Jeep Cherokee 2003 KJ Service Manual – PDF DOWNLOAD
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Jeep Cherokee 2003 KJ Service Manual – PDF DOWNLOAD
Description
Jeep Cherokee 2003 KJ Service Manual – PDF DOWNLOAD
FILE DETAILS:
Jeep Cherokee 2003 KJ Service Manual – PDF DOWNLOAD
Language : English
Pages : 2159
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Jeep Cherokee 2003 KJ Service Manual – PDF DOWNLOAD
sm-front 1
16142-kj_sm 3
KJ Service Manual 3
GROUP TAB LOCATOR 3
in-INTRODUCTION 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 EMISSION CONTROL INFORMATION (VECI) LABEL 11
DESCRIPTION 11
VEHICLE IDENTIFICATION NUMBER 11
DESCRIPTION 11
VEHICLE SAFETY CERTIFICATION LABEL 12
DESCRIPTION 12
0-LUBRICATION & MAINTENANCE 14
INTERNATIONAL SYMBOLS 14
DESCRIPTION 14
PARTS & LUBRICANT RECOMMENDATION 14
DESCRIPTION 14
DESCRIPTION – FLUID TYPES 14
SAE VISCOSITY RATING 14
API QUALITY CLASSIFICATION 15
GEAR LUBRICANTS 15
LUBRICANTS AND GREASES 15
SPECIALIZED LUBRICANTS AND OILS 15
DESCRIPTION – LUBRICANT RECOMMENDATIONS 15
Chassis 15
Body 15
FLUID TYPES 16
DESCRIPTION 16
DESCRIPTION – FLUID TYPES 16
SAE VISCOSITY RATING 16
API QUALITY CLASSIFICATION 16
GEAR LUBRICANTS 16
LUBRICANTS AND GREASES 16
SPECIALIZED LUBRICANTS AND OILS 16
DESCRIPTION – AXLE 16
DESCRIPTION – MANUAL TRANSMISSION 17
DESCRIPTION – AUTOMATIC TRANSMISSION FLUID 17
FLUID ADDITIVES 17
DESCRIPTION – TRANSFER CASE – NV231 17
DESCRIPTION – TRANSFER CASE – NV242 17
DESCRIPTION – ENGINE COOLANT 17
COOLANT PERFORMANCE 18
DESCRIPTION – ENGINE OIL – DIESEL ENGINES 18
SAE VISCOSITY GRADE 18
DESCRIPTION – POWER STEERING FLUID 18
OPERATION – AUTOMATIC TRANSMISSION FLUID 18
FLUID CAPACITIES 19
SPECIFICATIONS – FLUID CAPACITIES 19
FLUID FILL/CHECK LOCATIONS 19
DESCRIPTION 19
MAINTENANCE SCHEDULES 19
DESCRIPTION 19
Schedule “B” 20
Schedule “A” 25
HOISTING 27
STANDARD PROCEDURE – HOISTING RECOMMENDATIONS 27
HOIST 27
JUMP STARTING 27
STANDARD PROCEDURE – JUMP STARTING PROCEDURE 27
TO JUMP START A DISABLED VEHICLE: 28
DISCONNECT CABLE CLAMPS AS FOLLOWS: 28
TOWING 28
STANDARD PROCEDURE – TOWING 28
SAFETY PRECAUTIONS 29
TWO-WHEEL-DRIVE VEHICLE TOWING 29
TWO WHEEL DRIVE TOWING-REAR END LIFTED 29
TWO WHEEL DRIVE TOWING-FRONT END LIFTED 29
FOUR-WHEEL-DRIVE VEHICLE TOWING 29
FOUR WHEEL DRIVE TOWING—REAR END LIFTED 29
