Chrysler PT Cruiser Service & Repair Manual – PDF DOWNLOAD
DESCRIPTION:
Chrysler PT Cruiser Service & Repair Manual – PDF DOWNLOAD
INTRODUCTION
BODY CODE PLATE
DESCRIPTION
The Body Code Plate (Fig. 1) is located in the engine compartment on the plenum behind the right side strut tower
(Fig. 2). There are seven lines of information on the body code plate. Lines 4, 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 3 in the center of the plate to line 1 at the bottom of the plate.
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus
2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts (Fig. 3) and (Fig. 4).
TABLE OF CONTENTS:
Chrysler PT Cruiser Service & Repair Manual – PDF DOWNLOAD
PT Service Manual......................................................................................................................................................................................... 1 FOREWORD.............................................................................................................................................................................................. 0 GROUP TAB LOCATOR..................................................................................................................................................................................... 1 intro-INTRODUCTION.................................................................................................................................................................................... 3 BODY CODE PLATE................................................................................................................................................................................... 3 DESCRIPTION................................................................................................................................................................................... 3 BODY CODE PLATE LINE 2.................................................................................................................................................................... 3 BODY CODE PLATE LINE 1.................................................................................................................................................................... 4 IF TWO BODY CODE PLATES ARE REQUIRED...................................................................................................................................................... 4 FASTENER IDENTIFICATION........................................................................................................................................................................... 4 DESCRIPTION................................................................................................................................................................................... 4 FASTENER USAGE.................................................................................................................................................................................... 7 DESCRIPTION................................................................................................................................................................................... 7 DESCRIPTION - FASTENER USAGE.............................................................................................................................................................. 7 DESCRIPTION - THREADED HOLE REPAIR........................................................................................................................................................ 7 INTERNATIONAL SYMBOLS............................................................................................................................................................................. 7 DESCRIPTION................................................................................................................................................................................... 7 METRIC SYSTEM..................................................................................................................................................................................... 8 DESCRIPTION................................................................................................................................................................................... 8 TORQUE REFERENCES................................................................................................................................................................................. 10 DESCRIPTION................................................................................................................................................................................... 10 VEHICLE IDENTIFICATION NUMBER..................................................................................................................................................................... 11 DESCRIPTION - VEHICLE IDENTIFICATION NUMBER................................................................................................................................................... 11 VEHICLE SAFETY CERTIFICATION LABEL................................................................................................................................................................ 12 DESCRIPTION................................................................................................................................................................................... 12 E-MARK LABEL...................................................................................................................................................................................... 12 DESCRIPTION................................................................................................................................................................................... 12 VECI LABEL........................................................................................................................................................................................ 12 DESCRIPTION................................................................................................................................................................................... 12 MANUFACTURER PLATE................................................................................................................................................................................ 12 DESCRIPTION................................................................................................................................................................................... 12 0-LUBRICATION & MAINTENANCE........................................................................................................................................................................... 13 INTERNATIONAL SYMBOLS............................................................................................................................................................................. 13 DESCRIPTION................................................................................................................................................................................... 13 FLUID TYPES....................................................................................................................................................................................... 13 DESCRIPTION................................................................................................................................................................................... 13 DESCRIPTION - ENGINE OIL AND LUBRICANTS................................................................................................................................................... 13 API SERVICE GRADE CERTIFIED........................................................................................................................................................... 13 SAE VISCOSITY......................................................................................................................................................................... 14 ENERGY CONSERVING OIL................................................................................................................................................................. 14 CONTAINER IDENTIFICATION.............................................................................................................................................................. 14 SYNTHETIC ENGINE OILS................................................................................................................................................................. 14 MATERIALS ADDED TO ENGINE OIL......................................................................................................................................................... 14 GEAR LUBRICANTS....................................................................................................................................................................... 14 LUBRICANTS AND GREASES................................................................................................................................................................ 14 SPECIALIZED LUBRICANTS AND OILS....................................................................................................................................................... 14 DESCRIPTION - ENGINE COOLANT.............................................................................................................................................................. 15 DESCRIPTION - TRANSMISSION FLUID.......................................................................................................................................................... 15 TRANSMISSION FLUID.................................................................................................................................................................... 15 DESCRIPTION - FUEL REQUIREMENTS........................................................................................................................................................... 15 REFORMULATED GASOLINE................................................................................................................................................................. 16 GASOLINE/OXYGENATE BLENDS............................................................................................................................................................. 16 MMT IN GASOLINE....................................................................................................................................................................... 16 SULFUR IN GASOLINE.................................................................................................................................................................... 16 MATERIALS ADDED TO FUEL............................................................................................................................................................... 16 FUEL SYSTEM CAUTIONS.................................................................................................................................................................. 16 FLUID CAPACITIES.................................................................................................................................................................................. 17 SPECIFICATIONS - FLUID CAPACITIES............................................................................................................................................................. 17 FLUID FILL/CHECK LOCATIONS........................................................................................................................................................................ 17 DESCRIPTION................................................................................................................................................................................... 17 LUBRICATION POINTS................................................................................................................................................................................ 17 DESCRIPTION................................................................................................................................................................................... 17 MAINTENANCE SCHEDULES............................................................................................................................................................................. 17 DESCRIPTION................................................................................................................................................................................... 17 SCHEDULE “B”—ALL ENGINES.................................................................................................................................................................. 18 SCHEDULE “A”—NON TURBO CHARGED ENGINES.................................................................................................................................................... 22 SCHEDULE “A”—2.4L TURBO CHARGED ENGINES................................................................................................................................................... 24 HOISTING.......................................................................................................................................................................................... 26 STANDARD PROCEDURE - HOISTING................................................................................................................................................................. 26 JUMP STARTING..................................................................................................................................................................................... 26 STANDARD PROCEDURE - JUMP STARTING............................................................................................................................................................ 26 TO JUMP START A DISABLED VEHICLE:......................................................................................................................................................... 26 TOWING............................................................................................................................................................................................ 27 STANDARD PROCEDURE - TOWING................................................................................................................................................................... 27 2-SUSPENSION.......................................................................................................................................................................................... 29 FRONT SUSPENSION.................................................................................................................................................................................. 29 FRONT SUSPENSION.............................................................................................................................................................................. 30 DESCRIPTION - FRONT SUSPENSION............................................................................................................................................................ 30 OPERATION - FRONT SUSPENSION.............................................................................................................................................................. 30 WARNING................................................................................................................................................................................... 30 WARNINGS AND CAUTIONS................................................................................................................................................................. 30 STANDARD PROCEDURE - LUBRICATION.......................................................................................................................................................... 30 SPECIFICATIONS............................................................................................................................................................................ 32 FRONT SUSPENSION FASTENER TORQUE...................................................................................................................................................... 32 SPECIAL TOOLS............................................................................................................................................................................. 32 FRONT SUSPENSION...................................................................................................................................................................... 32 HUB / BEARING................................................................................................................................................................................. 34 DESCRIPTION............................................................................................................................................................................... 34 OPERATION................................................................................................................................................................................. 34 DIAGNOSIS AND TESTING - WHEEL BEARING AND HUB............................................................................................................................................. 34 REMOVAL................................................................................................................................................................................... 34 INSTALLATION.............................................................................................................................................................................. 34 KNUCKLE....................................................................................................................................................................................... 34 DESCRIPTION - STEERING KNUCKLE............................................................................................................................................................ 34 OPERATION - STEERING KNUCKLE.............................................................................................................................................................. 34 DIAGNOSIS AND TESTING - STEERING KNUCKLE.................................................................................................................................................. 34 REMOVAL - STEERING KNUCKLE................................................................................................................................................................ 34 DISASSEMBLY - STEERING KNUCKLE (WHEEL BEARING AND HUB).................................................................................................................................... 36 ASSEMBLY - STEERING KNUCKLE (WHEEL BEARING AND HUB)....................................................................................................................................... 38 INSTALLATION - STEERING KNUCKLE........................................................................................................................................................... 39 LOWER BALL JOINT.............................................................................................................................................................................. 40 DIAGNOSIS AND TESTING - BALL JOINT........................................................................................................................................................ 40 LOWER BALL JOINT SEAL BOOT.................................................................................................................................................................... 40 REMOVAL................................................................................................................................................................................... 40 INSTALLATION.............................................................................................................................................................................. 40 LOWER CONTROL ARM............................................................................................................................................................................. 41 DESCRIPTION............................................................................................................................................................................... 41 OPERATION................................................................................................................................................................................. 41 DIAGNOSIS AND TESTING - LOWER CONTROL ARM................................................................................................................................................. 41 REMOVAL - LOWER CONTROL ARM............................................................................................................................................................... 41 DISASSEMBLY............................................................................................................................................................................... 43 DISASSEMBLY - LOWER CONTROL ARM (BALL JOINT).......................................................................................................................................... 43 DISASSEMBLY - LOWER CONTROL ARM (REAR ISOLATOR BUSHING)............................................................................................................................... 43 ASSEMBLY.................................................................................................................................................................................. 44 ASSEMBLY - LOWER CONTROL ARM (BALL JOINT)............................................................................................................................................. 44 ASSEMBLY - LOWER CONTROL ARM (REAR ISOLATOR BUSHING).................................................................................................................................. 45 INSTALLATION - LOWER CONTROL ARM.......................................................................................................................................................... 45 STABILIZER BAR................................................................................................................................................................................ 47 DESCRIPTION............................................................................................................................................................................... 47 OPERATION................................................................................................................................................................................. 47 REMOVAL................................................................................................................................................................................... 47 INSPECTION................................................................................................................................................................................ 47 INSTALLATION.............................................................................................................................................................................. 47 STRUT ASSEMBLY................................................................................................................................................................................ 48 DESCRIPTION............................................................................................................................................................................... 48 OPERATION................................................................................................................................................................................. 48 DIAGNOSIS AND TESTING - STRUT ASSEMBLY (FRONT)............................................................................................................................................ 48 REMOVAL................................................................................................................................................................................... 48 DISASSEMBLY............................................................................................................................................................................... 49 ASSEMBLY.................................................................................................................................................................................. 52 INSTALLATION.............................................................................................................................................................................. 52 REAR SUSPENSION................................................................................................................................................................................... 54 REAR SUSPENSION............................................................................................................................................................................... 54 DESCRIPTION - REAR SUSPENSION............................................................................................................................................................. 54 OPERATION - REAR SUSPENSION............................................................................................................................................................... 54 WARNING................................................................................................................................................................................... 55 WARNINGS AND CAUTIONS................................................................................................................................................................. 55 SPECIFICATIONS............................................................................................................................................................................ 56 REAR SUSPENSION FASTENER TORQUE....................................................................................................................................................... 56 SPECIAL TOOLS............................................................................................................................................................................. 56 REAR SUSPENSION....................................................................................................................................................................... 56 AXLE - FRONT WHEEL DRIVE REAR................................................................................................................................................................. 57 DESCRIPTION............................................................................................................................................................................... 57 OPERATION................................................................................................................................................................................. 57 REMOVAL................................................................................................................................................................................... 57 INSPECTION................................................................................................................................................................................ 61 INSTALLATION.............................................................................................................................................................................. 61 AXLE PIVOT BUSHING............................................................................................................................................................................ 65 REMOVAL................................................................................................................................................................................... 65 INSTALLATION.............................................................................................................................................................................. 66 HUB / BEARING................................................................................................................................................................................. 67 DESCRIPTION............................................................................................................................................................................... 67 OPERATION................................................................................................................................................................................. 67 DIAGNOSIS AND TESTING - HUB AND BEARING (REAR)............................................................................................................................................ 67 REMOVAL................................................................................................................................................................................... 68 INSTALLATION.............................................................................................................................................................................. 69 JOUNCE BUMPER................................................................................................................................................................................. 69 REMOVAL................................................................................................................................................................................... 69 INSTALLATION.............................................................................................................................................................................. 69 SHOCK ABSORBER................................................................................................................................................................................ 69 DESCRIPTION............................................................................................................................................................................... 69 DIAGNOSIS AND TESTING - SHOCK ABSORBER.................................................................................................................................................... 69 REMOVAL................................................................................................................................................................................... 69 INSTALLATION.............................................................................................................................................................................. 69 SPINDLE....................................................................................................................................................................................... 70 REMOVAL................................................................................................................................................................................... 70 INSTALLATION.............................................................................................................................................................................. 71 SPRING........................................................................................................................................................................................ 72 DESCRIPTION............................................................................................................................................................................... 72 REMOVAL................................................................................................................................................................................... 72 INSTALLATION.............................................................................................................................................................................. 73 STABILIZER BAR................................................................................................................................................................................ 75 DESCRIPTION............................................................................................................................................................................... 75 OPERATION................................................................................................................................................................................. 75 REMOVAL................................................................................................................................................................................... 75 INSTALLATION.............................................................................................................................................................................. 75 STABILIZER BAR CUSHIONS....................................................................................................................................................................... 75 REMOVAL................................................................................................................................................................................... 75 INSTALLATION.............................................................................................................................................................................. 76 STABILIZER BAR LINK........................................................................................................................................................................... 76 REMOVAL................................................................................................................................................................................... 76 INSTALLATION.............................................................................................................................................................................. 76 WATTS LINK ASSEMBLY........................................................................................................................................................................... 76 DESCRIPTION............................................................................................................................................................................... 76 OPERATION................................................................................................................................................................................. 77 DIAGNOSIS AND TESTING - WATTS LINK ASSEMBLY............................................................................................................................................... 77 WATTS BELL CRANK.............................................................................................................................................................................. 77 REMOVAL................................................................................................................................................................................... 77 INSTALLATION.............................................................................................................................................................................. 77 WATTS LINK.................................................................................................................................................................................... 79 REMOVAL................................................................................................................................................................................... 79 INSTALLATION.............................................................................................................................................................................. 79 WHEEL ALIGNMENT................................................................................................................................................................................... 80 DESCRIPTION - WHEEL ALIGNMENT................................................................................................................................................................. 80 CAMBER.................................................................................................................................................................................... 80 CROSS CAMBER.............................................................................................................................................................................. 81 CASTER.................................................................................................................................................................................... 81 CROSS CASTER.............................................................................................................................................................................. 81 TOE....................................................................................................................................................................................... 81 TOE-OUT ON TURNS.......................................................................................................................................................................... 82 DYNAMIC TOE PATTERN....................................................................................................................................................................... 82 STEERING AXIS INCLINATION (S.A.I.)........................................................................................................................................................ 82 INCLUDED ANGLE (I.A.)..................................................................................................................................................................... 82 THRUST ANGLE.............................................................................................................................................................................. 83 DIAGNOSIS AND TESTING - SUSPENSION AND STEERING............................................................................................................................................... 83 STANDARD PROCEDURE............................................................................................................................................................................ 85 STANDARD PROCEDURE - CURB HEIGHT MEASUREMENT.............................................................................................................................................. 85 STANDARD PROCEDURE - WHEEL ALIGNMENT...................................................................................................................................................... 86 PRE-WHEEL ALIGNMENT INSPECTION........................................................................................................................................................ 86 WHEEL ALIGNMENT SETUP................................................................................................................................................................. 86 REAR CAMBER AND TOE................................................................................................................................................................... 86 FRONT CAMBER AND CASTER............................................................................................................................................................... 87 FRONT TOE............................................................................................................................................................................. 88 SPECIFICATIONS................................................................................................................................................................................ 88 WHEEL ALIGNMENT........................................................................................................................................................................... 88 3-DIFFERENTIAL & DRIVELINE............................................................................................................................................................................ 89 HALF SHAFT........................................................................................................................................................................................ 89 HALF SHAFT.................................................................................................................................................................................... 89 DESCRIPTION............................................................................................................................................................................... 89 All Models Except Diesel and Turbo.................................................................................................................................................... 89 Diesel and Turbo Models............................................................................................................................................................... 90 OPERATION................................................................................................................................................................................. 90 DIAGNOSIS AND TESTING - HALFSHAFT DIAGNOSIS............................................................................................................................................... 91 VEHICLE INSPECTION.................................................................................................................................................................... 91 NOISE AND/OR VIBRATION IN TURNS....................................................................................................................................................... 91 CLUNKING NOISE DURING ACCELERATION.................................................................................................................................................... 91 SHUDDER OR VIBRATION DURING ACCELERATION.............................................................................................................................................. 92 VIBRATION AT HIGHWAY SPEEDS........................................................................................................................................................... 92 REMOVAL................................................................................................................................................................................... 92 REMOVAL—EXCEPT DIESEL AND TURBO MODELS................................................................................................................................................ 92 REMOVAL—DIESEL AND TURBO MODELS....................................................................................................................................................... 94 INSTALLATION.............................................................................................................................................................................. 96 INSTALLATION—EXCEPT DIESEL AND TURBO MODELS........................................................................................................................................... 96 INSTALLATION—DIESEL AND TURBO MODELS.................................................................................................................................................. 98 SPECIFICATIONS - TORQUE................................................................................................................................................................... 100 SPECIAL TOOLS............................................................................................................................................................................. 100 HALFSHAFT............................................................................................................................................................................. 100 CV BOOT - INNER............................................................................................................................................................................... 101 REMOVAL................................................................................................................................................................................... 101 INSTALLATION.............................................................................................................................................................................. 102 CV BOOT - OUTER............................................................................................................................................................................... 106 REMOVAL................................................................................................................................................................................... 106 INSTALLATION.............................................................................................................................................................................. 107 5-BRAKES.............................................................................................................................................................................................. 109 BRAKES - BASE..................................................................................................................................................................................... 109 BRAKES - BASE................................................................................................................................................................................. 110 DESCRIPTION - BASE BRAKE SYSTEM........................................................................................................................................................... 110 OPERATION - BASE BRAKE SYSTEM............................................................................................................................................................. 111 WARNING................................................................................................................................................................................... 111 CAUTION................................................................................................................................................................................... 111 CAUTIONS.............................................................................................................................................................................. 111 DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM DIAGNOSIS CHARTS................................................................................................................................ 111 RED BRAKE WARNING INDICATOR........................................................................................................................................................... 112 BRAKE NOISE........................................................................................................................................................................... 112 OTHER BRAKE CONDITIONS................................................................................................................................................................ 113 STANDARD PROCEDURE - BASE BRAKE BLEEDING.................................................................................................................................................. 114 MANUAL BLEEDING....................................................................................................................................................................... 115 PRESSURE BLEEDING..................................................................................................................................................................... 115 SPECIFICATIONS............................................................................................................................................................................ 116 BRAKE ACTUATION SYSTEM................................................................................................................................................................ 116 BRAKE FASTENER TORQUE................................................................................................................................................................. 116 SPECIAL TOOLS............................................................................................................................................................................. 117 BASE BRAKE SYSTEM..................................................................................................................................................................... 117 BRAKE FLUID LEVEL SWITCH...................................................................................................................................................................... 118 REMOVAL................................................................................................................................................................................... 118 INSTALLATION.............................................................................................................................................................................. 118 HYDRAULIC/MECHANICAL.......................................................................................................................................................................... 118 DESCRIPTION............................................................................................................................................................................... 118 DESCRIPTION - DISC BRAKES (FRONT)..................................................................................................................................................... 118 DESCRIPTION - DISC BRAKES (REAR)...................................................................................................................................................... 121 DESCRIPTION - DRUM BRAKES (REAR)...................................................................................................................................................... 121 DIAGNOSIS AND TESTING - DRUM BRAKE AUTOMATIC ADJUSTER..................................................................................................................................... 122 BRAKE LINES................................................................................................................................................................................... 123 DESCRIPTION - BRAKE TUBES AND HOSES....................................................................................................................................................... 123 OPERATION - BRAKE TUBES AND HOSES......................................................................................................................................................... 123 INSPECTION - BRAKE TUBES AND HOSES........................................................................................................................................................ 123 BRAKE PADS/SHOES - FRONT...................................................................................................................................................................... 123 REMOVAL................................................................................................................................................................................... 123 CLEANING - DISC BRAKE SHOES............................................................................................................................................................... 124 INSPECTION - DISC BRAKE SHOES............................................................................................................................................................. 124 INSTALLATION.............................................................................................................................................................................. 124 BRAKE PADS/SHOES - REAR DISC.................................................................................................................................................................. 125 REMOVAL................................................................................................................................................................................... 125 CLEANING - DISC BRAKE SHOES............................................................................................................................................................... 126 INSPECTION - DISC BRAKE SHOES............................................................................................................................................................. 127 INSTALLATION.............................................................................................................................................................................. 127 BRAKE PADS/SHOES - REAR DRUM.................................................................................................................................................................. 127 REMOVAL................................................................................................................................................................................... 127 CLEANING - DRUM BRAKE SHOES............................................................................................................................................................... 129 INSPECTION - DRUM BRAKE SHOES............................................................................................................................................................. 129 INSTALLATION.............................................................................................................................................................................. 130 ADJUSTMENTS............................................................................................................................................................................... 131 ADJUSTMENT - DRUM BRAKE SHOES......................................................................................................................................................... 131 DISC BRAKE CALIPER - FRONT.................................................................................................................................................................... 132 REMOVAL................................................................................................................................................................................... 132 DISASSEMBLY............................................................................................................................................................................... 132 CLEANING - DISC BRAKE CALIPER............................................................................................................................................................. 133 INSPECTION - DISC BRAKE CALIPER........................................................................................................................................................... 133 ASSEMBLY.................................................................................................................................................................................. 133 INSTALLATION.............................................................................................................................................................................. 134 DISC BRAKE CALIPER - REAR..................................................................................................................................................................... 135 REMOVAL................................................................................................................................................................................... 135 DISASSEMBLY............................................................................................................................................................................... 136 DISASSEMBLY - DISC BRAKE CALIPER (GUIDE PIN BUSHINGS)................................................................................................................................. 136 DISASSEMBLY - DISC BRAKE CALIPER (PISTON AND SEAL).................................................................................................................................... 136 CLEANING - DISC BRAKE CALIPER............................................................................................................................................................. 138 INSPECTION - DISC BRAKE CALIPER........................................................................................................................................................... 138 ASSEMBLY.................................................................................................................................................................................. 138 ASSEMBLY - DISC BRAKE CALIPER (GUIDE PIN BUSHINGS).................................................................................................................................... 138 ASSEMBLY - DISC BRAKE CALIPER (PISTON AND SEAL)....................................................................................................................................... 140 INSTALLATION.............................................................................................................................................................................. 141 DISC BRAKE CALIPER ADAPTER - FRONT............................................................................................................................................................ 141 REMOVAL................................................................................................................................................................................... 141 INSTALLATION.............................................................................................................................................................................. 142 DISC BRAKE CALIPER GUIDE PINS................................................................................................................................................................. 142 REMOVAL................................................................................................................................................................................... 142 INSTALLATION.............................................................................................................................................................................. 143 DRUM.......................................................................................................................................................................................... 143 DIAGNOSIS AND TESTING - BRAKE DRUM........................................................................................................................................................ 143 STANDARD PROCEDURE - BRAKE DRUM MACHINING................................................................................................................................................. 143 REMOVAL................................................................................................................................................................................... 144 INSTALLATION.............................................................................................................................................................................. 144 FLUID......................................................................................................................................................................................... 145 DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION......................................................................................................................................... 145 STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING........................................................................................................................................... 145 SPECIFICATIONS............................................................................................................................................................................ 145 BRAKE FLUID........................................................................................................................................................................... 145 FLUID RESERVOIR............................................................................................................................................................................... 145 REMOVAL................................................................................................................................................................................... 145 INSTALLATION.............................................................................................................................................................................. 146 MASTER CYLINDER............................................................................................................................................................................... 146 DESCRIPTION............................................................................................................................................................................... 146 OPERATION................................................................................................................................................................................. 146 STANDARD PROCEDURE - MASTER CYLINDER BLEEDING............................................................................................................................................. 146 REMOVAL................................................................................................................................................................................... 147 REMOVAL - LHD WITH ABS................................................................................................................................................................ 147 REMOVAL - LHD WITHOUT ABS............................................................................................................................................................. 148 REMOVAL - RHD......................................................................................................................................................................... 149 INSTALLATION.............................................................................................................................................................................. 149 INSTALLATION - LHD WITH ABS........................................................................................................................................................... 149 INSTALLATION - LHD WITHOUT ABS........................................................................................................................................................ 149 INSTALLATION - RHD.................................................................................................................................................................... 150 PEDAL - WITH AUTOMATIC TRANSAXLE.............................................................................................................................................................. 150 REMOVAL................................................................................................................................................................................... 150 INSTALLATION.............................................................................................................................................................................. 151 PEDAL - WITH MANUAL TRANSAXLE................................................................................................................................................................. 152 REMOVAL................................................................................................................................................................................... 152 INSTALLATION.............................................................................................................................................................................. 152 POWER BRAKE BOOSTER........................................................................................................................................................................... 153 DESCRIPTION............................................................................................................................................................................... 153 OPERATION................................................................................................................................................................................. 154 DIAGNOSIS AND TESTING - POWER BRAKE BOOSTER............................................................................................................................................... 154 BASIC TEST............................................................................................................................................................................ 154 VACUUM LEAK TEST...................................................................................................................................................................... 154 REMOVAL................................................................................................................................................................................... 155 REMOVAL - LHD......................................................................................................................................................................... 155 REMOVAL - RHD......................................................................................................................................................................... 156 INSTALLATION.............................................................................................................................................................................. 156 INSTALLATION - LHD.................................................................................................................................................................... 156 INSTALLATION - RHD.................................................................................................................................................................... 157 PROPORTIONING VALVE........................................................................................................................................................................... 157 DESCRIPTION............................................................................................................................................................................... 157 OPERATION................................................................................................................................................................................. 158 DIAGNOSIS AND TESTING - PROPORTIONING VALVE............................................................................................................................................... 158 PROPORTIONING VALVE TEST.............................................................................................................................................................. 158 REMOVAL................................................................................................................................................................................... 160 INSTALLATION.............................................................................................................................................................................. 160 ROTOR......................................................................................................................................................................................... 160 DESCRIPTION............................................................................................................................................................................... 160 DIAGNOSIS AND TESTING - BRAKE ROTOR....................................................................................................................................................... 160 BRAKING SURFACE INSPECTION............................................................................................................................................................ 161 ROTOR MINIMUM THICKNESS............................................................................................................................................................... 161 ROTOR THICKNESS VARIATION............................................................................................................................................................. 161 ROTOR RUNOUT.......................................................................................................................................................................... 162 STANDARD PROCEDURE - BRAKE ROTOR MACHINING................................................................................................................................................ 163 REMOVAL................................................................................................................................................................................... 164 REMOVAL - FRONT BRAKE ROTOR........................................................................................................................................................... 164 REMOVAL - REAR BRAKE ROTOR............................................................................................................................................................ 164 INSTALLATION.............................................................................................................................................................................. 165 INSTALLATION - FRONT BRAKE ROTOR...................................................................................................................................................... 165 INSTALLATION - REAR BRAKE ROTOR....................................................................................................................................................... 165 SPECIFICATIONS............................................................................................................................................................................ 165 BRAKE ROTOR LIMITS/SPECIFICATIONS..................................................................................................................................................... 165 SUPPORT PLATE - DRUM BRAKES................................................................................................................................................................... 166 REMOVAL................................................................................................................................................................................... 166 INSTALLATION.............................................................................................................................................................................. 167 WHEEL CYLINDER - DRUM BRAKE................................................................................................................................................................... 168 REMOVAL................................................................................................................................................................................... 168 INSPECTION................................................................................................................................................................................ 169 INSTALLATION.............................................................................................................................................................................. 169 PARKING BRAKE................................................................................................................................................................................. 169 DESCRIPTION............................................................................................................................................................................... 169 OPERATION................................................................................................................................................................................. 170 STANDARD PROCEDURE - PARKING BRAKE AUTOMATIC ADJUSTER LOCKOUT............................................................................................................................. 170 LOCKING AUTOMATIC ADJUSTER OUT........................................................................................................................................................ 170 UNLOCKING AUTOMATIC ADJUSTER (UNLOADING).............................................................................................................................................. 171 CABLE - PARKING BRAKE......................................................................................................................................................................... 171 REMOVAL................................................................................................................................................................................... 171 INSTALLATION.............................................................................................................................................................................. 175 LEVER - PARKING BRAKE......................................................................................................................................................................... 176 REMOVAL................................................................................................................................................................................... 176 INSTALLATION.............................................................................................................................................................................. 177 SHOES - PARKING BRAKE......................................................................................................................................................................... 177 REMOVAL................................................................................................................................................................................... 177 INSTALLATION.............................................................................................................................................................................. 178 ADJUSTMENTS............................................................................................................................................................................... 179 ADJUSTMENT............................................................................................................................................................................ 179 BRAKES - ABS...................................................................................................................................................................................... 181 BRAKES - ABS.................................................................................................................................................................................. 181 DESCRIPTION............................................................................................................................................................................... 181 DESCRIPTION - ANTILOCK BRAKE SYSTEM................................................................................................................................................... 181 DESCRIPTION - ELECTRONIC VARIABLE BRAKE PROPORTIONING................................................................................................................................. 182 DESCRIPTION - TRACTION CONTROL SYSTEM................................................................................................................................................. 182 OPERATION................................................................................................................................................................................. 182 OPERATION - ANTILOCK BRAKE SYSTEM..................................................................................................................................................... 182 NORMAL BRAKING.................................................................................................................................................................... 182 ABS BRAKING....................................................................................................................................................................... 182 NOISE AND BRAKE PEDAL FEEL........................................................................................................................................................ 182 TIRE NOISE AND MARKS.............................................................................................................................................................. 183 START-UP CYCLE.................................................................................................................................................................... 183 DRIVE-OFF CYCLE................................................................................................................................................................... 183 PREMATURE ABS CYCLING............................................................................................................................................................. 183 OPERATION - ELECTRONIC VARIABLE BRAKE PROPORTIONING................................................................................................................................... 183 OPERATION - TRACTION CONTROL SYSTEM................................................................................................................................................... 183 CAUTION................................................................................................................................................................................... 184 CAUTIONS.............................................................................................................................................................................. 184 DIAGNOSIS AND TESTING - INSPECTION AND ROAD TEST.......................................................................................................................................... 184 STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING....................................................................................................................................... 185 SPECIFICATIONS............................................................................................................................................................................ 186 SPECIFICATIONS - ABS FASTENER TORQUE.................................................................................................................................................. 186 TONE WHEEL RUNOUT..................................................................................................................................................................... 186 WHEEL SPEED SENSOR AIR GAP............................................................................................................................................................ 186 FRONT WHEEL SPEED SENSOR...................................................................................................................................................................... 186 DESCRIPTION............................................................................................................................................................................... 186 OPERATION................................................................................................................................................................................. 186 REMOVAL................................................................................................................................................................................... 187 INSTALLATION.............................................................................................................................................................................. 188 REAR WHEEL SPEED SENSOR....................................................................................................................................................................... 188 DESCRIPTION............................................................................................................................................................................... 188 OPERATION................................................................................................................................................................................. 189 REMOVAL................................................................................................................................................................................... 189 INSTALLATION.............................................................................................................................................................................. 190 TONE WHEEL.................................................................................................................................................................................... 190 DESCRIPTION............................................................................................................................................................................... 190 OPERATION................................................................................................................................................................................. 190 INSPECTION................................................................................................................................................................................ 190 TRACTION CONTROL SWITCH....................................................................................................................................................................... 191 REMOVAL................................................................................................................................................................................... 191 INSTALLATION.............................................................................................................................................................................. 191 HCU - HYDRAULIC CONTROL UNIT.................................................................................................................................................................. 191 DESCRIPTION - HYDRAULIC CONTROL UNIT (HCU)................................................................................................................................................ 191 VALVES AND SOLENOIDS.................................................................................................................................................................. 191 BRAKE FLUID ACCUMULATORS.............................................................................................................................................................. 192 PUMP/MOTOR............................................................................................................................................................................ 192 OPERATION - HYDRAULIC CIRCUITS AND VALVES................................................................................................................................................. 192 NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL)........................................................................................... 192 ABS HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL)...................................................................................................... 194 NORMAL BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL).............................................................................. 195 ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL)................................................................................. 196 ABS TRACTION CONTROL HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL)........................................................................ 197 ICU - INTEGRATED CONTROL UNIT................................................................................................................................................................. 198 DESCRIPTION............................................................................................................................................................................... 198 OPERATION................................................................................................................................................................................. 198 REMOVAL................................................................................................................................................................................... 198 DISASSEMBLY - ICU......................................................................................................................................................................... 200 ASSEMBLY - ICU............................................................................................................................................................................ 200 INSTALLATION.............................................................................................................................................................................. 200 6-CLUTCH.............................................................................................................................................................................................. 203 CLUTCH............................................................................................................................................................................................ 204 DESCRIPTION................................................................................................................................................................................... 204 FLUID..................................................................................................................................................................................... 204 OPERATION..................................................................................................................................................................................... 204 T350-Equipped Models...................................................................................................................................................................... 204 G288-Equipped Models...................................................................................................................................................................... 205 DIAGNOSIS AND TESTING......................................................................................................................................................................... 205 DIAGNOSIS AND TESTING—CLUTCH SYSTEM DIAGNOSIS............................................................................................................................................. 205 DIAGNOSIS AND TESTING - CLUTCH CHATTER COMPLAINTS......................................................................................................................................... 208 DIAGNOSIS AND TESTING - DRIVE PLATE MISALIGNMENT.......................................................................................................................................... 208 DIAGNOSIS AND TESTING - CLASH-INTO-REVERSE COMPLAINTS..................................................................................................................................... 208 STANDARD PROCEDURE—BLEEDING CLUTCH HYDRAULIC CIRCUIT.......................................................................................................................................... 208 1.6/2.0/2.4L MODELS (Except Turbo)........................................................................................................................................................ 209 DIESEL AND TURBO MODELS................................................................................................................................................................... 209 SPECIFICATIONS................................................................................................................................................................................ 211 CLUTCH/HYDRAULICS/PEDALS.................................................................................................................................................................. 211 CLUTCH DISC AND PRESSURE PLATE.................................................................................................................................................................... 212 REMOVAL....................................................................................................................................................................................... 212 REMOVAL—1.6L.............................................................................................................................................................................. 212 REMOVAL—2.2L TD........................................................................................................................................................................... 213 INSTALLATION.................................................................................................................................................................................. 213 INSTALLATION—1.6L......................................................................................................................................................................... 213 INSTALLATION—2.2L TD...................................................................................................................................................................... 214 CLUTCH INTERLOCK/UPSTOP SWITCH.................................................................................................................................................................... 214 DESCRIPTION................................................................................................................................................................................... 214 OPERATION..................................................................................................................................................................................... 215 CLUTCH INTERLOCK SWITCH................................................................................................................................................................... 215 CLUTCH PEDAL UPSTOP SWITCH................................................................................................................................................................ 215 DIAGNOSIS AND TESTING—CLUTCH INTERLOCK/UPSTOP SWITCH.......................................................................................................................................... 215 LHD....................................................................................................................................................................................... 215 RHD....................................................................................................................................................................................... 215 CLUTCH INTERLOCK SWITCH................................................................................................................................................................... 216 UPSTOP SWITCH............................................................................................................................................................................. 217 REMOVAL....................................................................................................................................................................................... 218 REMOVAL - LHD............................................................................................................................................................................. 218 REMOVAL - RHD............................................................................................................................................................................. 219 INSTALLATION.................................................................................................................................................................................. 219 INSTALLATION - LHD........................................................................................................................................................................ 219 INSTALLATION - RHD........................................................................................................................................................................ 220 CLUTCH RELEASE BEARING............................................................................................................................................................................ 220 DESCRIPTION................................................................................................................................................................................... 220 OPERATION..................................................................................................................................................................................... 221 REMOVAL....................................................................................................................................................................................... 