2946
(P0715) INPUT SENSOR OVERSPEED 2950
(P0715) N2 INPUT SPEED SENSOR CIRCUIT 2953
(P0715) N3 INPUT SPEED SENSOR CIRCUIT 2960
(P0720) CAN BUS CIRCUIT 2967
(P0730) IMPROPER GEAR 2972
(P0730) IMPROPER RATIO 2975
(P0740) TCC OVERTEMP 2978
(P0740) TCC STUCK ON 2980
(P0743) TCC SOLENOID CIRCUIT 2983
(P0748) MODULATING PRESSURE SOLENOID CIRCUIT 2988
(P0753) 1-2/4-5 SOLENOID CIRCUIT 2993
2998
(P0758) 2-3 SOLENOID CIRCUIT 3000
3005
(P0763) 3-4 SOLENOID CIRCUIT 3007
3012
(P0778) SHIFT PRESSURE SOLENOID CIRCUIT 3014
(P0778) SOLENOID SUPPLY VOLTAGE 3019
(P0850) TRANS TEMP SENSOR – P/N SWITCH CIRCUIT 3024
(P1793) ENGINE TORQUE REDUCTION 3031
CAN BUS CIRCUIT 3035
INCORRECT CAN MESSAGE FROM ABS 3038
INTERNAL CONTROLLER 3040
LR WHEEL SPIN CAN MESSAGE NOT VALID 3042
RR WHEEL SPIN CAN MESSAGE NOT VALID 3044
OVERVOLTAGE 3046
UNDERVOLTAGE 3048
TRANSMISSION VERIFICATION TEST 3050
SCHEMATICS AND DIAGRAMS 3051
AUTOMATIC – NAG1 SERVICE INFORMATION 3052
DESCRIPTION 3053
TRANSMISSION IDENTIFICATION 3054
TRANSMISSION GEAR RATIOS 3054
TRANSMISSION HOUSING 3054
MECHANICAL SECTION 3054
ELECTROHYDRAULIC CONTROL UNIT 3054
SHIFT GROUPS 3054
OPERATION 3055
EMERGENCY RUNNING FUNCTION 3055
CLUTCH APPLICATION 3055
FIRST GEAR POWERFLOW 3056
SECOND GEAR POWERFLOW 3057
THIRD GEAR POWERFLOW 3058
FOURTH GEAR POWERFLOW 3060
FIFTH GEAR POWERFLOW 3061
REVERSE GEAR POWERFLOW 3062
SHIFT GROUPS/SHIFT SEQUENCE 3064
DIAGNOSIS AND TESTING 3070
AUTOMATIC TRANSMISSION 3070
DIAGNOSIS AND TESTING – PRELIMINARY 3070
IF VEHICLE IS DRIVEABLE 3070
IF VEHICLE IS DISABLED 3070
DIAGNOSIS AND TESTING – ROAD TESTING 3070
DIAGNOSIS AND TESTING – AUTOMATIC TRANSMISSION 3071
STANDARD PROCEDURE – ALUMINUM THREAD REPAIR 3074
REMOVAL 3074
DISASSEMBLY 3078
ASSEMBLY 3085
INSTALLATION 3092
SCHEMATICS AND DIAGRAMS 3097
SPECIFICATIONS – NAG1 AUTOMATIC TRANSMISSION 3118
SPECIAL TOOLS – NAG1 AUTOMATIC TRANSMISSION 3120
DRIVING CLUTCHES 3122
DESCRIPTION 3122
OPERATION 3122
DRIVING CLUTCH K1 3124
DISASSEMBLY 3124
ASSEMBLY 3125
DRIVING CLUTCH K2 3128
DISASSEMBLY 3128
ASSEMBLY 3130
DRIVING CLUTCH K3 3133
DISASSEMBLY 3133
ASSEMBLY 3134
ELECTROHYDRAULIC UNIT 3135
DESCRIPTION 3135
ELECTRICAL CONTROL UNIT 3136
HYDRAULIC CONTROL UNIT 3136
OPERATION 3142
ELECTRICAL CONTROL UNIT 3142
HYDRAULIC CONTROL UNIT 3143
REMOVAL 3148
DISASSEMBLY 3149
ASSEMBLY 3153
INSTALLATION 3157
FLUID AND FILTER 3159
DESCRIPTION 3159
OPERATION 3160
DIAGNOSIS AND TESTING 3160
EFFECTS OF INCORRECT FLUID LEVEL 3160
DIAGNOSIS AND TESTING – CAUSES OF BURNT FLUID 3160
DIAGNOSIS AND TESTING – FLUID CONTAMINATION 3160
STANDARD PROCEDURE 3161
CHECK OIL LEVEL 3161
STANDARD PROCEDURE – TRANSMISSION FILL 3163
STANDARD PROCEDURE – FILTER CHANGE 3163
FREEWHEELING CLUTCH 3165
DESCRIPTION 3165
OPERATION 3165
DISASSEMBLY 3166
ASSEMBLY 3167
HOLDING CLUTCHES 3168
DESCRIPTION 3168
OPERATION 3169
HOLDING CLUTCH B1 3170
DISASSEMBLY 3170
ASSEMBLY 3171
HOLDING CLUTCH B2 3173
DISASSEMBLY 3173
ASSEMBLY 3174
SPEED SENSOR 3177
DESCRIPTION 3177
OPERATION 3177
OIL PUMP 3177
DESCRIPTION 3177
OPERATION 3178
DISASSEMBLY 3178
ASSEMBLY 3179
OUTPUT SHAFT BEARING 3180
REMOVAL 3180
INSTALLATION 3182
OUTPUT SHAFT SEAL 3184
REMOVAL 3184
INSTALLATION 3185
PISTONS 3186
DESCRIPTION 3186
OPERATION 3186
PRESSURE 3186
PRESSURE ON A CONFINED FLUID 3187
FORCE MULTIPLICATION 3187
PISTON TRAVEL 3188
PLANETARY GEARTRAIN 3188
DESCRIPTION 3188
OPERATION 3188
DISASSEMBLY 3189
ASSEMBLY 3190
SHIFT INTERLOCK SOLENOID 3190
DESCRIPTION 3190
UPSHIFT/DOWNSHIFT SOLENOID VALVES 3191
MODULATING PRESSURE CONTROL SOLENOID VALVE 3192
TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID VALVE 3192