FOUR WHEEL DRIVE TOWING—FRONT END LIFTED 30
0a-MAINTENANCE SCHEDULES 32
MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U S , CANADA and MEXICO 32
DESCRIPTION 32
DESCRIPTION 32
Schedule “B” 32
Schedule “A” 37
DESCRIPTION — DIESEL ENGINES 39
Schedule “B” 39
Schedule “A” 42
2-SUSPENSION 44
SUSPENSION 44
DIAGNOSIS AND TESTING – SUSPENSION AND STEERING SYSTEM 44
WHEEL ALIGNMENT 46
WHEEL ALIGNMENT 46
DESCRIPTION 46
OPERATION 46
STANDARD PROCEDURE 47
STANDARD PROCEDURE – HEIGHT MEASUREMENT 47
RIDE HEIGHT 47
STANDARD PROCEDURE – CAMBER AND CASTER ADJUSTMENT 48
STANDARD PROCEDURE – TOE ADJUSTMENT 48
STANDARD PROCEDURE – CAMBER, CASTER AND TOE ADJUSTMENT 48
CASTER 48
CAMBER 48
TOE ADJUSTMENT 48
SPECIFICATIONS 49
ALIGNMENT 49
FRONT 49
REAR 49
FRONT 50
FRONT 50
DESCRIPTION 50
WARNING 51
SPECIFICATIONS 51
TORQUE CHART 51
SPECIAL TOOLS 52
FRONT SUSPENSION 52
BUSHINGS 53
REMOVAL 53
REMOVAL – STABILIZER BAR BUSHINGS 53
REMOVAL – LOWER CONTROL ARM BUSHING 53
REMOVAL – CLEVIS BRACKET BUSHING 53
REMOVAL – UPPER CONTROL ARM BUSHINGS 53
INSTALLATION 53
INSTALLATION – STABILIZER BAR BUSHINGS 53
INSTALLATION – LOWER CONTROL ARM BUSHING 54
INSTALLATION – CLEVIS BRACKET BUSHING 54
INSTALLATION – UPPER CONTROL ARM BUSHINGS 55
HUB / BEARING 55
REMOVAL 55
INSTALLATION 55
KNUCKLE 56
REMOVAL 56
INSTALLATION 56
LOWER BALL JOINT 56
DIAGNOSIS AND TESTING – LOWER BALL JOINT 56
REMOVAL 57
INSTALLATION 57
LOWER CONTROL ARM 58
REMOVAL 58
INSTALLATION 58
SHOCK 58
REMOVAL 58
REMOVAL – LEFT SIDE 58
REMOVAL – RIGHT SIDE 59
INSTALLATION 59
INSTALLATION – LEFT SIDE 59
INSTALLATION – RIGHT SIDE 60
SPRING 60
REMOVAL 60
INSTALLATION 60
CLEVIS BRACKET 61
REMOVAL 61
INSTALLATION 61
STABILIZER BAR 61
REMOVAL 61
INSTALLATION 61
STABILIZER LINK 62
REMOVAL 62
INSTALLATION 62
UPPER CONTROL ARM 62
REMOVAL 62
REMOVAL – RIGHT SIDE 62
REMOVAL – LEFT SIDE 62
INSTALLATION 63
INSTALLATION – RIGHT SIDE 63
INSTALLATION – LEFT SIDE 63
REAR 64
REAR 64
DESCRIPTION 64
WARNING 65
DIAGNOSIS AND TESTING – REAR SUSPENSION 65
SPECIFICATIONS 65
TORQUE CHART 65
SPECIAL TOOLS 66
REAR SUSPENSION 66
SHOCK 66
REMOVAL 66
INSTALLATION 66
SPRING 67
REMOVAL 67
INSTALLATION 67
JOUNCE BUMPER 67
REMOVAL 67
INSTALLATION 67
STABILIZER BAR 67
REMOVAL 67
INSTALLATION 68
UPPER BALL JOINT 68
REMOVAL 68
INSTALLATION 68
UPPER CONTROL ARM 69
DESCRIPTION – UPPER SUSPENSION ARM, BUSHINGS, AND BALL JOINT 69