221 INSTALLATION.................................................................................................................................................................................. 221 FLYWHEEL.......................................................................................................................................................................................... 222 DESCRIPTION................................................................................................................................................................................... 222 1.6L Equipped Models...................................................................................................................................................................... 222 2.2L Turbo Diesel Equipped Models......................................................................................................................................................... 222 OPERATION..................................................................................................................................................................................... 223 REMOVAL....................................................................................................................................................................................... 223 INSTALLATION.................................................................................................................................................................................. 223 MASTER CYLINDER - LHD............................................................................................................................................................................. 224 DESCRIPTION................................................................................................................................................................................... 224 OPERATION..................................................................................................................................................................................... 224 REMOVAL....................................................................................................................................................................................... 224 INSTALLATION.................................................................................................................................................................................. 227 MASTER CYLINDER - RHD............................................................................................................................................................................. 228 DESCRIPTION................................................................................................................................................................................... 228 OPERATION..................................................................................................................................................................................... 228 REMOVAL....................................................................................................................................................................................... 228 INSTALLATION.................................................................................................................................................................................. 231 MODULAR CLUTCH.................................................................................................................................................................................... 232 DESCRIPTION................................................................................................................................................................................... 232 2.0/2.4L MODELS (Except Turbo)............................................................................................................................................................ 232 2.4L TURBO MODELS......................................................................................................................................................................... 232 OPERATION..................................................................................................................................................................................... 232 REMOVAL....................................................................................................................................................................................... 233 INSPECTION.................................................................................................................................................................................... 233 OIL CONTAMINATION......................................................................................................................................................................... 233 GREASE CONTAMINATION...................................................................................................................................................................... 234 ROAD SPLASH/WATER CONTAMINATION........................................................................................................................................................... 234 INSTALLATION.................................................................................................................................................................................. 234 SLAVE CYLINDER.................................................................................................................................................................................... 234 DESCRIPTION................................................................................................................................................................................... 234 1.6/2.0L/2.4L MODELS (Except Diesel & Turbo).............................................................................................................................................. 234 DIESEL AND TURBO MODELS................................................................................................................................................................... 234 REMOVAL....................................................................................................................................................................................... 235 REMOVAL—1.6/2.0/2.4L (Except Diesel and Turbo)............................................................................................................................................ 235 REMOVAL—DIESEL AND TURBO MODELS........................................................................................................................................................... 236 INSTALLATION.................................................................................................................................................................................. 236 INSTALLATION—1.6/2.0/2.4L MODELS (Except Diesel and Turbo)................................................................................................................................ 236 INSTALLATION—DIESEL AND TURBO MODELS...................................................................................................................................................... 236 7-COOLING............................................................................................................................................................................................. 237 COOLING........................................................................................................................................................................................... 237 COOLING....................................................................................................................................................................................... 237 WARNING................................................................................................................................................................................... 237 COOLING SYSTEM WARNINGS............................................................................................................................................................... 237 SPECIFICATIONS............................................................................................................................................................................ 237 TORQUE - 1.6L SOHC.................................................................................................................................................................... 237 TORQUE - 2.0/2.4L..................................................................................................................................................................... 238 SPECIAL TOOLS............................................................................................................................................................................. 238 COOLING SYSTEM........................................................................................................................................................................ 238 ACCESSORY DRIVE - 1.6L SOHC....................................................................................................................................................................... 239 ACCESSORY DRIVE - 1.6L SOHC................................................................................................................................................................... 239 DESCRIPTION............................................................................................................................................................................... 239 DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT DIAGNOSIS.................................................................................................................................... 239 ACCESSORY DRIVE BELT.......................................................................................................................................................................... 240 REMOVAL................................................................................................................................................................................... 240 CLEANING.................................................................................................................................................................................. 240 INSPECTION................................................................................................................................................................................ 240 INSTALLATION.............................................................................................................................................................................. 240 ACCESSORY DRIVE BELT TENSIONER................................................................................................................................................................ 241 REMOVAL................................................................................................................................................................................... 241 INSTALLATION.............................................................................................................................................................................. 241 IDLER PULLEY.................................................................................................................................................................................. 241 REMOVAL................................................................................................................................................................................... 241 INSTALLATION.............................................................................................................................................................................. 241 ACCESSORY DRIVE - 2.0/2.4L DOHC................................................................................................................................................................... 242 DRIVE BELTS................................................................................................................................................................................... 242 DESCRIPTION............................................................................................................................................................................... 242 DIAGNOSIS AND TESTING..................................................................................................................................................................... 243 ACCESSORY DRIVE BELTS................................................................................................................................................................. 243 REMOVAL................................................................................................................................................................................... 244 POWER STEERING PUMP/AIR CONDITIONING COMPRESSOR BELT.................................................................................................................................. 244 GENERATOR BELT........................................................................................................................................................................ 244 CLEANING.................................................................................................................................................................................. 244 INSPECTION................................................................................................................................................................................ 244 INSTALLATION.............................................................................................................................................................................. 246 GENERATOR BELT........................................................................................................................................................................ 246 POWER STEERING PUMP/AIR CONDITIONING COMPRESSOR BELT.................................................................................................................................. 246 ADJUSTMENTS............................................................................................................................................................................... 247 BELT TENSION.......................................................................................................................................................................... 247 AUTOMATIC BELT TENSIONER AND PULLEY........................................................................................................................................................... 247 DESCRIPTION............................................................................................................................................................................... 247 REMOVAL................................................................................................................................................................................... 247 INSTALLATION.............................................................................................................................................................................. 247 ENGINE - 1.6L SOHC................................................................................................................................................................................ 248 ENGINE - 1.6L SOHC............................................................................................................................................................................ 249 DESCRIPTION............................................................................................................................................................................... 249 OPERATION................................................................................................................................................................................. 249 DIAGNOSIS AND TESTING..................................................................................................................................................................... 250 DIAGNOSIS AND TESTING - COOLING SYSTEM AERATION....................................................................................................................................... 250 DIAGNOSIS AND TESTING - COOLING SYSTEM DEAERATION..................................................................................................................................... 250 DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK..................................................................................................................................... 250 DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TESTING................................................................................................................................... 250 STANDARD PROCEDURE........................................................................................................................................................................ 251 STANDARD PROCEDURE - DRAINING COOLING SYSTEM.......................................................................................................................................... 251 STANDARD PROCEDURE - FILLING COOLING SYSTEM........................................................................................................................................... 251 CLEANING.................................................................................................................................................................................. 252 INSPECTION................................................................................................................................................................................ 252 COOLANT....................................................................................................................................................................................... 253 DESCRIPTION............................................................................................................................................................................... 253 DIAGNOSIS AND TESTING - COOLANT CONCENTRATION TESTING..................................................................................................................................... 253 STANDARD PROCEDURE........................................................................................................................................................................ 253 STANDARD PROCEDURE - COOLANT SERVICE.................................................................................................................................................. 253 STANDARD PROCEDURE - ROUTINE COOLANT LEVEL CHECK...................................................................................................................................... 253 STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT........................................................................................................................................ 253 HOSE CLAMPS................................................................................................................................................................................... 254 DESCRIPTION - HOSE CLAMPS................................................................................................................................................................. 254 COOLANT RECOVERY CONTAINER.................................................................................................................................................................... 254 DESCRIPTION............................................................................................................................................................................... 254 OPERATION................................................................................................................................................................................. 254 REMOVAL................................................................................................................................................................................... 254 INSTALLATION.............................................................................................................................................................................. 254 ENGINE BLOCK HEATER........................................................................................................................................................................... 255 DESCRIPTION............................................................................................................................................................................... 255 OPERATION................................................................................................................................................................................. 255 DIAGNOSIS AND TESTING - ENGINE BLOCK HEATER TESTING....................................................................................................................................... 255 REMOVAL................................................................................................................................................................................... 255 INSTALLATION.............................................................................................................................................................................. 255 ENGINE COOLANT TEMP SENSOR.................................................................................................................................................................... 256 DESCRIPTION............................................................................................................................................................................... 256 OPERATION................................................................................................................................................................................. 256 REMOVAL................................................................................................................................................................................... 256 INSTALLATION.............................................................................................................................................................................. 256 ENGINE COOLANT THERMOSTAT AND HOUSING......................................................................................................................................................... 256 REMOVAL................................................................................................................................................................................... 256 INSTALLATION.............................................................................................................................................................................. 256 RADIATOR PRESSURE CAP......................................................................................................................................................................... 257 DESCRIPTION............................................................................................................................................................................... 257 OPERATION................................................................................................................................................................................. 257 DIAGNOSIS AND TESTING..................................................................................................................................................................... 257 DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP TESTING........................................................................................................................... 257 DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE RELIEF TESTING........................................................................................................................ 258 CLEANING.................................................................................................................................................................................. 258 INSPECTION................................................................................................................................................................................ 258 RADIATOR DRAINCOCK............................................................................................................................................................................ 258 REMOVAL................................................................................................................................................................................... 258 INSTALLATION.............................................................................................................................................................................. 259 RADIATOR FAN.................................................................................................................................................................................. 259 DESCRIPTION............................................................................................................................................................................... 259 OPERATION................................................................................................................................................................................. 259 DIAGNOSIS AND TESTING - RADIATOR FAN...................................................................................................................................................... 260 REMOVAL................................................................................................................................................................................... 260 INSTALLATION.............................................................................................................................................................................. 261 RADIATOR...................................................................................................................................................................................... 261 REMOVAL................................................................................................................................................................................... 261 CLEANING.................................................................................................................................................................................. 262 INSPECTION................................................................................................................................................................................ 262 INSTALLATION.............................................................................................................................................................................. 262 HEATER RETURN TUBE............................................................................................................................................................................ 263 REMOVAL................................................................................................................................................................................... 263 INSTALLATION.............................................................................................................................................................................. 263 WATER PUMP/POWER STEERING PUMP ASSEMBLY....................................................................................................................................................... 263 DESCRIPTION............................................................................................................................................................................... 263 REMOVAL................................................................................................................................................................................... 264 DISASSEMBLY............................................................................................................................................................................... 264 ASSEMBLY.................................................................................................................................................................................. 265 INSTALLATION.............................................................................................................................................................................. 266 ENGINE - 2.0/2.4L DOHC............................................................................................................................................................................ 267 ENGINE - 2.0/2.4L DOHC........................................................................................................................................................................ 268 DESCRIPTION............................................................................................................................................................................... 268 Non-Turbo............................................................................................................................................................................. 268 Turbo................................................................................................................................................................................. 268 OPERATION................................................................................................................................................................................. 268 DIAGNOSIS AND TESTING..................................................................................................................................................................... 269 COOLING SYSTEM........................................................................................................................................................................ 269 DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TESTING................................................................................................................................... 275 DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK..................................................................................................................................... 276 PREFERRED METHOD.................................................................................................................................................................. 276 ALTERNATIVE METHOD................................................................................................................................................................ 276 COOLING SYSTEM AERATION............................................................................................................................................................... 276 DIAGNOSIS AND TESTING - COOLING SYSTEM DEAERATION..................................................................................................................................... 276 STANDARD PROCEDURE........................................................................................................................................................................ 276 STANDARD PROCEDURE - DRAINING COOLING SYSTEM.......................................................................................................................................... 276 STANDARD PROCEDURE - FILLING COOLING SYSTEM........................................................................................................................................... 277 CLEANING.................................................................................................................................................................................. 278 INSPECTION................................................................................................................................................................................ 278 COOLANT....................................................................................................................................................................................... 278 DESCRIPTION............................................................................................................................................................................... 278 DIAGNOSIS AND TESTING - COOLANT CONCENTRATION TESTING..................................................................................................................................... 278 STANDARD PROCEDURE........................................................................................................................................................................ 279 STANDARD PROCEDURE - ROUTINE COOLANT LEVEL CHECK0 - 2 PT (Continued).............................................................................................................. 279 STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT........................................................................................................................................ 279 STANDARD PROCEDURE - COOLANT LEVEL SERVICING.......................................................................................................................................... 279 COOLANT RECOVERY CONTAINER.................................................................................................................................................................... 281 DESCRIPTION............................................................................................................................................................................... 281 OPERATION................................................................................................................................................................................. 281 REMOVAL................................................................................................................................................................................... 281 Non - Turbo........................................................................................................................................................................... 281 Turbo................................................................................................................................................................................. 281 INSTALLATION.............................................................................................................................................................................. 281 Non - Turbo........................................................................................................................................................................... 281 Turbo................................................................................................................................................................................. 282 COOLING SYSTEM PRESSURE CAP................................................................................................................................................................... 282 DESCRIPTION............................................................................................................................................................................... 282 OPERATION................................................................................................................................................................................. 283 DIAGNOSIS AND TESTING..................................................................................................................................................................... 283 DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP TESTING........................................................................................................................... 283 DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE RELIEF TESTING........................................................................................................................ 283 CLEANING.................................................................................................................................................................................. 284 INSPECTION................................................................................................................................................................................ 284 ENGINE BLOCK HEATER........................................................................................................................................................................... 284 DESCRIPTION............................................................................................................................................................................... 284 OPERATION................................................................................................................................................................................. 284 DIAGNOSIS AND TESTING..................................................................................................................................................................... 285 ENGINE BLOCK HEATER................................................................................................................................................................... 285 REMOVAL................................................................................................................................................................................... 285 INSTALLATION.............................................................................................................................................................................. 285 ENGINE COOLANT TEMPERATURE SENSOR............................................................................................................................................................. 285 DESCRIPTION............................................................................................................................................................................... 285 OPERATION................................................................................................................................................................................. 285 REMOVAL................................................................................................................................................................................... 286 Non-Turbo............................................................................................................................................................................. 286 Turbo................................................................................................................................................................................. 286 INSTALLATION.............................................................................................................................................................................. 286 Non-Turbo............................................................................................................................................................................. 286 Turbo................................................................................................................................................................................. 286 ENGINE COOLANT THERMOSTAT..................................................................................................................................................................... 286 DESCRIPTION............................................................................................................................................................................... 286 OPERATION................................................................................................................................................................................. 287 DIAGNOSIS AND TESTING - ENGINE COOLANT THERMOSTAT......................................................................................................................................... 287 REMOVAL................................................................................................................................................................................... 287 INSTALLATION.............................................................................................................................................................................. 287 HOSE CLAMPS................................................................................................................................................................................... 288 DESCRIPTION - HOSE CLAMPS................................................................................................................................................................. 288 OPERATION................................................................................................................................................................................. 288 RADIATOR FAN.................................................................................................................................................................................. 288 DESCRIPTION............................................................................................................................................................................... 288 Non-Turbo............................................................................................................................................................................. 288 Turbo................................................................................................................................................................................. 288 OPERATION................................................................................................................................................................................. 289 Non-Turbo............................................................................................................................................................................. 289 Turbo................................................................................................................................................................................. 289 DIAGNOSIS AND TESTING..................................................................................................................................................................... 290 RADIATOR FAN MOTOR TEST............................................................................................................................................................... 290 REMOVAL................................................................................................................................................................................... 290 INSTALLATION.............................................................................................................................................................................. 291 RADIATOR...................................................................................................................................................................................... 291 REMOVAL................................................................................................................................................................................... 291 CLEANING.................................................................................................................................................................................. 293 INSPECTION................................................................................................................................................................................ 293 INSTALLATION.............................................................................................................................................................................. 293 RADIATOR DRAINCOCK............................................................................................................................................................................ 293 REMOVAL................................................................................................................................................................................... 293 INSTALLATION.............................................................................................................................................................................. 294 THERMOSTAT HOUSING............................................................................................................................................................................ 294 REMOVAL................................................................................................................................................................................... 294 INSTALLATION.............................................................................................................................................................................. 294 WATER PUMP.................................................................................................................................................................................... 295 DIAGNOSIS AND TESTING..................................................................................................................................................................... 295 WATER PUMP............................................................................................................................................................................ 295 REMOVAL................................................................................................................................................................................... 295 INSPECTION................................................................................................................................................................................ 295 INSTALLATION.............................................................................................................................................................................. 295 WATER PUMP INLET TUBE......................................................................................................................................................................... 296 REMOVAL................................................................................................................................................................................... 296 INSTALLATION.............................................................................................................................................................................. 296 TRANSMISSION...................................................................................................................................................................................... 297 TRANSMISSION COOLER HOSES..................................................................................................................................................................... 297 DESCRIPTION............................................................................................................................................................................... 297 AUTOMATIC TRANSMISSION OIL COOLER............................................................................................................................................................. 297 DESCRIPTION............................................................................................................................................................................... 297 Non - Turbo........................................................................................................................................................................... 297 Turbo................................................................................................................................................................................. 297 REMOVAL................................................................................................................................................................................... 297 Non - Turbo........................................................................................................................................................................... 297 Turbo................................................................................................................................................................................. 298 CLEANING.................................................................................................................................................................................. 298 INSPECTION................................................................................................................................................................................ 299 INSTALLATION.............................................................................................................................................................................. 299 Non - Turbo........................................................................................................................................................................... 299 Turbo................................................................................................................................................................................. 299 8a-AUDIO.............................................................................................................................................................................................. 301 AUDIO............................................................................................................................................................................................. 301 DESCRIPTION................................................................................................................................................................................... 301 OPERATION..................................................................................................................................................................................... 301 DIAGNOSIS AND TESTING - AUDIO................................................................................................................................................................. 302 ANTENNA BODY & CABLE.............................................................................................................................................................................. 303 DESCRIPTION................................................................................................................................................................................... 303 OPERATION..................................................................................................................................................................................... 303 DIAGNOSIS AND TESTING - ANTENNA BODY AND CABLE................................................................................................................................................ 304 TEST 1.................................................................................................................................................................................... 304 TEST 2.................................................................................................................................................................................... 304 TEST 3.................................................................................................................................................................................... 305 TEST 4.................................................................................................................................................................................... 305 REMOVAL....................................................................................................................................................................................... 305 INSTALLATION.................................................................................................................................................................................. 305 ANTENNA - SATELLITE RADIO......................................................................................................................................................................... 306 DESCRIPTION................................................................................................................................................................................... 306 OPERATION..................................................................................................................................................................................... 306 REMOVAL....................................................................................................................................................................................... 306 INSTALLATION.................................................................................................................................................................................. 306 ANTENNA CABLE - SATELLITE RADIO................................................................................................................................................................... 307 DESCRIPTION................................................................................................................................................................................... 307 REMOVAL....................................................................................................................................................................................... 307 INSTALLATION.................................................................................................................................................................................. 307 RADIO............................................................................................................................................................................................. 307 DESCRIPTION................................................................................................................................................................................... 307 OPERATION..................................................................................................................................................................................... 307 REMOVAL....................................................................................................................................................................................... 308 INSTALLATION.................................................................................................................................................................................. 308 RADIO NOISE SUPPRESSION COMPONENTS................................................................................................................................................................ 308 DESCRIPTION................................................................................................................................................................................... 308 OPERATION..................................................................................................................................................................................... 308 REMOVAL....................................................................................................................................................................................... 309 ENGINE GROUND STRAP....................................................................................................................................................................... 309 HOOD HINGE GROUND STRAP................................................................................................................................................................... 310 MUFFLER GROUND STRAP...................................................................................................................................................................... 310 RADIO NOISE SUPPRESSION CAPACITOR......................................................................................................................................................... 310 STRUT BRACKET TO BODY GROUND STRAP........................................................................................................................................................ 310 INSTALLATION.................................................................................................................................................................................. 311 ENGINE GROUND STRAP....................................................................................................................................................................... 311 HOOD HINGE GROUND STRAP................................................................................................................................................................... 311 MUFFLER GROUND STRAP...................................................................................................................................................................... 311 RADIO NOISE SUPPRESSION CAPACITOR......................................................................................................................................................... 311 STRUT BRACKET TO BODY GROUND STRAP........................................................................................................................................................ 311 SATELLITE RECEIVER MODULE......................................................................................................................................................................... 311 DESCRIPTION................................................................................................................................................................................... 311 OPERATION..................................................................................................................................................................................... 311 REMOVAL....................................................................................................................................................................................... 311 INSTALLATION.................................................................................................................................................................................. 311 SPEAKER........................................................................................................................................................................................... 311 REMOVAL....................................................................................................................................................................................... 311 FRONT DOOR SPEAKER........................................................................................................................................................................ 311 INSTRUMENT PANEL SPEAKER.................................................................................................................................................................. 312 REAR SPEAKER.............................................................................................................................................................................. 312 INSTALLATION.................................................................................................................................................................................. 312 FRONT DOOR SPEAKER........................................................................................................................................................................ 312 INSTRUMENT PANEL SPEAKER.................................................................................................................................................................. 312 REAR SPEAKER.............................................................................................................................................................................. 312 8b-CHIME/BUZZER....................................................................................................................................................................................... 313 CHIME/BUZZER...................................................................................................................................................................................... 313 DESCRIPTION................................................................................................................................................................................... 313 OPERATION..................................................................................................................................................................................... 313 FASTEN SEAT BELT.......................................................................................................................................................................... 313 HEADLAMPS REMINDER........................................................................................................................................................................ 313 KEY IN IGNITION REMINDER.................................................................................................................................................................. 313 DOOR AJAR CHIME........................................................................................................................................................................... 313 TURN SIGNAL ON............................................................................................................................................................................ 313 PARK BRAKE REMINDER....................................................................................................................................................................... 313 LOW FUEL REMINDER......................................................................................................................................................................... 313 REVERSE CHIME (DIESEL and TURBO ONLY EQUIPPED WITH THE GETRAG MANUAL TRANSMISSION)........................................................................................................ 313 DIAGNOSIS AND TESTING......................................................................................................................................................................... 314 DIAGNOSIS AND TESTING - BRAKE/PARK BRAKE INDICATOR........................................................................................................................................ 314 To test the system:................................................................................................................................................................... 314 If lamp fails to light inspect for:................................................................................................................................................... 314 DIAGNOSIS AND TESTING - CHIME CONDITIONS.................................................................................................................................................. 314 NO TONE WHEN IGNITION SWITCH IS TURNED ON AND DRIVERS SEAT BELT IS UNBUCKLED.......................................................................................................... 314 NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS ON................................................................................................................................... 314 NO TONE WHEN HEADLAMPS ARE ON AND DRIVERS DOOR IS OPEN................................................................................................................................ 314 NO TONE WHEN KEY IS LEFT IN IGNITION AND DRIVERS DOOR IS OPEN......................................................................................................................... 314 DIAGNOSIS AND TESTING - FASTEN SEAT BELTS................................................................................................................................................. 314 DIAGNOSIS AND TESTING - KEY IN IGNITION................................................................................................................................................... 314 8e-ELECTRONIC CONTROL MODULES......................................................................................................................................................................... 315 CONTROLLER ANTILOCK BRAKE......................................................................................................................................................................... 315 DESCRIPTION................................................................................................................................................................................... 315 OPERATION..................................................................................................................................................................................... 315 CONTROLLER ANTILOCK BRAKE INPUTS.......................................................................................................................................................... 316 CONTROLLER ANTILOCK BRAKE OUTPUTS......................................................................................................................................................... 316 REMOVAL....................................................................................................................................................................................... 316 INSTALLATION.................................................................................................................................................................................. 317 DATA LINK CONNECTOR............................................................................................................................................................................... 317 DESCRIPTION................................................................................................................................................................................... 317 OPERATION..................................................................................................................................................................................... 317 HEATED SEAT MODULE................................................................................................................................................................................ 317 DESCRIPTION................................................................................................................................................................................... 317 OPERATION..................................................................................................................................................................................... 318 DIAGNOSIS AND TESTING - HEATED SEAT MODULE.................................................................................................................................................... 318 REMOVAL....................................................................................................................................................................................... 319 INSTALLATION.................................................................................................................................................................................. 319 POWERTRAIN CONTROL MODULE......................................................................................................................................................................... 319 DESCRIPTION................................................................................................................................................................................... 319 OPERATION - SENSOR RETURN - PCM INPUT..................................................................................................................................................... 319 OPERATION - DATA BUS COMMUNICATION RECEIVE - PCM INPUT.................................................................................................................................... 319 OPERATION - IGNITION SENSE - PCM INPUT.................................................................................................................................................... 319 OPERATION - PCM GROUND.................................................................................................................................................................... 319 OPERATION..................................................................................................................................................................................... 320 OPERATION................................................................................................................................................................................. 320 Powertrain Control Module Connectors.................................................................................................................................................. 321 TRANSMISSION CONTROL.................................................................................................................................................................. 321 OPERATION - 5 VOLT SUPPLY - PCM OUTPUT.................................................................................................................................................... 324 STANDARD PROCEDURE............................................................................................................................................................................ 324 STANDARD PROCEDURE - OBTAINING DIAGNOSTIC TROUBLE CODES................................................................................................................................... 324 BULB CHECK............................................................................................................................................................................ 324 OBTAINING DTC'S USING DRB SCAN TOOL................................................................................................................................................... 324 STANDARD PROCEDURE - PINION FACTOR SETTING................................................................................................................................................ 324 STANDARD PROCEDURE - QUICK LEARN PROCEDURE................................................................................................................................................ 324 REMOVAL....................................................................................................................................................................................... 325 REMOVAL - 1.6L............................................................................................................................................................................ 325 REMOVAL - 2.0, 2.4, and 2.4L Turbo........................................................................................................................................................ 326 INSTALLATION.................................................................................................................................................................................. 328 INSTALLATION - 1.6L....................................................................................................................................................................... 328 INSTALLATION - 2.0, 2.4, and 2.4L TURBO................................................................................................................................................... 329 SENTRY KEY IMMOBILIZER MODULE..................................................................................................................................................................... 329 DESCRIPTION................................................................................................................................................................................... 329 OPERATION..................................................................................................................................................................................... 330 STANDARD PROCEDURE - SENTRY KEY IMMOBILIZER SYSTEM INITIALIZATION............................................................................................................................. 330 REMOVAL....................................................................................................................................................................................... 330 INSTALLATION.................................................................................................................................................................................. 331 TRANSMISSION CONTROL MODULE....................................................................................................................................................................... 331 DESCRIPTION................................................................................................................................................................................... 331 OPERATION..................................................................................................................................................................................... 331 CLUTCH VOLUME INDEX (CVI)................................................................................................................................................................. 332 SHIFT SCHEDULES........................................................................................................................................................................... 333 REMOVAL....................................................................................................................................................................................... 334 INSTALLATION.................................................................................................................................................................................. 334 8f-ENGINE SYSTEMS..................................................................................................................................................................................... 337 BATTERY SYSTEM.................................................................................................................................................................................... 337 BATTERY SYSTEM................................................................................................................................................................................ 338 DESCRIPTION............................................................................................................................................................................... 338 OPERATION................................................................................................................................................................................. 338 DIAGNOSIS AND TESTING - BATTERY SYSTEM.................................................................................................................................................... 338 MICRO 420 BATTERY TESTER.............................................................................................................................................................. 338 ABNORMAL BATTERY DISCHARGING.......................................................................................................................................................... 340 CLEANING.................................................................................................................................................................................. 340 INSPECTION................................................................................................................................................................................ 342 SPECIFICATIONS............................................................................................................................................................................ 342 SPECIFICATIONS........................................................................................................................................................................ 342 TORQUE SPECIFICATIONS................................................................................................................................................................. 343 SPECIAL TOOLS............................................................................................................................................................................. 343 BATTERY SYSTEM SPECIAL TOOLS.......................................................................................................................................................... 343 BATTERY....................................................................................................................................................................................... 343 DESCRIPTION............................................................................................................................................................................... 343 SPIRAL PLATE BATTERY - DIESEL ENGINE.................................................................................................................................................. 343 CONVENTIONAL BATTERY - GASOLINE ENGINE................................................................................................................................................ 343 OPERATION................................................................................................................................................................................. 343 DIAGNOSIS AND TESTING - BATTERY........................................................................................................................................................... 344 MICRO 420 BATTERY TESTER.............................................................................................................................................................. 344 STANDARD PROCEDURE........................................................................................................................................................................ 344 STANDARD PROCEDURE - SPIRAL PLATE BATTERY CHARGING.................................................................................................................................... 344 CHARGING A COMPLETELY DISCHARGED BATTERY – SPIRAL PLATE BATTERY................................................................................................................... 345 CHARGING TIME REQUIRED............................................................................................................................................................ 345 STANDARD PROCEDURE - CONVENTIONAL BATTERY CHARGING.................................................................................................................................... 346 CHARGING A COMPLETELY DISCHARGED CONVENTIONAL BATTERY............................................................................................................................. 346 CHARGING TIME REQUIRED............................................................................................................................................................ 347 STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER................................................................................................................................... 347 BATTERY TESTING................................................................................................................................................................... 348 STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST........................................................................................................................................ 348 STANDARD PROCEDURE - IGNITION-OFF DRAW TEST........................................................................................................................................... 349 REMOVAL................................................................................................................................................................................... 350 REMOVAL - GASOLINE ENGINE............................................................................................................................................................. 350 REMOVAL - DIESEL ENGINE............................................................................................................................................................... 350 INSTALLATION.............................................................................................................................................................................. 352 INSTALLATION - GASOLINE ENGINE........................................................................................................................................................ 352 INSTALLATION - DIESEL ENGINE.......................................................................................................................................................... 352 BATTERY HOLDDOWN.............................................................................................................................................................................. 353 DESCRIPTION............................................................................................................................................................................... 353 OPERATION................................................................................................................................................................................. 353 REMOVAL................................................................................................................................................................................... 353 INSTALLATION.............................................................................................................................................................................. 353 BATTERY CABLES................................................................................................................................................................................ 354 DESCRIPTION............................................................................................................................................................................... 354 OPERATION................................................................................................................................................................................. 354 DIAGNOSIS AND TESTING - BATTERY CABLES.................................................................................................................................................... 354 VOLTAGE DROP TEST..................................................................................................................................................................... 354 REMOVAL................................................................................................................................................................................... 355 INSTALLATION.............................................................................................................................................................................. 356 BATTERY TRAY.................................................................................................................................................................................. 356 DESCRIPTION............................................................................................................................................................................... 356 OPERATION................................................................................................................................................................................. 356 REMOVAL................................................................................................................................................................................... 356 REMOVAL - GASOLINE ENGINE............................................................................................................................................................. 356 REMOVAL - DIESEL ENGINE............................................................................................................................................................... 356 INSTALLATION.............................................................................................................................................................................. 356 INSTALLATION - GASOLINE ENGINE........................................................................................................................................................ 356 INSTALLATION - DIESEL ENGINE.......................................................................................................................................................... 356 THERMAL GUARD................................................................................................................................................................................. 357 DESCRIPTION............................................................................................................................................................................... 357 OPERATION................................................................................................................................................................................. 357 REMOVAL................................................................................................................................................................................... 357 INSTALLATION.............................................................................................................................................................................. 357 BATTERY TRAY SUPPORT BRACKET.................................................................................................................................................................. 358 REMOVAL................................................................................................................................................................................... 358 INSTALLATION.............................................................................................................................................................................. 358 CHARGING.......................................................................................................................................................................................... 359 CHARGING...................................................................................................................................................................................... 359 DESCRIPTION - CHARGING SYSTEM............................................................................................................................................................. 359 OPERATION - CHARGING SYSTEM............................................................................................................................................................... 359 DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTIC SYSTEM........................................................................................................................................ 360 BATTERY TEMPERATURE SENSOR.................................................................................................................................................................... 361 OPERATION................................................................................................................................................................................. 361 REMOVAL - 2.0, 2.4, and 2.4L TURBO........................................................................................................................................................ 361 INSTALLATION - 2.0, 2.4, and 2.4L TURBO................................................................................................................................................... 362 GENERATOR..................................................................................................................................................................................... 362 DESCRIPTION............................................................................................................................................................................... 362 OPERATION................................................................................................................................................................................. 362 REMOVAL................................................................................................................................................................................... 363 REMOVAL - 2.0/2.4L.................................................................................................................................................................... 363 REMOVAL - 2.4L TURBO.................................................................................................................................................................. 364 REMOVAL - 2.2 DIESEL.................................................................................................................................................................. 367 INSTALLATION.............................................................................................................................................................................. 367 INSTALLATION - 2.0/2.4L............................................................................................................................................................... 367 INSTALLATION - 2.4L TURBO............................................................................................................................................................. 368 INSTALLATION - 2.2 DIESEL............................................................................................................................................................. 368 VOLTAGE REGULATOR............................................................................................................................................................................. 369 DESCRIPTION............................................................................................................................................................................... 369 OPERATION................................................................................................................................................................................. 369 STARTING.......................................................................................................................................................................................... 370 STARTING...................................................................................................................................................................................... 370 DESCRIPTION............................................................................................................................................................................... 370 OPERATION................................................................................................................................................................................. 370 DIAGNOSIS AND TESTING..................................................................................................................................................................... 370 DIAGNOSIS AND TESTING - STARTING SYSTEM TEST.......................................................................................................................................... 370 INSPECTION........................................................................................................................................................................ 370 DIAGNOSIS AND TESTING - CONTROL CIRCUIT TEST.......................................................................................................................................... 372 STARTER SOLENOID.................................................................................................................................................................. 372 STARTER RELAY..................................................................................................................................................................... 373 RELAY TEST........................................................................................................................................................................ 373 RELAY CIRCUIT TEST................................................................................................................................................................ 374 SAFETY SWITCHES................................................................................................................................................................... 374 IGNITION SWITCH................................................................................................................................................................... 374 BATTERY........................................................................................................................................................................... 374 ALL RELATED WIRING AND CONNECTORS................................................................................................................................................. 