SHIFT PRESSURE CONTROL SOLENOID VALVE 3193
OPERATION 3193
UPSHIFT/DOWNSHIFT SOLENOID VALVES 3193
SHIFT PRESSURE CONTROL SOLENOID VALVE 3193
TEMP SENSOR/PARK-NEUTRAL SWITCH 3194
DESCRIPTION 3194
PARK/NEUTRAL CONTACT 3194
DESCRIPTION – TRANSMISSION TEMPERATURE SENSOR 3194
OPERATION 3195
PARK/NEUTRAL CONTACT 3195
OPERATION – TRANSMISSION TEMPERATURE SENSOR 3195
TORQUE CONVERTER 3197
DESCRIPTION 3197
IMPELLER 3198
TURBINE 3199
STATOR 3199
TORQUE CONVERTER CLUTCH (TCC) 3200
OPERATION0 – 14 ZH 3200
TURBINE 3200
STATOR 3201
TORQUE CONVERTER CLUTCH (TCC) 3201
REMOVAL 3202
INSTALLATION 3202
TORQUE CONVERTER HUB SEAL 3203
REMOVAL 3203
INSTALLATION 3203
SHIFT INTERLOCK SOLENOID 3204
DESCRIPTION 3204
ADJUSTMENTS – SHIFT INTERLOCK SOLENOID 3205
SHIFT LEVER ASSEMBLY 3206
DESCRIPTION 3206
OPERATION 3206
Brake Transmission Shift Interlock 3206
REMOVAL 3207
INSTALLATION 3207
GEAR SHIFT ROD 3207
REMOVAL 3207
INSTALLATION 3208
MANUAL – SERVICE INFORMATION 3209
DESCRIPTION 3209
OPERATION 3210
DIAGNOSIS AND TESTING 3210
LOW LUBRICANT LEVEL 3210
HARD SHIFTING 3211
TRANSMISSION NOISE 3211
REMOVAL 3211
CLEANING 3214
INSTALLATION 3214
SPECIFICATIONS 3217
SPECIFICATIONS – GEAR RATIOS 3217
SPECIFICATIONS – FLUID CAPACITY 3218
SPECIAL TOOLS 3219
FLUID 3221
DESCRIPTION 3221
STANDARD PROCEDURE 3221
STANDARD PROCEDURE – FLUID DRAIN AND FILL 3221
STANDARD PROCEDURE – CHECKING FLUID LEVEL 3221
BACKUP LAMP SWITCH 3222
REMOVAL 3222
INSTALLATION 3223
OUTPUT FLANGE SEAL 3223
REMOVAL 3223
INSTALLATION 3225
DETENT PLUG 3227
REMOVAL 3227
INSTALLATION 3227
INPUT SHAFT SEAL 3228
REMOVAL 3228
INSTALLATION 3228
TRANSMISSION FRONT SECTION 3229
DISASSEMBLY 3229
ASSEMBLY 3229
REAR SECTION HOUSING 3230
DISASSEMBLY 3230
ASSEMBLY 3230
REVERSE SHAFT 3231
DESCRIPTION 3231
GEARTRAIN HOUSING 3231
DISASSEMBLY 3231
ASSEMBLY 3233
MAINSHAFT W/INPUT SHAFT 3237
DESCRIPTION 3237
DISASSEMBLY 3237
ASSEMBLY 3244
COUNTERSHAFT 3251
DISASSEMBLY 3251
ASSEMBLY 3255
SYNCHRONIZER 3258
DESCRIPTION 3258
ASSEMBLY 3259
GEAR SHIFT LEVER HANDLE 3259
REMOVAL 3259
INSTALLATION 3260
REVERSE LOCKOUT CABLE 3260
DESCRIPTION 3260
STANDARD PROCEDURE – REVERSE LOCKOUT CABLE ADJUSTMENT 3260
SHIFT MECHANISM 3266
DESCRIPTION 3266
REMOVAL 3266
INSTALLATION 3268
22-TIRES/WHEELS 3271
TIRES/WHEELS – ELECTRICAL DIAGNOSTICS 3271
DIAGNOSIS AND TESTING 3271
NO TIRES TRAINED 3272
TIRE PRESSURE MONITOR MODULE FAILURE 3274
TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED 3276
SIGNAL JAMMED 3279
LEFT FRONT TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED 3281
LEFT REAR TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED 3283
RIGHT FRONT TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED 3285
RIGHT REAR TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED 3287
TIRE PRESSURE SENSOR/TRANSMITTER 3289
TRANSMITTER FAILURE 3292
LEFT FRONT TIRE PRESSURE SENSOR/TRANSMITTER 3294
LEFT REAR TIRE PRESSURE SENSOR/TRANSMITTER 3296
RIGHT FRONT TIRE PRESSURE SENSOR/TRANSMITTER 3298
RIGHT REAR TIRE PRESSURE SENSOR/TRANSMITTER 3300
TIRE PRESSURE SENSOR/TRANSMITTER LOW BATTERY 3302
TIRE PRESSURE VERIFICATION TEST 3305
SCHEMATICS AND DIAGRAMS 3306
TIRES/WHEELS – SERVICE INFORMATION 3307
DIAGNOSIS AND TESTING – TIRE AND WHEEL RUNOUT 3308
WHEELS 3308
TIRES 3309
METHOD 1 (RELOCATE WHEEL ON HUB) 3309
METHOD 2 (RELOCATE TIRE ON WHEEL) 3310
STANDARD PROCEDURE 3311
TIRE AND WHEEL BALANCE 3311
STANDARD PROCEDURE – MATCH MOUNTING 3312
STANDARD PROCEDURE – TIRE ROTATION 3314
STANDARD PROCEDURE – TIRE AND WHEEL INSTALLATION 3314
TIRE PRESSURE MONITORING 3315
DESCRIPTION 3315
OPERATION 3317
CAUTION 3317