OPERATION – UPPER SUSPENSION ARM, BUSHINGS, AND BALL JOINT 69
REMOVAL 69
INSTALLATION 69
LOWER CONTROL ARM 70
DESCRIPTION 70
OPERATION 70
REMOVAL 70
INSTALLATION 70
BUSHINGS 70
REMOVAL 70
REMOVAL – LOWER SUSPENSION ARM BUSHING 70
REMOVAL – UPPER SUSPENSION ARM BUSHING 71
INSTALLATION 71
INSTALLATION – LOWER SUSPENSION ARM BUSHING 71
INSTALLATION – UPPER SUSPENSION ARM BUSHING 72
3-DIFFERENTIAL & DRIVELINE 74
PROPELLER SHAFT 74
PROPELLER SHAFT 74
DIAGNOSIS AND TESTING 74
VIBRATION 74
BALANCE 75
RUNOUT 76
STANDARD PROCEDURE 76
STANDARD PROCEDURES 76
PROPELLER SHAFT ANGLE 76
SPECIFICATIONS 78
SPECIAL TOOLS 79
PROPELLER SHAFT – FRONT 79
REMOVAL 79
REMOVAL – 2 5L DIESEL 79
REMOVAL 79
INSTALLATION 80
INSTALLATION – 2 5L DIESEL 80
INSTALLATION 80
PROPELLER SHAFT – REAR 80
REMOVAL 80
INSTALLATION 80
SINGLE CARDAN UNIVERSAL JOINTS 81
DISASSEMBLY 81
ASSEMBLY 82
HALF SHAFT 83
HALF SHAFT 83
CAUTION 83
DIAGNOSIS AND TESTING 83
NOISE/VIBRATION IN TURNS 83
CLUNKING NOISE DURING ACCELERATION 83
SHUDDER/VIBRATION DURING ACCELERATION 83
VIBRATION AT HIGHWAY SPEEDS 83
REMOVAL 83
INSTALLATION 84
SPECIFICATIONS 84
SPECIAL TOOLS 85
CV JOINT/BOOT-OUTER 85
REMOVAL 85
INSTALLATION 86
CV JOINT/BOOT-INNER 88
REMOVAL 88
INSTALLATION 89
FRONT AXLE – 186FIA 91
FRONT AXLE – 186FIA 91
DESCRIPTION 91
OPERATION 91
DIAGNOSIS AND TESTING 92
GEAR NOISE 92
BEARING NOISE 92
LOW SPEED KNOCK 92
VIBRATION 92
DRIVELINE SNAP 92
REMOVAL 95
INSTALLATION 97
ADJUSTMENTS 97
PINION DEPTH MEASUREMENT 98
DIFFERENTIAL 99
SHIM SELECTION 99
GEAR CONTACT PATTERN 102
DIFFERENTIAL BEARING PRELOAD CHECK 104
SPECIFICATIONS 104
SPECIAL TOOLS 104
AXLE SHAFTS 107
REMOVAL 107
INSTALLATION 107
AXLE SHAFT SEALS 108
REMOVAL 108
INSTALLATION 108
AXLE BEARINGS 108
REMOVAL 108
INSTALLATION 109
PINION SEAL 109
REMOVAL 109
INSTALLATION 109
DIFFERENTIAL 110
REMOVAL 110
DISASSEMBLY 111
ASSEMBLY 112
INSTALLATION 112
DIFFERENTIAL CASE BEARINGS 113
REMOVAL 113
INSTALLATION 113
PINION GEAR/RING GEAR 114
REMOVAL 114
INSTALLATION 116
REAR AXLE – 8 1/4 119
REAR AXLE – 8 1/4 119
DESCRIPTION 119
OPERATION 119
DIAGNOSIS AND TESTING 119
GEAR NOISE 119
BEARING NOISE 119
LOW SPEED KNOCK 120
VIBRATION 120
DRIVELINE SNAP 120
REMOVAL 122
INSTALLATION 122
ADJUSTMENTS 123
PINION DEPTH MEASUREMENT 125
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH 126
GEAR CONTACT PATTERN 127