374 DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST.................................................................................................................................. 374 DIAGNOSIS AND TESTING - FEED CIRCUIT TEST............................................................................................................................................. 375 SPECIFICATIONS............................................................................................................................................................................ 375 STARTER MOTOR......................................................................................................................................................................... 375 TORQUE................................................................................................................................................................................ 376 STARTER MOTOR................................................................................................................................................................................. 376 REMOVAL................................................................................................................................................................................... 376 REMOVAL - 1.6L........................................................................................................................................................................ 376 REMOVAL - 2.2 DIESEL.................................................................................................................................................................. 377 REMOVAL - 2.0/2.4L.................................................................................................................................................................... 378 REMOVAL - STARTER 2.4L TURBO.......................................................................................................................................................... 378 INSTALLATION.............................................................................................................................................................................. 380 INSTALLATION - 1.6L................................................................................................................................................................... 380 INSTALLATION - 2.2L DIESEL............................................................................................................................................................ 380 INSTALLATION - 2.0/2.4L............................................................................................................................................................... 381 INSTALLATION - STARTER 2.4L TURBO..................................................................................................................................................... 381 8g-HEATED SYSTEMS..................................................................................................................................................................................... 383 HEATED SEAT SYSTEM................................................................................................................................................................................ 383 HEATED SEAT SYSTEM............................................................................................................................................................................ 383 DESCRIPTION............................................................................................................................................................................... 383 OPERATION................................................................................................................................................................................. 384 DIAGNOSIS AND TESTING - HEATED SEAT SYSTEM................................................................................................................................................ 384 SELF-DIAGNOSTICS - HEATED SEAT SYSTEM................................................................................................................................................. 385 DRIVER HEATED SEAT SWITCH..................................................................................................................................................................... 386 DESCRIPTION............................................................................................................................................................................... 386 OPERATION................................................................................................................................................................................. 386 DIAGNOSIS AND TESTING - DRIVER HEATED SEAT SWITCH......................................................................................................................................... 386 REMOVAL................................................................................................................................................................................... 387 INSTALLATION.............................................................................................................................................................................. 387 HEATED SEAT ELEMENT........................................................................................................................................................................... 387 DESCRIPTION............................................................................................................................................................................... 387 OPERATION................................................................................................................................................................................. 388 DIAGNOSIS AND TESTING - HEATED SEAT ELEMENT............................................................................................................................................... 388 REMOVAL................................................................................................................................................................................... 388 INSTALLATION.............................................................................................................................................................................. 388 HEATED SEAT RELAY............................................................................................................................................................................. 389 DESCRIPTION............................................................................................................................................................................... 389 OPERATION................................................................................................................................................................................. 389 DIAGNOSIS AND TESTING - MICRO-RELAY....................................................................................................................................................... 389 REMOVAL................................................................................................................................................................................... 389 INSTALLATION.............................................................................................................................................................................. 390 HEATED SEAT SENSOR............................................................................................................................................................................ 390 DESCRIPTION............................................................................................................................................................................... 390 OPERATION................................................................................................................................................................................. 390 DIAGNOSIS AND TESTING - HEATED SEAT SENSOR................................................................................................................................................ 390 REMOVAL................................................................................................................................................................................... 390 PASSENGER HEATED SEAT SWITCH.................................................................................................................................................................. 390 DESCRIPTION............................................................................................................................................................................... 390 OPERATION................................................................................................................................................................................. 390 DIAGNOSIS AND TESTING - PASSENGER HEATED SEAT SWITCH...................................................................................................................................... 391 REMOVAL................................................................................................................................................................................... 391 INSTALLATION.............................................................................................................................................................................. 391 HEATED WINDOW DEFOGGER............................................................................................................................................................................ 392 HEATED WINDOW DEFOGGER........................................................................................................................................................................ 392 DESCRIPTION............................................................................................................................................................................... 392 OPERATION................................................................................................................................................................................. 392 DIAGNOSIS AND TESTING..................................................................................................................................................................... 392 REAR WINDOW DEFOGGER SYSTEM........................................................................................................................................................... 392 DEFOGGER SWITCH............................................................................................................................................................................... 393 DESCRIPTION............................................................................................................................................................................... 393 OPERATION................................................................................................................................................................................. 393 DIAGNOSIS AND TESTING..................................................................................................................................................................... 393 REAR WINDOW DEFOGGER SWITCH........................................................................................................................................................... 393 IN-VEHICLE TESTING................................................................................................................................................................ 393 BENCH TESTING..................................................................................................................................................................... 394 REAR WINDOW DEFOGGER GRID..................................................................................................................................................................... 394 DIAGNOSIS AND TESTING..................................................................................................................................................................... 394 GRID LINES............................................................................................................................................................................ 394 STANDARD PROCEDURE........................................................................................................................................................................ 395 GRID LINE AND TERMINAL REPAIR......................................................................................................................................................... 395 REAR WINDOW DEFOGGER GRID LINES....................................................................................................................................................... 395 8h-HORN............................................................................................................................................................................................... 397 HORN SYSTEM....................................................................................................................................................................................... 397 DESCRIPTION................................................................................................................................................................................... 397 OPERATION..................................................................................................................................................................................... 397 DIAGNOSIS AND TESTING - HORN SYSTEM........................................................................................................................................................... 397 HORN.............................................................................................................................................................................................. 399 DIAGNOSIS AND TESTING - HORN.................................................................................................................................................................. 399 REMOVAL....................................................................................................................................................................................... 399 INSTALLATION.................................................................................................................................................................................. 399 HORN RELAY........................................................................................................................................................................................ 399 DIAGNOSIS AND TESTING - HORN RELAY............................................................................................................................................................ 399 REMOVAL....................................................................................................................................................................................... 400 INSTALLATION.................................................................................................................................................................................. 400 HORN SWITCH....................................................................................................................................................................................... 400 DESCRIPTION................................................................................................................................................................................... 400 OPERATION..................................................................................................................................................................................... 400 REMOVAL....................................................................................................................................................................................... 400 8i-IGNITION CONTROL................................................................................................................................................................................... 401 IGNITION CONTROL.................................................................................................................................................................................. 401 DESCRIPTION - IGNITION SYSTEM................................................................................................................................................................. 401 OPERATION - IGNITION SYSTEM................................................................................................................................................................... 401 SPECIFICATIONS................................................................................................................................................................................ 402 FIRING ORDER—1.6/2.0L..................................................................................................................................................................... 402 TORQUE.................................................................................................................................................................................... 402 IGNITION COILS............................................................................................................................................................................ 403 SPARK PLUGS............................................................................................................................................................................... 403 SPARK PLUG CABLE RESISTANCE............................................................................................................................................................... 403 SPECIAL TOOLS - EXPORT........................................................................................................................................................................ 403 AUTO SHUT DOWN RELAY.............................................................................................................................................................................. 403 DESCRIPTION................................................................................................................................................................................... 403 OPERATION..................................................................................................................................................................................... 403 CAMSHAFT POSITION SENSOR.......................................................................................................................................................................... 404 DESCRIPTION................................................................................................................................................................................... 404 OPERATION..................................................................................................................................................................................... 404 REMOVAL....................................................................................................................................................................................... 405 REMOVAL - 2.0/2.4L........................................................................................................................................................................ 405 REMOVAL - 1.6L............................................................................................................................................................................ 406 INSTALLATION.................................................................................................................................................................................. 406 INSTALLATION - 2.0/2.4L................................................................................................................................................................... 406 INSTALLATION - 1.6L....................................................................................................................................................................... 406 IGNITION COIL..................................................................................................................................................................................... 406 DESCRIPTION................................................................................................................................................................................... 406 OPERATION..................................................................................................................................................................................... 406 REMOVAL....................................................................................................................................................................................... 407 REMOVAL - 1.6L............................................................................................................................................................................ 407 REMOVAL - 2.0/2.4L........................................................................................................................................................................ 408 REMOVAL - 2.4L TURBO...................................................................................................................................................................... 409 INSTALLATION.................................................................................................................................................................................. 410 INSTALLATION - 1.6L....................................................................................................................................................................... 410 INSTALLATION- 2.0/2.4L.................................................................................................................................................................... 410 INSTALLATION - 2.4L TURBO................................................................................................................................................................. 411 IGNITION COIL CAPACITOR........................................................................................................................................................................... 411 REMOVAL - 2.4L TURBO.......................................................................................................................................................................... 411 INSTALLATION - 2.4L TURBO..................................................................................................................................................................... 411 KNOCK SENSOR...................................................................................................................................................................................... 411 DESCRIPTION................................................................................................................................................................................... 411 OPERATION..................................................................................................................................................................................... 411 REMOVAL....................................................................................................................................................................................... 412 REMOVAL - 1.6L............................................................................................................................................................................ 412 REMOVAL - 2.0/2.4L........................................................................................................................................................................ 412 INSTALLATION.................................................................................................................................................................................. 412 INSTALLATION - 1.6L....................................................................................................................................................................... 412 INSTALLATION - 2.0/2.4L................................................................................................................................................................... 412 SPARK PLUG........................................................................................................................................................................................ 413 REMOVAL....................................................................................................................................................................................... 413 REMOVAL - 1.6L............................................................................................................................................................................ 413 REMOVAL - 2.0/2.4L........................................................................................................................................................................ 413 REMOVAL - 2.4L TURBO...................................................................................................................................................................... 413 INSTALLATION.................................................................................................................................................................................. 413 INSTALLATION - 1.6L....................................................................................................................................................................... 413 INSTALLATION - 2.0/2.4L................................................................................................................................................................... 414 INSTALLATION - 2.4L TURBO................................................................................................................................................................. 414 SPARK PLUG CABLE.................................................................................................................................................................................. 414 DESCRIPTION................................................................................................................................................................................... 414 REMOVAL....................................................................................................................................................................................... 415 REMOVAL - 1.6L............................................................................................................................................................................ 415 REMOVAL - 2.0/2.4L........................................................................................................................................................................ 415 INSTALLATION.................................................................................................................................................................................. 415 INSTALLATION - 1.6L....................................................................................................................................................................... 415 INSTALLATION - 2.0/2.4L................................................................................................................................................................... 415 8j-INSTRUMENT CLUSTER................................................................................................................................................................................. 417 INSTRUMENT CLUSTER................................................................................................................................................................................ 417 DESCRIPTION................................................................................................................................................................................... 417 CHIME..................................................................................................................................................................................... 417 KEY IN IGNITION SWITCH.................................................................................................................................................................... 417 INSTRUMENT CLUSTER - EXPORT............................................................................................................................................................... 418 OPERATION..................................................................................................................................................................................... 418 INSTRUMENT CLUSTER - EXPORT............................................................................................................................................................... 418 DIAGNOSIS AND TESTING......................................................................................................................................................................... 419 DIAGNOSIS AND TESTING - INSTRUMENT CLUSTER WARNING/INDICATOR LAMPS........................................................................................................................ 419 DIAGNOSIS AND TESTING - MULTIPLE/INDIVIDUAL GAUGES INOPERATIVE............................................................................................................................ 419 STANDARD PROCEDURE - SELF-DIAGNOSTICS......................................................................................................................................................... 420 REMOVAL....................................................................................................................................................................................... 420 INSTALLATION.................................................................................................................................................................................. 421 CLUSTER MASK/LENS................................................................................................................................................................................. 421 REMOVAL....................................................................................................................................................................................... 421 INSTALLATION.................................................................................................................................................................................. 421 8l-LAMPS.............................................................................................................................................................................................. 423 LAMPS/LIGHTTING - EXTERIOR........................................................................................................................................................................ 423 LAMPS/LIGHTING - EXTERIOR..................................................................................................................................................................... 424 SPECIFICATIONS............................................................................................................................................................................ 424 EXTERIOR LAMPS........................................................................................................................................................................ 424 BACK-UP LAMP.................................................................................................................................................................................. 424 REMOVAL................................................................................................................................................................................... 424 INSTALLATION.............................................................................................................................................................................. 424 BACK-UP LAMP UNIT............................................................................................................................................................................. 425 REMOVAL................................................................................................................................................................................... 425 INSTALLATION.............................................................................................................................................................................. 425 BRAKE LAMP SWITCH............................................................................................................................................................................. 425 DESCRIPTION............................................................................................................................................................................... 425 OPERATION................................................................................................................................................................................. 426 DIAGNOSIS AND TESTING - BRAKE LAMP SWITCH................................................................................................................................................. 426 REMOVAL................................................................................................................................................................................... 426 INSTALLATION.............................................................................................................................................................................. 427 CENTER HIGH MOUNTED STOP LAMP................................................................................................................................................................. 427 REMOVAL................................................................................................................................................................................... 427 INSTALLATION.............................................................................................................................................................................. 427 CENTER HIGH MOUNTED STOP LAMP UNIT............................................................................................................................................................ 427 REMOVAL................................................................................................................................................................................... 427 INSTALLATION.............................................................................................................................................................................. 428 COMBINATION FLASHER........................................................................................................................................................................... 428 DESCRIPTION............................................................................................................................................................................... 428 OPERATION................................................................................................................................................................................. 428 REMOVAL................................................................................................................................................................................... 428 INSTALLATION.............................................................................................................................................................................. 428 DAYTIME RUNNING LAMP MODULE................................................................................................................................................................... 429 DESCRIPTION............................................................................................................................................................................... 429 OPERATION................................................................................................................................................................................. 429 FOG LAMP...................................................................................................................................................................................... 429 DIAGNOSIS AND TESTING - FOG LAMP.......................................................................................................................................................... 429 REMOVAL................................................................................................................................................................................... 430 INSTALLATION.............................................................................................................................................................................. 430 FOG LAMP UNIT................................................................................................................................................................................. 430 STANDARD PROCEDURE - FOG LAMP UNIT ALIGNMENT.............................................................................................................................................. 430 REMOVAL................................................................................................................................................................................... 430 INSTALLATION.............................................................................................................................................................................. 430 FRONT POSITION LAMP - EXPORT.................................................................................................................................................................. 431 DESCRIPTION............................................................................................................................................................................... 431 OPERATION................................................................................................................................................................................. 431 DIAGNOSIS AND TESTING - FRONT POSITION LAMP - EXPORT...................................................................................................................................... 431 REMOVAL................................................................................................................................................................................... 432 INSTALLATION.............................................................................................................................................................................. 432 HEADLAMP...................................................................................................................................................................................... 432 DIAGNOSIS AND TESTING - HEADLAMPS......................................................................................................................................................... 432 REMOVAL................................................................................................................................................................................... 433 INSTALLATION.............................................................................................................................................................................. 433 HEADLAMP UNIT................................................................................................................................................................................. 434 STANDARD PROCEDURE........................................................................................................................................................................ 434 STANDARD PROCEDURE - HEADLAMP UNIT ALIGNMENT.......................................................................................................................................... 434 ALIGNMENT SCREEN PREPARATION...................................................................................................................................................... 434 HEADLAMP UNIT ALIGNMENT........................................................................................................................................................... 435 STANDARD PROCEDURE - HEADLAMP UNIT ALIGNMENT - EXPORT................................................................................................................................. 435 VEHICLE PREPARATION FOR HEADLAMP UNIT ALIGNMENT................................................................................................................................... 435 ALIGNMENT SCREEN PREPARATION...................................................................................................................................................... 435 HEADLAMP UNIT ALIGNMENT........................................................................................................................................................... 435 REMOVAL................................................................................................................................................................................... 435 INSTALLATION.............................................................................................................................................................................. 437 HEADLAMP LEVELING MOTOR - EXPORT.............................................................................................................................................................. 437 DESCRIPTION............................................................................................................................................................................... 437 OPERATION................................................................................................................................................................................. 438 DIAGNOSIS AND TESTING - HEADLAMP LEVELING MOTOR - EXPORT.................................................................................................................................. 438 REMOVAL................................................................................................................................................................................... 438 INSTALLATION.............................................................................................................................................................................. 439 HEADLAMP LEVELING SWITCH - EXPORT............................................................................................................................................................. 439 DESCRIPTION............................................................................................................................................................................... 439 OPERATION................................................................................................................................................................................. 439 DIAGNOSIS AND TESTING - HEADLAMP LEVELING SWITCH - EXPORT................................................................................................................................. 439 REMOVAL................................................................................................................................................................................... 439 INSTALLATION.............................................................................................................................................................................. 440 HEADLAMP SWITCH............................................................................................................................................................................... 440 DESCRIPTION............................................................................................................................................................................... 440 OPERATION................................................................................................................................................................................. 440 LICENSE PLATE LAMP............................................................................................................................................................................ 440 REMOVAL................................................................................................................................................................................... 440 INSTALLATION.............................................................................................................................................................................. 440 LICENSE PLATE LAMP UNIT....................................................................................................................................................................... 441 REMOVAL................................................................................................................................................................................... 441 INSTALLATION.............................................................................................................................................................................. 441 MULTI-FUNCTION SWITCH......................................................................................................................................................................... 441 DESCRIPTION............................................................................................................................................................................... 441 MULTI-FUNCTION SWITCH................................................................................................................................................................. 441 HAZARD WARNING SYSTEM................................................................................................................................................................. 442 OPERATION................................................................................................................................................................................. 442 MULTI-FUNCTION SWITCH................................................................................................................................................................. 442 HAZARD WARNING SYSTEM................................................................................................................................................................. 442 DIAGNOSIS AND TESTING - MULTI-FUNCTION SWITCH............................................................................................................................................. 442 FLASHER DIAGNOSIS..................................................................................................................................................................... 442 SWITCH DIAGNOSIS...................................................................................................................................................................... 444 REMOVAL................................................................................................................................................................................... 446 INSTALLATION.............................................................................................................................................................................. 446 PARK/TURN SIGNAL LAMP......................................................................................................................................................................... 447 REMOVAL................................................................................................................................................................................... 447 INSTALLATION.............................................................................................................................................................................. 447 REAR FOG LAMP SWITCH - EXPORT................................................................................................................................................................. 447 DESCRIPTION............................................................................................................................................................................... 447 OPERATION................................................................................................................................................................................. 447 SIDE REPEATER LAMP - EXPORT................................................................................................................................................................... 448 DIAGNOSIS AND TESTING - SIDE REPEATER LAMP................................................................................................................................................ 448 REMOVAL................................................................................................................................................................................... 448 INSTALLATION.............................................................................................................................................................................. 448 SIDE REPEATER LAMP UNIT - EXPORT.............................................................................................................................................................. 448 REMOVAL................................................................................................................................................................................... 448 INSTALLATION.............................................................................................................................................................................. 448 TAIL LAMP..................................................................................................................................................................................... 448 REMOVAL................................................................................................................................................................................... 448 INSTALLATION.............................................................................................................................................................................. 448 TAIL LAMP UNIT................................................................................................................................................................................ 449 REMOVAL................................................................................................................................................................................... 449 INSTALLATION.............................................................................................................................................................................. 449 LAMPS/LIGHTING - INTERIOR......................................................................................................................................................................... 450 LAMPS/LIGHTING - INTERIOR..................................................................................................................................................................... 450 SPECIFICATIONS............................................................................................................................................................................ 450 INTERIOR LAMPS........................................................................................................................................................................ 450 CENTER CONSOLE FLOOD LAMP..................................................................................................................................................................... 451 REMOVAL................................................................................................................................................................................... 451 INSTALLATION.............................................................................................................................................................................. 451 CENTER CONSOLE FLOOD LAMP HOUSING............................................................................................................................................................. 451 REMOVAL................................................................................................................................................................................... 451 INSTALLATION.............................................................................................................................................................................. 451 COURTESY/READING LAMP......................................................................................................................................................................... 452 REMOVAL................................................................................................................................................................................... 452 INSTALLATION.............................................................................................................................................................................. 452 DOME LAMP..................................................................................................................................................................................... 452 REMOVAL................................................................................................................................................................................... 452 INSTALLATION.............................................................................................................................................................................. 452 DOME LAMP UNIT................................................................................................................................................................................ 452 REMOVAL................................................................................................................................................................................... 452 INSTALLATION.............................................................................................................................................................................. 452 DOME LAMP WITH INTRUSION SENSOR - EXPORT...................................................................................................................................................... 452 REMOVAL................................................................................................................................................................................... 452 INSTALLATION.............................................................................................................................................................................. 452 DOME LAMP UNIT WITH INTRUSION SENSOR - EXPORT................................................................................................................................................. 452 REMOVAL................................................................................................................................................................................... 452 INSTALLATION.............................................................................................................................................................................. 453 CLUSTER ILLUMINATION LAMPS.................................................................................................................................................................... 453 REMOVAL................................................................................................................................................................................... 453 INSTALLATION.............................................................................................................................................................................. 454 REAR CARGO LAMP............................................................................................................................................................................... 454 REMOVAL................................................................................................................................................................................... 454 INSTALLATION.............................................................................................................................................................................. 454 REAR CARGO LAMP UNIT.......................................................................................................................................................................... 454 REMOVAL................................................................................................................................................................................... 454 INSTALLATION.............................................................................................................................................................................. 454 TRANS RANGE INDICATOR ILLUMINATION............................................................................................................................................................ 455 REMOVAL................................................................................................................................................................................... 455 INSTALLATION.............................................................................................................................................................................. 455 VANITY LAMP................................................................................................................................................................................... 455 REMOVAL................................................................................................................................................................................... 455 INSTALLATION.............................................................................................................................................................................. 455 8m-MESSAGE SYSTEMS.................................................................................................................................................................................... 457 OVERHEAD CONSOLE.................................................................................................................................................................................. 457 DESCRIPTION................................................................................................................................................................................... 457 OPERATION..................................................................................................................................................................................... 457 AUTOMATIC COMPASS CALIBRATION............................................................................................................................................................. 458 MANUAL COMPASS CALIBRATION................................................................................................................................................................ 458 ZONE VARIANCE............................................................................................................................................................................. 458 OUTSIDE TEMPERATURE....................................................................................................................................................................... 458 STANDARD PROCEDURE............................................................................................................................................................................ 458 STANDARD PROCEDURE - COMPASS CALIBRATION.................................................................................................................................................. 458 STANDARD PROCEDURE - COMPASS VARIATION ADJUSTMENT......................................................................................................................................... 459 PROGRAMMING ZONE VARIATION............................................................................................................................................................ 459 STANDARD PROCEDURE - COMPASS DEMAGNETIZING................................................................................................................................................ 460 REMOVAL....................................................................................................................................................................................... 460 INSTALLATION.................................................................................................................................................................................. 461 SPECIAL TOOLS................................................................................................................................................................................. 461 OVERHEAD CONSOLE.......................................................................................................................................................................... 461 AMBIENT TEMP SENSOR............................................................................................................................................................................... 461 DESCRIPTION................................................................................................................................................................................... 461 OPERATION..................................................................................................................................................................................... 461 DIAGNOSIS AND TESTING - AMBIENT TEMPERATURE SENSOR............................................................................................................................................ 461 SENSOR TESTING............................................................................................................................................................................ 461 SENSOR CIRCUIT TESTING.................................................................................................................................................................... 462 REMOVAL....................................................................................................................................................................................... 462 INSTALLATION.................................................................................................................................................................................. 462 8n-POWER SYSTEMS...................................................................................................................................................................................... 463 POWER LOCKS....................................................................................................................................................................................... 463 POWER LOCKS................................................................................................................................................................................... 463 DESCRIPTION............................................................................................................................................................................... 463 POWER LOCKS........................................................................................................................................................................... 463 CHILD PROTECTION LOCKS................................................................................................................................................................ 464 DOOR LOCK INHIBIT..................................................................................................................................................................... 464 REMOTE KEYLESS ENTRY.................................................................................................................................................................. 464 OPERATION................................................................................................................................................................................. 464 POWER LOCKS........................................................................................................................................................................... 464 CENTRAL LOCKING/UNLOCKING (IF EQUIPPED)0 - 4 PT (Continued)....................................................................................................................... 464 REMOTE KEYLESS ENTRY.................................................................................................................................................................. 464 ROLLING DOOR LOCKS.................................................................................................................................................................... 464 DIAGNOSIS AND TESTING - POWER LOCKS....................................................................................................................................................... 465 STANDARD PROCEDURE........................................................................................................................................................................ 465 STANDARD PROCEDURE - DOUBLE ACTIVATION UNLOCK......................................................................................................................................... 465 DRB lll PROGRAMMING............................................................................................................................................................... 465 CUSTOMER PROGRAMMING.............................................................................................................................................................. 465 STANDARD PROCEDURE - ROLLING DOOR LOCKS............................................................................................................................................... 465 DRB lll PROGRAMMING............................................................................................................................................................... 465 CUSTOMER PROGRAMMING.............................................................................................................................................................. 465 DOOR LOCK SWITCH.............................................................................................................................................................................. 465 DIAGNOSIS AND TESTING - DOOR LOCK SWITCH.................................................................................................................................................. 465 REMOVAL................................................................................................................................................................................... 466 INSTALLATION.............................................................................................................................................................................. 466 DOOR LOCK MOTOR............................................................................................................................................................................... 466 DESCRIPTION............................................................................................................................................................................... 466 OPERATION................................................................................................................................................................................. 466 DIAGNOSIS AND TESTING - DOOR LOCK MOTOR................................................................................................................................................... 466 LIFTGATE LOCK MOTOR........................................................................................................................................................................... 467 REMOVAL................................................................................................................................................................................... 467 INSTALLATION.............................................................................................................................................................................. 467 REMOTE KEYLESS ENTRY MODULE................................................................................................................................................................... 467 DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY MODULE....................................................................................................................................... 467 REMOVAL................................................................................................................................................................................... 467 INSTALLATION.............................................................................................................................................................................. 467 REMOTE KEYLESS ENTRY TRANSMITTER.............................................................................................................................................................. 468 DESCRIPTION............................................................................................................................................................................... 468 OPERATION................................................................................................................................................................................. 468 DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY TRANSMITTER.................................................................................................................................. 468 STANDARD PROCEDURE........................................................................................................................................................................ 468 STANDARD PROCEDURE - HORN CHIRP TOGGLE................................................................................................................................................ 468 DRB lll PROGRAMMING............................................................................................................................................................... 468 CUSTOMER PROGRAMMING.............................................................................................................................................................. 468 STANDARD PROCEDURE - TRANSMITTER PROGRAMING........................................................................................................................................... 469 DRB lll PROGRAMMING............................................................................................................................................................... 469 CUSTOMER PROGRAMMING.............................................................................................................................................................. 469 STANDARD PROCEDURE - RKE TRANSMITTER BATTERIES........................................................................................................................................ 469 SPECIFICATIONS - TRANSMITTER RANGE........................................................................................................................................................ 469 POWER MIRRORS..................................................................................................................................................................................... 470 POWER MIRRORS................................................................................................................................................................................. 470 DESCRIPTION............................................................................................................................................................................... 470 OPERATION................................................................................................................................................................................. 470 DIAGNOSIS AND TESTING - POWER MIRRORS..................................................................................................................................................... 470 WIRING VOLTAGE TEST (LHD)............................................................................................................................................................. 470 POWER MIRROR MOTOR TEST (LHD)......................................................................................................................................................... 470 POWER MIRROR SWITCH - LHD..................................................................................................................................................................... 471 DIAGNOSIS AND TESTING - POWER MIRROR SWITCH - LHD......................................................................................................................................... 471 REMOVAL................................................................................................................................................................................... 471 INSTALLATION.............................................................................................................................................................................. 471 POWER FOLDAWAY MIRROR SWITCH - RHD............................................................................................................................................................ 472 DIAGNOSIS AND TESTING - POWER FOLDAWAY MIRROR SWITCH - RHD................................................................................................................................ 472 EXTENDED MIRROR SWITCH CIRCUIT TEST................................................................................................................................................... 472 RETRACTED MIRROR SWITCH CIRCUIT TEST.................................................................................................................................................. 473 REMOVAL................................................................................................................................................................................... 473 INSTALLATION.............................................................................................................................................................................. 473 POWER SEAT SYSTEM................................................................................................................................................................................. 474 POWER SEAT SYSTEM............................................................................................................................................................................. 474 DESCRIPTION............................................................................................................................................................................... 474 OPERATION................................................................................................................................................................................. 474 DIAGNOSIS AND TESTING - POWER SEAT SYSTEM................................................................................................................................................. 475 DRIVER SEAT SWITCH............................................................................................................................................................................ 475 DESCRIPTION............................................................................................................................................................................... 475 OPERATION................................................................................................................................................................................. 475 DIAGNOSIS AND TESTING - DRIVER SEAT SWITCH................................................................................................................................................ 475 REMOVAL................................................................................................................................................................................... 476 INSTALLATION.............................................................................................................................................................................. 476 POWER SEAT TRACK.............................................................................................................................................................................. 476 DESCRIPTION............................................................................................................................................................................... 476 OPERATION................................................................................................................................................................................. 476 DIAGNOSIS AND TESTING - POWER SEAT TRACK.................................................................................................................................................. 476 REMOVAL................................................................................................................................................................................... 477 INSTALLATION.............................................................................................................................................................................. 477 LUMBAR........................................................................................................................................................................................ 478 DESCRIPTION............................................................................................................................................................................... 478 OPERATION................................................................................................................................................................................. 478 REMOVAL................................................................................................................................................................................... 478 INSTALLATION.............................................................................................................................................................................. 478 POWER WINDOWS..................................................................................................................................................................................... 479 POWER WINDOWS................................................................................................................................................................................. 479 DESCRIPTION............................................................................................................................................................................... 479 OPERATION................................................................................................................................................................................. 479 DIAGNOSIS AND TESTING - POWER WINDOWS..................................................................................................................................................... 479 WIRING VOLTAGE TEST................................................................................................................................................................... 479 POWER WINDOW MOTOR TEST............................................................................................................................................................... 479 POWER WINDOW SWITCH........................................................................................................................................................................... 480 DIAGNOSIS AND TESTING - POWER WINDOW SWITCH............................................................................................................................................... 480 REMOVAL................................................................................................................................................................................... 481 FRONT................................................................................................................................................................................. 481 REAR.................................................................................................................................................................................. 481 INSTALLATION.............................................................................................................................................................................. 481 FRONT................................................................................................................................................................................. 481 REAR.................................................................................................................................................................................. 481 WINDOW MOTOR.................................................................................................................................................................................. 481 REMOVAL................................................................................................................................................................................... 481 INSTALLATION.............................................................................................................................................................................. 481 8o-RESTRAINTS......................................................................................................................................................................................... 483 RESTRAINTS........................................................................................................................................................................................ 483 DESCRIPTION................................................................................................................................................................................... 483 FRONT AIRBAG SYSTEM....................................................................................................................................................................... 483 SIDE IMPACT AIRBAG SYSTEM................................................................................................................................................................. 484 BELT TENSIONER SYSTEM..................................................................................................................................................................... 484 OPERATION..................................................................................................................................................................................... 484 FRONT AIRBAG SYSTEM....................................................................................................................................................................... 484 SIDE IMPACT AIRBAG SYSTEM................................................................................................................................................................. 484 BELT TENSIONER SYSTEM..................................................................................................................................................................... 485 WARNING....................................................................................................................................................................................... 485 FRONT AIRBAG SYSTEM....................................................................................................................................................................... 485 SIDE IMPACT AIRBAG SYSTEM................................................................................................................................................................. 486 DIAGNOSIS AND TESTING - AIRBAG SYSTEM......................................................................................................................................................... 486 STANDARD PROCEDURE............................................................................................................................................................................ 486 STANDARD PROCEDURE - HANDLING AIRBAGS..................................................................................................................................................... 486 DEPLOYED AIRBAG....................................................................................................................................................................... 486 UNDEPLOYED AIRBAG..................................................................................................................................................................... 486 STANDARD PROCEDURE - SERVICE AFTER AN AIRBAG DEPLOYMENT................................................................................................................................... 487 DRIVER AIRBAG......................................................................................................................................................................... 487 PASSENGER AIRBAG...................................................................................................................................................................... 487 SEAT AIRBAG........................................................................................................................................................................... 487 SEAT BELT TENSIONERS.................................................................................................................................................................. 487 CLEAN UP PROCEDURE.................................................................................................................................................................... 487 CLOCK SPRING...................................................................................................................................................................................... 487 DESCRIPTION................................................................................................................................................................................... 487 OPERATION..................................................................................................................................................................................... 488 STANDARD PROCEDURE - CLOCK SPRING CENTERING................................................................................................................................................... 488 REMOVAL....................................................................................................................................................................................... 488 INSTALLATION.................................................................................................................................................................................. 489 DRIVER AIRBAG..................................................................................................................................................................................... 489 DESCRIPTION................................................................................................................................................................................... 489 OPERATION..................................................................................................................................................................................... 490 REMOVAL....................................................................................................................................................................................... 490 INSTALLATION.................................................................................................................................................................................. 491 DRIVER AIRBAG COVER............................................................................................................................................................................... 491 REMOVAL....................................................................................................................................................................................... 491 INSTALLATION.................................................................................................................................................................................. 492 FRONT SEAT BELT & RETRACTOR....................................................................................................................................................................... 493 REMOVAL....................................................................................................................................................................................... 493 INSTALLATION.................................................................................................................................................................................. 493 FRONT SEAT BELT BUCKLE............................................................................................................................................................................ 493 REMOVAL....................................................................................................................................................................................... 493 INSTALLATION.................................................................................................................................................................................. 493 FRONT SEAT BELT HEIGHT ADJUSTER................................................................................................................................................................... 494 REMOVAL....................................................................................................................................................................................... 494 INSTALLATION.................................................................................................................................................................................. 494 OCCUPANT RESTRAINT CONTROLLER..................................................................................................................................................................... 494 DESCRIPTION................................................................................................................................................................................... 494 OPERATION..................................................................................................................................................................................... 494 REMOVAL....................................................................................................................................................................................... 495 INSTALLATION.................................................................................................................................................................................. 495 PASSENGER AIRBAG.................................................................................................................................................................................. 495 DESCRIPTION................................................................................................................................................................................... 495 OPERATION..................................................................................................................................................................................... 496 REMOVAL....................................................................................................................................................................................... 496 NON-DEPLOYED AIRBAG....................................................................................................................................................................... 496 DEPLOYED AIRBAG........................................................................................................................................................................... 496 INSTALLATION.................................................................................................................................................................................. 497 PASSENGER AIRBAG COVER............................................................................................................................................................................ 497 REMOVAL....................................................................................................................................................................................... 