DIAGNOSIS AND TESTING – TIRE PRESSURE MONITORING SYSTEM 3318
SPECIFICATIONS 3318
TIRE PRESSURE MONITORING SYSTEM 3318
MODULE 3318
DESCRIPTION 3318
OPERATION 3318
STANDARD PROCEDURE – TPM MODULE PROGRAMMING 3319
REMOVAL 3320
INSTALLATION 3320
SENSOR 3320
DESCRIPTION 3320
VALVE STEM CORE AND CAP 3321
OPERATION 3321
REMOVAL 3321
INSTALLATION 3323
TIRES 3324
DESCRIPTION 3324
TIRES 3324
TIRE IDENTIFICATION 3325
RADIAL – PLY TIRES 3325
TIRE INFLATION PRESSURES 3325
TIRE PRESSURE FOR HIGH SPEED 3327
REPLACEMENT TIRES 3327
DIAGNOSIS AND TESTING 3327
DIAGNOSIS AND TESTING – TREAD WEAR INDICATORS 3327
DIAGNOSIS AND TESTING – TIRE WEAR PATTERNS 3328
DIAGNOSIS AND TESTING – TIRE NOISE OR VIBRATION 3328
DIAGNOSIS AND TESTING – TIRE/VEHICLE LEAD 3328
STANDARD PROCEDURE 3329
STANDARD PROCEDURE – REPAIRING LEAKS 3329
STANDARD PROCEDURE – DRAINING TIREFIT 3329
CLEANING 3330
SPECIFICATIONS – TIRES 3330
WHEELS 3330
DESCRIPTION 3330
WHEELS 3330
DIAGNOSIS AND TESTING 3331
WHEEL INSPECTION 3331
STANDARD PROCEDURE – WHEEL REPLACEMENT 3331
SPECIFICATIONS – TORQUE 3332
23-BODY 3333
BODY – ELECTRICAL DIAGNOSTICS 3333
DIAGNOSIS AND TESTING 3333
BODY CONTROL MODULE INTERNAL FAILURE 3334
REAR SPOILER SWITCH SENSE CIRCUIT 3336
REAR SPOILER LIMIT SWITCH SIGNAL (UP) CIRCUIT 3339
REAR SPOILER LIMIT SWITCH SIGNAL (DOWN) CIRCUIT 3342
REAR SPOILER DRIVER (UP) CIRCUIT 3345
REAR SPOILER DRIVER (DOWN) CIRCUIT 3348
REAR SPOILER LIMIT SWITCH FAILURE 3351
REAR SPOILER MOTOR FAILURE 3354
* REAR SPOILER INOPERATIVE 3358
REAR SPOILER VERIFICATION TEST 3361
SCHEMATICS AND DIAGRAMS 3362
CONVERTIBLE TOP 3363
DIAGNOSIS AND TESTING 3364
9004 POWER TOP CONTROL MODULE (PTCM) EEPROM TIMING 3365
9003/9004 POWER TOP CONTROL MODULE EEPROM ERROR 3367
9009/9010 POWER TOP CONTROL MODULE (PTCM) LOW VOLTAGE 3369
9011 POWER TOP CONTROL MODULE (PTCM) OVER VOLTAGE 3371
9012 STOP MODE LONGER THAN 10 MINUTES 3373
9076 NO COMMUNICATION WITH BODY CONTROL MODULE (BCM) 3375
9078 NO COMMUNICATION WITH CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE (CPL/SSM) 3377
9610 MAIN CYLINDER TRAVEL SENSOR (ROD SIDE) +/- CIRCUITS OPEN/SHORT TO GROUND 3380
9611 MAIN CYLINDER TRAVEL SENSOR (ROD SIDE) (-) CIRCUIT SHORT TO B(+) 3386
9612 MAIN CYLINDER TRAVEL SENSOR (ROD SIDE) (+) CIRCUIT TO B(+) 3389
9620 MAIN CYLINDER TRAVEL SENSOR (BASE SIDE) +/- CIRCUIT OPEN/SHORT TO GROUND 3392
9621 MAIN CYLINDER TRAVEL SENSOR (BASE SIDE) (-) CIRCUIT SHORT TO B(+) 3398
9622 MAIN CYLINDER TRAVEL SENSOR (BASE SIDE) (+) SHORT CIRCUIT TO B(+) 3401
9630 REAR BOW TRAVEL SENSOR (ROD SIDE) +/- CIRCUIT OPEN/SHORT TO GROUND 3404
9631 REAR BOW TRAVEL SENSOR (ROD SIDE) (-) CIRCUIT SHORT TO B(+) 3409
9632 REAR BOW CYLINDER TRAVEL SENSOR (ROD SIDE) (+) SHORT CIRCUIT TO B(+) 3412
9640 REAR BOW TRAVEL SENSOR (BASE SIDE) +/- CIRCUIT OPEN/SHORT TO GROUND 3415
9641 REAR BOW CYLINDER TRAVEL SENSOR (BASE SIDE) (-) CIRCUIT SHORT TO B(+) 3420
9642 REAR BOW CYLINDER TRAVEL SENSOR (BASE SIDE) (+) SHORT CIRCUIT TO B(+) 3423
9650 TONNEAU COVER CYLINDER TRAVEL SENSOR +/- CIRCUIT OPEN/SHORT TO GROUND 3426
9651 TONNEAU COVER CYLINDER TRAVEL SENSOR (-) CIRCUIT SHORT TO B(+) 3429
9652 TONNEAU COVER CYLINDER TRAVEL SENSOR (+) CIRCUIT SHORT TO B(+) 3431
9701/9702 THERMO PROTECTION ACTIVE 3433
9710 RIGHT ROTATION RELAY CONTROL CIRCUIT SHORT TO GROUND 3435
9711 RIGHT ROTATION RELAY CONTROL CIRCUIT OPEN/SHORT TO B(+) 3436
9710 LEFT ROTATION RELAY CONTROL CIRCUIT SHORT TO GROUND 3440
9721 LEFT ROTATION RELAY CONTROL CIRCUIT OPEN/SHORT TO B(+) 3442
9810 HYDRAULIC SOLENOID S1 SUPPLY VOLTAGE CIRCUIT SHORT TO GROUND 3446