SIDE GEAR CLEARANCE 128
SPECIFICATIONS 129
SPECIAL TOOLS 129
AXLE SHAFTS 132
REMOVAL 132
INSTALLATION 133
AXLE SHAFT SEALS 133
REMOVAL 133
INSTALLATION 133
AXLE BEARINGS 133
REMOVAL 133
INSTALLATION 133
PINION SEAL 133
REMOVAL 133
INSTALLATION 134
DIFFERENTIAL 135
DESCRIPTION 135
OPERATION 135
REMOVAL 135
DISASSEMBLY 136
ASSEMBLY 136
INSTALLATION 137
DIFFERENTIAL – TRAC-LOK 137
DESCRIPTION 137
OPERATION 138
DIAGNOSIS AND TESTING 138
DIFFERENTIAL TEST 138
DISASSEMBLY 138
ASSEMBLY 140
DIFFERENTIAL CASE BEARINGS 141
REMOVAL 141
INSTALLATION 142
PINION GEAR/RING GEAR/TONE RING 142
REMOVAL 142
INSTALLATION 144
5-BRAKES 148
BRAKES – BASE 148
BRAKES – BASE 149
DESCRIPTION 149
WARNING 150
DIAGNOSIS AND TESTING – BASE BRAKE SYSTEM 150
PRELIMINARY BRAKE CHECK 150
ROAD TESTING 150
BRAKE NOISES 152
STANDARD PROCEDURE 152
STANDARD PROCEDURE – PRESSURE BLEEDING 152
STANDARD PROCEDURE – MANUAL BLEEDING 153
SPECIFICATIONS 153
BRAKE COMPONENTS 153
TORQUE 154
SPECIAL TOOLS 154
BASE BRAKES 154
BRAKE LINES 155
DESCRIPTION 155
DIAGNOSIS AND TESTING – BRAKE LINE AND HOSES 155
STANDARD PROCEDURE – DOUBLE INVERTED FLARING 155
REMOVAL 156
REMOVAL – FRONT HOSE 156
REMOVAL – REAR BRAKE HOSE 156
INSTALLATION 157
INSTALLATION – FRONT OR REAR BRAKE CALIPER HOSE 157
INSTALLATION – REAR BRAKE HOSE 157
BRAKE PADS / SHOES 157
REMOVAL 157
REMOVAL – FRONT BRAKE PADS 157
REMOVAL – REAR DISC BRAKE PADS 157
INSTALLATION 157
INSTALLATION – FRONT BRAKE PADS 157
INSTALLATION – REAR DISC BRAKE PADS 157
DISC BRAKE CALIPERS 158
DESCRIPTION 158
OPERATION 158
REMOVAL 159
REMOVAL – FRONT 159
REMOVAL – REAR 159
DISASSEMBLY 159
CLEANING 160
INSPECTION 160
ASSEMBLY 161
INSTALLATION 162
INSTALLATION – FRONT 162
INSTALLATION – REAR 162
DISC BRAKE CALIPER ADAPTER 163
REMOVAL 163
INSTALLATION 163
ROTORS 163
DIAGNOSIS AND TESTING 163
DIAGNOSIS AND TESTING – DISC BRAKE ROTOR 163
ROTOR MINIMUM THICKNESS 163
ROTOR RUNOUT 163
ROTOR THICKNESS VARIATION 164
DIAGNOSIS AND TESTING – BRAKE DRUM IN HAT ROTOR 164
BRAKE DRUM RUNOUT 164
STANDARD PROCEDURE 164
STANDARD PROCEDURE – DISC BRAKE ROTOR 164
STANDARD PROCEDURE – BRAKE DRUM IN HAT ROTOR MACHINING 164
REMOVAL 165
REMOVAL – FRONT 165
REMOVAL – REAR 165
INSTALLATION 165
INSTALLATION – FRONT 165
INSTALLATION – REAR 165
BRAKE JUNCTION BLOCK 166
DESCRIPTION 166
OPERATION 166
PROPORTIONING VALVE 166