497 INSTALLATION.................................................................................................................................................................................. 497 REAR CENTER SEAT BELT & RETRACTOR................................................................................................................................................................. 498 REMOVAL....................................................................................................................................................................................... 498 INSTALLATION.................................................................................................................................................................................. 498 REAR SEAT BELT & RETRACTOR........................................................................................................................................................................ 498 REMOVAL....................................................................................................................................................................................... 498 INSTALLATION.................................................................................................................................................................................. 498 REAR SEAT BELT BUCKLE............................................................................................................................................................................. 498 REMOVAL....................................................................................................................................................................................... 498 SEAT AIRBAG....................................................................................................................................................................................... 498 DESCRIPTION................................................................................................................................................................................... 498 OPERATION..................................................................................................................................................................................... 499 REMOVAL....................................................................................................................................................................................... 499 DEPLOYED SEAT AIRBAG...................................................................................................................................................................... 499 NONDEPLOYED SEAT AIRBAG................................................................................................................................................................... 499 INSTALLATION.................................................................................................................................................................................. 500 DEPLOYED SEAT AIRBAG...................................................................................................................................................................... 500 NONDEPLOYED SEAT AIRBAG................................................................................................................................................................... 500 SIDE IMPACT AIRBAG CONTROL MODULE................................................................................................................................................................. 501 DESCRIPTION................................................................................................................................................................................... 501 OPERATION..................................................................................................................................................................................... 501 REMOVAL....................................................................................................................................................................................... 501 INSTALLATION.................................................................................................................................................................................. 502 8p-SPEED CONTROL...................................................................................................................................................................................... 503 SPEED CONTROL..................................................................................................................................................................................... 503 DESCRIPTION................................................................................................................................................................................... 503 OPERATION..................................................................................................................................................................................... 504 OPERATION................................................................................................................................................................................. 504 OPERATION - INTERACTIVE SPEED CONTROL (4 Speed EATX Only)................................................................................................................................. 504 CLIMBING A GRADE...................................................................................................................................................................... 504 GRADE HUNTING......................................................................................................................................................................... 505 AUTOMATIC SPEED CONTROL OVERSPEED REDUCTION........................................................................................................................................... 505 OPERATION - CHECKING FOR DIAGNOSTIC CODES................................................................................................................................................. 505 DIAGNOSIS AND TESTING - ROAD TEST............................................................................................................................................................. 505 CABLE............................................................................................................................................................................................. 506 DESCRIPTION................................................................................................................................................................................... 506 OPERATION..................................................................................................................................................................................... 506 REMOVAL....................................................................................................................................................................................... 506 REMOVAL................................................................................................................................................................................... 506 REMOVAL - 2.4L TURBO...................................................................................................................................................................... 507 INSTALLATION.................................................................................................................................................................................. 507 INSTALLATION.............................................................................................................................................................................. 507 INSTALLATION - 2.4L TURBO................................................................................................................................................................. 508 SERVO............................................................................................................................................................................................. 508 DESCRIPTION................................................................................................................................................................................... 508 OPERATION..................................................................................................................................................................................... 509 REMOVAL....................................................................................................................................................................................... 509 REMOVAL................................................................................................................................................................................... 509 REMOVAL - 2.4L TURBO...................................................................................................................................................................... 509 INSTALLATION.................................................................................................................................................................................. 510 INSTALLATION.............................................................................................................................................................................. 510 INSTALLATION - 2.4L TURBO................................................................................................................................................................. 510 SWITCH............................................................................................................................................................................................ 510 REMOVAL....................................................................................................................................................................................... 510 INSTALLATION.................................................................................................................................................................................. 510 VACUUM RESERVOIR.................................................................................................................................................................................. 511 DESCRIPTION................................................................................................................................................................................... 511 OPERATION..................................................................................................................................................................................... 511 REMOVAL....................................................................................................................................................................................... 511 INSTALLATION.................................................................................................................................................................................. 512 8q-VEHICLE THEFT SECURITY............................................................................................................................................................................. 513 VEHICLE THEFT SECURITY............................................................................................................................................................................ 513 DESCRIPTION................................................................................................................................................................................... 513 VEHICLE THEFT SECURITY SYSTEM............................................................................................................................................................. 513 VEHICLE THEFT SECURITY SYSTEM - EXPORT.................................................................................................................................................... 513 SENTRY KEY IMMOBILIZER SYSTEM............................................................................................................................................................. 513 OPERATION..................................................................................................................................................................................... 514 VEHICLE THEFT SECURITY SYSTEM............................................................................................................................................................. 514 TRIGGERING THE VTSS....................................................................................................................................................................... 514 VEHICLE THEFT SECURITY SYSTEM - EXPORT.................................................................................................................................................... 514 SENTRY KEY IMMOBILIZER SYSTEM............................................................................................................................................................. 514 DIAGNOSIS AND TESTING - SENTRY KEY IMMOBILIZER SYSTEM......................................................................................................................................... 514 GENERAL TROUBLESHOOTING TIPS.............................................................................................................................................................. 515 STANDARD PROCEDURE............................................................................................................................................................................ 515 STANDARD PROCEDURE - RKE/VTSS CONFIGURING A NEW MODULE.................................................................................................................................... 515 STANDARD PROCEDURE - SENTRY KEY IMMOBILIZER SYSTEM INITIALIZATION......................................................................................................................... 515 DOOR CYLINDER LOCK SWITCH......................................................................................................................................................................... 516 REMOVAL....................................................................................................................................................................................... 516 INSTALLATION.................................................................................................................................................................................. 516 HOOD AJAR SWITCH - EXPORT......................................................................................................................................................................... 517 REMOVAL....................................................................................................................................................................................... 517 INSTALLATION.................................................................................................................................................................................. 517 INTRUSION SENSOR - EXPORT......................................................................................................................................................................... 517 DESCRIPTION................................................................................................................................................................................... 517 OPERATION..................................................................................................................................................................................... 517 DISARMING THE INTRUSION SENSOR............................................................................................................................................................ 517 REMOVAL....................................................................................................................................................................................... 517 INSTALLATION.................................................................................................................................................................................. 518 LIFTGATE CYLINDER LOCK SWITCH..................................................................................................................................................................... 518 REMOVAL....................................................................................................................................................................................... 518 INSTALLATION.................................................................................................................................................................................. 518 SKIS INDICATOR LAMP............................................................................................................................................................................... 519 DESCRIPTION................................................................................................................................................................................... 519 OPERATION..................................................................................................................................................................................... 519 SIREN - EXPORT.................................................................................................................................................................................... 519 DESCRIPTION................................................................................................................................................................................... 519 OPERATION..................................................................................................................................................................................... 519 REMOVAL....................................................................................................................................................................................... 519 INSTALLATION.................................................................................................................................................................................. 520 TRANSPONDER KEY................................................................................................................................................................................... 520 DESCRIPTION................................................................................................................................................................................... 520 OPERATION..................................................................................................................................................................................... 520 STANDARD PROCEDURE - TRANSPONDER PROGRAMMING.................................................................................................................................................. 520 USING A DRB III SCAN TOOL................................................................................................................................................................. 520 “CUSTOMER LEARN” MODE..................................................................................................................................................................... 521 8r-WIPERS/WASHERS..................................................................................................................................................................................... 523 WIPERS/WASHERS.................................................................................................................................................................................... 523 DESCRIPTION................................................................................................................................................................................... 523 FRONT WINDSHIELD WIPER SYSTEM............................................................................................................................................................. 523 FRONT WINDSHIELD WASHER SYSTEM............................................................................................................................................................ 524 REAR WINDSHIELD WIPER SYSTEM.............................................................................................................................................................. 524 REAR WINDSHIELD WASHER SYSTEM............................................................................................................................................................. 524 OPERATION..................................................................................................................................................................................... 525 FRONT WINDSHIELD WIPER SYSTEM............................................................................................................................................................. 525 FRONT WINDSHIELD WASHER SYSTEM............................................................................................................................................................ 525 REAR WINDSHIELD WIPER SYSTEM.............................................................................................................................................................. 525 REAR WINDSHIELD WASHER SYSTEM............................................................................................................................................................. 525 DIAGNOSIS AND TESTING......................................................................................................................................................................... 525 DIAGNOSIS AND TESTING - FRONT WIPER CONDITIONS............................................................................................................................................ 525 MOTOR WILL NOT OPERATE ALL SWITCH POSITIONS........................................................................................................................................... 525 MOTOR OPERATES SLOWLY AT ALL SPEEDS................................................................................................................................................... 526 WIPERS RUN AT HIGH SPEED WITH SWITCH IN LOW SPEED POSITION OR WIPERS RUN AT LOW SPEED WITH SWITCH IN HIGH SPEED POSITION.............................................................. 526 WIPERS WILL OPERATE CONTINUOUSLY WITH THE SWITCH IN THE INTERMITTENT POSITION - WHEN WIPER SWITCH IS TURNED OFF, WIPERS STOP WHEREVER THEY ARE WITHOUT RETURNING TO PARK POSITION..... 527 WIPERS DO NOT OPERATE WHEN WASHER MOTOR IS ENGAGED (PULSE WIPE) OR WIPERS DO OPERATE IN INTERMITTENT POSITION......................................................................... 527 DIAGNOSIS AND TESTING - REAR WIPER SYSTEM................................................................................................................................................. 527 DIAGNOSIS AND TESTING - WASHER SYSTEM..................................................................................................................................................... 527 FRONT WASHER NOZZLE............................................................................................................................................................................... 528 REMOVAL....................................................................................................................................................................................... 528 INSTALLATION.................................................................................................................................................................................. 528 FRONT WIPER ARMS.................................................................................................................................................................................. 528 REMOVAL....................................................................................................................................................................................... 528 INSTALLATION.................................................................................................................................................................................. 529 ADJUSTMENTS................................................................................................................................................................................... 529 ADJUSTMENT - FRONT WIPER ARMS............................................................................................................................................................. 529 ADJUSTMENT - FRONT WIPER ARMS - RHD....................................................................................................................................................... 529 FRONT WIPER BLADES................................................................................................................................................................................ 529 REMOVAL....................................................................................................................................................................................... 529 CLEANING - FRONT WIPER BLADES................................................................................................................................................................. 530 INSTALLATION.................................................................................................................................................................................. 530 FRONT WIPER BLADE ELEMENTS........................................................................................................................................................................ 530 REMOVAL....................................................................................................................................................................................... 530 INSTALLATION.................................................................................................................................................................................. 530 FRONT WIPER MODULE................................................................................................................................................................................ 531 REMOVAL....................................................................................................................................................................................... 531 INSTALLATION.................................................................................................................................................................................. 531 FRONT WIPER MODULE - RHD.......................................................................................................................................................................... 532 REMOVAL....................................................................................................................................................................................... 532 INSTALLATION.................................................................................................................................................................................. 532 FRONT WIPER MOTOR................................................................................................................................................................................. 532 DIAGNOSIS AND TESTING - WIPER MOTOR........................................................................................................................................................... 532 REMOVAL....................................................................................................................................................................................... 534 INSTALLATION.................................................................................................................................................................................. 534 FRONT WIPER MOTOR - RHD........................................................................................................................................................................... 534 REMOVAL....................................................................................................................................................................................... 534 INSTALLATION.................................................................................................................................................................................. 535 FRONT WIPER SWITCH................................................................................................................................................................................ 535 DIAGNOSIS AND TESTING - FRONT WIPER/WASHER SWITCH............................................................................................................................................. 535 REMOVAL....................................................................................................................................................................................... 535 INSTALLATION.................................................................................................................................................................................. 535 REAR WASHER NOZZLE................................................................................................................................................................................ 536 REMOVAL....................................................................................................................................................................................... 536 INSTALLATION.................................................................................................................................................................................. 536 REAR WIPER ARMS................................................................................................................................................................................... 536 REMOVAL....................................................................................................................................................................................... 536 INSTALLATION.................................................................................................................................................................................. 537 REAR WIPER BLADE.................................................................................................................................................................................. 537 REMOVAL....................................................................................................................................................................................... 537 INSTALLATION.................................................................................................................................................................................. 537 REAR WIPER MOTOR.................................................................................................................................................................................. 537 REMOVAL....................................................................................................................................................................................... 537 INSTALLATION.................................................................................................................................................................................. 538 REAR WIPER SWITCH................................................................................................................................................................................. 538 DIAGNOSIS AND TESTING - REAR WIPER SWITCH..................................................................................................................................................... 538 IN-VEHICLE TESTING........................................................................................................................................................................ 538 BENCH TESTING............................................................................................................................................................................. 538 REMOVAL....................................................................................................................................................................................... 539 WASHER HOSES...................................................................................................................................................................................... 539 REMOVAL....................................................................................................................................................................................... 539 INSTALLATION.................................................................................................................................................................................. 539 WASHER PUMP MOTOR................................................................................................................................................................................. 539 REMOVAL....................................................................................................................................................................................... 539 INSTALLATION.................................................................................................................................................................................. 540 WASHER PUMP MOTOR - RHD........................................................................................................................................................................... 540 REMOVAL....................................................................................................................................................................................... 540 INSTALLATION.................................................................................................................................................................................. 540 WASHER RESERVOIR.................................................................................................................................................................................. 541 REMOVAL....................................................................................................................................................................................... 541 INSTALLATION.................................................................................................................................................................................. 541 8w-WIRING............................................................................................................................................................................................. 543 8W-01 WIRING DIAGRAM INFORMATION.................................................................................................................................................................. 545 WIRING DIAGRAM INFORMATION.................................................................................................................................................................... 545 DESCRIPTION............................................................................................................................................................................... 545 DESCRIPTION - HOW TO USE WIRING DIAGRAMS.............................................................................................................................................. 545 SYMBOLS........................................................................................................................................................................... 545 TERMINOLOGY....................................................................................................................................................................... 549 DESCRIPTION - CIRCUIT INFORMATION..................................................................................................................................................... 549 DESCRIPTION - CIRCUIT FUNCTIONS....................................................................................................................................................... 550 DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION.................................................................................................................................. 550 DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION................................................................................................................................ 551 IDENTIFICATION.................................................................................................................................................................... 551 LOCATIONS......................................................................................................................................................................... 551 WARNING................................................................................................................................................................................... 551 WARNINGS - GENERAL.................................................................................................................................................................... 551 DIAGNOSIS AND TESTING - WIRING HARNESS.................................................................................................................................................... 551 TROUBLESHOOTING TOOLS................................................................................................................................................................. 551 INTERMITTENT AND POOR CONNECTIONS..................................................................................................................................................... 552 TROUBLESHOOTING WIRING PROBLEMS....................................................................................................................................................... 552 STANDARD PROCEDURE........................................................................................................................................................................ 552 STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES.................................................................................................................. 552 STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL..................................................................................................................................... 553 STANDARD PROCEDURE - TESTING FOR CONTINUITY........................................................................................................................................... 553 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND.................................................................................................................................... 553 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS.................................................................................................... 553 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP....................................................................................................................................... 554 SPECIAL TOOLS............................................................................................................................................................................. 554 WIRING/TERMINAL....................................................................................................................................................................... 554 CONNECTOR..................................................................................................................................................................................... 555 REMOVAL................................................................................................................................................................................... 555 INSTALLATION.............................................................................................................................................................................. 555 DIODE......................................................................................................................................................................................... 558 REMOVAL................................................................................................................................................................................... 558 INSTALLATION.............................................................................................................................................................................. 558 TERMINAL...................................................................................................................................................................................... 558 REMOVAL................................................................................................................................................................................... 558 INSTALLATION.............................................................................................................................................................................. 558 WIRE.......................................................................................................................................................................................... 559 STANDARD PROCEDURE - WIRE SPLICING........................................................................................................................................................ 559 8W-02 COMPONENT INDEX............................................................................................................................................................................. 561 8W-10 POWER DISTRIBUTION.......................................................................................................................................................................... 563 8W-11 FUSE BLOCK.................................................................................................................................................................................. 595 8W-15 GROUND DISTRIBUTION......................................................................................................................................................................... 615 8W-18 BUS COMMUNICATIONS.......................................................................................................................................................................... 643 8W-20 CHARGING SYSTEM............................................................................................................................................................................. 649 8W-21 STARTING SYSTEM............................................................................................................................................................................. 657 8W-30 FUEL/IGNITION SYSTEM........................................................................................................................................................................ 661 8W-31 TRANSMISSION CONTROL SYSTEM................................................................................................................................................................. 711 8W-33 VEHICLE SPEED CONTROL....................................................................................................................................................................... 719 8W-35 ANTILOCK BRAKES............................................................................................................................................................................. 727 8W-39 VEHICLE THEFT SECURITY SYSTEM............................................................................................................................................................... 731 8W-40 INSTRUMENT CLUSTER.......................................................................................................................................................................... 745 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET............................................................................................................................................................. 763 8W-42 AIR CONDITIONING-HEATER..................................................................................................................................................................... 767 8W-43 OCCUPANT RESTRAINT SYSTEM................................................................................................................................................................... 777 8W-44 INTERIOR LIGHTING........................................................................................................................................................................... 783 8W-47 AUDIO SYSTEM................................................................................................................................................................................ 789 8W-48 REAR WINDOW DEFOGGER........................................................................................................................................................................ 793 8W-49 OVERHEAD CONSOLE............................................................................................................................................................................ 795 8W-50 FRONT LIGHTING.............................................................................................................................................................................. 799 8W-51 REAR LIGHTING............................................................................................................................................................................... 809 8W-52 TURN SIGNALS................................................................................................................................................................................ 819 8W-53 WIPERS...................................................................................................................................................................................... 825 8W-60 POWER WINDOWS............................................................................................................................................................................... 829 8W-61 POWER DOOR LOCKS............................................................................................................................................................................ 835 8W-62 POWER MIRRORS............................................................................................................................................................................... 845 8W-63 POWER SEAT.................................................................................................................................................................................. 853 8W-64 POWER SUNROOF............................................................................................................................................................................... 859 8W-70 SPLICE INFORMATION.......................................................................................................................................................................... 861 8W-80 CONNECTOR PIN-OUTS.......................................................................................................................................................................... 865 8W-91 CONNECTOR/GROUND/SPLICE LOCATION............................................................................................................................................................ 957 CONNECTOR/GROUND/SPLICE LOCATION.............................................................................................................................................................. 957 DESCRIPTION............................................................................................................................................................................... 957 8W-97 POWER DISTRIBUTION..........................................................................................................................................................................1015 POWER DISTRIBUTION............................................................................................................................................................................1015 DESCRIPTION...............................................................................................................................................................................1015 OPERATION.................................................................................................................................................................................1015 CIGAR LIGHTER/POWER OUTLET....................................................................................................................................................................1015 DESCRIPTION...............................................................................................................................................................................1015 INSTRUMENT PANEL MOUNTED..............................................................................................................................................................1015 FRONT CONSOLE AND REAR CARGO MOUNTED..................................................................................................................................................1016 OPERATION.................................................................................................................................................................................1016 CIGAR LIGHTER/POWER OUTLET (INSTRUMENT PANEL AND CONSOLE MOUNTED).....................................................................................................................1016 POWER OUTLET (REAR CARGO AREA MOUNTED)................................................................................................................................................1017 REMOVAL...................................................................................................................................................................................1017 INSTALLATION..............................................................................................................................................................................1017 FUSE BLOCK....................................................................................................................................................................................1018 DESCRIPTION...............................................................................................................................................................................1018 OPERATION.................................................................................................................................................................................1018 REMOVAL...................................................................................................................................................................................1018 INSTALLATION..............................................................................................................................................................................1018 IOD FUSE......................................................................................................................................................................................1018 DESCRIPTION...............................................................................................................................................................................1018 OPERATION.................................................................................................................................................................................1018 REMOVAL...................................................................................................................................................................................1019 INSTALLATION..............................................................................................................................................................................1019 POWER DISTRIBUTION CENTER.....................................................................................................................................................................1019 DESCRIPTION...............................................................................................................................................................................1019 OPERATION.................................................................................................................................................................................1019 REMOVAL...................................................................................................................................................................................1020 INSTALLATION..............................................................................................................................................................................1020 RELAY.........................................................................................................................................................................................1020 REMOVAL...................................................................................................................................................................................1020 INSTALLATION..............................................................................................................................................................................1020 9-ENGINE..............................................................................................................................................................................................1021 ENGINE 1.6L SOHC..................................................................................................................................................................................1021 ENGINE 1.6L SOHC..............................................................................................................................................................................1023 DESCRIPTION...............................................................................................................................................................................1023 DIAGNOSIS AND TESTING.....................................................................................................................................................................1023 DIAGNOSIS AND TESTING - INTRODUCTION..................................................................................................................................................1023 DIAGNOSIS AND TESTING - ENGINE PERFORMANCE............................................................................................................................................1024 DIAGNOSIS AND TESTING - ENGINE MECHANICAL.............................................................................................................................................1026 DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST............................................................................................................................1028 DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST.....................................................................................................................1029 DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET............................................................................................................................................1029 CYLINDER-TO-CYLINDER LEAKAGE TEST.................................................................................................................................................1029 CYLINDER-TO-WATER JACKET LEAKAGE TEST.............................................................................................................................................1029 DIAGNOSIS AND TESTING - LASH ADJUSTER NOISE DIAGNOSIS.................................................................................................................................1029 DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION....................................................................................................................................1030 INSPECTION FOR REAR SEAL AREA LEAKS...............................................................................................................................................1030 STANDARD PROCEDURE........................................................................................................................................................................1031 STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS................................................................................................................................1031 STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE........................................................................................................................................1031 STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS................................................................................................................................1031 SEALER APPLICATION................................................................................................................................................................1032 STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION................................................................................................................................1032 STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE.....................................................................................................................1033 STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS................................................................................................................................1033 REMOVAL - ENGINE ASSEMBLY.................................................................................................................................................................1033 INSTALLATION - ENGINE ASSEMBLY............................................................................................................................................................1035 SPECIFICATIONS............................................................................................................................................................................1037 1.6L SOHC ENGINE......................................................................................................................................................................1037 TORQUE................................................................................................................................................................................1041 SPECIAL TOOLS.............................................................................................................................................................................1041 1.6L SOHC ENGINE......................................................................................................................................................................1041 AIR CLEANER ELEMENT...........................................................................................................................................................................1045 REMOVAL...................................................................................................................................................................................1045 INSTALLATION..............................................................................................................................................................................1045 AIR CLEANER HOUSING...........................................................................................................................................................................1045 REMOVAL...................................................................................................................................................................................1045 INSTALLATION..............................................................................................................................................................................1046 CYLINDER HEAD.................................................................................................................................................................................1046 REMOVAL - CYLINDER HEAD...................................................................................................................................................................1046 CLEANING..................................................................................................................................................................................1047 INSPECTION................................................................................................................................................................................1047 INSTALLATION - CYLINDER HEAD..............................................................................................................................................................1048 CYLINDER HEAD COVER...........................................................................................................................................................................1051 REMOVAL...................................................................................................................................................................................1051 CLEANING..................................................................................................................................................................................1051 INSPECTION................................................................................................................................................................................1051 INSTALLATION..............................................................................................................................................................................1051 SPARK PLUG TUBE SEAL..........................................................................................................................................................................1052 DESCRIPTION...............................................................................................................................................................................1052 REMOVAL...................................................................................................................................................................................1052 INSTALLATION..............................................................................................................................................................................1052 SPARK PLUG TUBE...............................................................................................................................................................................1053 REMOVAL...................................................................................................................................................................................1053 INSTALLATION..............................................................................................................................................................................1053 ROCKER ARM SHAFT / ROCKER ARM / LASH ADJUSTER.................................................................................................................................................1054 DESCRIPTION...............................................................................................................................................................................1054 REMOVAL...................................................................................................................................................................................1054 INSTALLATION..............................................................................................................................................................................1055 CAMSHAFT......................................................................................................................................................................................1055 REMOVAL...................................................................................................................................................................................1055 INSPECTION................................................................................................................................................................................1056 INSTALLATION..............................................................................................................................................................................1056 VALVE SPRINGS AND SEALS (ON VEHICLE SERVICE)..................................................................................................................................................1057 STANDARD PROCEDURE - VALVE SPRINGS AND SEALS (ON VEHICLE SERVICE).........................................................................................................................1057 VALVE SPRINGS AND SEALS (CYLINDER HEAD REMOVED)...............................................................................................................................................1059 STANDARD PROCEDURE - VALVE SPRINGS AND SEALS (CYLINDER HEAD REMOVED)......................................................................................................................1059 INSPECTION................................................................................................................................................................................1059 INTAKE/EXHAUST VALVES & SEATS.................................................................................................................................................................1060 STANDARD PROCEDURE - VALVE AND VALVE SEAT REFACING........................................................................................................................................1060 ENGINE BLOCK..................................................................................................................................................................................1061 DESCRIPTION...............................................................................................................................................................................1061 STANDARD PROCEDURE - CYLINDER BORE HONING.................................................................................................................................................1061 CLEANING..................................................................................................................................................................................1063 INSPECTION................................................................................................................................................................................1063 ENGINE BLOCK..........................................................................................................................................................................1063 CYLINDER BORE.........................................................................................................................................................................1063 CRANKSHAFT MAIN BEARINGS......................................................................................................................................................................1064 DESCRIPTION...............................................................................................................................................................................1064 CRANKSHAFT....................................................................................................................................................................................1064 DESCRIPTION...............................................................................................................................................................................1064 STANDARD PROCEDURE - CRANKSHAFT END PLAY..................................................................................................................................................1064 REMOVAL...................................................................................................................................................................................1064 INSPECTION................................................................................................................................................................................1065 INSTALLATION..............................................................................................................................................................................1065 CRANKSHAFT OIL SEAL - FRONT...................................................................................................................................................................1067 REMOVAL...................................................................................................................................................................................1067 INSTALLATION..............................................................................................................................................................................1067 CRANKSHAFT OIL SEAL - REAR....................................................................................................................................................................1067 REMOVAL...................................................................................................................................................................................1067 INSTALLATION..............................................................................................................................................................................1067 PISTON & CONNECTING ROD.......................................................................................................................................................................1068 DESCRIPTION...............................................................................................................................................................................1068 STANDARD PROCEDURE........................................................................................................................................................................1068 STANDARD PROCEDURE - CONNECTING ROD AND BEARING - FITTING.............................................................................................................................1068 STANDARD PROCEDURE - CYLINDER BORE AND PISTON - FITTING...............................................................................................................................1068 REMOVAL...................................................................................................................................................................................1069 INSTALLATION..............................................................................................................................................................................1070 PISTON RINGS..................................................................................................................................................................................1070 STANDARD PROCEDURE - PISTON RING - FITTING................................................................................................................................................1070 REMOVAL...................................................................................................................................................................................1071 INSTALLATION..............................................................................................................................................................................1071 VIBRATION DAMPER..............................................................................................................................................................................1072 REMOVAL...................................................................................................................................................................................1072 INSTALLATION..............................................................................................................................................................................1072 ENGINE MOUNTING...............................................................................................................................................................................1072 DESCRIPTION...............................................................................................................................................................................1072 TORQUE STRUTS.................................................................................................................................................................................1073 REMOVAL...................................................................................................................................................................................1073 UPPER TORQUE STRUT....................................................................................................................................................................1073 LOWER TORQUE STRUT....................................................................................................................................................................1073 INSTALLATION..............................................................................................................................................................................1074 UPPER TORQUE STRUT....................................................................................................................................................................1074 LOWER TORQUE STRUT....................................................................................................................................................................1074 ADJUSTMENTS...............................................................................................................................................................................1074 ADJUSTMENT............................................................................................................................................................................1074 RIGHT ENGINE MOUNT BRACKET....................................................................................................................................................................1074 REMOVAL...................................................................................................................................................................................1074 INSTALLATION..............................................................................................................................................................................1075 RIGHT MOUNT...................................................................................................................................................................................1075 REMOVAL...................................................................................................................................................................................1075 INSTALLATION..............................................................................................................................................................................1075 LEFT MOUNT....................................................................................................................................................................................1076 REMOVAL...................................................................................................................................................................................1076 INSTALLATION..............................................................................................................................................................................1076 LUBRICATION...................................................................................................................................................................................1077 DESCRIPTION...............................................................................................................................................................................1077 OPERATION.................................................................................................................................................................................1077 DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE......................................................................................................................................1077 OIL FILTER CARTRIDGE..........................................................................................................................................................................1079 REMOVAL...................................................................................................................................................................................1079 INSTALLATION..............................................................................................................................................................................1079 OIL FILTER CARTRIDGE HOUSING..................................................................................................................................................................1080 DESCRIPTION...............................................................................................................................................................................1080 REMOVAL...................................................................................................................................................................................1080 INSTALLATION..............................................................................................................................................................................1080 OIL PAN.......................................................................................................................................................................................1080 REMOVAL...................................................................................................................................................................................1080 INSTALLATION..............................................................................................................................................................................1081 OIL PUMP......................................................................................................................................................................................1082 REMOVAL...................................................................................................................................................................................1082 INSTALLATION..............................................................................................................................................................................1082 OIL PUMP PICK-UP..............................................................................................................................................................................1082 REMOVAL...................................................................................................................................................................................1082 INSTALLATION..............................................................................................................................................................................1082 INTAKE MANIFOLD...............................................................................................................................................................................1083 REMOVAL...................................................................................................................................................................................1083 REMOVAL - UPPER INTAKE MANIFOLD.......................................................................................................................................................1083 REMOVAL - LOWER INTAKE MANIFOLD.......................................................................................................................................................1083 INSTALLATION..............................................................................................................................................................................1083 INSTALLATION - UPPER INTAKE MANIFOLD..................................................................................................................................................1083 INSTALLATION - LOWER INTAKE MANIFOLD..................................................................................................................................................1083 EXHAUST MANIFOLD..............................................................................................................................................................................1084 REMOVAL...................................................................................................................................................................................1084 CLEANING..................................................................................................................................................................................1084 INSPECTION................................................................................................................................................................................1084 INSTALLATION..............................................................................................................................................................................1084 VALVE TIMING..................................................................................................................................................................................1085 DESCRIPTION...............................................................................................................................................................................1085 STANDARD PROCEDURE - VALVE TIMING VERIFICATION............................................................................................................................................1085 TIMING CHAIN COVER............................................................................................................................................................................1085 REMOVAL...................................................................................................................................................................................1085 INSTALLATION..............................................................................................................................................................................1086 TIMING CHAIN/GUIDES/SPROCKETS.................................................................................................................................................................1087 REMOVAL...................................................................................................................................................................................1087 REMOVAL - TIMING CHAIN AND GUIDES.....................................................................................................................................................1087 REMOVAL - CAMSHAFT SPROCKET...........................................................................................................................................................1088 REMOVAL - CRANKSHAFT SPROCKET.........................................................................................................................................................1089 INSTALLATION..............................................................................................................................................................................1089 INSTALLATION - CRANKSHAFT SPROCKET....................................................................................................................................................1089 INSTALLATION - CAMSHAFT SPROCKET......................................................................................................................................................1089 INSTALLATION - TIMING CHAIN AND GUIDES................................................................................................................................................1090 ENGINE 2.0L DOHC..................................................................................................................................................................................1093 ENGINE 2.0L DOHC..............................................................................................................................................................................1095 DESCRIPTION...............................................................................................................................................................................1095 DIAGNOSIS AND TESTING.....................................................................................................................................................................1096 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION...............................................................................................................................1096 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE................................................................................................................................1096 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL.................................................................................................................................1098 DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST.....................................................................................................................1100 DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST............................................................................................................................1100 DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION....................................................................................................................................1101 INSPECTION FOR REAR SEAL AREA LEAKS...............................................................................................................................................1101 STANDARD PROCEDURE........................................................................................................................................................................1102 STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS................................................................................................................................1102 STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE........................................................................................................................................1102 STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS................................................................................................................................1102 SEALER APPLICATION................................................................................................................................................................1103 STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION................................................................................................................................1103 STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS................................................................................................................................1104 STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE.....................................................................................................................1104 REMOVAL - ENGINE ASSEMBLY.................................................................................................................................................................1104 INSTALLATION - ENGINE ASSEMBLY............................................................................................................................................................1107 SPECIFICATIONS............................................................................................................................................................................1109 2.0L DOHC ENGINE......................................................................................................................................................................1109 TORQUE................................................................................................................................................................................1112 SPECIAL TOOLS.............................................................................................................................................................................1112 2.0L DOHC ENGINE......................................................................................................................................................................1112 AIR CLEANER ELEMENT...........................................................................................................................................................................1116 REMOVAL...................................................................................................................................................................................1116 INSTALLATION..............................................................................................................................................................................1116 AIR CLEANER HOUSING...........................................................................................................................................................................1116 REMOVAL...................................................................................................................................................................................1116 INSTALLATION..............................................................................................................................................................................1116 CYLINDER HEAD.................................................................................................................................................................................1116 DESCRIPTION...............................................................................................................................................................................1116 DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET................................................................................................................................................1116 CYLINDER-TO-CYLINDER LEAKAGE TEST.....................................................................................................................................................1117 CYLINDER-TO-WATER JACKET LEAKAGE TEST.................................................................................................................................................1117 REMOVAL...................................................................................................................................................................................1117 CLEANING..................................................................................................................................................................................1118 INSPECTION................................................................................................................................................................................1118 INSTALLATION..............................................................................................................................................................................1119 CAMSHAFT OIL SEAL(S)..........................................................................................................................................................................1120 REMOVAL...................................................................................................................................................................................1120 INSTALLATION..............................................................................................................................................................................1121 CAMSHAFT(S)...................................................................................................................................................................................1121 DESCRIPTION...............................................................................................................................................................................1121 