9811 HYDRAULIC SOLENOID S1 SUPPLY VOLTAGE CIRCUIT OPEN/SHORT TO B(+) 3448
9820 HYDRAULIC SOLENOID S2 SUPPLY VOLTAGE CIRCUIT SHORT TO GROUND 3452
9821 HYDRAULIC SOLENOID S2 SUPPLY VOLTAGE CIRCUIT OPEN/SHORT TO B(+) 3454
9830 HYDRAULIC SOLENOID S3 SUPPLY VOLTAGE CIRCUIT SHORT TO GROUND 3458
9831 HYDRAULIC SOLENOID S3 SUPPLY VOLTAGE CIRCUIT OPEN/SHORT TO B(+) 3460
9840 HYDRAULIC SOLENOID S4 SUPPLY VOLTAGE CIRCUIT SHORT TO GROUND 3464
9841 HYDRAULIC SOLENOID S4 SUPPLY VOLTAGE CIRCUIT OPEN/SHORT TO B(+) 3466
9860 TRUNK LATCH ACTUATOR UNLOCK CONTROL CIRCUIT SHORT TO GROUND 3471
9861 TRUNK LATCH ACTUATOR UNLOCK CONTROL CIRCUIT SHORT TO B(+) 3474
9870 TRUNK LATCH ACTUATOR LOCK CONTROL CIRCUIT SHORT TO GROUND 3478
9871 TRUNK LATCH ACTUATOR LOCK CONTROL CIRCUIT SHORT TO B(+) 3481
9901 MAIN CYLINDER TRAVEL SENSOR (ROD SIDE) INOPERATIVE 3485
9902 MAIN CYLINDER TRAVEL SENSOR (ROD SIDE) STUCK 3487
9903 MAIN CYLINDER TRAVEL SENSOR (BASE SIDE) INOPERATIVE 3489
9904 MAIN CYLINDER TRAVEL SENSOR (BASE SIDE) STUCK 3491
9905 REAR BOW CYLINDER TRAVEL SENSOR (ROD SIDE) INOPERATIVE 3493
9906 REAR BOW CYLINDER TRAVEL SENSOR (ROD SIDE) STUCK 3495
9907 REAR BOW CYLINDER TRAVEL SENSOR (BASE SIDE) INOPERATIVE 3497
9908 REAR BOW CYLINDER TRAVEL SENSOR (BASE SIDE) STUCK 3499
9909 REAR BOW SWITCH SENSE CIRCUIT OPEN 3501
9910 REAR BOW SWITCH SENSE CIRCUIT SHORT TO GROUND 3504
9911/9912 TONNEAU COVER SWITCH SENSE CIRCUIT OPEN 3506
9913_9914 TONNEAU COVER SWITCH SENSE CIRCUIT SHORT TO GROUND 3509
9915 TRUNK LATCH LOCKED SIGNAL CIRCUIT OPEN 3511
9916 TRUNK LATCH LOCKED SIGNAL CIRCUIT STUCK OR SHORT TO GROUND 3514
9917 TRUNK LATCH UNLOCKED SIGNAL CIRCUIT OPEN 3516
9918 TRUNK LATCH UNLOCKED SIGNAL CIRCUIT SHORT TO GROUND 3519
9919 POWER TOP SWITCH (OPEN) CIRCUIT SHORT TO GROUND 3521
9920 POWER TOP SWITCH (CLOSE) CIRCUIT SHORT TO GROUND 3523
9921 POWER TOP SWITCH (ROOF OPEN/CLOSE) CIRCUIT SHORT TO B(+) 3525
9930 UNKNOWN TOP POSITION 3527
9931 TOP POSITION UNKNOWN (MAIN CYLINDER TRAVEL SENSORS (ROD SIDE)/MAIN CYLINDER TRAVEL SENSORS (BASE SIDE) 3529
9932 TOP POSITION UNKNOWN (MAIN TRAVEL SENSORS (BASE)/LATCH RETAINER SWITCH) 3531
9933 TOP POSITION UNKNOWN (REAR BOW UP/REAR BOW DOWN) 3533
9934 TOP POSITION UNKNOWN (REAR BOW CYLINDER (BASE SIDE)/REAR BOW SWITCH) 3535
9935 TOP POSITION UNKNOWN (TONNEAU COVER LATCHED/TONNEAU COVER TRAVEL SENSOR) 3537
9936 TOP POSITION UNKNOWN (TRUNK LATCH UNLOCK SIGNAL/TRUNK LATCH LOCK SIGNAL) 3539
9937 TOP POSITION UNKNOWN (REAR BOW SWITCH LATCHED/MAIN CYLINDER TRAVEL SENSOR (BASE SIDE)) 3541
9938 TOP POSITION UNKNOWN (REAR BOW SWITCH LATCHED/TONNEAU COVER TRAVEL SENSOR) 3543
POWER TOP VERIFICATION TEST 3545
BODY – SERVICE INFORMATION 3546
DIAGNOSIS AND TESTING 3546
WATER LEAKS 3546
VISUAL INSPECTION BEFORE WATER LEAK TESTS 3546
WATER LEAK TESTS 3546
WATER LEAK DETECTION 3547
MIRROR INSPECTION METHOD 3547
BRIGHT LIGHT LEAK TEST METHOD 3547
PRESSURIZED LEAK TEST METHOD 3547
WIND NOISE 3547
VISUAL INSPECTION BEFORE TESTS 3547
ROAD TESTING WIND NOISE 3547
POSSIBLE CAUSE OF WIND NOISE 3547
STANDARD PROCEDURE 3548
BODY LUBRICATION 3548
DRILLING AND WELDING 3548
SPECIFICATIONS 3549
SPECIFICATIONS – BODY LUBRICATION 3549
SPECIFICATIONS – TORQUE 3550
SPECIAL TOOLS 3551
DECKLID/LIFTGATE 3552
EXTERIOR HANDLE 3552
REMOVAL 3552
DISASSEMBLY 3554
INSTALLATION 3555
ASSEMBLY 3555
GAS PROP 3558
REMOVAL 3558
INSTALLATION 3559
HINGE 3560
REMOVAL 3560
INSTALLATION 3561
LATCH 3561
REMOVAL 3561
INSTALLATION 3561
LATCH STRIKER 3561
REMOVAL 3561
INSTALLATION 3562
LIFTGATE 3562
REMOVAL 3562
INSTALLATION 3564
TRIM PANEL 3566
REMOVAL 3566
REMOVAL – COUPE 3566