DIAGNOSIS AND TESTING – PROPORTIONING VALVE 166
REMOVAL 166
INSTALLATION 166
PEDAL 166
DESCRIPTION 166
OPERATION 166
REMOVAL 166
INSTALLATION 166
POWER BRAKE BOOSTER 167
DESCRIPTION 167
OPERATION 167
DIAGNOSIS AND TESTING – MASTER CYLINDER/POWER BOOSTER 168
POWER BOOSTER VACUUM TEST 168
POWER BOOSTER CHECK VALVE TEST 168
REMOVAL 169
REMOVAL – LHD 169
REMOVAL – RHD 169
INSTALLATION 170
INSTALLATION – LHD 170
INSTALLATION – RHD 170
MASTER CYLINDER 171
DESCRIPTION 171
OPERATION 171
DIAGNOSIS AND TESTING – MASTER CYLINDER/POWER BOOSTER 171
POWER BOOSTER VACUUM TEST 171
POWER BOOSTER CHECK VALVE TEST 172
STANDARD PROCEDURE – MASTER CYLINDER BLEEDING 172
REMOVAL 172
INSTALLATION 172
FLUID RESERVOIR 173
REMOVAL 173
INSTALLATION 173
FLUID 173
DIAGNOSIS AND TESTING – BRAKE FLUID CONTAMINATION 173
STANDARD PROCEDURE – MASTER CYLINDER FLUID LEVEL 173
SPECIFICATIONS 173
BRAKE FLUID 173
SUPPORT PLATE 174
REMOVAL 174
INSTALLATION 174
PARKING BRAKE 174
DESCRIPTION 174
OPERATION 175
ADJUSTMENTS 175
ADJUSTMENT – LOCK OUT 175
CABLES 175
REMOVAL 175
INSTALLATION 176
LEVER 176
REMOVAL 176
INSTALLATION 176
SHOES 177
DESCRIPTION 177
OPERATION 177
REMOVAL 177
CLEANING – REAR DRUM IN HAT BRAKE 177
INSPECTION – REAR DRUM IN HAT BRAKE 178
INSTALLATION 178
ADJUSTMENTS 179
ADJUSTMENT – REAR DRUM IN HAT PARK BRAKE (ROTOR REMOVED) 179
ADJUSTMENT – WITH ADJUSTING TOOL 180
ADJUSTMENT – REAR DRUM IN HAT PARK BRAKE (ROTOR REMOVED) 180
BRAKES – ABS 183
BRAKES – ABS 183
DESCRIPTION 183
ANTILOCK BRAKING SYSTEM 183
ELECTRONIC BRAKE DISTRIBUTION 183
OPERATION 183
ANTILOCK BRAKING SYSTEM 183
ELECTRONIC BRAKE DISTRIBUTION 183
DIAGNOSIS AND TESTING – ANTILOCK BRAKING SYSTEM 184
STANDARD PROCEDURE – ABS BRAKE BLEEDING 184
SPECIFICATIONS 184
ELECTRICAL 185
DESCRIPTION 185
OPERATION 185
FRONT WHEEL SPEED SENSOR 185
REMOVAL 185
INSTALLATION 185
REAR WHEEL SPEED SENSOR 186
REMOVAL 186
INSTALLATION 186
HCU (HYDRAULIC CONTROL UNIT) 186
DESCRIPTION 186
OPERATION 186
PRESSURE DECREASE 186
PRESSURE HOLD 186
PRESSURE INCREASE 186
REMOVAL 186
INSTALLATION 187
6-CLUTCH 188
CLUTCH 188
DESCRIPTION 188
OPERATION 188
WARNING 189
DIAGNOSIS AND TESTING – CLUTCH 189
CLUTCH CONTAMINATION 189
IMPROPER RELEASE OR CLUTCH ENGAGEMENT 189
CLUTCH MISALIGNMENT 189
PRESSURE PLATE AND DISC RUNOUT 189
FLYWHEEL RUNOUT 189
DIAGNOSIS CHART 190
SPECIFICATIONS 192