OPERATION.................................................................................................................................................................................1121 STANDARD PROCEDURE - MEASURING CAMSHAFT END PLAY..........................................................................................................................................1121 REMOVAL...................................................................................................................................................................................1121 CLEANING..................................................................................................................................................................................1122 INSPECTION................................................................................................................................................................................1122 INSTALLATION..............................................................................................................................................................................1122 CYLINDER HEAD COVER...........................................................................................................................................................................1123 REMOVAL...................................................................................................................................................................................1123 INSTALLATION..............................................................................................................................................................................1123 HYDRAULIC LASH ADJUSTERS......................................................................................................................................................................1125 DIAGNOSIS AND TESTING.....................................................................................................................................................................1125 HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS...............................................................................................................................................1125 REMOVAL...................................................................................................................................................................................1125 INSTALLATION..............................................................................................................................................................................1125 INTAKE/EXHAUST VALVES & SEATS.................................................................................................................................................................1126 DESCRIPTION...............................................................................................................................................................................1126 OPERATION.................................................................................................................................................................................1126 CLEANING..................................................................................................................................................................................1126 ROCKER ARMS...................................................................................................................................................................................1126 REMOVAL...................................................................................................................................................................................1126 INSPECTION................................................................................................................................................................................1126 INSTALLATION..............................................................................................................................................................................1126 VALVE SPRINGS AND SEALS.......................................................................................................................................................................1127 REMOVAL...................................................................................................................................................................................1127 REMOVAL - CYLINDER HEAD ON............................................................................................................................................................1127 REMOVAL - CYLINDER HEAD OFF...........................................................................................................................................................1127 INSPECTION................................................................................................................................................................................1127 INSTALLATION..............................................................................................................................................................................1127 INSTALLATION - CYLINDER HEAD ON.......................................................................................................................................................1127 INSTALLATION - CYLINDER HEAD OFF......................................................................................................................................................1127 ENGINE BLOCK..................................................................................................................................................................................1128 DESCRIPTION...............................................................................................................................................................................1128 STANDARD PROCEDURE - CYLINDER BORE HONING.................................................................................................................................................1128 CLEANING..................................................................................................................................................................................1129 INSPECTION................................................................................................................................................................................1129 ENGINE BLOCK..........................................................................................................................................................................1129 CYLINDER BORE.........................................................................................................................................................................1129 CRANKSHAFT....................................................................................................................................................................................1130 STANDARD PROCEDURE - CRANKSHAFT END PLAY..................................................................................................................................................1130 REMOVAL - CRANKSHAFT......................................................................................................................................................................1130 INSPECTION................................................................................................................................................................................1132 INSTALLATION - CRANKSHAFT.................................................................................................................................................................1132 CRANKSHAFT MAIN BEARING LOCATION......................................................................................................................................................1132 CRANKSHAFT OIL SEAL - FRONT...................................................................................................................................................................1134 REMOVAL...................................................................................................................................................................................1134 INSTALLATION..............................................................................................................................................................................1134 CRANKSHAFT OIL SEAL - REAR....................................................................................................................................................................1135 REMOVAL...................................................................................................................................................................................1135 INSTALLATION0 - 6 PT (Continued)......................................................................................................................................................1135 PISTON & CONNECTING ROD.......................................................................................................................................................................1137 DESCRIPTION...............................................................................................................................................................................1137 STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING......................................................................................................................................1137 REMOVAL...................................................................................................................................................................................1138 INSTALLATION..............................................................................................................................................................................1138 CONNECTING ROD BEARINGS.......................................................................................................................................................................1139 STANDARD PROCEDURE........................................................................................................................................................................1139 CONNECTING ROD - FITTING..............................................................................................................................................................1139 PISTON RINGS..................................................................................................................................................................................1140 STANDARD PROCEDURE - PISTON RING - FITTING................................................................................................................................................1140 REMOVAL...................................................................................................................................................................................1140 INSTALLATION..............................................................................................................................................................................1140 STRUCTURAL COLLAR.............................................................................................................................................................................1141 REMOVAL...................................................................................................................................................................................1141 INSTALLATION..............................................................................................................................................................................1141 VIBRATION DAMPER..............................................................................................................................................................................1142 REMOVAL...................................................................................................................................................................................1142 INSTALLATION..............................................................................................................................................................................1142 ENGINE MOUNTING...............................................................................................................................................................................1142 DESCRIPTION...............................................................................................................................................................................1142 OPERATION.................................................................................................................................................................................1142 LEFT MOUNT....................................................................................................................................................................................1143 REMOVAL...................................................................................................................................................................................1143 INSTALLATION..............................................................................................................................................................................1143 RIGHT MOUNT...................................................................................................................................................................................1143 REMOVAL...................................................................................................................................................................................1143 INSTALLATION..............................................................................................................................................................................1143 TORQUE STRUT..................................................................................................................................................................................1144 REMOVAL...................................................................................................................................................................................1144 REMOVAL - UPPER.......................................................................................................................................................................1144 REMOVAL - LOWER.......................................................................................................................................................................1145 INSTALLATION..............................................................................................................................................................................1145 INSTALLATION - UPPER..................................................................................................................................................................1145 INSTALLATION - LOWER..................................................................................................................................................................1145 ADJUSTMENTS...............................................................................................................................................................................1145 ENGINE TORQUE STRUT ADJUSTMENT........................................................................................................................................................1145 LUBRICATION...................................................................................................................................................................................1146 DESCRIPTION...............................................................................................................................................................................1146 OPERATION.................................................................................................................................................................................1146 DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE......................................................................................................................................1146 OIL...........................................................................................................................................................................................1148 STANDARD PROCEDURE........................................................................................................................................................................1148 ENGINE OIL LEVEL CHECK................................................................................................................................................................1148 STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE.....................................................................................................................................1149 OIL FILTER SPECIFICATION..........................................................................................................................................................1149 USED ENGINE OIL DISPOSAL..........................................................................................................................................................1149 OIL FILTER....................................................................................................................................................................................1149 REMOVAL...................................................................................................................................................................................1149 INSTALLATION..............................................................................................................................................................................1149 OIL FILTER ADAPTER............................................................................................................................................................................1150 REMOVAL...................................................................................................................................................................................1150 INSTALLATION..............................................................................................................................................................................1150 OIL PAN.......................................................................................................................................................................................1150 REMOVAL...................................................................................................................................................................................1150 INSTALLATION..............................................................................................................................................................................1150 OIL PRESSURE SENSOR/SWITCH....................................................................................................................................................................1151 REMOVAL...................................................................................................................................................................................1151 INSTALLATION..............................................................................................................................................................................1151 OIL PUMP......................................................................................................................................................................................1151 REMOVAL...................................................................................................................................................................................1151 DISASSEMBLY...............................................................................................................................................................................1152 INSPECTION................................................................................................................................................................................1152 ASSEMBLY..................................................................................................................................................................................1154 INSTALLATION..............................................................................................................................................................................1154 INTAKE MANIFOLD...............................................................................................................................................................................1155 DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS.............................................................................................................................................1155 REMOVAL...................................................................................................................................................................................1155 REMOVAL - UPPER INTAKE MANIFOLD.......................................................................................................................................................1155 REMOVAL - LOWER INTAKE MANIFOLD.......................................................................................................................................................1158 CLEANING..................................................................................................................................................................................1158 INSPECTION................................................................................................................................................................................1158 INSTALLATION..............................................................................................................................................................................1158 INSTALLATION - UPPER INTAKE MANIFOLD..................................................................................................................................................1158 INSTALLATION - LOWER INTAKE MANIFOLD..................................................................................................................................................1159 EXHAUST MANIFOLD..............................................................................................................................................................................1160 REMOVAL...................................................................................................................................................................................1160 CLEANING..................................................................................................................................................................................1160 INSPECTION................................................................................................................................................................................1160 INSTALLATION..............................................................................................................................................................................1161 VALVE TIMING..................................................................................................................................................................................1162 STANDARD PROCEDURE - VALVE TIMING VERIFICATION............................................................................................................................................1162 TIMING BELT COVER(S)..........................................................................................................................................................................1162 REMOVAL...................................................................................................................................................................................1162 FRONT COVER...........................................................................................................................................................................1162 REAR COVER............................................................................................................................................................................1162 INSTALLATION..............................................................................................................................................................................1163 REAR COVER............................................................................................................................................................................1163 FRONT COVER...........................................................................................................................................................................1163 TIMING BELT AND SPROCKETS.....................................................................................................................................................................1163 REMOVAL...................................................................................................................................................................................1163 REMOVAL - TIMING BELT.................................................................................................................................................................1163 REMOVAL - CAMSHAFT SPROCKET(S)........................................................................................................................................................1165 REMOVAL - CRANKSHAFT SPROCKET.........................................................................................................................................................1165 CLEANING..................................................................................................................................................................................1166 INSTALLATION..............................................................................................................................................................................1166 INSTALLATION - CRANKSHAFT SPROCKET....................................................................................................................................................1166 INSTALLATION - CAMSHAFT SPROCKETS.....................................................................................................................................................1166 INSTALLATION - TIMING BELT............................................................................................................................................................1166 TIMING BELT TENSIONER & PULLEY................................................................................................................................................................1168 REMOVAL...................................................................................................................................................................................1168 INSTALLATION..............................................................................................................................................................................1168 ENGINE 2.4L DOHC..................................................................................................................................................................................1169 ENGINE 2.4L DOHC..............................................................................................................................................................................1171 DESCRIPTION...............................................................................................................................................................................1171 DIAGNOSIS AND TESTING.....................................................................................................................................................................1171 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION...............................................................................................................................1171 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE................................................................................................................................1172 DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL.................................................................................................................................1174 DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST.....................................................................................................................1176 DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST............................................................................................................................1176 DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION....................................................................................................................................1177 INSPECTION FOR REAR SEAL AREA LEAKS...............................................................................................................................................1177 STANDARD PROCEDURE........................................................................................................................................................................1178 STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS................................................................................................................................1178 STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE........................................................................................................................................1178 STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS................................................................................................................................1178 SEALER APPLICATION................................................................................................................................................................1179 STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION................................................................................................................................1179 STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS................................................................................................................................1180 STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE.....................................................................................................................1180 REMOVAL - ENGINE ASSEMBLY.................................................................................................................................................................1180 INSTALLATION - ENGINE ASSEMBLY............................................................................................................................................................1184 SPECIFICATIONS............................................................................................................................................................................1186 2.4L ENGINE...........................................................................................................................................................................1186 TORQUE................................................................................................................................................................................1189 SPECIAL TOOLS.............................................................................................................................................................................1190 2.4L ENGINE...........................................................................................................................................................................1190 AIR CLEANER ELEMENT...........................................................................................................................................................................1193 REMOVAL...................................................................................................................................................................................1193 INSTALLATION..............................................................................................................................................................................1193 AIR CLEANER HOUSING...........................................................................................................................................................................1193 REMOVAL...................................................................................................................................................................................1193 INSTALLATION..............................................................................................................................................................................1193 CYLINDER HEAD.................................................................................................................................................................................1194 DESCRIPTION...............................................................................................................................................................................1194 DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET................................................................................................................................................1194 CYLINDER-TO-CYLINDER LEAKAGE TEST.....................................................................................................................................................1195 CYLINDER-TO-WATER JACKET LEAKAGE TEST.................................................................................................................................................1195 REMOVAL - CYLINDER HEAD...................................................................................................................................................................1195 CLEANING..................................................................................................................................................................................1197 INSPECTION................................................................................................................................................................................1197 INSTALLATION - CYLINDER HEAD..............................................................................................................................................................1197 CAMSHAFT OIL SEAL(S)..........................................................................................................................................................................1199 REMOVAL...................................................................................................................................................................................1199 INSTALLATION..............................................................................................................................................................................1199 CAMSHAFT(S)...................................................................................................................................................................................1200 DESCRIPTION...............................................................................................................................................................................1200 OPERATION.................................................................................................................................................................................1200 STANDARD PROCEDURE - MEASURING CAMSHAFT END PLAY..........................................................................................................................................1200 REMOVAL...................................................................................................................................................................................1200 CLEANING..................................................................................................................................................................................1201 INSPECTION................................................................................................................................................................................1201 INSTALLATION..............................................................................................................................................................................1201 CYLINDER HEAD COVER...........................................................................................................................................................................1202 REMOVAL...................................................................................................................................................................................1202 INSTALLATION..............................................................................................................................................................................1202 HYDRAULIC LASH ADJUSTERS......................................................................................................................................................................1204 DIAGNOSIS AND TESTING.....................................................................................................................................................................1204 HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS...............................................................................................................................................1204 REMOVAL...................................................................................................................................................................................1204 INSTALLATION..............................................................................................................................................................................1204 INTAKE/EXHAUST VALVES & SEATS.................................................................................................................................................................1205 DESCRIPTION...............................................................................................................................................................................1205 OPERATION.................................................................................................................................................................................1205 CLEANING..................................................................................................................................................................................1205 ROCKER ARMS...................................................................................................................................................................................1205 REMOVAL...................................................................................................................................................................................1205 INSPECTION................................................................................................................................................................................1205 INSTALLATION..............................................................................................................................................................................1205 VALVE SPRINGS & SEALS.........................................................................................................................................................................1206 REMOVAL...................................................................................................................................................................................1206 REMOVAL - CYLINDER HEAD ON............................................................................................................................................................1206 REMOVAL - CYLINDER HEAD OFF...........................................................................................................................................................1206 INSPECTION................................................................................................................................................................................1206 INSTALLATION..............................................................................................................................................................................1206 INSTALLATION - CYLINDER HEAD ON.......................................................................................................................................................1206 INSTALLATION - CYLINDER HEAD OFF......................................................................................................................................................1207 ENGINE BLOCK..................................................................................................................................................................................1207 DESCRIPTION...............................................................................................................................................................................1207 STANDARD PROCEDURE - CYLINDER BORE HONING.................................................................................................................................................1207 CLEANING..................................................................................................................................................................................1208 INSPECTION................................................................................................................................................................................1208 ENGINE BLOCK..........................................................................................................................................................................1208 CYLINDER BORE.........................................................................................................................................................................1208 CRANKSHAFT....................................................................................................................................................................................1209 STANDARD PROCEDURE - MEASURING CRANKSHAFT END PLAY........................................................................................................................................1209 REMOVAL - CRANKSHAFT......................................................................................................................................................................1209 INSPECTION................................................................................................................................................................................1210 INSTALLATION - CRANKSHAFT.................................................................................................................................................................1210 CRANKSHAFT MAIN BEARING LOCATION......................................................................................................................................................1210 CRANKSHAFT OIL SEAL - FRONT...................................................................................................................................................................1212 REMOVAL...................................................................................................................................................................................1212 INSTALLATION..............................................................................................................................................................................1212 CRANKSHAFT OIL SEAL - REAR....................................................................................................................................................................1213 REMOVAL...................................................................................................................................................................................1213 INSTALLATION..............................................................................................................................................................................1213 PISTON & CONNECTING ROD.......................................................................................................................................................................1215 DESCRIPTION...............................................................................................................................................................................1215 Non-Turbo.............................................................................................................................................................................1215 Turbo.................................................................................................................................................................................1215 STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING......................................................................................................................................1215 REMOVAL...................................................................................................................................................................................1215 INSTALLATION..............................................................................................................................................................................1217 CONNECTING ROD BEARINGS.......................................................................................................................................................................1218 STANDARD PROCEDURE........................................................................................................................................................................1218 CONNECTING ROD - FITTING..............................................................................................................................................................1218 PISTON RINGS..................................................................................................................................................................................1218 STANDARD PROCEDURE........................................................................................................................................................................1218 PISTON RING - FITTING.................................................................................................................................................................1218 REMOVAL...................................................................................................................................................................................1219 INSTALLATION..............................................................................................................................................................................1219 STRUCTURAL COLLAR.............................................................................................................................................................................1220 REMOVAL...................................................................................................................................................................................1220 STRUCTURAL COLLAR—AUTOMATIC TRANSAXLE EQUIPPED........................................................................................................................................1220 STRUCTURAL COLLAR—MANUAL TRANSAXLE EQUIPPED...........................................................................................................................................1220 INSTALLATION..............................................................................................................................................................................1220 STRUCTURAL COLLAR—AUTOMATIC TRANSAXLE EQUIPPED........................................................................................................................................1220 STRUCTURAL COLLAR—MANUAL TRANSAXLE EQUIPPED...........................................................................................................................................1221 VIBRATION DAMPER..............................................................................................................................................................................1221 REMOVAL...................................................................................................................................................................................1221 INSTALLATION..............................................................................................................................................................................1221 ENGINE MOUNTING...............................................................................................................................................................................1222 DESCRIPTION...............................................................................................................................................................................1222 OPERATION.................................................................................................................................................................................1222 LEFT MOUNT....................................................................................................................................................................................1222 REMOVAL...................................................................................................................................................................................1222 INSTALLATION..............................................................................................................................................................................1222 RIGHT MOUNT...................................................................................................................................................................................1223 REMOVAL...................................................................................................................................................................................1223 INSTALLATION..............................................................................................................................................................................1223 TORQUE STRUT..................................................................................................................................................................................1224 REMOVAL...................................................................................................................................................................................1224 REMOVAL - UPPER.......................................................................................................................................................................1224 REMOVAL - LOWER.......................................................................................................................................................................1224 INSTALLATION..............................................................................................................................................................................1224 INSTALLATION - UPPER..................................................................................................................................................................1224 INSTALLATION - LOWER..................................................................................................................................................................1225 ADJUSTMENTS...............................................................................................................................................................................1225 ENGINE TORQUE STRUT ADJUSTMENT........................................................................................................................................................1225 LUBRICATION...................................................................................................................................................................................1226 DESCRIPTION...............................................................................................................................................................................1226 OPERATION.................................................................................................................................................................................1226 DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE......................................................................................................................................1226 OIL...........................................................................................................................................................................................1227 STANDARD PROCEDURE........................................................................................................................................................................1227 ENGINE OIL LEVEL CHECK................................................................................................................................................................1227 STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE.....................................................................................................................................1227 OIL FILTER SPECIFICATION..........................................................................................................................................................1229 USED ENGINE OIL DISPOSAL..........................................................................................................................................................1229 OIL FILTER....................................................................................................................................................................................1229 REMOVAL...................................................................................................................................................................................1229 INSTALLATION..............................................................................................................................................................................1229 OIL FILTER ADAPTER............................................................................................................................................................................1229 REMOVAL...................................................................................................................................................................................1229 INSTALLATION..............................................................................................................................................................................1229 OIL PAN.......................................................................................................................................................................................1230 REMOVAL...................................................................................................................................................................................1230 INSTALLATION..............................................................................................................................................................................1230 OIL PRESSURE SENSOR/SWITCH....................................................................................................................................................................1230 DESCRIPTION...............................................................................................................................................................................1230 OPERATION.................................................................................................................................................................................1231 REMOVAL...................................................................................................................................................................................1231 INSTALLATION..............................................................................................................................................................................1231 OIL PUMP......................................................................................................................................................................................1231 REMOVAL...................................................................................................................................................................................1231 DISASSEMBLY...............................................................................................................................................................................1231 CLEANING..................................................................................................................................................................................1231 INSPECTION................................................................................................................................................................................1232 ASSEMBLY..................................................................................................................................................................................1232 INSTALLATION..............................................................................................................................................................................1233 OIL JET - 2.4L TURBO..........................................................................................................................................................................1234 DESCRIPTION...............................................................................................................................................................................1234 REMOVAL...................................................................................................................................................................................1234 INSTALLATION..............................................................................................................................................................................1234 OIL COOLER & LINES - 2.4L TURBO...............................................................................................................................................................1235 DESCRIPTION...............................................................................................................................................................................1235 REMOVAL...................................................................................................................................................................................1235 INSTALLATION..............................................................................................................................................................................1235 INTAKE MANIFOLD...............................................................................................................................................................................1236 DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS.............................................................................................................................................1236 REMOVAL...................................................................................................................................................................................1236 REMOVAL - UPPER INTAKE MANIFOLD.......................................................................................................................................................1236 Non-Turbo.........................................................................................................................................................................1236 Turbo.............................................................................................................................................................................1238 REMOVAL - LOWER INTAKE MANIFOLD.......................................................................................................................................................1240 CLEANING..................................................................................................................................................................................1241 INSPECTION................................................................................................................................................................................1241 INSTALLATION..............................................................................................................................................................................1241 INSTALLATION - UPPER INTAKE MANIFOLD..................................................................................................................................................1241 Non-Turbo.........................................................................................................................................................................1241 Turbo.............................................................................................................................................................................1241 INSTALLATION - LOWER INTAKE MANIFOLD..................................................................................................................................................1242 EXHAUST MANIFOLD..............................................................................................................................................................................1243 REMOVAL...................................................................................................................................................................................1243 CLEANING..................................................................................................................................................................................1244 INSPECTION................................................................................................................................................................................1244 INSTALLATION..............................................................................................................................................................................1244 TIMING BELT COVER(S)..........................................................................................................................................................................1245 REMOVAL...................................................................................................................................................................................1245 FRONT COVER—UPPER.....................................................................................................................................................................1245 FRONT COVER—LOWER.....................................................................................................................................................................1245 REAR COVER............................................................................................................................................................................1245 INSTALLATION..............................................................................................................................................................................1245 FRONT COVER—UPPER.....................................................................................................................................................................1245 FRONT COVER—LOWER.....................................................................................................................................................................1247 REAR COVER............................................................................................................................................................................1247 TIMING BELT AND SPROCKETS.....................................................................................................................................................................1247 REMOVAL...................................................................................................................................................................................1247 REMOVAL - TIMING BELT.................................................................................................................................................................1247 REMOVAL - CAMSHAFT SPROCKET(S)........................................................................................................................................................1247 REMOVAL - CRANKSHAFT SPROCKET.........................................................................................................................................................1248 INSTALLATION..............................................................................................................................................................................1248 INSTALLATION - CRANKSHAFT SPROCKET....................................................................................................................................................1248 INSTALLATION - CAMSHAFT SPROCKET(S)...................................................................................................................................................1249 INSTALLATION - TIMING BELT............................................................................................................................................................1249 TIMING BELT TENSIONER & PULLEY................................................................................................................................................................1251 REMOVAL...................................................................................................................................................................................1251 INSTALLATION..............................................................................................................................................................................1251 BALANCE SHAFTS AND CARRIER ASSEMBLY...........................................................................................................................................................1252 DESCRIPTION...............................................................................................................................................................................1252 OPERATION.................................................................................................................................................................................1252 REMOVAL...................................................................................................................................................................................1252 BALANCE SHAFTS/CHAIN/SPROCKETS........................................................................................................................................................1252 BALANCE SHAFT CARRIER.................................................................................................................................................................1253 INSTALLATION..............................................................................................................................................................................1253 BALANCE SHAFT INSTALLATION/TIMING.....................................................................................................................................................1253 11-EXHAUST SYSTEM AND TURBOCHARGER....................................................................................................................................................................1257 EXHAUST SYSTEM AND TURBOCHARGER...................................................................................................................................................................1258 DESCRIPTION - EXHAUST SYSTEM..................................................................................................................................................................1258 DIAGNOSIS AND TESTING.........................................................................................................................................................................1258 EXHAUST SYSTEM DIAGNOSIS..................................................................................................................................................................1258 DIAGNOSIS AND TESTING - EXHAUST SYSTEM RESTRICTION CHECK..................................................................................................................................1259 INSPECTION....................................................................................................................................................................................1259 ADJUSTMENTS...................................................................................................................................................................................1259 EXHAUST SYSTEM ALIGNMENT..................................................................................................................................................................1259 SPECIFICATIONS................................................................................................................................................................................1260 EXHAUST SYSTEM CLEARANCE..................................................................................................................................................................1260 TORQUE - EXHAUST SYSTEM COMPONENTS........................................................................................................................................................1261 TORQUE - TURBOCHARGER COMPONENTS..........................................................................................................................................................1261 SPECIAL TOOLS.................................................................................................................................................................................1261 EXHAUST SYSTEM............................................................................................................................................................................1261 MUFFLER...........................................................................................................................................................................................1262 REMOVAL.......................................................................................................................................................................................1262 INSTALLATION..................................................................................................................................................................................1262 INTERMEDIATE PIPE.................................................................................................................................................................................1263 REMOVAL.......................................................................................................................................................................................1263 INSTALLATION..................................................................................................................................................................................1264 CATALYTIC CONVERTER...............................................................................................................................................................................1265 DESCRIPTION...................................................................................................................................................................................1265 OPERATION.....................................................................................................................................................................................1265 REMOVAL.......................................................................................................................................................................................1265 INSPECTION....................................................................................................................................................................................1266 INSTALLATION..................................................................................................................................................................................1266 SUPPORT BRACKETS AND ISOLATORS....................................................................................................................................................................1267 REMOVAL.......................................................................................................................................................................................1267 INSTALLATION..................................................................................................................................................................................1267 HEAT SHIELDS......................................................................................................................................................................................1268 DESCRIPTION...................................................................................................................................................................................1268 REMOVAL.......................................................................................................................................................................................1268 INSTALLATION..................................................................................................................................................................................1268 TURBOCHARGER SYSTEM...............................................................................................................................................................................1269 DIAGNOSIS AND TESTING - TURBOCHARGER..........................................................................................................................................................1269 TURBOCHARGER......................................................................................................................................................................................1270 DESCRIPTION...................................................................................................................................................................................1270 OPERATION.....................................................................................................................................................................................1270 REMOVAL - TURBOCHARGER........................................................................................................................................................................1271 INSTALLATION - TURBOCHARGER...................................................................................................................................................................1274 CHARGE AIR COOLER AND HOSES.......................................................................................................................................................................1275 REMOVAL.......................................................................................................................................................................................1275 REMOVAL - CHARGE AIR COOLER HOSES.........................................................................................................................................................1275 HOSE - CHARGE AIR COOLER TO THROTTLE BODY.............................................................................................................................................1275 HOSE - TURBOCHARGER TO CHARGE AIR COOLER..............................................................................................................................................1276 REMOVAL - CHARGE AIR COOLER...............................................................................................................................................................1276 INSTALLATION..................................................................................................................................................................................1277 INSTALLATION - CHARGE AIR COOLER HOSES....................................................................................................................................................1277 HOSE - CHARGE AIR COOLER TO THROTTLE BODY.............................................................................................................................................1277 HOSE - TURBOCHARGER TO CHARGE AIR COOLER..............................................................................................................................................1277 INSTALLATION - CHARGE AIR COOLER..........................................................................................................................................................1277 LINES AND HOSES...................................................................................................................................................................................1278 REMOVAL - LINES AND HOSES.....................................................................................................................................................................1278 COOLANT SUPPLY LINE.......................................................................................................................................................................1278 COOLANT RETURN LINE.......................................................................................................................................................................1278 OIL SUPPLY LINE...........................................................................................................................................................................1279 OIL RETURN LINE...........................................................................................................................................................................1279 INSTALLATION - LINES AND HOSES................................................................................................................................................................1280 COOLANT SUPPLY LINE.......................................................................................................................................................................1280 COOLANT RETURN LINE.......................................................................................................................................................................1280 OIL SUPPLY LINE...........................................................................................................................................................................1280 OIL RETURN LINE...........................................................................................................................................................................1280 SOLENOIDS AND VACUUM HARNESS......................................................................................................................................................................1281 DESCRIPTION...................................................................................................................................................................................1281 REMOVAL.......................................................................................................................................................................................1281 INSTALLATION..................................................................................................................................................................................1282 13-FRAMES & BUMPERS...................................................................................................................................................................................1283 FRONT BUMPER REINFORCEMENT........................................................................................................................................................................1283 REMOVAL.......................................................................................................................................................................................1283 INSTALLATION..................................................................................................................................................................................1283 FRONT BUMPER FASCIA...............................................................................................................................................................................1284 REMOVAL.......................................................................................................................................................................................1284 INSTALLATION..................................................................................................................................................................................1284 REAR BUMPER FASCIA................................................................................................................................................................................1285 REMOVAL.......................................................................................................................................................................................1285 INSTALLATION..................................................................................................................................................................................1285 REAR BUMPER REINFORCEMENT.........................................................................................................................................................................1285 REMOVAL.......................................................................................................................................................................................1285 INSTALLATION..................................................................................................................................................................................1285 FRAME.............................................................................................................................................................................................1286 SPECIFICATIONS................................................................................................................................................................................1286 SPECIFICATIONS - FRAME DIMENSIONS.........................................................................................................................................................1286 VEHICLE PREPARATION...................................................................................................................................................................1286 SPECIFICATIONS - TORQUE...................................................................................................................................................................1290 FRONT CROSSMEMBER.................................................................................................................................................................................1291 REMOVAL.......................................................................................................................................................................................1291 INSTALLATION..................................................................................................................................................................................1293 FRONT EMERGENCY TOW EYE...........................................................................................................................................................................1295 REMOVAL.......................................................................................................................................................................................1295 INSTALLATION..................................................................................................................................................................................1295 REAR EMERGENCY TOW EYE............................................................................................................................................................................1295 REMOVAL.......................................................................................................................................................................................1295 INSTALLATION..................................................................................................................................................................................1295 14-FUEL SYSTEM........................................................................................................................................................................................1297 FUEL DELIVERY.....................................................................................................................................................................................1297 FUEL DELIVERY.................................................................................................................................................................................1298 DESCRIPTION...............................................................................................................................................................................1298 OPERATION.................................................................................................................................................................................1298 DIAGNOSIS AND TESTING - FUEL DELIVERY SYSTEM..............................................................................................................................................1298 STANDARD PROCEDURE........................................................................................................................................................................1298 STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE...........................................................................................................................1298 STANDARD PROCEDURE - DRAINING FUEL TANK...............................................................................................................................................1298 SPECIFICATIONS............................................................................................................................................................................1299 TORQUE................................................................................................................................................................................1299 FUEL SYSTEM PRESSURE..................................................................................................................................................................1299 SPECIAL TOOLS.............................................................................................................................................................................1299 FUEL..................................................................................................................................................................................1299 FUEL FILTER...................................................................................................................................................................................1300 DESCRIPTION...............................................................................................................................................................................1300 FUEL LEVEL SENDING UNIT / SENSOR..............................................................................................................................................................1300 DESCRIPTION...............................................................................................................................................................................1300 OPERATION.................................................................................................................................................................................1300 REMOVAL...................................................................................................................................................................................1300 INSTALLATION..............................................................................................................................................................................1301 FUEL LINES....................................................................................................................................................................................1301 DESCRIPTION - FUEL LINES/HOSES AND CLAMPS.................................................................................................................................................1301 STANDARD PROCEDURE - HOSES AND CLAMP......................................................................................................................................................1302 FUEL PRESSURE REGULATOR.......................................................................................................................................................................1302 DESCRIPTION...............................................................................................................................................................................1302 OPERATION.................................................................................................................................................................................1302 REMOVAL...................................................................................................................................................................................1302 INSTALLATION..............................................................................................................................................................................1303 FUEL PUMP.....................................................................................................................................................................................1303 DESCRIPTION...............................................................................................................................................................................1303 OPERATION.................................................................................................................................................................................1303 FUEL PUMP MODULE..............................................................................................................................................................................1303 DESCRIPTION...............................................................................................................................................................................1303 OPERATION.................................................................................................................................................................................1303 FUEL PUMP ELECTRICAL CONTROL..........................................................................................................................................................1304 ELECTRICAL PUMP REPLACEMENT...........................................................................................................................................................1304 REMOVAL...................................................................................................................................................................................1304 INSTALLATION..............................................................................................................................................................................1304 FUEL RAIL.....................................................................................................................................................................................1305 DESCRIPTION...............................................................................................................................................................................1305 OPERATION.................................................................................................................................................................................1305 REMOVAL...................................................................................................................................................................................1305 REMOVAL...............................................................................................................................................................................1305 