LOWER LIFTGATE TRIM PANEL 3566
UPPER LIFTGATE TRIM PANEL 3567
REMOVAL – ROADSTER 3568
INSTALLATION 3568
INSTALLATION – COUPE 3568
UPPER LIFTGATE TRIM PANEL 3568
LOWER LIFTGATE TRIM PANEL 3569
INSTALLATION – ROADSTER 3570
BUMPER 3570
REMOVAL 3570
INSTALLATION 3570
DECKLID 3571
REMOVAL 3571
INSTALLATION 3572
BODY STRUCTURE 3573
GAP AND FLUSH 3574
SPECIFICATIONS – BODY GAP MEASUREMENTS 3574
FRONT AND SIDE GAP DIMENSIONS 3574
REAR AND SIDE GAP AND FLUSH DIMENSIONS 3575
OPENING DIMENSIONS 3576
SPECIFICATIONS – BODY DIMENSIONS 3576
SEALER LOCATIONS 3579
SPECIFICATIONS – SEALER LOCATIONS 3579
WELD LOCATIONS 3596
SPECIFICATIONS – WELD LOCATIONS 3596
STRUCTURAL ADHESIVE LOCATIONS 3609
SPECIFICATIONS – STRUCTURAL ADHESIVES 3609
DOOR 3611
CHECK STRAP 3611
REMOVAL 3611
INSTALLATION 3612
REMOVAL 3613
INSTALLATION 3614
ADJUSTMENTS 3615
ADJUSTMENT 3615
DOOR GLASS 3616
REMOVAL 3616
INSTALLATION 3617
ADJUSTMENTS 3619
ADJUSTMENT 3619
EXTERIOR HANDLE 3621
REMOVAL 3621
INSTALLATION 3622
WINDOW REGULATOR 3624
REMOVAL 3624
INSTALLATION 3625
LATCH 3626
REMOVAL 3626
INSTALLATION 3627
LOCK CYLINDER 3628
REMOVAL 3628
INSTALLATION 3629
TRIM PANEL 3631
REMOVAL 3631
INSTALLATION 3632
EXTERIOR 3633
GRILLE 3633
REMOVAL 3633
INSTALLATION 3634
FRONT FENDERS 3634
REMOVAL0 – 16 ZH 3634
INSTALLATION 3635
LF WHEELHOUSE SPLASH SHIELD 3636
REMOVAL 3636
INSTALLATION 3636
RF WHEELHOUSE SPLASH SHIELD 3637
REMOVAL 3637
INSTALLATION 3637
COWL GRILLE 3638
REMOVAL 3638
INSTALLATION 3638
EXTERIOR NAME PLATES 3639
REMOVAL 3639
REMOVAL – WITH DOUBLE SIDED TAPE 3639
REMOVAL – WITH ADHESIVES 3639
INSTALLATION 3639
INSTALLATION – WITH DOUBLE SIDED TAPE 3639
INSTALLATION – WITH ADHESIVES 3639
FUEL FILL DOOR 3640
REMOVAL 3640
INSTALLATION 3640
REAR SPOILER 3641
DESCRIPTION 3641
OPERATION 3641
REMOVAL 3642
REMOVAL – SPOILER WING 3642
REMOVAL – MOUNTING PLATE 3643
REMOVAL – MOTOR 3646
INSTALLATION 3647
INSTALLATION – SPOILER WING 3647
INSTALLATION – MOUNTING PLATE 3648
INSTALLATION – MOTOR 3651
ROCKER PANEL MOLDING 3651
REMOVAL 3651
INSTALLATION 3652
SIDE LOUVER 3652
REMOVAL 3652
INSTALLATION 3654
HOOD 3657
GAS PROP 3657
REMOVAL 3657
INSTALLATION 3658
HINGE 3659
REMOVAL 3659
INSTALLATION 3660
STANDARD PROCEDURE – MOVING THE HOOD TO ITS FULLY UPRIGHT POSITION 3661
OPENING 3661
CLOSING 3662
REMOVAL 3662
INSTALLATION 3664
ADJUSTMENTS 3665
ADJUSTMENT – HOOD 3665
ADJUSTING IN LONGITUDINAL AND VERTICAL DIRECTIONS 3665
ADJUSTING IN LATERAL DIRECTION 3666
INSULATION 3667
REMOVAL 3667
INSTALLATION 3667
LATCH 3668
REMOVAL 3668
INSTALLATION 3669
LATCH RELEASE CABLE 3670
REMOVAL 3670
INSTALLATION 3671
LATCH STRIKER 3672
REMOVAL 3672
INSTALLATION 3672
INSTRUMENT PANEL 3673
GLOVE COMPARTMENT 3673
STANDARD PROCEDURE 3673
ADJUSTING THE GLOVE COMPARTMENT 3673
REMOVAL 3675
REMOVAL – GLOVE COMPARTMENT 3675
REMOVAL – DRAWER 3676
INSTALLATION 3678
INSTALLATION – GLOVE COMPARTMENT 3678
INSTALLATION – DRAWER 3679
INSTRUMENT PANEL ASSEMBLY 3681
REMOVAL 3681
REMOVAL – INSTRUMENT PANEL (TOP SECTION) 3681
REMOVAL – INSTRUMENT PANEL (TOP SECTION) – RHD 3685
REMOVAL – LOWER I/P PANEL LEFT 3688
REMOVAL – LEFT I/P PANEL – RHD 3689
REMOVAL – LOWER INSTRUMENT PANEL (RIGHT) 3691
REMOVAL – LOWER I/P PANEL RIGHT – RHD 3691
REMOVAL – INSTRUMENT CLUSTER COVER 3693
REMOVAL – INSTRUMENT CLUSTER COVER – RHD 3694
INSTALLATION 3695
INSTALLATION – INSTRUMENT PANEL (TOP SECTION) 3695
INSTALLATION – INSTRUMENT PANEL (TOP SECTION) – RHD 3699
INSTALLATION – LOWER INSTRUMENT PANEL (LEFT) 3702
INSTALLATION – LOWER INSTRUMENT PANEL (RIGHT) – RHD 3703
INSTALLATION – LOWER INSTRUMENT PANEL (RIGHT) 3705
INSTALLATION – LOWER I/P PANEL – RHD 3705