REMOVAL - 2.4L TURBO..................................................................................................................................................................1306 REMOVAL - 1.6L........................................................................................................................................................................1309 INSTALLATION..............................................................................................................................................................................1310 INSTALLATION..........................................................................................................................................................................1310 INSTALLATION - 2.4L TURBO.............................................................................................................................................................1310 INSTALLATION - 1.6L...................................................................................................................................................................1310 FUEL TANK.....................................................................................................................................................................................1310 DESCRIPTION...............................................................................................................................................................................1310 OPERATION.................................................................................................................................................................................1310 REMOVAL...................................................................................................................................................................................1311 INSTALLATION..............................................................................................................................................................................1312 FUEL TANK FILLER TUBE.........................................................................................................................................................................1312 REMOVAL...................................................................................................................................................................................1312 INSTALLATION..............................................................................................................................................................................1313 INLET FILTER..................................................................................................................................................................................1313 DESCRIPTION...............................................................................................................................................................................1313 QUICK CONNECT FITTING.........................................................................................................................................................................1313 STANDARD PROCEDURE - QUICK-CONNECT FITTINGS...............................................................................................................................................1313 REMOVAL...............................................................................................................................................................................1313 INSTALLATION..........................................................................................................................................................................1313 TWO-TAB TYPE FITTING..................................................................................................................................................................1314 PLASTIC RETAINER RING TYPE FITTING....................................................................................................................................................1315 FUEL INJECTION....................................................................................................................................................................................1316 FUEL INJECTION................................................................................................................................................................................1317 OPERATION.................................................................................................................................................................................1317 OPERATION - INJECTION SYSTEM..........................................................................................................................................................1317 OPERATION - MODES OF OPERATION........................................................................................................................................................1317 IGNITION SWITCH ON (ZERO RPM) MODE................................................................................................................................................1317 ENGINE START-UP MODE..............................................................................................................................................................1318 ENGINE WARM-UP MODE...............................................................................................................................................................1318 CRUISE OR IDLE MODE...............................................................................................................................................................1318 ACCELERATION MODE.................................................................................................................................................................1319 DECELERATION MODE.................................................................................................................................................................1319 WIDE-OPEN-THROTTLE MODE...........................................................................................................................................................1319 IGNITION SWITCH OFF MODE..........................................................................................................................................................1319 FUEL CORRECTION or ADAPTIVE MEMORIES..................................................................................................................................................1319 DESCRIPTION.......................................................................................................................................................................1319 OPERATION.........................................................................................................................................................................1319 PROGRAMMABLE COMMUNICATIONS INTERFACE (PCI) BUS.......................................................................................................................................1320 DESCRIPTION.......................................................................................................................................................................1320 OPERATION.........................................................................................................................................................................1320 SYSTEM DIAGNOSIS......................................................................................................................................................................1321 OPERATION.........................................................................................................................................................................1321 SPECIFICATIONS............................................................................................................................................................................1321 TORQUE................................................................................................................................................................................1321 SPECIAL TOOLS.............................................................................................................................................................................1322 FUEL..................................................................................................................................................................................1322 ACCELERATOR PEDAL.............................................................................................................................................................................1322 REMOVAL...................................................................................................................................................................................1322 INSTALLATION..............................................................................................................................................................................1323 ACCELERATOR PEDAL POSITION SENSOR - 1.6L......................................................................................................................................................1323 DESCRIPTION...............................................................................................................................................................................1323 REMOVAL - LHD.............................................................................................................................................................................1323 INSTALLATION - LHD........................................................................................................................................................................1323 CRANKSHAFT POSITION SENSOR....................................................................................................................................................................1324 DESCRIPTION...............................................................................................................................................................................1324 OPERATION.................................................................................................................................................................................1324 REMOVAL...................................................................................................................................................................................1325 REMOVAL - 1.6L........................................................................................................................................................................1325 REMOVAL - 2.0, 2.4, 2.4L TURBO........................................................................................................................................................1325 INSTALLATION..............................................................................................................................................................................1326 INSTALLATION - 1.6L...................................................................................................................................................................1326 INSTALLATION - 2.0, 2.4, 2.4L Turbo...................................................................................................................................................1326 FUEL INJECTOR.................................................................................................................................................................................1326 DESCRIPTION...............................................................................................................................................................................1326 OPERATION.................................................................................................................................................................................1326 STANDARD PROCEDURE........................................................................................................................................................................1327 REMOVAL - INJECTOR CONNECTOR..........................................................................................................................................................1327 REMOVAL...................................................................................................................................................................................1327 REMOVAL - 2.0, 2.4L...................................................................................................................................................................1327 REMOVAL - 1.6L........................................................................................................................................................................1328 REMOVAL - 2.4L TURBO..................................................................................................................................................................1328 INSTALLATION..............................................................................................................................................................................1331 INSTALLATION - 2.0, 2.4L..............................................................................................................................................................1331 INSTALLATION - 1.6L...................................................................................................................................................................1332 INSTALLATION - 2.4L TURBO.............................................................................................................................................................1332 FUEL PUMP RELAY...............................................................................................................................................................................1332 DESCRIPTION...............................................................................................................................................................................1332 OPERATION.................................................................................................................................................................................1332 IDLE AIR CONTROL MOTOR........................................................................................................................................................................1333 DESCRIPTION...............................................................................................................................................................................1333 OPERATION.................................................................................................................................................................................1333 Target Idle...........................................................................................................................................................................1333 REMOVAL...................................................................................................................................................................................1333 INSTALLATION..............................................................................................................................................................................1333 INLET AIR TEMPERATURE SENSOR..................................................................................................................................................................1334 DESCRIPTION...............................................................................................................................................................................1334 OPERATION.................................................................................................................................................................................1334 Inlet/Intake Air Temperature (NGC)....................................................................................................................................................1334 Battery Temperature (SBEC Vehicles without Battery Temperature sensor)................................................................................................................1334 REMOVAL...................................................................................................................................................................................1334 INSTALLATION..............................................................................................................................................................................1334 MAP SENSOR....................................................................................................................................................................................1335 DESCRIPTION...............................................................................................................................................................................1335 OPERATION.................................................................................................................................................................................1335 REMOVAL...................................................................................................................................................................................1336 REMOVAL - 2.0, 2.4, 2.4L TURBO........................................................................................................................................................1336 REMOVAL - 1.6L........................................................................................................................................................................1336 INSTALLATION..............................................................................................................................................................................1336 INSTALLATION - 2.0, 2.4, 2.4L Turbo...................................................................................................................................................1336 INSTALLATION - 1.6L...................................................................................................................................................................1336 O2 SENSOR.....................................................................................................................................................................................1336 DESCRIPTION...............................................................................................................................................................................1336 OPERATION.................................................................................................................................................................................1336 UPSTREAM OXYGEN SENSOR................................................................................................................................................................1337 DOWNSTREAM OXYGEN SENSOR..............................................................................................................................................................1338 REMOVAL...................................................................................................................................................................................1338 REMOVAL - 1/1 UPSTREAM................................................................................................................................................................1338 REMOVAL - 1/2 DOWNSTREAM..............................................................................................................................................................1338 REMOVAL - 2.4L TURBO..................................................................................................................................................................1338 INSTALLATION..............................................................................................................................................................................1339 INSTALLATION - 1/1 UPSTREAM...........................................................................................................................................................1339 INSTALLATION - 1/2 DOWNSTREAM.........................................................................................................................................................1339 INSTALLATION - 2.4L TURBO.............................................................................................................................................................1339 THROTTLE BODY.................................................................................................................................................................................1340 DESCRIPTION...............................................................................................................................................................................1340 OPERATION.................................................................................................................................................................................1340 REMOVAL...................................................................................................................................................................................1340 REMOVAL - 2.0, 2.4L...................................................................................................................................................................1340 REMOVAL - 1.6L........................................................................................................................................................................1341 REMOVAL - 2.4L TURBO..................................................................................................................................................................1342 INSTALLATION..............................................................................................................................................................................1343 INSTALLATION - 2.0, 2.4L..............................................................................................................................................................1343 INSTALLATION - 1.6L...................................................................................................................................................................1343 INSTALLATION - 2.4L TURBO.............................................................................................................................................................1344 THROTTLE CONTROL CABLE........................................................................................................................................................................1344 REMOVAL...................................................................................................................................................................................1344 INSTALLATION..............................................................................................................................................................................1344 THROTTLE POSITION SENSOR......................................................................................................................................................................1345 DESCRIPTION...............................................................................................................................................................................1345 OPERATION.................................................................................................................................................................................1345 REMOVAL...................................................................................................................................................................................1345 INSTALLATION..............................................................................................................................................................................1346 19-STEERING...........................................................................................................................................................................................1347 STEERING..........................................................................................................................................................................................1347 STEERING......................................................................................................................................................................................1347 DESCRIPTION - POWER STEERING SYSTEM.......................................................................................................................................................1347 OPERATION - POWER STEERING SYSTEM.........................................................................................................................................................1347 WARNING...................................................................................................................................................................................1347 WARNINGS AND CAUTIONS.................................................................................................................................................................1347 DIAGNOSIS AND TESTING.....................................................................................................................................................................1347 DIAGNOSIS AND TESTING - POWER STEERING FLOW AND PRESSURE TEST.........................................................................................................................1347 TEST PROCEDURE....................................................................................................................................................................1348 DIAGNOSIS AND TESTING - STEERING DIAGNOSIS CHARTS.....................................................................................................................................1349 POWER STEERING NOISE..............................................................................................................................................................1349 STEERING WHEEL FEEL...............................................................................................................................................................1351 POWER STEERING FLUID..............................................................................................................................................................1354 SPECIFICATIONS - POWER STEERING FASTENER TORQUE...........................................................................................................................................1354 SPECIAL TOOLS.............................................................................................................................................................................1355 POWER STEERING........................................................................................................................................................................1355 COLUMN............................................................................................................................................................................................1356 COLUMN........................................................................................................................................................................................1356 DESCRIPTION...............................................................................................................................................................................1356 OPERATION.................................................................................................................................................................................1356 WARNING...................................................................................................................................................................................1357 WARNINGS AND CAUTIONS.................................................................................................................................................................1357 DIAGNOSIS AND TESTING - STEERING COLUMN...................................................................................................................................................1357 REMOVAL...................................................................................................................................................................................1357 REMOVAL...............................................................................................................................................................................1357 REMOVAL - RHD.........................................................................................................................................................................1362 INSTALLATION..............................................................................................................................................................................1362 INSTALLATION..........................................................................................................................................................................1362 INSTALLATION - RHD....................................................................................................................................................................1364 SPECIFICATIONS - STEERING COLUMN FASTENER TORQUE..........................................................................................................................................1364 IGNITION SWITCH...............................................................................................................................................................................1364 REMOVAL...................................................................................................................................................................................1364 INSTALLATION..............................................................................................................................................................................1365 KEY/LOCK CYLINDER.............................................................................................................................................................................1366 REMOVAL...................................................................................................................................................................................1366 INSTALLATION..............................................................................................................................................................................1366 SHROUD - UPPER/LOWER..........................................................................................................................................................................1367 REMOVAL...................................................................................................................................................................................1367 INSTALLATION..............................................................................................................................................................................1367 STEERING COUPLING - LOWER.....................................................................................................................................................................1367 DESCRIPTION...............................................................................................................................................................................1367 OPERATION.................................................................................................................................................................................1367 DIAGNOSIS AND TESTING - STEERING COLUMN LOWER COUPLING....................................................................................................................................1368 REMOVAL...................................................................................................................................................................................1368 INSTALLATION..............................................................................................................................................................................1371 STEERING WHEEL................................................................................................................................................................................1372 REMOVAL...................................................................................................................................................................................1372 INSTALLATION..............................................................................................................................................................................1372 GEAR..............................................................................................................................................................................................1374 GEAR..........................................................................................................................................................................................1374 DESCRIPTION...............................................................................................................................................................................1374 OPERATION.................................................................................................................................................................................1374 REMOVAL...................................................................................................................................................................................1375 REMOVAL...............................................................................................................................................................................1375 REMOVAL - RHD.........................................................................................................................................................................1378 INSTALLATION..............................................................................................................................................................................1378 INSTALLATION..........................................................................................................................................................................1378 INSTALLATION - RHD....................................................................................................................................................................1380 POWER STEERING PRESSURE SWITCH................................................................................................................................................................1380 DESCRIPTION...............................................................................................................................................................................1380 OPERATION.................................................................................................................................................................................1380 REMOVAL...................................................................................................................................................................................1380 INSTALLATION..............................................................................................................................................................................1381 TIE ROD - OUTER...............................................................................................................................................................................1381 REMOVAL...................................................................................................................................................................................1381 INSTALLATION..............................................................................................................................................................................1382 PUMP..............................................................................................................................................................................................1383 PUMP..........................................................................................................................................................................................1383 DESCRIPTION...............................................................................................................................................................................1383 DESCRIPTION - 1.6L ENGINE.............................................................................................................................................................1383 DESCRIPTION - 2.0L/2.4L/2.4L TURBO ENGINE.............................................................................................................................................1384 DESCRIPTION - 2.2L DIESEL.............................................................................................................................................................1384 STANDARD PROCEDURE - POWER STEERING PUMP INITIAL OPERATION................................................................................................................................1384 REMOVAL...................................................................................................................................................................................1385 REMOVAL - 1.6L ENGINE.................................................................................................................................................................1385 REMOVAL - 2.0L/2.4L ENGINE............................................................................................................................................................1385 REMOVAL - 2.4L TURBO..................................................................................................................................................................1388 REMOVAL - 2.2L DIESEL.................................................................................................................................................................1390 DISASSEMBLY...............................................................................................................................................................................1390 ASSEMBLY..................................................................................................................................................................................1390 INSTALLATION..............................................................................................................................................................................1391 INSTALLATION - 1.6L ENGINE............................................................................................................................................................1391 INSTALLATION - 2.0L/2.4L ENGINE.......................................................................................................................................................1391 INSTALLATION - 2.4L TURBO.............................................................................................................................................................1391 INSTALLATION - 2.2L DIESEL............................................................................................................................................................1392 FLUID.........................................................................................................................................................................................1392 STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING0 - 8 PT (Continued)..........................................................................................................1392 1.6L GAS/2.2L DIESEL ENGINE...........................................................................................................................................................1392 2.0L/2.4L ENGINE......................................................................................................................................................................1392 2.4L TURBO ENGINE.....................................................................................................................................................................1392 FLUID COOLER..................................................................................................................................................................................1393 DESCRIPTION...............................................................................................................................................................................1393 REMOVAL - NON-TURBO ENGINES...............................................................................................................................................................1393 INSTALLATION - NON-TURBO ENGINES..........................................................................................................................................................1393 HOSE - POWER STEERING PRESSURE................................................................................................................................................................1394 REMOVAL...................................................................................................................................................................................1394 REMOVAL - 2.0L ENGINE.................................................................................................................................................................1394 REMOVAL - 2.4L ENGINE.................................................................................................................................................................1395 REMOVAL - 2.2L DIESEL.................................................................................................................................................................1396 INSTALLATION..............................................................................................................................................................................1397 INSTALLATION - 2.0L ENGINE............................................................................................................................................................1397 INSTALLATION - 2.4L ENGINE............................................................................................................................................................1398 INSTALLATION - 2.2L DIESEL............................................................................................................................................................1399 HOSE - POWER STEERING PRESSURE/RETURN.........................................................................................................................................................1399 REMOVAL - 2.4L TURBO......................................................................................................................................................................1399 INSTALLATION - 2.4L TURBO.................................................................................................................................................................1402 HOSE - POWER STEERING RETURN..................................................................................................................................................................1403 REMOVAL...................................................................................................................................................................................1403 REMOVAL - 2.0L/2.4L ENGINE............................................................................................................................................................1403 REMOVAL - 2.4L TURBO..................................................................................................................................................................1404 REMOVAL - 2.2L DIESEL.................................................................................................................................................................1404 INSTALLATION..............................................................................................................................................................................1404 INSTALLATION - 2.0L/2.4L ENGINE.......................................................................................................................................................1404 INSTALLATION - 2.4L TURBO.............................................................................................................................................................1405 INSTALLATION - 2.2L DIESEL............................................................................................................................................................1405 HOSE - POWER STEERING SUPPLY..................................................................................................................................................................1405 REMOVAL...................................................................................................................................................................................1405 REMOVAL - 2.0L/2.4L ENGINE............................................................................................................................................................1405 REMOVAL - 2.2L DIESEL.................................................................................................................................................................1406 INSTALLATION..............................................................................................................................................................................1407 INSTALLATION - 2.0L/2.4L ENGINE.......................................................................................................................................................1407 INSTALLATION - 2.2L DIESEL............................................................................................................................................................1407 PULLEY........................................................................................................................................................................................1408 REMOVAL - 2.2L DIESEL.....................................................................................................................................................................1408 INSTALLATION - 2.2L DIESEL................................................................................................................................................................1408 RESERVOIR.....................................................................................................................................................................................1408 DESCRIPTION...............................................................................................................................................................................1408 REMOVAL...................................................................................................................................................................................1408 REMOVAL - 1.6L ENGINE.................................................................................................................................................................1408 REMOVAL - 2.0L/2.4L ENGINE............................................................................................................................................................1409 REMOVAL - 2.2L DIESEL.................................................................................................................................................................1409 INSTALLATION..............................................................................................................................................................................1410 INSTALLATION - 1.6L ENGINE............................................................................................................................................................1410 INSTALLATION - 2.0L/2.4L ENGINE.......................................................................................................................................................1410 INSTALLATION - 2.2L DIESEL............................................................................................................................................................1411 21-TRANSAXLE..........................................................................................................................................................................................1413 G288 MANUAL TRANSAXLE.............................................................................................................................................................................1413 G288 MANUAL TRANSAXLE.........................................................................................................................................................................1414 DESCRIPTION...............................................................................................................................................................................1414 TRANSAXLE IDENTIFICATION..............................................................................................................................................................1416 OPERATION.................................................................................................................................................................................1417 NEUTRAL...............................................................................................................................................................................1417 FIRST GEAR............................................................................................................................................................................1418 SECOND GEAR...........................................................................................................................................................................1419 THIRD GEAR............................................................................................................................................................................1420 FOURTH GEAR...........................................................................................................................................................................1421 FIFTH GEAR............................................................................................................................................................................1422 REVERSE GEAR..........................................................................................................................................................................1423 SHIFT SYSTEM..........................................................................................................................................................................1424 REMOVAL...................................................................................................................................................................................1425 REMOVAL—2.2L TURBO DIESEL.............................................................................................................................................................1425 REMOVAL—2.4L TURBO....................................................................................................................................................................1429 DISASSEMBLY...............................................................................................................................................................................1434 ASSEMBLY..................................................................................................................................................................................1439 INSTALLATION..............................................................................................................................................................................1446 INSTALLATION—2.2L TURBO DIESEL........................................................................................................................................................1446 INSTALLATION—2.4L TURBO...............................................................................................................................................................1450 SPECIFICATIONS............................................................................................................................................................................1455 SPECIAL TOOLS.............................................................................................................................................................................1456 AXLE SEAL.....................................................................................................................................................................................1460 REMOVAL...................................................................................................................................................................................1460 INSTALLATION..............................................................................................................................................................................1460 BACKUP LAMP SWITCH............................................................................................................................................................................1460 REMOVAL...................................................................................................................................................................................1460 INSTALLATION..............................................................................................................................................................................1461 CLUTCH BELLHOUSING............................................................................................................................................................................1461 DISASSEMBLY...............................................................................................................................................................................1461 ASSEMBLY..................................................................................................................................................................................1463 DETENT PLUG...................................................................................................................................................................................1465 DESCRIPTION...............................................................................................................................................................................1465 REMOVAL...................................................................................................................................................................................1467 INSTALLATION..............................................................................................................................................................................1467 DIFFERENTIAL..................................................................................................................................................................................1468 DESCRIPTION...............................................................................................................................................................................1468 OPERATION.................................................................................................................................................................................1468 REMOVAL...................................................................................................................................................................................1468 DISASSEMBLY...............................................................................................................................................................................1468 ASSEMBLY..................................................................................................................................................................................1469 INSTALLATION..............................................................................................................................................................................1469 FLUID.........................................................................................................................................................................................1470 STANDARD PROCEDURE........................................................................................................................................................................1470 STANDARD PROCEDURE - FLUID LEVEL CHECKING.............................................................................................................................................1470 STANDARD PROCEDURE - FLUID DRAIN AND FILL.............................................................................................................................................1470 GEAR SHIFT BOOT...............................................................................................................................................................................1471 REMOVAL...................................................................................................................................................................................1471 INSTALLATION..............................................................................................................................................................................1471 GEAR SHIFT CABLE..............................................................................................................................................................................1471 REMOVAL...................................................................................................................................................................................1471 INSTALLATION..............................................................................................................................................................................1475 ADJUSTMENTS...............................................................................................................................................................................1478 ADJUSTMENT - GEARSHIFT CROSSOVER CABLE................................................................................................................................................1478 GEAR SHIFT KNOB...............................................................................................................................................................................1478 REMOVAL...................................................................................................................................................................................1478 INSTALLATION..............................................................................................................................................................................1478 GEAR SHIFT MECHANISM..........................................................................................................................................................................1479 REMOVAL...................................................................................................................................................................................1479 INSTALLATION..............................................................................................................................................................................1480 INPUT SHAFT...................................................................................................................................................................................1481 DESCRIPTION...............................................................................................................................................................................1481 DISASSEMBLY...............................................................................................................................................................................1482 ASSEMBLY..................................................................................................................................................................................1484 OUTPUT SHAFT..................................................................................................................................................................................1489 DESCRIPTION...............................................................................................................................................................................1489 DISASSEMBLY...............................................................................................................................................................................1490 ASSEMBLY..................................................................................................................................................................................1492 REVERSE SHAFT.................................................................................................................................................................................1497 DESCRIPTION...............................................................................................................................................................................1497 DISASSEMBLY...............................................................................................................................................................................1498 ASSEMBLY..................................................................................................................................................................................1499 SYNCHRONIZER..................................................................................................................................................................................1502 DESCRIPTION...............................................................................................................................................................................1502 REMOVAL...................................................................................................................................................................................1503 DISASSEMBLY...............................................................................................................................................................................1503 INSPECTION................................................................................................................................................................................1503 ASSEMBLY..................................................................................................................................................................................1503 INSTALLATION..............................................................................................................................................................................1503 TRANSAXLE HOUSING.............................................................................................................................................................................1504 DISASSEMBLY...............................................................................................................................................................................1504 ASSEMBLY..................................................................................................................................................................................1505 T350 MANUAL TRANSAXLE.............................................................................................................................................................................1506 T350 MANUAL TRANSAXLE.........................................................................................................................................................................1507 DESCRIPTION...............................................................................................................................................................................1507 TRANSAXLE IDENTIFICATION..............................................................................................................................................................1507 GEAR RATIOS...........................................................................................................................................................................1508 GEARSHIFT PATTERN.....................................................................................................................................................................1508 LUBRICANT/ADDITIVES...................................................................................................................................................................1508 SEALANTS..............................................................................................................................................................................1508 DIAGNOSIS AND TESTING - COMMON PROBLEM CAUSES.............................................................................................................................................1508 HARD SHIFTING.........................................................................................................................................................................1508 NOISY OPERATION.......................................................................................................................................................................1508 SLIPS OUT OF GEAR.....................................................................................................................................................................1508 LOW LUBRICANT LEVEL...................................................................................................................................................................1509 CLUTCH PROBLEMS.......................................................................................................................................................................1509 REMOVAL...................................................................................................................................................................................1509 DISASSEMBLY...............................................................................................................................................................................1513 CLEANING..................................................................................................................................................................................1520 INSPECTION................................................................................................................................................................................1520 ASSEMBLY..................................................................................................................................................................................1520 BEARING ADJUSTMENT PROCEDURE..........................................................................................................................................................1524 DIFFERENTIAL BEARING PRELOAD ADJUSTMENT...............................................................................................................................................1524 INSTALLATION..............................................................................................................................................................................1526 SPECIFICATIONS............................................................................................................................................................................1527 SPECIAL TOOLS.............................................................................................................................................................................1528 AXLE SEAL.....................................................................................................................................................................................1530 REMOVAL...................................................................................................................................................................................1530 INSTALLATION..............................................................................................................................................................................1530 BACK-UP LAMP SWITCH...........................................................................................................................................................................1530 REMOVAL...................................................................................................................................................................................1530 INSTALLATION..............................................................................................................................................................................1530 DIFFERENTIAL..................................................................................................................................................................................1531 DISASSEMBLY...............................................................................................................................................................................1531 ASSEMBLY..................................................................................................................................................................................1533 Measure and Adjust Side Gear End-Play.................................................................................................................................................1536 ADJUSTMENTS...............................................................................................................................................................................1536 DIFFERENTIAL BEARING PRELOAD ADJUSTMENT / SHIM SELECTION..............................................................................................................................1536 DIFFERENTIAL BEARING CUPS.....................................................................................................................................................................1537 REMOVAL...................................................................................................................................................................................1537 INSTALLATION..............................................................................................................................................................................1538 FLUID.........................................................................................................................................................................................1538 STANDARD PROCEDURE - FLUID DRAIN AND FILL.................................................................................................................................................1538 GEAR SHIFT BOOT...............................................................................................................................................................................1538 REMOVAL...................................................................................................................................................................................1538 INSTALLATION..............................................................................................................................................................................1539 GEAR SHIFT CABLE..............................................................................................................................................................................1539 REMOVAL...................................................................................................................................................................................1539 INSTALLATION..............................................................................................................................................................................1542 ADJUSTMENTS...............................................................................................................................................................................1545 ADJUSTMENT - GEARSHIFT CROSSOVER CABLE................................................................................................................................................1545 GEAR SHIFT KNOB...............................................................................................................................................................................1546 REMOVAL...................................................................................................................................................................................1546 INSTALLATION..............................................................................................................................................................................1546 GEAR SHIFT MECHANISM..........................................................................................................................................................................1546 REMOVAL...................................................................................................................................................................................1546 INSTALLATION..............................................................................................................................................................................1546 INPUT BEARING AND SLEEVE......................................................................................................................................................................1548 REMOVAL...................................................................................................................................................................................1548 INSTALLATION..............................................................................................................................................................................1548 INPUT SHAFT...................................................................................................................................................................................1549 DISASSEMBLY...............................................................................................................................................................................1549 ASSEMBLY..................................................................................................................................................................................1552 OUTPUT SHAFT..................................................................................................................................................................................1554 DISASSEMBLY...............................................................................................................................................................................1554 OUTPUT BEARING AND RACE.......................................................................................................................................................................1555 REMOVAL...................................................................................................................................................................................1555 INSTALLATION..............................................................................................................................................................................1556 REAR BEARING OIL FEED TROUGH..................................................................................................................................................................1556 REMOVAL...................................................................................................................................................................................1556 INSTALLATION..............................................................................................................................................................................1556 SHIFT CROSSOVER LEVER.........................................................................................................................................................................1556 REMOVAL...................................................................................................................................................................................1556 INSTALLATION..............................................................................................................................................................................1557 SHIFT CROSSOVER SHAFT.........................................................................................................................................................................1557 REMOVAL...................................................................................................................................................................................1557 INSTALLATION..............................................................................................................................................................................1557 SHIFT CROSSOVER SHAFT BUSHING.................................................................................................................................................................1557 REMOVAL...................................................................................................................................................................................1557 INSTALLATION..............................................................................................................................................................................1557 SHIFT RAIL AND FORK...........................................................................................................................................................................1558 DISASSEMBLY...............................................................................................................................................................................1558 SHIFT RAIL BUSHINGS...........................................................................................................................................................................1558 REMOVAL...................................................................................................................................................................................1558 INSTALLATION..............................................................................................................................................................................1558 SHIFT SELECTOR SHAFT..........................................................................................................................................................................1558 REMOVAL...................................................................................................................................................................................1558 INSTALLATION..............................................................................................................................................................................1558 SHIFT SELECTOR SHAFT BUSHING..................................................................................................................................................................1558 REMOVAL...................................................................................................................................................................................1558 INSTALLATION..............................................................................................................................................................................1559 SHIFT SHAFT SEALS.............................................................................................................................................................................1559 REMOVAL...................................................................................................................................................................................1559 INSTALLATION..............................................................................................................................................................................1559 SYNCHRONIZER..................................................................................................................................................................................1559 DISASSEMBLY...............................................................................................................................................................................1559 CLEANING..................................................................................................................................................................................1559 CLEAN.................................................................................................................................................................................1559 INSPECTION................................................................................................................................................................................1559 INSPECT...............................................................................................................................................................................1559 ASSEMBLY..................................................................................................................................................................................1559 VEHICLE SPEED SENSOR..........................................................................................................................................................................1561 DESCRIPTION...............................................................................................................................................................................1561 VEHICLE SPEED SENSOR..................................................................................................................................................................1561 REMOVAL...................................................................................................................................................................................1561 INSTALLATION..............................................................................................................................................................................1561 41TE AUTOMATIC TRANSAXLE..........................................................................................................................................................................1562 41TE AUTOMATIC TRANSAXLE......................................................................................................................................................................1563 DESCRIPTION...............................................................................................................................................................................1563 TRANSAXLE IDENTIFICATION..............................................................................................................................................................1565 OPERATION.................................................................................................................................................................................1565 DIAGNOSIS AND TESTING.....................................................................................................................................................................1565 DIAGNOSIS AND TESTING - 41TE TRANSAXLE GENERAL DIAGNOSIS..............................................................................................................................1565 DIAGNOSIS AND TESTING - ROAD TEST.....................................................................................................................................................1566 DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TESTS......................................................................................................................................1566 TEST ONE-SELECTOR IN LOW (1st GEAR)...............................................................................................................................................1567 TEST TWO-SELECTOR IN DRIVE (2nd GEAR).............................................................................................................................................1567 TEST TWO A–SELECTOR IN OD (4th Gear)..............................................................................................................................................1567 TEST THREE-OVERDRIVE CLUTCH CHECK (3rd and 2nd Gear)..............................................................................................................................1567 TEST FOUR-SELECTOR IN OVERDRIVE (4th Gear)........................................................................................................................................1567 TEST FIVE-SELECTOR IN OVERDRIVE (4th Gear-CC on)..................................................................................................................................1567 TEST SIX-SELECTOR IN REVERSE......................................................................................................................................................1567 TEST RESULT INDICATIONS...........................................................................................................................................................1568 DIAGNOSIS AND TESTING - CLUTCH AIR PRESSURE TESTS.....................................................................................................................................1569 OVERDRIVE CLUTCH..................................................................................................................................................................1569 REVERSE CLUTCH....................................................................................................................................................................1569 2/4 CLUTCH........................................................................................................................................................................1569 LOW/REVERSE CLUTCH................................................................................................................................................................1569 UNDERDRIVE CLUTCH.................................................................................................................................................................1569 DIAGNOSIS AND TESTING - TORQUE CONVERTER HOUSING FLUID LEAKAGE........................................................................................................................1570 TORQUE CONVERTER LEAKAGE..........................................................................................................................................................1570 REMOVAL...................................................................................................................................................................................1570 DISASSEMBLY...............................................................................................................................................................................1574 ASSEMBLY..................................................................................................................................................................................1592 INSTALLATION..............................................................................................................................................................................1614 SCHEMATICS AND DIAGRAMS...................................................................................................................................................................1615 41TE TRANSAXLE HYDRAULIC SCHEMATICS...................................................................................................................................................1615 SPECIFICATIONS............................................................................................................................................................................1627 SPECIAL TOOLS.............................................................................................................................................................................1629 ACCUMULATOR...................................................................................................................................................................................1635 DESCRIPTION...............................................................................................................................................................................1635 OPERATION.................................................................................................................................................................................1635 DRIVING CLUTCHES..............................................................................................................................................................................1635 DESCRIPTION...............................................................................................................................................................................1635 OPERATION.................................................................................................................................................................................1636 UNDERDRIVE CLUTCH.....................................................................................................................................................................1636 OVERDRIVE CLUTCH......................................................................................................................................................................1636 REVERSE CLUTCH........................................................................................................................................................................1636 FINAL DRIVE...................................................................................................................................................................................1636 DESCRIPTION...............................................................................................................................................................................1636 OPERATION.................................................................................................................................................................................1636 DISASSEMBLY...............................................................................................................................................................................1637 ASSEMBLY..................................................................................................................................................................................1640 ADJUSTMENTS...............................................................................................................................................................................1641 DIFFERENTIAL BEARING PRELOAD MEASUREMENT AND ADJUSTMENT...............................................................................................................................1641 FLUID.........................................................................................................................................................................................1643 STANDARD PROCEDURE........................................................................................................................................................................1643 FLUID LEVEL AND CONDITION CHECK.......................................................................................................................................................1643 FLUID LEVEL CHECK.................................................................................................................................................................1643 FLUID LEVEL CHECK USING DRB.......................................................................................................................................................1644 FLUID CONDITION...................................................................................................................................................................1644 STANDARD PROCEDURE - FLUID AND FILTER SERVICE.........................................................................................................................................1645 FLUID/FILTER SERVICE (RECOMMENDED)................................................................................................................................................1645 DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE)..................................................................................................................................1645 GEAR SHIFT CABLE..............................................................................................................................................................................1646 