INSTALLATION – INSTRUMENT CLUSTER COVER 3707
INSTALLATION – INSTRUMENT CLUSTER COVER – RHD 3708
INTERIOR 3709
A-PILLAR TRIM 3709
REMOVAL 3709
INSTALLATION 3710
CARPET 3711
REMOVAL 3711
REMOVAL – CARPET (LEFT SIDE) 3711
REMOVAL – CARPET (RIGHT SIDE) 3715
INSTALLATION 3717
INSTALLATION – CARPET (LEFT SIDE) 3717
INSTALLATION – CARPET (RIGHT SIDE) 3721
CENTER CONSOLE 3724
REMOVAL 3724
REMOVAL – CENTER CONSOLE (FRONT) 3724
REMOVAL – CENTER CONSOLE COVER 3725
REMOVAL – REAR CENTER CONSOLE 3727
REMOVAL – ASHTRAY 3730
REMOVAL – SHIFT LEVER ASSEMBLY COVER 3732
INSTALLATION 3733
INSTALLATION – CENTER CONSOLE (FRONT) 3733
INSTALLATION – CENTER CONSOLE COVER 3737
INSTALLATION – REAR CENTER CONSOLE 3739
INSTALLATION – ASH TRAY 3741
INSTALLATION – SHIFT LEVER ASSEMBLY COVER 3743
DOOR SILL TRIM PLATE 3745
REMOVAL 3745
INSTALLATION 3745
HEADLINER 3746
REMOVAL 3746
INSTALLATION 3749
SPORT BAR 3751
REMOVAL 3751
INSTALLATION 3753
PAINT 3756
SPECIFICATIONS – PAINT CODE 3756
PAINT CODE 3756
DESCRIPTION 3756
BASE COAT/CLEAR COAT FINISH 3756
DESCRIPTION 3756
PAINT TOUCH – UP 3757
DESCRIPTION 3757
OPERATION 3757
WET SANDING/BUFFING & POLISHING 3757
DESCRIPTION 3757
SEATS 3758
DESCRIPTION 3758
SEAT 3759
REMOVAL 3759
INSTALLATION 3760
SEAT BACK 3761
REMOVAL 3761
REMOVAL – SEAT BACK 3761
REMOVAL – PLASTIC BACK COVER 3761
INSTALLATION 3762
INSTALLATION – SEAT BACK 3762
INSTALLATION – PLASTIC BACK COVER 3762
SEAT BACK COVER 3763
REMOVAL 3763
INSTALLATION 3766
SEAT CUSHION 3769
REMOVAL 3769
INSTALLATION 3771
SEAT CUSHION COVER 3773
REMOVAL 3773
INSTALLATION 3776
STATIONARY GLASS 3778
BACKLITE 3778
REMOVAL 3778
INSTALLATION 3779
QUARTER WINDOW 3780
REMOVAL 3780
INSTALLATION 3780
WINDSHIELD 3781
REMOVAL 3781
INSTALLATION 3781
CONVERTIBLE TOP 3785
DESCRIPTION 3786
OPERATION 3787
UNLOCK REAR BOW (OPEN TOP) 3789
LIFT REAR BOW (OPEN TOP) 3791
UNLOCK AND OPEN TONNEAU COVER (OPEN TOP) 3793
LOWER REAR BOW (OPEN TOP) 3795
OPENING CONVERTIBLE TOP (OPEN TOP) 3797
CLOSE AND LOCK TONNEAU COVER (OPEN TOP) 3799
CONVERTIBLE TOP OPEN 3801
UNLOCK AND OPEN TONNEAU COVER (CLOSE) 3803
CLOSING CONVERTIBLE TOP (CLOSE TOP) 3805
LIFT REAR BOW (CLOSE TOP) 3807
CLOSE AND LOCK TONNEAU COVER (CLOSE TOP) 3809
LOWER AND LATCH REAR BOW (CLOSE TOP) 3811
CONVERTIBLE TOP CLOSED 3813
STANDARD PROCEDURE 3814
STANDARD PROCEDURE – RELIEVING HYDRAULIC PRESSURE 3814
STANDARD PROCEDURE – MANUALLY LOWER TOP 3814
STANDARD PROCEDURE – MANUALLY RAISE TOP 3818
HYDRAULIC CYLINDER 3823
DESCRIPTION 3823
Main Bow Cylinders 3823
Rear Bow Cylinders 3823
Tonneau Cover Cylinder 3823
OPERATION 3824
Hydraulic Cylinder – Rod Extended 3824
Hydraulic Cylinder – Rod Retracted 3825
Hydraulic Cylinder – Travel Sensors 3826
REMOVAL 3827
REMOVAL – TONNEAU COVER CYLINDER 3827
REMOVAL – MAIN CYLINDER 3827
REMOVAL – REAR BOW CYLINDER 3828
REMOVAL – CYLINDER TRAVEL SENSOR 3832
INSTALLATION 3833
INSTALLATION – TONNEAU COVER CYLINDER 3833
INSTALLATION – MAIN CYLINDER 3833
INSTALLATION – REAR BOW CYLINDER 3834
INSTALLATION – CYLINDER TRAVEL SENSOR 3838
HYDRAULIC LINES 3839
DESCRIPTION 3839
OPERATION 3840
REMOVAL 3840
INSTALLATION 3842
HYDRAULIC PUMP MOTOR 3845
DESCRIPTION 3845
OPERATION 3846
Hydraulic Pump 3846
Rotational Relays 3846
Hydraulic Solenoids 3846
REMOVAL 3847
REMOVAL – HYDRAULIC PUMP MOTOR 3847
REMOVAL – PUMP RESERVOIR 3848
INSTALLATION 3848
INSTALLATION – HYDRAULIC PUMP MOTOR 3848
INSTALLATION – PUMP RESERVOIR 3849
SWITCH 3850
REMOVAL 3850
REMOVAL – POWER TOP SWITCH 3850
REMOVAL – CARGO DIVIDER SWITCH 3850
REMOVAL – LATCH RETAINER SWITCH 3850
REMOVAL – ROOF OPEN SWITCH 3851