REMOVAL...................................................................................................................................................................................1646 INSTALLATION..............................................................................................................................................................................1648 ADJUSTMENTS...............................................................................................................................................................................1649 GEARSHIFT CABLE.......................................................................................................................................................................1649 ADJUSTMENT........................................................................................................................................................................1649 HOLDING CLUTCHES..............................................................................................................................................................................1650 DESCRIPTION...............................................................................................................................................................................1650 OPERATION.................................................................................................................................................................................1650 2/4 CLUTCH............................................................................................................................................................................1650 LOW/REVERSE CLUTCH....................................................................................................................................................................1650 INPUT CLUTCH ASSEMBLY.........................................................................................................................................................................1651 DISASSEMBLY...............................................................................................................................................................................1651 ASSEMBLY..................................................................................................................................................................................1660 OIL PUMP......................................................................................................................................................................................1675 DESCRIPTION...............................................................................................................................................................................1675 OPERATION.................................................................................................................................................................................1675 DISASSEMBLY...............................................................................................................................................................................1675 ASSEMBLY..................................................................................................................................................................................1676 PLANETARY GEARTRAIN...........................................................................................................................................................................1676 DESCRIPTION...............................................................................................................................................................................1676 OPERATION.................................................................................................................................................................................1676 SEAL - OIL PUMP...............................................................................................................................................................................1677 REMOVAL...................................................................................................................................................................................1677 INSTALLATION..............................................................................................................................................................................1677 SHIFT INTERLOCK CABLE.........................................................................................................................................................................1677 REMOVAL...................................................................................................................................................................................1677 INSTALLATION..............................................................................................................................................................................1679 SHIFT INTERLOCK MECHANISM.....................................................................................................................................................................1680 REMOVAL...................................................................................................................................................................................1680 INSTALLATION..............................................................................................................................................................................1681 SHIFT INTERLOCK SYSTEM........................................................................................................................................................................1682 ADJUSTMENTS...............................................................................................................................................................................1682 BRAKE/TRANSMISSION SHIFT INTERLOCK SYSTEM.............................................................................................................................................1682 VERIFICATION......................................................................................................................................................................1682 ADJUSTMENT........................................................................................................................................................................1682 SOLENOID/PRESSURE SWITCH ASSY.................................................................................................................................................................1683 DESCRIPTION...............................................................................................................................................................................1683 OPERATION.................................................................................................................................................................................1683 SOLENOIDS.............................................................................................................................................................................1683 PRESSURE SWITCHES.....................................................................................................................................................................1684 REMOVAL...................................................................................................................................................................................1684 INSTALLATION..............................................................................................................................................................................1685 SPEED SENSOR - INPUT..........................................................................................................................................................................1686 DESCRIPTION...............................................................................................................................................................................1686 OPERATION.................................................................................................................................................................................1686 REMOVAL...................................................................................................................................................................................1687 INSTALLATION..............................................................................................................................................................................1688 SPEED SENSOR - OUTPUT.........................................................................................................................................................................1688 DESCRIPTION...............................................................................................................................................................................1688 OPERATION.................................................................................................................................................................................1689 VEHICLE SPEED SIGNAL..................................................................................................................................................................1689 REMOVAL...................................................................................................................................................................................1689 INSTALLATION..............................................................................................................................................................................1690 TORQUE CONVERTER..............................................................................................................................................................................1691 DESCRIPTION...............................................................................................................................................................................1691 IMPELLER..............................................................................................................................................................................1692 TURBINE...............................................................................................................................................................................1693 STATOR................................................................................................................................................................................1694 TORQUE CONVERTER CLUTCH (TCC).........................................................................................................................................................1694 OPERATION.................................................................................................................................................................................1695 TURBINE...............................................................................................................................................................................1695 STATOR................................................................................................................................................................................1696 TORQUE CONVERTER CLUTCH (TCC).........................................................................................................................................................1696 REMOVAL...................................................................................................................................................................................1696 INSTALLATION..............................................................................................................................................................................1696 TRANSMISSION CONTROL RELAY....................................................................................................................................................................1697 DESCRIPTION...............................................................................................................................................................................1697 OPERATION.................................................................................................................................................................................1697 TRANSMISSION RANGE SENSOR.....................................................................................................................................................................1697 DESCRIPTION...............................................................................................................................................................................1697 OPERATION.................................................................................................................................................................................1698 TRANSMISSION TEMPERATURE SENSOR.......................................................................................................................................................1698 CALCULATED TEMPERATURE................................................................................................................................................................1698 VALVE BODY....................................................................................................................................................................................1699 DESCRIPTION...............................................................................................................................................................................1699 OPERATION.................................................................................................................................................................................1699 REGULATOR VALVE.......................................................................................................................................................................1699 SOLENOID SWITCH VALVE.................................................................................................................................................................1699 MANUAL VALVE..........................................................................................................................................................................1700 CONVERTER CLUTCH SWITCH VALVE.........................................................................................................................................................1700 CONVERTER CLUTCH CONTROL VALVE........................................................................................................................................................1700 T/C REGULATOR VALVE...................................................................................................................................................................1700 LOW/REVERSE SWITCH VALVE..............................................................................................................................................................1700 REMOVAL...................................................................................................................................................................................1700 DISASSEMBLY...............................................................................................................................................................................1703 ASSEMBLY..................................................................................................................................................................................1707 INSTALLATION..............................................................................................................................................................................1712 22-TIRES/WHEELS.......................................................................................................................................................................................1713 TIRES/WHEELS......................................................................................................................................................................................1713 DIAGNOSIS AND TESTING - TIRE AND WHEEL RUNOUT.................................................................................................................................................1713 METHOD 1 (RELOCATE WHEEL ON HUB)..........................................................................................................................................................1714 METHOD 2 (RELOCATE TIRE ON WHEEL).........................................................................................................................................................1714 STANDARD PROCEDURE............................................................................................................................................................................1715 STANDARD PROCEDURE - TIRE AND WHEEL BALANCE...............................................................................................................................................1715 STANDARD PROCEDURE - TIRE AND WHEEL MATCH MOUNTING........................................................................................................................................1716 STANDARD PROCEDURE - TIRE AND WHEEL ROTATION..............................................................................................................................................1718 NON-DIRECTIONAL TREAD PATTERN TIRES...................................................................................................................................................1718 DIRECTIONAL TREAD PATTERN TIRES.......................................................................................................................................................1718 REMOVAL.......................................................................................................................................................................................1718 REMOVAL - TIRE AND WHEEL ASSEMBLY (ALUMINUM WHEEL)........................................................................................................................................1718 REMOVAL - TIRE AND WHEEL ASSEMBLY (STEEL WHEEL)...........................................................................................................................................1718 INSTALLATION..................................................................................................................................................................................1719 INSTALLATION - TIRE AND WHEEL ASSEMBLY (ALUMINUM WHEEL)...................................................................................................................................1719 INSTALLATION - TIRE AND WHEEL ASSEMBLY (STEEL WHEEL)......................................................................................................................................1719 TIRES.............................................................................................................................................................................................1719 DESCRIPTION...................................................................................................................................................................................1719 DESCRIPTION - TIRE........................................................................................................................................................................1719 TIRE IDENTIFICATION...................................................................................................................................................................1720 TIRE CHAINS...........................................................................................................................................................................1720 DESCRIPTION - RADIAL-PLY TIRES............................................................................................................................................................1720 DESCRIPTION - REPLACEMENT TIRES...........................................................................................................................................................1720 DESCRIPTION - SPARE TIRE (TEMPORARY)......................................................................................................................................................1721 DIAGNOSIS AND TESTING.........................................................................................................................................................................1721 DIAGNOSIS AND TESTING - TIRE NOISE OR VIBRATION...........................................................................................................................................1721 DIAGNOSIS AND TESTING - TIRE WEAR PATTERNS................................................................................................................................................1721 DIAGNOSIS AND TESTING - TREAD WEAR INDICATORS.............................................................................................................................................1721 DIAGNOSIS AND TESTING - VEHICLE LEAD DIAGNOSIS AND CORRECTION.............................................................................................................................1722 STANDARD PROCEDURE............................................................................................................................................................................1722 STANDARD PROCEDURE - TIRE INFLATION PRESSURES.............................................................................................................................................1722 STANDARD PROCEDURE - TIRE PRESSURE FOR HIGH SPEED OPERATION...............................................................................................................................1722 STANDARD PROCEDURE - TIRE LEAK REPAIRING..................................................................................................................................................1722 CLEANING - TIRES..............................................................................................................................................................................1722 WHEELS............................................................................................................................................................................................1724 DESCRIPTION - WHEEL...........................................................................................................................................................................1724 DIAGNOSIS AND TESTING - WHEEL INSPECTION......................................................................................................................................................1725 CLEANING......................................................................................................................................................................................1725 WHEEL AND WHEEL TRIM CARE.................................................................................................................................................................1725 SPECIFICATIONS................................................................................................................................................................................1725 WHEEL.....................................................................................................................................................................................1725 WHEEL COVER.......................................................................................................................................................................................1726 REMOVAL.......................................................................................................................................................................................1726 INSTALLATION..................................................................................................................................................................................1726 WHEEL MOUNTING STUDS - FRONT......................................................................................................................................................................1726 REMOVAL.......................................................................................................................................................................................1726 INSTALLATION..................................................................................................................................................................................1727 WHEEL MOUNTING STUDS - REAR.......................................................................................................................................................................1728 REMOVAL.......................................................................................................................................................................................1728 INSTALLATION..................................................................................................................................................................................1728 23-BODY...............................................................................................................................................................................................1729 BODY..............................................................................................................................................................................................1729 BODY..........................................................................................................................................................................................1729 DESCRIPTION - VEHICLE IDENTIFICATION......................................................................................................................................................1729 WARNING...................................................................................................................................................................................1729 SAFETY PRECAUTIONS AND WARNINGS.......................................................................................................................................................1729 DIAGNOSIS AND TESTING.....................................................................................................................................................................1730 DIAGNOSIS AND TESTING - WATER LEAKS...................................................................................................................................................1730 VISUAL INSPECTION BEFORE WATER LEAK TESTS.........................................................................................................................................1730 WATER LEAK TESTS..................................................................................................................................................................1730 WATER LEAK DETECTION..............................................................................................................................................................1730 DIAGNOSIS AND TESTING - WIND NOISE....................................................................................................................................................1731 VISUAL INSPECTION BEFORE TESTS....................................................................................................................................................1731 STANDARD PROCEDURE........................................................................................................................................................................1731 STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR........................................................................................................................................1731 Rigid Plastics:...................................................................................................................................................................1731 Semi-Rigid Plastics:..............................................................................................................................................................1731 Flexible Plastics:................................................................................................................................................................1731 Repair Procedure:.................................................................................................................................................................1731 Adhesion Promoter/Surface Modifier:...............................................................................................................................................1731 SAFETY PRECAUTION AND WARNINGS....................................................................................................................................................1731 RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES...............................................................................................................................1732 PANEL SECTIONING..................................................................................................................................................................1734 PANEL REINFORCEMENT...............................................................................................................................................................1734 VISUAL INSPECTION.................................................................................................................................................................1735 PANEL SURFACE PREPARATION.........................................................................................................................................................1735 PATCHING PANELS...................................................................................................................................................................1735 PANEL PATCH FABRICATIONS..........................................................................................................................................................1736 PANEL PATCH INSTALLATION..........................................................................................................................................................1736 PATCHED PANEL SURFACING...........................................................................................................................................................1737 STANDARD PROCEDURE - HEAT STAKING.....................................................................................................................................................1738 SPECIFICATIONS............................................................................................................................................................................1738 BODY LUBRICATION......................................................................................................................................................................1738 LUBRICATION REQUIREMENTS..........................................................................................................................................................1738 LUBRICANT APPLICATION.............................................................................................................................................................1738 LUBRICANT USAGE...................................................................................................................................................................1739 SPECIFICATIONS - TORQUE...............................................................................................................................................................1739 SPECIAL TOOLS.............................................................................................................................................................................1740 BODY..................................................................................................................................................................................1740 LIFTGATE..........................................................................................................................................................................................1741 LIFTGATE CHMSL ACCESS PANEL...................................................................................................................................................................1741 REMOVAL...................................................................................................................................................................................1741 INSTALLATION..............................................................................................................................................................................1741 LIFTGATE OUTSIDE HANDLE.......................................................................................................................................................................1741 REMOVAL...................................................................................................................................................................................1741 INSTALLATION..............................................................................................................................................................................1741 LIFTGATE HINGE................................................................................................................................................................................1742 REMOVAL...................................................................................................................................................................................1742 INSTALLATION..............................................................................................................................................................................1742 LIFTGATE LATCH................................................................................................................................................................................1743 REMOVAL...................................................................................................................................................................................1743 INSTALLATION..............................................................................................................................................................................1743 LIFTGATE INNER CONTROL ASSEMBLY PANEL.........................................................................................................................................................1743 REMOVAL...................................................................................................................................................................................1743 INSTALLATION..............................................................................................................................................................................1743 LATCH STRIKER.................................................................................................................................................................................1743 REMOVAL...................................................................................................................................................................................1743 INSTALLATION..............................................................................................................................................................................1743 LIFTGATE......................................................................................................................................................................................1744 REMOVAL...................................................................................................................................................................................1744 INSTALLATION..............................................................................................................................................................................1744 LIFTGATE LOCK CYLINDER........................................................................................................................................................................1745 REMOVAL...................................................................................................................................................................................1745 INSTALLATION..............................................................................................................................................................................1745 LIFTGATE SUPPORT ROD..........................................................................................................................................................................1745 REMOVAL...................................................................................................................................................................................1745 INSTALLATION..............................................................................................................................................................................1745 LIFTGATE TRIM PANEL...........................................................................................................................................................................1746 REMOVAL...................................................................................................................................................................................1746 INSTALLATION..............................................................................................................................................................................1746 DOOR - FRONT......................................................................................................................................................................................1747 FRONT DOOR APPLIQUE...........................................................................................................................................................................1747 REMOVAL...................................................................................................................................................................................1747 INSTALLATION..............................................................................................................................................................................1747 FRONT DOOR CHECK STRAP........................................................................................................................................................................1748 REMOVAL...................................................................................................................................................................................1748 INSTALLATION..............................................................................................................................................................................1748 FRONT DOOR....................................................................................................................................................................................1748 REMOVAL...................................................................................................................................................................................1748 INSTALLATION..............................................................................................................................................................................1748 FRONT DOOR GLASS..............................................................................................................................................................................1749 REMOVAL...................................................................................................................................................................................1749 INSTALLATION..............................................................................................................................................................................1749 FRONT DOOR OUTSIDE HANDLE.....................................................................................................................................................................1749 REMOVAL...................................................................................................................................................................................1749 INSTALLATION..............................................................................................................................................................................1749 FRONT DOOR HINGE..............................................................................................................................................................................1750 REMOVAL...................................................................................................................................................................................1750 INSTALLATION..............................................................................................................................................................................1750 FRONT DOOR INSIDE HANDLE ACTUATOR.............................................................................................................................................................1750 REMOVAL...................................................................................................................................................................................1750 INSTALLATION..............................................................................................................................................................................1751 FRONT DOOR LATCH..............................................................................................................................................................................1751 REMOVAL...................................................................................................................................................................................1751 INSTALLATION..............................................................................................................................................................................1751 ADJUSTMENTS...............................................................................................................................................................................1752 FRONT DOOR LATCH ADJUSTMENT...........................................................................................................................................................1752 FRONT DOOR LATCH STRIKER......................................................................................................................................................................1752 REMOVAL...................................................................................................................................................................................1752 INSTALLATION..............................................................................................................................................................................1752 FRONT DOOR LOCK CYLINDER......................................................................................................................................................................1753 REMOVAL...................................................................................................................................................................................1753 INSTALLATION..............................................................................................................................................................................1753 FRONT DOOR VERTICAL GUIDE BAR.................................................................................................................................................................1753 REMOVAL...................................................................................................................................................................................1753 INSTALLATION..............................................................................................................................................................................1753 SIDE VIEW MIRROR TRIM BEZEL...................................................................................................................................................................1753 REMOVAL...................................................................................................................................................................................1753 INSTALLATION..............................................................................................................................................................................1753 FRONT DOOR TRIM PANEL.........................................................................................................................................................................1753 REMOVAL...................................................................................................................................................................................1753 INSTALLATION..............................................................................................................................................................................1753 FRONT DOOR WATER DAM..........................................................................................................................................................................1754 REMOVAL...................................................................................................................................................................................1754 INSTALLATION..............................................................................................................................................................................1755 FRONT DOOR WINDOW REGULATOR...................................................................................................................................................................1755 REMOVAL...................................................................................................................................................................................1755 INSTALLATION..............................................................................................................................................................................1755 DOORS-REAR........................................................................................................................................................................................1756 REAR DOOR APPLIQUE............................................................................................................................................................................1756 REMOVAL...................................................................................................................................................................................1756 INSTALLATION..............................................................................................................................................................................1757 REAR DOOR CHECK STRAP.........................................................................................................................................................................1757 REMOVAL...................................................................................................................................................................................1757 INSTALLATION..............................................................................................................................................................................1757 REAR DOOR.....................................................................................................................................................................................1758 REMOVAL...................................................................................................................................................................................1758 INSTALLATION..............................................................................................................................................................................1758 REAR DOOR GLASS...............................................................................................................................................................................1758 REMOVAL0 - 10 PT (Continued)..........................................................................................................................................................1758 INSTALLATION..............................................................................................................................................................................1758 REAR DOOR OUTSIDE HANDLE......................................................................................................................................................................1759 REMOVAL...................................................................................................................................................................................1759 INSTALLATION..............................................................................................................................................................................1759 REAR DOOR HINGE...............................................................................................................................................................................1759 REMOVAL...................................................................................................................................................................................1759 INSTALLATION..............................................................................................................................................................................1759 REAR DOOR LATCH...............................................................................................................................................................................1760 REMOVAL...................................................................................................................................................................................1760 INSTALLATION..............................................................................................................................................................................1760 ADJUSTMENTS...............................................................................................................................................................................1760 REAR DOOR LATCH ADJUSTMENT............................................................................................................................................................1760 REAR DOOR LATCH STRIKER.......................................................................................................................................................................1760 REMOVAL...................................................................................................................................................................................1760 INSTALLATION..............................................................................................................................................................................1760 REAR DOOR TRIM PANEL..........................................................................................................................................................................1760 REMOVAL...................................................................................................................................................................................1760 INSTALLATION..............................................................................................................................................................................1761 REAR DOOR WATER DAM...........................................................................................................................................................................1761 REMOVAL...................................................................................................................................................................................1761 INSTALLATION..............................................................................................................................................................................1761 REAR DOOR WINDOW REGULATOR....................................................................................................................................................................1762 REMOVAL...................................................................................................................................................................................1762 INSTALLATION..............................................................................................................................................................................1762 EXTERIOR..........................................................................................................................................................................................1763 COWL GRILLE SCREEN............................................................................................................................................................................1763 REMOVAL...................................................................................................................................................................................1763 INSTALLATION..............................................................................................................................................................................1763 EXTERIOR NAME PLATES..........................................................................................................................................................................1763 REMOVAL...................................................................................................................................................................................1763 REMOVAL - EXTERIOR BADGING............................................................................................................................................................1763 REMOVAL - BADGING/TAPE................................................................................................................................................................1764 INSTALLATION..............................................................................................................................................................................1764 INSTALLATION - EXTERIOR BADGING.......................................................................................................................................................1764 INSTALLATION - BADGING/TAPE...........................................................................................................................................................1764 FRONT WHEELHOUSE SPLASH SHIELDS...............................................................................................................................................................1764 REMOVAL...................................................................................................................................................................................1764 INSTALLATION..............................................................................................................................................................................1764 FRONT FENDER..................................................................................................................................................................................1765 REMOVAL...................................................................................................................................................................................1765 INSTALLATION..............................................................................................................................................................................1765 FUEL FILL DOOR................................................................................................................................................................................1765 REMOVAL...................................................................................................................................................................................1765 INSTALLATION..............................................................................................................................................................................1765 GRILLE........................................................................................................................................................................................1766 REMOVAL...................................................................................................................................................................................1766 INSTALLATION..............................................................................................................................................................................1766 FRONT SIDE RAIL ACCESS PULLEY SPLASH SHIELD...................................................................................................................................................1766 REMOVAL...................................................................................................................................................................................1766 INSTALLATION..............................................................................................................................................................................1766 LUGGAGE RACK CROSSBAR.........................................................................................................................................................................1767 REMOVAL...................................................................................................................................................................................1767 INSTALLATION..............................................................................................................................................................................1767 LUGGAGE RACK SIDE RAIL........................................................................................................................................................................1767 REMOVAL...................................................................................................................................................................................1767 INSTALLATION..............................................................................................................................................................................1767 RADIATOR CLOSURE PANEL........................................................................................................................................................................1767 REMOVAL...................................................................................................................................................................................1767 INSTALLATION..............................................................................................................................................................................1768 SIDE VIEW MIRROR..............................................................................................................................................................................1768 REMOVAL...................................................................................................................................................................................1768 INSTALLATION..............................................................................................................................................................................1768 SIDE VIEW MIRROR GLASS........................................................................................................................................................................1769 REMOVAL...................................................................................................................................................................................1769 INSTALLATION..............................................................................................................................................................................1769 BODY SIDE MOLDINGS............................................................................................................................................................................1769 REMOVAL...................................................................................................................................................................................1769 INSTALLATION..............................................................................................................................................................................1769 WOOD GRAIN/FLAME DECALS.......................................................................................................................................................................1769 REMOVAL...................................................................................................................................................................................1769 INSTALLATION..............................................................................................................................................................................1769 Surface Preparation...................................................................................................................................................................1769 Application...........................................................................................................................................................................1769 HOOD..............................................................................................................................................................................................1771 HOOD HINGE....................................................................................................................................................................................1771 REMOVAL...................................................................................................................................................................................1771 INSTALLATION..............................................................................................................................................................................1771 HOOD..........................................................................................................................................................................................1771 REMOVAL...................................................................................................................................................................................1771 INSTALLATION..............................................................................................................................................................................1771 HOOD LATCH....................................................................................................................................................................................1772 REMOVAL...................................................................................................................................................................................1772 INSTALLATION..............................................................................................................................................................................1772 HOOD LATCH RELEASE CABLE......................................................................................................................................................................1772 REMOVAL...................................................................................................................................................................................1772 INSTALLATION..............................................................................................................................................................................1773 HOOD LATCH STRIKER............................................................................................................................................................................1773 REMOVAL...................................................................................................................................................................................1773 INSTALLATION..............................................................................................................................................................................1773 SILENCER PAD..................................................................................................................................................................................1773 REMOVAL...................................................................................................................................................................................1773 INSTALLATION..............................................................................................................................................................................1773 INSTRUMENT PANEL..................................................................................................................................................................................1774 ACCESSORY SWITCH BEZEL........................................................................................................................................................................1774 REMOVAL...................................................................................................................................................................................1774 INSTALLATION..............................................................................................................................................................................1774 CLUSTER BEZEL.................................................................................................................................................................................1774 REMOVAL...................................................................................................................................................................................1774 INSTALLATION..............................................................................................................................................................................1776 GLOVE BOX.....................................................................................................................................................................................1776 REMOVAL...................................................................................................................................................................................1776 INSTALLATION..............................................................................................................................................................................1776 GLOVE BOX LATCH...............................................................................................................................................................................1777 REMOVAL...................................................................................................................................................................................1777 INSTALLATION..............................................................................................................................................................................1777 GLOVE BOX LOCK CYLINDER.......................................................................................................................................................................1777 REMOVAL...................................................................................................................................................................................1777 INSTALLATION..............................................................................................................................................................................1778 INSTRUMENT PANEL ASSEMBLY.....................................................................................................................................................................1778 REMOVAL...................................................................................................................................................................................1778 INSTALLATION..............................................................................................................................................................................1781 INSTRUMENT PANEL CENTER BEZEL.................................................................................................................................................................1784 REMOVAL...................................................................................................................................................................................1784 INSTALLATION..............................................................................................................................................................................1784 INSTRUMENT PANEL CENTER BEZEL CONTROL KNOBS...................................................................................................................................................1784 REMOVAL...................................................................................................................................................................................1784 INSTALLATION..............................................................................................................................................................................1785 INSTRUMENT PANEL END CAP......................................................................................................................................................................1785 REMOVAL...................................................................................................................................................................................1785 LEFT END CAP..........................................................................................................................................................................1785 RIGHT END CAP.........................................................................................................................................................................1785 INSTALLATION..............................................................................................................................................................................1785 LEFT END CAP..........................................................................................................................................................................1785 RIGHT END CAP.........................................................................................................................................................................1785 INSTRUMENT PANEL TOP COVER....................................................................................................................................................................1785 REMOVAL...................................................................................................................................................................................1785 INSTALLATION..............................................................................................................................................................................1786 STEERING COLUMN OPENING COVER.................................................................................................................................................................1787 REMOVAL...................................................................................................................................................................................1787 INSTALLATION..............................................................................................................................................................................1787 INTERIOR..........................................................................................................................................................................................1788 A-PILLAR TRIM.................................................................................................................................................................................1788 REMOVAL...................................................................................................................................................................................1788 INSTALLATION..............................................................................................................................................................................1788 B-PILLAR TRIM.................................................................................................................................................................................1788 REMOVAL...................................................................................................................................................................................1788 INSTALLATION..............................................................................................................................................................................1788 BODY VENT.....................................................................................................................................................................................1789 REMOVAL...................................................................................................................................................................................1789 INSTALLATION..............................................................................................................................................................................1789 FLOOR CARPET..................................................................................................................................................................................1789 REMOVAL...................................................................................................................................................................................1789 INSTALLATION..............................................................................................................................................................................1789 SIDE COWL TRIM PANEL..........................................................................................................................................................................1790 REMOVAL...................................................................................................................................................................................1790 INSTALLATION..............................................................................................................................................................................1790 UPPER C-PILLAR TRIM...........................................................................................................................................................................1791 REMOVAL...................................................................................................................................................................................1791 INSTALLATION..............................................................................................................................................................................1791 DOOR SILL TRIM................................................................................................................................................................................1791 REMOVAL...................................................................................................................................................................................1791 INSTALLATION..............................................................................................................................................................................1791 UPPER D-PILLAR TRIM...........................................................................................................................................................................1791 REMOVAL...................................................................................................................................................................................1791 INSTALLATION..............................................................................................................................................................................1791 HEADLINER.....................................................................................................................................................................................1791 REMOVAL...................................................................................................................................................................................1791 INSTALLATION..............................................................................................................................................................................1792 LOWER QUARTER TRIM PANEL......................................................................................................................................................................1792 REMOVAL...................................................................................................................................................................................1792 INSTALLATION..............................................................................................................................................................................1792 INSIDE REAR VIEW MIRROR.......................................................................................................................................................................1793 REMOVAL...................................................................................................................................................................................1793 INSTALLATION..............................................................................................................................................................................1793 SUN VISOR.....................................................................................................................................................................................1793 REMOVAL...................................................................................................................................................................................1793 INSTALLATION..............................................................................................................................................................................1793 PAINT.............................................................................................................................................................................................1794 PAINT.........................................................................................................................................................................................1794 SPECIFICATIONS - COLOR CODES..............................................................................................................................................................1794 BASECOAT/CLEARCOAT FINISH.....................................................................................................................................................................1794 DESCRIPTION...............................................................................................................................................................................1794 PAINT CODE....................................................................................................................................................................................1794 DESCRIPTION...............................................................................................................................................................................1794 PAINT TOUCH-UP................................................................................................................................................................................1795 DESCRIPTION...............................................................................................................................................................................1795 TOUCH UP PROCEDURE....................................................................................................................................................................1795 FINESSE SANDING/BUFFING & POLISHING...........................................................................................................................................................1795 DESCRIPTION...............................................................................................................................................................................1795 SEATS.............................................................................................................................................................................................1796 FRONT SEAT....................................................................................................................................................................................1796 REMOVAL...................................................................................................................................................................................1796 INSTALLATION..............................................................................................................................................................................1796 FRONT SEAT BACK...............................................................................................................................................................................1797 REMOVAL...................................................................................................................................................................................1797 INSTALLATION..............................................................................................................................................................................1797 FRONT SEAT BACK COVER.........................................................................................................................................................................1797 REMOVAL...................................................................................................................................................................................1797 INSTALLATION..............................................................................................................................................................................1797 FRONT SEAT CUSHION............................................................................................................................................................................1798 REMOVAL...................................................................................................................................................................................1798 INSTALLATION..............................................................................................................................................................................1798 FRONT SEAT CUSHION COVER......................................................................................................................................................................1798 REMOVAL...................................................................................................................................................................................1798 INSTALLATION..............................................................................................................................................................................1798 FRONT SEAT HEAD RESTRAINT.....................................................................................................................................................................1798 REMOVAL...................................................................................................................................................................................1798 INSTALLATION..............................................................................................................................................................................1798 REAR SEAT.....................................................................................................................................................................................1798 REMOVAL...................................................................................................................................................................................1798 INSTALLATION..............................................................................................................................................................................1798 REAR SEAT BACK................................................................................................................................................................................1799 REMOVAL...................................................................................................................................................................................1799 INSTALLATION..............................................................................................................................................................................1799 REAR SEAT BACK COVER..........................................................................................................................................................................1799 REMOVAL...................................................................................................................................................................................1799 INSTALLATION..............................................................................................................................................................................1799 REAR SEAT CUSHION.............................................................................................................................................................................1799 REMOVAL...................................................................................................................................................................................1799 INSTALLATION..............................................................................................................................................................................1799 REAR SEAT BACK CUSHION / COVER................................................................................................................................................................1799 REMOVAL...................................................................................................................................................................................1799 INSTALLATION..............................................................................................................................................................................1800 UNDER SEAT STORAGE BIN........................................................................................................................................................................1800 REMOVAL...................................................................................................................................................................................1800 INSTALLATION..............................................................................................................................................................................1800 REAR SEAT PIVOT BEZEL.........................................................................................................................................................................1800 REMOVAL...................................................................................................................................................................................1800 INSTALLATION..............................................................................................................................................................................1800 CHILD SEAT TETHER ANCHOR BEZEL................................................................................................................................................................1801 REMOVAL...................................................................................................................................................................................1801 INSTALLATION..............................................................................................................................................................................1801 STATIONARY GLASS..................................................................................................................................................................................1802 BACKLITE......................................................................................................................................................................................1802 REMOVAL...................................................................................................................................................................................1802 INSTALLATION..............................................................................................................................................................................1802 QUARTER WINDOW................................................................................................................................................................................1804 REMOVAL...................................................................................................................................................................................1804 INSTALLATION..............................................................................................................................................................................1804 WINDSHIELD....................................................................................................................................................................................1805 DESCRIPTION...............................................................................................................................................................................1805 RECOMMENDED TOOLS AND ADHESIVE........................................................................................................................................................1806 ADHESIVE, PRIMER AND CLEANER..........................................................................................................................................................1806 RECOMMENDED TOOLS AND ADHESIVE........................................................................................................................................................1806 WARNING...................................................................................................................................................................................1806 WINDSHIELD SAFETY PRECAUTIONS.........................................................................................................................................................1806 REMOVAL...................................................................................................................................................................................1806 REMOVAL - EXTERIOR METHOD.............................................................................................................................................................1806 REMOVAL - INTERIOR METHOD.............................................................................................................................................................1806 INSTALLATION..............................................................................................................................................................................1807 SUNROOF...........................................................................................................................................................................................1809 SUNROOF.......................................................................................................................................................................................1809 DESCRIPTION...............................................................................................................................................................................1809 DIAGNOSIS AND TESTING - SUNROOF...........................................................................................................................................................1809 WATER DRAINAGE AND WIND NOISE