INSTALLATION 3855
INSTALLATION – POWER TOP SWITCH 3855
INSTALLATION – CARGO COMPARTMENT DIVIDER SWITCH 3856
INSTALLATION – LATCH RETAINER SWITCH 3856
INSTALLATION – ROOF OPEN SWITCH 3856
LATCH 3861
REMOVAL 3861
REMOVAL – REAR BOW LATCH 3861
REMOVAL – TONNEAU COVER LATCH 3861
REMOVAL – LINKAGE ASSEMBLY 3862
REMOVAL – TOP CATCH 3863
REMOVAL – LATCH RETAINER 3864
INSTALLATION 3864
INSTALLATION – REAR BOW LATCH 3864
INSTALLATION – TONNEAU COVER LATCH 3865
INSTALLATION – LINKAGE ASSEMBLY 3865
INSTALLATION – TOP CATCH 3866
INSTALLATION – LATCH RETAINER 3867
CABLE 3868
REMOVAL 3868
REMOVAL – COVER SUPPORT CABLE 3868
REMOVAL – DETENT CABLE 3872
INSTALLATION 3873
INSTALLATION – COVER SUPPORT CABLE 3873
INSTALLATION – DETENT CABLE 3877
FLUID 3877
DESCRIPTION 3877
REAR WINDOW 3877
DESCRIPTION 3877
RELEASE HANDLE 3878
REMOVAL 3878
INSTALLATION 3878
FOLDING TOP COVER 3879
REMOVAL 3879
INSTALLATION 3886
WEATHERSTRIP/SEALS 3893
HEADER / A-PILLAR WEATHERSTRIP 3893
REMOVAL 3893
INSTALLATION 3894
CONVERTIBLE RAIL WEATHERSTRIP 3894
REMOVAL 3894
INSTALLATION 3895
TRUNK OPENING WEATHERSTRIP 3896
REMOVAL 3896
INSTALLATION 3897
REAR BOW WEATHERSTRIPS 3897
REMOVAL 3897
INSTALLATION 3898
TONNEAU COVER WEATHERSTRIP 3898
REMOVAL 3898
INSTALLATION 3899
24-HEATING & AIR CONDITIONING 3901
HEATING & AIR CONDITIONING – ELECTRICAL DIAGNOSTICS 3901
DESCRIPTION 3901
OPERATION 3901
DIAGNOSIS AND TESTING 3902
AMBIENT TEMPERATURE SENSOR CIRCUIT 3903
LEFT HEATER CORE TEMPERATURE SENSOR CIRCUIT 3909
RIGHT HEATER CORE TEMPERATURE SENSOR CIRCUIT 3915
EVAPORATOR TEMPERATURE SENSOR CIRCUIT 3921
ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT 3927
A/C PRESSURE SENSOR CIRCUIT 3933
COOLANT CIRCULATION PUMP CIRCUIT 3940
LEFT COOLANT CIRCULATION VALVE CIRCUIT 3943
RIGHT COOLANT CIRCULATION VALVE CIRCUIT 3946
A/C COMPRESSOR CLUTCH CIRCUIT 3949
RECIRCULATED AIR SWITCHOVER VALVE CIRCUIT 3952
NO COMMUNICATION FROM INSTRUMENT CLUSTER 3955
NO COMMUNICATION TO INSTRUMENT CLUSTER 3957
BODY VERIFICATION TEST 3959
SCHEMATICS AND DIAGRAMS 3960
HEATING & AIR CONDITIONING – SERVICE INFORMATION 3961
DESCRIPTION 3961
COOLING SYSTEM REQUIREMENTS 3961
DESCRIPTION – HEATER AND AIR CONDITIONER 3961
DESCRIPTION – RESIDUAL ENGINE HEAT SYSTEM (REST) 3963
DESCRIPTION – REFRIGERANT SYSTEM SERVICE PORT 3963
OPERATION 3965
HEATER AND AIR CONDITIONER 3965
AIR CONDITIONING 3966
HEATER SYSTEM 3967
R E S T SYSTEM 3968
OPERATION – REST SYSTEM 3969
DIAGNOSIS AND TESTING 3970
A/C PERFORMANCE 3970
DIAGNOSIS AND TESTING – HEATER PERFORMANCE 3973
MAXIMUM HEATER OUTPUT 3974
OBSTRUCTED COOLANT FLOW 3974
MECHANICAL PROBLEMS 3974
TEMPERATURE CONTROL 3974
SPECIFICATIONS 3975
A/C APPLICATION TABLE 3975
SPECIFICATIONS – CHARGE CAPACITY 3975
SPECIFICATIONS – TORQUE 3975
CONTROLS 3976
A/C COMPRESSOR CLUTCH 3976
DESCRIPTION 3976
OPERATION 3977
DIAGNOSIS AND TESTING – COMPRESSOR CLUTCH COIL 3977
STANDARD PROCEDURE – COMPRESSOR CLUTCH BREAK-IN 3978
BLOWER MOTOR REGULATOR 3978
REMOVAL 3978
INSTALLATION 3980
A/C HEATER CONTROL MODULE 3982
DESCRIPTION 3982
OPERATION 3982
REMOVAL 3983
INSTALLATION 3984
REMOVAL 3986
INSTALLATION 3987
EVAPORATOR TEMPERATURE SENSOR 3987
REMOVAL 3987
INSTALLATION 3988
HEATER CORE TEMPERATURE SENSOR 3988
REMOVAL 3988
INSTALLATION 3989
A/C PRESSURE TRANSDUCER 3989
REMOVAL 3989
INSTALLATION 3990
RECIRC AIR SWITCHOVER VALVE 3990
REMOVAL 3990
INSTALLATION 3991
DISTRIBUTION0 – 18 ZH 3992
BLOWER MOTOR 3992
REMOVAL 3992
REMOVAL – RHD 3994
INSTALLATION 3996
INSTALLATION – RHD 3998
HVAC HOUSING 4000
REMOVAL 4000
REMOVAL – RHD 4007
INSTALLATION 4012
INSTALLATION – RHD 4018
AIR OUTLETS 4022