DIAGNOSIS...............................................................................................................................................1811 SUNROOF MODULE ASSEMBLY.......................................................................................................................................................................1811 REMOVAL...................................................................................................................................................................................1811 INSTALLATION..............................................................................................................................................................................1811 ELECTRONIC CONTROL MODULE.....................................................................................................................................................................1812 REMOVAL...................................................................................................................................................................................1812 INSTALLATION..............................................................................................................................................................................1812 SUNROOF DRIVE MOTOR...........................................................................................................................................................................1812 REMOVAL...................................................................................................................................................................................1812 INSTALLATION..............................................................................................................................................................................1813 SUNROOF CONTROL SWITCH........................................................................................................................................................................1813 REMOVAL...................................................................................................................................................................................1813 INSTALLATION..............................................................................................................................................................................1813 WIND DEFLECTOR................................................................................................................................................................................1813 REMOVAL...................................................................................................................................................................................1813 INSTALLATION..............................................................................................................................................................................1813 GLASS PANEL...................................................................................................................................................................................1814 REMOVAL...................................................................................................................................................................................1814 INSTALLATION..............................................................................................................................................................................1814 ADJUSTMENTS...............................................................................................................................................................................1814 SUNROOF GLASS PANEL ADJUSTMENT........................................................................................................................................................1814 SUNROOF SUNSHADE..............................................................................................................................................................................1814 REMOVAL...................................................................................................................................................................................1814 INSTALLATION..............................................................................................................................................................................1815 SUNROOF GLASS PANEL SEAL......................................................................................................................................................................1815 REMOVAL...................................................................................................................................................................................1815 INSTALLATION..............................................................................................................................................................................1815 OPENING TRIM LACE.............................................................................................................................................................................1815 REMOVAL...................................................................................................................................................................................1815 INSTALLATION..............................................................................................................................................................................1815 SUNROOF TROUGH GUIDE ASSEMBLY.................................................................................................................................................................1815 REMOVAL...................................................................................................................................................................................1815 INSTALLATION..............................................................................................................................................................................1816 DRAIN TUBE....................................................................................................................................................................................1816 REMOVAL...................................................................................................................................................................................1816 FRONT HOSES...........................................................................................................................................................................1816 REAR HOUSING HOSE.....................................................................................................................................................................1816 INSTALLATION..............................................................................................................................................................................1816 FRONT HOSES...........................................................................................................................................................................1816 REAR HOUSING HOSE.....................................................................................................................................................................1817 WEATHERSTRIP/SEALS................................................................................................................................................................................1818 FRONT AND REAR DOOR OPENING WEATHERSTRIP......................................................................................................................................................1818 REMOVAL...................................................................................................................................................................................1818 INSTALLATION..............................................................................................................................................................................1818 FRONT AND REAR DOOR UPPER SECONDARY WEATHERSTRIP..............................................................................................................................................1818 REMOVAL...................................................................................................................................................................................1818 INSTALLATION..............................................................................................................................................................................1818 FRONT DOOR GLASS RUN WEATHERSTRIP.............................................................................................................................................................1818 REMOVAL...................................................................................................................................................................................1818 INSTALLATION..............................................................................................................................................................................1818 FRONT DOOR INNER BELT WEATHERSTRIP............................................................................................................................................................1820 REMOVAL...................................................................................................................................................................................1820 INSTALLATION..............................................................................................................................................................................1820 FRONT DOOR OUTER BELT WEATHERSTRIP............................................................................................................................................................1820 REMOVAL...................................................................................................................................................................................1820 INSTALLATION..............................................................................................................................................................................1820 LIFTGATE WEATHERSTRIP.........................................................................................................................................................................1820 REMOVAL...................................................................................................................................................................................1820 INSTALLATION..............................................................................................................................................................................1820 REAR DOOR GLASS RUN WEATHERSTRIP..............................................................................................................................................................1820 REMOVAL...................................................................................................................................................................................1820 INSTALLATION..............................................................................................................................................................................1821 REAR DOOR INNER BELT WEATHERSTRIP.............................................................................................................................................................1821 REMOVAL...................................................................................................................................................................................1821 INSTALLATION..............................................................................................................................................................................1821 SILL SECONDARY WEATHERSTRIP...................................................................................................................................................................1821 REMOVAL...................................................................................................................................................................................1821 INSTALLATION..............................................................................................................................................................................1821 BODY STRUCTURE....................................................................................................................................................................................1823 GAP AND FLUSH.................................................................................................................................................................................1823 SPECIFICATIONS - BODY GAP AND FLUSH MEASUREMENTS..........................................................................................................................................1823 OPENING DIMENSIONS............................................................................................................................................................................1825 SPECIFICATIONS - BODY OPENING DIMENSION...................................................................................................................................................1825 SEALER LOCATIONS..............................................................................................................................................................................1827 SPECIFICATIONS - BODY SEALING LOCATIONS...................................................................................................................................................1827 STRUCTURAL ADHESIVE LOCATIONS.................................................................................................................................................................1842 SPECIFICATIONS - STRUCTURAL ADHESIVES.....................................................................................................................................................1842 WELD LOCATIONS................................................................................................................................................................................1847 SPECIFICATIONS - WELD LOCATIONS...........................................................................................................................................................1847 24-HEATING & AIR CONDITIONING.........................................................................................................................................................................1907 HEATING & AIR COND. - LHD.........................................................................................................................................................................1907 HEATING & AIR COND. - LHD.....................................................................................................................................................................1909 DESCRIPTION...............................................................................................................................................................................1909 ENGINE COOLING SYSTEM REQUIREMENTS....................................................................................................................................................1909 SAFETY PRECAUTIONS AND WARNINGS.......................................................................................................................................................1909 DIAGNOSIS AND TESTING.....................................................................................................................................................................1909 DIAGNOSIS AND TESTING - HEATER PERFORMANCE TEST.......................................................................................................................................1909 PRE-DIAGNOSTIC PREPARATIONS.......................................................................................................................................................1909 MAXIMUM HEATER OUTPUT: TEST AND ACTION............................................................................................................................................1909 POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW............................................................................................................................1910 POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT...................................................................................................................................1910 TEMPERATURE CONTROL...............................................................................................................................................................1910 DIAGNOSIS AND TESTING - A/C PERFORMANCE TEST..........................................................................................................................................1910 PERFORMANCE TEST PROCEDURE........................................................................................................................................................1910 STANDARD PROCEDURE........................................................................................................................................................................1911 STANDARD PROCEDURE - HANDLING TUBING AND FITTINGS.....................................................................................................................................1911 STANDARD PROCEDURE - SYSTEM CHARGE LEVEL TEST.........................................................................................................................................1911 STANDARD PROCEDURE - CHARGING A/C SYSTEM..............................................................................................................................................1912 PARTIAL CHARGE....................................................................................................................................................................1912 EVACUATION........................................................................................................................................................................1913 CHARGING A/C SYSTEM...............................................................................................................................................................1913 STANDARD PROCEDURE - EVACUATING REFRIGERANT SYSTEM....................................................................................................................................1914 STANDARD PROCEDURE - SYSTEM LEAK CHECKING.............................................................................................................................................1915 EMPTY REFRIGERANT SYSTEM LEAK TEST................................................................................................................................................1915 LOW REFRIGERANT LEVEL LEAK TEST...................................................................................................................................................1915 STANDARD PROCEDURE - REFRIGERANT RECOVERY0 - 12 PT (Continued)....................................................................................................................1915 SPECIFICATIONS............................................................................................................................................................................1916 A/C APPLICATION TABLE.................................................................................................................................................................1916 TORQUE................................................................................................................................................................................1917 A/C COMPRESSOR CLUTCH RELAY...................................................................................................................................................................1917 DESCRIPTION...............................................................................................................................................................................1917 OPERATION.................................................................................................................................................................................1918 REMOVAL...................................................................................................................................................................................1918 INSTALLATION..............................................................................................................................................................................1918 A/C HEATER CONTROL............................................................................................................................................................................1919 DESCRIPTION...............................................................................................................................................................................1919 DIAGNOSIS AND TESTING - VACUUM CONTROL SYSTEM.............................................................................................................................................1919 ONE-WAY CHECK VALVE...................................................................................................................................................................1920 HEATER-A/C CONTROLS...................................................................................................................................................................1920 LOCATING VACUUM LEAKS.................................................................................................................................................................1920 LOCATING PINCHED VACUUM LINES.........................................................................................................................................................1920 REMOVAL...................................................................................................................................................................................1921 INSTALLATION..............................................................................................................................................................................1921 A/C COMPRESSOR CLUTCH COIL....................................................................................................................................................................1922 REMOVAL...................................................................................................................................................................................1922 INSTALLATION..............................................................................................................................................................................1923 CLUTCH BREAK-IN.......................................................................................................................................................................1924 A/C HIGH PRESSURE SWITCH......................................................................................................................................................................1924 DESCRIPTION...............................................................................................................................................................................1924 REMOVAL...................................................................................................................................................................................1924 INSTALLATION..............................................................................................................................................................................1924 A/C LOW PRESSURE SWITCH.......................................................................................................................................................................1925 DESCRIPTION...............................................................................................................................................................................1925 OPERATION.................................................................................................................................................................................1925 DIAGNOSIS AND TESTING - A/C LOW PRESSURE CLUTCH CYCLING SWITCH............................................................................................................................1925 REMOVAL...................................................................................................................................................................................1925 INSTALLATION..............................................................................................................................................................................1925 A/C PRESSURE TRANSDUCER.......................................................................................................................................................................1926 DESCRIPTION...............................................................................................................................................................................1926 OPERATION.................................................................................................................................................................................1926 DIAGNOSIS AND TESTING - A/C PRESSURE TRANSDUCER...........................................................................................................................................1926 REMOVAL...................................................................................................................................................................................1926 INSTALLATION..............................................................................................................................................................................1926 BLOWER MOTOR RESISTOR BLOCK...................................................................................................................................................................1927 DESCRIPTION...............................................................................................................................................................................1927 REMOVAL...................................................................................................................................................................................1927 INSTALLATION..............................................................................................................................................................................1927 MODE DOOR CABLE...............................................................................................................................................................................1928 REMOVAL...................................................................................................................................................................................1928 INSTALLATION..............................................................................................................................................................................1928 ADJUSTMENT............................................................................................................................................................................1928 RECIRCULATION DOOR ACTUATOR...................................................................................................................................................................1929 DESCRIPTION...............................................................................................................................................................................1929 REMOVAL...................................................................................................................................................................................1929 INSTALLATION..............................................................................................................................................................................1930 TEMPERATURE CONTROL CABLES....................................................................................................................................................................1930 REMOVAL...................................................................................................................................................................................1930 INSTALLATION..............................................................................................................................................................................1930 ADJUSTMENTS...........................................................................................................................................................................1931 DISTRIBUTION..................................................................................................................................................................................1931 DESCRIPTION...............................................................................................................................................................................1931 DESCRIPTION - SYSTEM AIRFLOW..........................................................................................................................................................1931 DESCRIPTION - HEATER AND AIR CONDITIONING.............................................................................................................................................1931 AIR FILTER - EXPORT...........................................................................................................................................................................1932 DESCRIPTION...............................................................................................................................................................................1932 REMOVAL...................................................................................................................................................................................1932 INSTALLATION..............................................................................................................................................................................1932 AIR FLOW DISTRIBUTION.........................................................................................................................................................................1932 DESCRIPTION...............................................................................................................................................................................1932 OPERATION.................................................................................................................................................................................1933 AIR OUTLETS...................................................................................................................................................................................1933 DESCRIPTION...............................................................................................................................................................................1933 REMOVAL - CENTER AIR OUTLET DUCT..........................................................................................................................................................1933 INSTALLATION - CENTER AIR OUTLET DUCT.....................................................................................................................................................1933 BLOWER MOTOR..................................................................................................................................................................................1934 DESCRIPTION - BLOWER MOTOR WHEEL..........................................................................................................................................................1934 OPERATION.................................................................................................................................................................................1934 DIAGNOSIS AND TESTING - BLOWER MOTOR......................................................................................................................................................1934 REMOVAL...................................................................................................................................................................................1934 WITH AIR CONDITIONING.................................................................................................................................................................1936 WITHOUT AIR CONDITIONING..............................................................................................................................................................1936 INSTALLATION..............................................................................................................................................................................1936 WITH AIR CONDITIONING.................................................................................................................................................................1936 WITHOUT AIR CONDITIONING..............................................................................................................................................................1936 HVAC HOUSING..................................................................................................................................................................................1936 REMOVAL...................................................................................................................................................................................1936 DISASSEMBLY...............................................................................................................................................................................1937 ASSEMBLY..................................................................................................................................................................................1938 INSTALLATION..............................................................................................................................................................................1938 A/C COMPRESSOR................................................................................................................................................................................1939 DESCRIPTION...............................................................................................................................................................................1939 DESCRIPTION...........................................................................................................................................................................1939 DESCRIPTION - COMPRESSOR FRONT SHAFT SEAL.............................................................................................................................................1939 OPERATION.................................................................................................................................................................................1939 DIAGNOSIS AND TESTING - COMPRESSOR NOISE..................................................................................................................................................1939 REMOVAL...................................................................................................................................................................................1940 INSTALLATION..............................................................................................................................................................................1941 A/C CONDENSER.................................................................................................................................................................................1942 DESCRIPTION...............................................................................................................................................................................1942 OPERATION.................................................................................................................................................................................1942 REMOVAL...................................................................................................................................................................................1942 INSTALLATION..............................................................................................................................................................................1943 A/C DISCHARGE LINE............................................................................................................................................................................1943 DESCRIPTION - DISCHARGE LINE..............................................................................................................................................................1943 REMOVAL...................................................................................................................................................................................1943 INSTALLATION..............................................................................................................................................................................1943 A/C EVAPORATOR................................................................................................................................................................................1944 DESCRIPTION...............................................................................................................................................................................1944 OPERATION.................................................................................................................................................................................1944 REMOVAL...................................................................................................................................................................................1944 INSTALLATION..............................................................................................................................................................................1945 A/C HIGH PRESSURE RELIEF VALVE................................................................................................................................................................1946 REMOVAL - HIGH PRESSURE RELIEF VALVE......................................................................................................................................................1946 INSTALLATION - HIGH PRESSURE RELIEF VALVE.................................................................................................................................................1946 A/C VARIABLE ORIFICE TUBE.....................................................................................................................................................................1946 DESCRIPTION...............................................................................................................................................................................1946 REMOVAL - INSTALLATION....................................................................................................................................................................1946 ACCUMULATOR...................................................................................................................................................................................1947 DESCRIPTION...............................................................................................................................................................................1947 OPERATION.................................................................................................................................................................................1947 REMOVAL...................................................................................................................................................................................1947 INSTALLATION..............................................................................................................................................................................1947 CONDENSATION DRAIN TUBE.......................................................................................................................................................................1948 DESCRIPTION...............................................................................................................................................................................1948 REMOVAL...................................................................................................................................................................................1948 INSTALLATION..............................................................................................................................................................................1949 HEATER CORE...................................................................................................................................................................................1949 DESCRIPTION...............................................................................................................................................................................1949 OPERATION.................................................................................................................................................................................1949 REMOVAL...................................................................................................................................................................................1949 INSTALLATION..............................................................................................................................................................................1950 HEATER INLET HOSE.............................................................................................................................................................................1950 REMOVAL...................................................................................................................................................................................1950 INSTALLATION..............................................................................................................................................................................1950 HEATER RETURN HOSE............................................................................................................................................................................1951 REMOVAL...................................................................................................................................................................................1951 INSTALLATION..............................................................................................................................................................................1951 LIQUID LINE...................................................................................................................................................................................1952 DESCRIPTION...............................................................................................................................................................................1952 REMOVAL...................................................................................................................................................................................1952 INSTALLATION..............................................................................................................................................................................1953 REFRIGERANT...................................................................................................................................................................................1953 DESCRIPTION...............................................................................................................................................................................1953 OPERATION.................................................................................................................................................................................1953 STANDARD PROCEDURE - REFRIGERANT..........................................................................................................................................................1953 REFRIGERANT OIL...............................................................................................................................................................................1954 DESCRIPTION...............................................................................................................................................................................1954 OPERATION.................................................................................................................................................................................1954 STANDARD PROCEDURE........................................................................................................................................................................1955 STANDARD PROCEDURE - SERVICING REFRIGERANT OIL LEVEL..................................................................................................................................1955 STANDARD PROCEDURE - REFRIGERANT OIL LEVEL CHECK......................................................................................................................................1955 SUCTION LINE..................................................................................................................................................................................1956 DESCRIPTION...............................................................................................................................................................................1956 OPERATION.................................................................................................................................................................................1957 REMOVAL...................................................................................................................................................................................1957 INSTALLATION..............................................................................................................................................................................1958 SUCTION AND LIQUID LINE ASSEMBLY..............................................................................................................................................................1959 REMOVAL...................................................................................................................................................................................1959 INSTALLATION..............................................................................................................................................................................1959 SERVICE PORT VALVE CORE.......................................................................................................................................................................1960 DESCRIPTION...............................................................................................................................................................................1960 A/C SERVICE PORT VALVE CORES..........................................................................................................................................................1960 REMOVAL– SERVICE PORT VALVE CORES.........................................................................................................................................................1961 INSTALLATION - SERVICE PORT VALVE CORES...................................................................................................................................................1961 A/C VARIABLE ORIFICE TUBE.....................................................................................................................................................................1961 DESCRIPTION...............................................................................................................................................................................1961 REMOVAL - INSTALLATION....................................................................................................................................................................1961 CABIN HEATER..................................................................................................................................................................................1961 DESCRIPTION...............................................................................................................................................................................1961 OPERATION.................................................................................................................................................................................1961 DIAGNOSIS AND TESTING - DIESEL ENGINE CABIN HEATER........................................................................................................................................1962 HEATING & AIR COND. - RHD.........................................................................................................................................................................1963 HEATING & AIR COND. - RHD.....................................................................................................................................................................1965 DESCRIPTION...............................................................................................................................................................................1965 ENGINE COOLING SYSTEM REQUIREMENTS....................................................................................................................................................1965 SAFETY PRECAUTIONS AND WARNINGS.......................................................................................................................................................1965 DIAGNOSIS AND TESTING.....................................................................................................................................................................1965 DIAGNOSIS AND TESTING - HEATER PERFORMANCE TEST.......................................................................................................................................1965 PRE-DIAGNOSTIC PREPARATIONS.......................................................................................................................................................1965 MAXIMUM HEATER OUTPUT: TEST AND ACTION............................................................................................................................................1965 POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW............................................................................................................................1966 POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT...................................................................................................................................1966 TEMPERATURE CONTROL...............................................................................................................................................................1966 DIAGNOSIS AND TESTING - A/C PERFORMANCE TEST..........................................................................................................................................1966 PERFORMANCE TEST PROCEDURE........................................................................................................................................................1966 STANDARD PROCEDURE........................................................................................................................................................................1967 STANDARD PROCEDURE - HANDLING TUBING AND FITTINGS.....................................................................................................................................1967 STANDARD PROCEDURE - SYSTEM CHARGE LEVEL TEST.........................................................................................................................................1967 STANDARD PROCEDURE - EVACUATING REFRIGERANT SYSTEM....................................................................................................................................1968 STANDARD PROCEDURE - CHARGING A/C SYSTEM..............................................................................................................................................1969 PARTIAL CHARGE....................................................................................................................................................................1969 EVACUATION........................................................................................................................................................................1969 CHARGING A/C SYSTEM...............................................................................................................................................................1970 STANDARD PROCEDURE - SYSTEM LEAK CHECKING.............................................................................................................................................1971 EMPTY REFRIGERANT SYSTEM LEAK TEST................................................................................................................................................1971 LOW REFRIGERANT LEVEL LEAK TEST...................................................................................................................................................1971 STANDARD PROCEDURE - REFRIGERANT RECOVERY.............................................................................................................................................1971 SPECIFICATIONS............................................................................................................................................................................1972 A/C APPLICATION TABLE.................................................................................................................................................................1972 TORQUE................................................................................................................................................................................1973 A/C COMPRESSOR CLUTCH RELAY...................................................................................................................................................................1973 DESCRIPTION...............................................................................................................................................................................1973 OPERATION.................................................................................................................................................................................1974 REMOVAL...................................................................................................................................................................................1974 INSTALLATION..............................................................................................................................................................................1974 A/C HEATER CONTROL............................................................................................................................................................................1975 DESCRIPTION...............................................................................................................................................................................1975 DIAGNOSIS AND TESTING - VACUUM CONTROL SYSTEM.............................................................................................................................................1975 ONE-WAY CHECK VALVE...................................................................................................................................................................1976 HEATER-A/C CONTROLS...................................................................................................................................................................1976 LOCATING VACUUM LEAKS.................................................................................................................................................................1976 LOCATING PINCHED VACUUM LINES.........................................................................................................................................................1976 REMOVAL...................................................................................................................................................................................1977 INSTALLATION..............................................................................................................................................................................1977 A/C COMPRESSOR CLUTCH COIL....................................................................................................................................................................1978 REMOVAL...................................................................................................................................................................................1978 INSTALLATION..............................................................................................................................................................................1979 CLUTCH BREAK-IN.......................................................................................................................................................................1980 A/C HIGH PRESSURE SWITCH......................................................................................................................................................................1980 DESCRIPTION...............................................................................................................................................................................1980 REMOVAL...................................................................................................................................................................................1980 INSTALLATION..............................................................................................................................................................................1980 A/C LOW PRESSURE SWITCH.......................................................................................................................................................................1981 DESCRIPTION...............................................................................................................................................................................1981 OPERATION.................................................................................................................................................................................1981 DIAGNOSIS AND TESTING - A/C LOW PRESSURE CLUTCH CYCLING SWITCH............................................................................................................................1981 REMOVAL...................................................................................................................................................................................1981 INSTALLATION..............................................................................................................................................................................1981 A/C PRESSURE TRANSDUCER.......................................................................................................................................................................1982 DESCRIPTION...............................................................................................................................................................................1982 OPERATION.................................................................................................................................................................................1982 DIAGNOSIS AND TESTING - A/C PRESSURE TRANSDUCER...........................................................................................................................................1982 REMOVAL...................................................................................................................................................................................1982 INSTALLATION..............................................................................................................................................................................1982 BLOWER MOTOR RESISTOR BLOCK...................................................................................................................................................................1982 DESCRIPTION...............................................................................................................................................................................1982 REMOVAL...................................................................................................................................................................................1982 INSTALLATION..............................................................................................................................................................................1983 MODE DOOR CABLE...............................................................................................................................................................................1983 REMOVAL...................................................................................................................................................................................1983 INSTALLATION..............................................................................................................................................................................1984 ADJUSTMENT............................................................................................................................................................................1984 RECIRCULATION DOOR ACTUATOR...................................................................................................................................................................1984 DESCRIPTION...............................................................................................................................................................................1984 REMOVAL...................................................................................................................................................................................1985 INSTALLATION..............................................................................................................................................................................1985 TEMPERATURE CONTROL CABLES....................................................................................................................................................................1985 REMOVAL...................................................................................................................................................................................1985 INSTALLATION..............................................................................................................................................................................1986 ADJUSTMENTS...........................................................................................................................................................................1986 DISTRIBUTION..................................................................................................................................................................................1986 DESCRIPTION...............................................................................................................................................................................1986 DESCRIPTION - SYSTEM AIRFLOW..........................................................................................................................................................1986 DESCRIPTION - HEATER AND AIR CONDITIONING.............................................................................................................................................1987 AIR FILTER - EXPORT...........................................................................................................................................................................1987 DESCRIPTION...............................................................................................................................................................................1987 REMOVAL...................................................................................................................................................................................1987 INSTALLATION..............................................................................................................................................................................1988 AIR FLOW DISTRIBUTION.........................................................................................................................................................................1988 DESCRIPTION...............................................................................................................................................................................1988 OPERATION.................................................................................................................................................................................1988 AIR OUTLETS...................................................................................................................................................................................1989 DESCRIPTION...............................................................................................................................................................................1989 REMOVAL - CENTER AIR OUTLET DUCT..........................................................................................................................................................1989 INSTALLATION - CENTER AIR OUTLET DUCT.....................................................................................................................................................1989 BLOWER MOTOR..................................................................................................................................................................................1989 DESCRIPTION - BLOWER MOTOR WHEEL..........................................................................................................................................................1989 OPERATION.................................................................................................................................................................................1989 DIAGNOSIS AND TESTING - BLOWER MOTOR......................................................................................................................................................1989 REMOVAL...................................................................................................................................................................................1989 WITH AIR CONDITIONING.................................................................................................................................................................1991 WITHOUT AIR CONDITIONING..............................................................................................................................................................1991 INSTALLATION..............................................................................................................................................................................1991 WITH AIR CONDITIONING.................................................................................................................................................................1991 WITHOUT AIR CONDITIONING..............................................................................................................................................................1991 HVAC HOUSING..................................................................................................................................................................................1991 REMOVAL...................................................................................................................................................................................1991 DISASSEMBLY...............................................................................................................................................................................1992 ASSEMBLY..................................................................................................................................................................................1992 INSTALLATION..............................................................................................................................................................................1993 A/C COMPRESSOR................................................................................................................................................................................1994 DESCRIPTION...............................................................................................................................................................................1994 DESCRIPTION...........................................................................................................................................................................1994 DESCRIPTION - COMPRESSOR FRONT SHAFT SEAL.............................................................................................................................................1994 OPERATION.................................................................................................................................................................................1994 DIAGNOSIS AND TESTING - COMPRESSOR NOISE..................................................................................................................................................1994 REMOVAL...................................................................................................................................................................................1994 INSTALLATION..............................................................................................................................................................................1995 A/C CONDENSER.................................................................................................................................................................................1996 DESCRIPTION...............................................................................................................................................................................1996 OPERATION.................................................................................................................................................................................1997 REMOVAL...................................................................................................................................................................................1997 INSTALLATION..............................................................................................................................................................................1997 A/C DISCHARGE LINE............................................................................................................................................................................1998 DESCRIPTION - DISCHARGE LINE..............................................................................................................................................................1998 REMOVAL...................................................................................................................................................................................1998 INSTALLATION..............................................................................................................................................................................1999 A/C EVAPORATOR................................................................................................................................................................................1999 REMOVAL...................................................................................................................................................................................1999 INSTALLATION..............................................................................................................................................................................2000 A/C HIGH PRESSURE RELIEF VALVE................................................................................................................................................................2001 REMOVAL - HIGH PRESSURE RELIEF VALVE......................................................................................................................................................2001 INSTALLATION - HIGH PRESSURE RELIEF VALVE.................................................................................................................................................2001 ACCUMULATOR...................................................................................................................................................................................2001 DESCRIPTION...............................................................................................................................................................................2001 OPERATION.................................................................................................................................................................................2001 REMOVAL...................................................................................................................................................................................2001 INSTALLATION..............................................................................................................................................................................2002 CONDENSATION DRAIN TUBE.......................................................................................................................................................................2003 DESCRIPTION...............................................................................................................................................................................2003 REMOVAL...................................................................................................................................................................................2003 INSTALLATION..............................................................................................................................................................................2003 HEATER CORE - EXPORT..........................................................................................................................................................................2003 DESCRIPTION...............................................................................................................................................................................2003 OPERATION.................................................................................................................................................................................2004 REMOVAL...................................................................................................................................................................................2004 INSTALLATION..............................................................................................................................................................................2005 HEATER INLET HOSE.............................................................................................................................................................................2006 REMOVAL...................................................................................................................................................................................2006 INSTALLATION..............................................................................................................................................................................2006 HEATER RETURN HOSE............................................................................................................................................................................2007 REMOVAL...................................................................................................................................................................................2007 INSTALLATION..............................................................................................................................................................................2007 LIQUID LINE...................................................................................................................................................................................2008 DESCRIPTION...............................................................................................................................................................................2008 REMOVAL...................................................................................................................................................................................2008 INSTALLATION..............................................................................................................................................................................2008 REFRIGERANT...................................................................................................................................................................................2009 DESCRIPTION...............................................................................................................................................................................2009 OPERATION.................................................................................................................................................................................2009 STANDARD PROCEDURE - REFRIGERANT..........................................................................................................................................................2009 REFRIGERANT OIL...............................................................................................................................................................................2010 DESCRIPTION...............................................................................................................................................................................2010 OPERATION.................................................................................................................................................................................2010 STANDARD PROCEDURE........................................................................................................................................................................2010 STANDARD PROCEDURE - SERVICING REFRIGERANT OIL LEVEL..................................................................................................................................2010 STANDARD PROCEDURE - REFRIGERANT OIL LEVEL CHECK......................................................................................................................................2010 SUCTION LINE..................................................................................................................................................................................2011 DESCRIPTION...............................................................................................................................................................................2011 OPERATION.................................................................................................................................................................................2012 REMOVAL...................................................................................................................................................................................2013 INSTALLATION..............................................................................................................................................................................2014 SUCTION AND LIQUID LINE ASSEMBLY..............................................................................................................................................................2015 REMOVAL...................................................................................................................................................................................2015 INSTALLATION..............................................................................................................................................................................2015 SERVICE PORT VALVE CORE0 - 14 PT (Continued)..............................................................................................................................................2016 DESCRIPTION...............................................................................................................................................................................2016 A/C SERVICE PORT VALVE CORES..........................................................................................................................................................2016 REMOVAL– SERVICE PORT VALVE CORES.........................................................................................................................................................2017 INSTALLATION - SERVICE PORT VALVE CORES...................................................................................................................................................2017 A/C VARIABLE ORIFICE TUBE.....................................................................................................................................................................2017 DESCRIPTION...............................................................................................................................................................................2017 REMOVAL - INSTALLATION....................................................................................................................................................................2017 CABIN HEATER..................................................................................................................................................................................2017 DESCRIPTION...............................................................................................................................................................................2017 OPERATION.................................................................................................................................................................................2017 DIAGNOSIS AND TESTING - DIESEL ENGINE CABIN HEATER........................................................................................................................................2017 HEATER UNIT...................................................................................................................................................................................2018 REMOVAL...................................................................................................................................................................................2018 INSTALLATION..............................................................................................................................................................................2018 25-EMISSIONS CONTROL..................................................................................................................................................................................2019 EMISSIONS CONTROL.................................................................................................................................................................................2019 EMISSIONS CONTROL.............................................................................................................................................................................2019 DESCRIPTION...............................................................................................................................................................................2019 DESCRIPTION - MONITORED COMPONENT.....................................................................................................................................................2019 DESCRIPTION - VEHICLE EMISSION CONTROL INFORMATION LABEL..............................................................................................................................2023 DESCRIPTION - TRIP DEFINITION.........................................................................................................................................................2023 OPERATION - NON-MONITORED CIRCUITS....................................................................................................................................................2023 DESCRIPTION - MONITORED SYSTEMS.......................................................................................................................................................2024 DESCRIPTION - HIGH AND LOW LIMITS.....................................................................................................................................................2027 OPERATION.................................................................................................................................................................................2027 OPERATION - SYSTEM....................................................................................................................................................................2027 DRB III STATE DISPLAY TEST MODE.......................................................................................................................................................2028 OPERATION.........................................................................................................................................................................2028 EVAPORATIVE EMISSIONS.............................................................................................................................................................................2029 EVAPORATIVE EMISSIONS.........................................................................................................................................................................2029 OPERATION - EVAPORATION CONTROL SYSTEM....................................................................................................................................................2029 EVAP/PURGE SOLENOID...........................................................................................................................................................................2031 DESCRIPTION...............................................................................................................................................................................2031 OPERATION.................................................................................................................................................................................2031 REMOVAL...................................................................................................................................................................................2031 REMOVAL...............................................................................................................................................................................2031 REMOVAL - 2.4L TURBO..................................................................................................................................................................2031 INSTALLATION..............................................................................................................................................................................2032 INSTALLATION..........................................................................................................................................................................2032 INSTALLATION - 2.4L TURBO.............................................................................................................................................................2032 FUEL FILLER CAP...............................................................................................................................................................................2032 DESCRIPTION...............................................................................................................................................................................2032 OPERATION.................................................................................................................................................................................2032 NATURAL VAC LEAK DETECTION ASSY...............................................................................................................................................................2032 REMOVAL...................................................................................................................................................................................2032 INSTALLATION..............................................................................................................................................................................2033 ORVR..........................................................................................................................................................................................2033 DESCRIPTION...............................................................................................................................................................................2033 OPERATION.................................................................................................................................................................................2033 DIAGNOSIS AND TESTING - VEHICLE DOES NOT FILL.............................................................................................................................................2035 PCV VALVE.....................................................................................................................................................................................2036 DESCRIPTION...............................................................................................................................................................................2036 OPERATION.................................................................................................................................................................................2036 DIAGNOSIS AND TESTING - PCV SYSTEM........................................................................................................................................................2036 REMOVAL - 1.6L............................................................................................................................................................................2037 INSTALLATION - 1.6L.......................................................................................................................................................................2037 VAPOR CANISTER................................................................................................................................................................................2037 DESCRIPTION...............................................................................................................................................................................2037 OPERATION.................................................................................................................................................................................2037 Purge Free Cells......................................................................................................................................................................2037 REMOVAL...................................................................................................................................................................................2038 INSTALLATION..............................................................................................................................................................................2039 ON-BOARD DIAGNOSTICS..............................................................................................................................................................................2040 TASK MANAGER..................................................................................................................................................................................2040 DESCRIPTION...............................................................................................................................................................................2040 OPERATION.................................................................................................................................................................................2040 INDEX.................................................................................................................................................................................................2045 SERVICE MANUAL COMMENTS...............................................................................................................................................................................2077
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