REMOVAL 4022
SIDE AIR NOZZLE 4022
REMOVAL – CENTER AIR NOZZLE 4022
INSTALLATION 4023
SIDE AIR NOZZLE 4023
INSTALLATION – CENTER AIR NOZZLE 4023
DEFROSTER DUCTS 4024
REMOVAL 4024
INSTALLATION 4024
FLOOR DISTRIBUTION DUCTS 4025
REMOVAL – FOOTWELL AIR OUTLET COVER 4025
INSTALLATION – FOOTWELL AIR OUTLET COVER 4026
PLUMBING 4028
DESCRIPTION – REFRIGERANT LINES/HOSES/TUBES 4029
WARNING 4030
CAUTION 4030
DIAGNOSIS AND TESTING – REFRIGERANT SYSTEM LEAKS 4031
SYSTEM EMPTY 4031
SYSTEM LOW 4031
STANDARD PROCEDURE 4031
REFRIGERANT SYSTEM SERVICE EQUIPMENT 4031
MANIFOLD GAUGE SET CONNECTIONS 4032
STANDARD PROCEDURE – REFRIGERANT RECOVERY 4032
STANDARD PROCEDURE – REFRIGERANT SYSTEM EVACUATE 4032
STANDARD PROCEDURE – REFRIGERANT SYSTEM CHARGE 4033
PARTIAL CHARGE METHOD 4033
A/C COMPRESSOR 4034
DESCRIPTION – A/C COMPRESSOR 4034
OPERATION – A/C COMPRESSOR 4034
DIAGNOSIS AND TESTING – COMPRESSOR NOISE 4035
REMOVAL 4036
INSTALLATION 4036
DESCRIPTION 4036
OPERATION 4037
FUNCTION IN HEATING MODE 4037
FUNCTION WITH RESIDUAL ENGINE HEAT UTILIZATION 4037
REMOVAL 4037
INSTALLATION 4038
A/C CONDENSER 4039
DESCRIPTION 4039
OPERATION 4039
REMOVAL 4039
INSTALLATION 4041
A/C EVAPORATOR 4043
DESCRIPTION 4043
OPERATION 4043
REMOVAL 4043
INSTALLATION 4045
LIQUID LINE 4047
REMOVAL 4047
INSTALLATION 4047
SUCTION LINE 4048
REMOVAL 4048
INSTALLATION 4049
A/C EXPANSION VALVE 4051
DESCRIPTION 4051
OPERATION 4051
DIAGNOSIS AND TESTING – A/C EXPANSION VALVE 4051
REMOVAL 4052
INSTALLATION 4052
HEATER CORE 4053
DESCRIPTION 4053
OPERATION 4053
REMOVAL 4053
INSTALLATION 4055
RECEIVER / DRIER 4057
DESCRIPTION 4057
OPERATION 4057
REMOVAL 4057
INSTALLATION 4059
REFRIGERANT 4059
DESCRIPTION 4059
OPERATION 4059
REFRIGERANT OIL 4060
DESCRIPTION 4060
OPERATION 4060
STANDARD PROCEDURE – REFRIGERANT OIL LEVEL 4060
COOLANT CIRCULATION VALVE 4061
DESCRIPTION 4061
OPERATION 4061
RESIDUAL ENGINE HEAT UTILIZATION 4062
REMOVAL 4062
INSTALLATION 4063
25-EMISSIONS CONTROL 4065
EMISSIONS CONTROL 4065
DESCRIPTION 4065
DESCRIPTION – MONITORED COMPONENTS 4065
DESCRIPTION – MONITORED SYSTEMS 4069
DESCRIPTION – NON-MONITORED CIRCUITS 4073
DESCRIPTION – DRB III STATE DISPLAY TEST MODE 4074
DESCRIPTION – HIGH AND LOW LIMITS 4074
DESCRIPTION – TRIP DEFINITION 4074
DESCRIPTION – VEHICLE EMISSION CONTROL INFORMATION LABEL 4074
OPERATION 4075
OPERATION – SYSTEM 4075
OPERATION – SYSTEM 4075
EVAPORATIVE EMISSIONS 4077
DESCRIPTION – EVAPORATION CONTROL SYSTEM 4078
CHARCOAL CANISTER SHUTOFF VALVE 4078
DESCRIPTION 4078
OPERATION 4078
REMOVAL 4079
INSTALLATION 4079
CRANKCASE VENT HOSE 4079
DESCRIPTION 4079
OPERATION 4080
DIAGNOSIS AND TESTING – CRANKCASE VENTILATION SYSTEM 4080
TESTING/CLEANING 4080
EVAP PURGE SOLENOID 4081
DESCRIPTION 4081
OPERATION 4081
REMOVAL 4081
INSTALLATION 4082
FUEL FILLER CAP 4083
DESCRIPTION 4083
OPERATION 4083
ORVR 4083
DESCRIPTION 4083
OPERATION 4084
VAPOR CANISTER 4084
DESCRIPTION 4084
OPERATION 4084
REMOVAL 4085
INSTALLATION 4086
EXHAUST GAS RECIRCULATION 4087
SPECIFICATIONS – TORQUE 4087
SOLENOID 4087
REMOVAL 4087
INSTALLATION 4088
TUBE 4089
REMOVAL 4089
INSTALLATION 4089
VALVE 4090
DESCRIPTION 4090
OPERATION 4090
REMOVAL 4090
INSTALLATION 4091
AIR INJECTION 4093
DESCRIPTION 4093
OPERATION 4094
SPECIFICATIONS 4094
AIR PUMP 4095
REMOVAL 4095
REMOVAL – SRT 4096
INSTALLATION 4097
INSTALLATION – SRT 4098
SWITCHOVER SOLENOID 4099
REMOVAL 4099
INSTALLATION 4100
SWITCHOVER VALVE 4101
REMOVAL 4101
INSTALLATION 4101
AIR PUMP TUBE 4102
REMOVAL – SRT 4102
INSTALLATION – SRT 4103
INDEX 4109
DTC INDEX 4113
COMMENTS 4119
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