SPECIFICATIONS 192
SPECIFICATIONS – 2 5L DIESEL 193
CLUTCH DISC 193
REMOVAL 193
INSTALLATION 193
INSTALLATION 193
INSTALLATION – 2 5L DIESEL 194
CLUTCH RELEASE BEARING 194
REMOVAL 194
INSTALLATION 194
FLYWHEEL 195
DESCRIPTION 195
STANDARD FLYWHEEL 195
DUAL MASS FLYWHEEL 195
OPERATION 195
DIAGNOSIS AND TESTING – FLYWHEEL 196
PILOT BEARING 196
REMOVAL 196
INSTALLATION 196
LINKAGE 196
REMOVAL 196
INSTALLATION 197
MASTER CYLINDER 197
INSPECTION 197
CLUTCH PEDAL 198
REMOVAL 198
INSTALLATION 198
CLUTCH SWITCH OVERRIDE RELAY 198
DESCRIPTION 198
OPERATION 198
REMOVAL 198
INSTALLATION 198
CLUTCH PEDAL POSITION SWITCH 199
DESCRIPTION 199
OPERATION 199
DIAGNOSIS AND TESTING – CLUTCH PEDAL POSITION SWITCH 199
REMOVAL 199
INSTALLATION 199
7-COOLING 200
COOLING 200
DESCRIPTION 200
DESCRIPTION – COOLING SYSTEM 2 4L ENGINE 200
DESCRIPTION – COOLING SYSTEM 3 7L ENGINE 200
DESCRIPTION – COOLING SYSTEM ROUTING 3 7L ENGINE 200
DESCRIPTION – HOSE CLAMPS 201
OPERATION 202
OPERATION – COOLING SYSTEM 202
OPERATION – HOSE CLAMPS 202
DIAGNOSIS AND TESTING 202
DIAGNOSIS AND TESTING – ON-BOARD DIAGNOSTICS (OBD) 202
COOLING SYSTEM RELATED DIAGNOSTICS 202
ACCESSING DIAGNOSTIC TROUBLE CODES 202
ERASING TROUBLE CODES 202
DIAGNOSIS AND TESTING – PRELIMINARY CHECKS 202
ENGINE COOLING SYSTEM OVERHEATING 202
DIAGNOSIS AND TESTING – COOLING SYSTEM LEAKS 203
ULTRAVIOLET LIGHT METHOD 203
PRESSURE TESTER METHOD 203
INTERNAL LEAKAGE INSPECTION 204
COMBUSTION LEAKAGE TEST – WITHOUT PRESSURE TESTER 204
DIAGNOSIS AND TESTING – COOLING SYSTEM DIAGNOSIS CHART 205
STANDARD PROCEDURE 211
STANDARD PROCEDURE – DRAINING COOLING SYSTEM 211
STANDARD PROCEDURE – REFILLING COOLING SYSTEM 211
STANDARD PROCEDURE – COOLING SYSTEM – REVERSE FLUSHING 211
CHEMICAL CLEANING 212
REVERSE FLUSHING RADIATOR 212
REVERSE FLUSHING ENGINE 212
SPECIFICATIONS 212
TORQUE 212
SPECIAL TOOLS 213
COOLING 213
ACCESSORY DRIVE 214
ACCESSORY DRIVE 214
DIAGNOSIS AND TESTING – SERPENTINE DRIVE BELT DIAGNOSIS 214
BELT TENSIONERS 216
REMOVAL 216
REMOVAL – 3 7L ENGINE 216
REMOVAL – 2 4L ENGINE 216
INSTALLATION 217
INSTALLATION – 3 7L ENGINE 217
INSTALLATION – 2 4L ENGINE 217
DRIVE BELTS -2 4L 217
REMOVAL – 2 4L ENGINE 217
INSTALLATION – 2 4L ENGINE 217
DRIVE BELTS – 3 7L 218
REMOVAL – 3 7L ENGINE 218
INSTALLATION – 3 7L ENGINE 219
ENGINE 220
COOLANT 221
DESCRIPTION 221
DESCRIPTION – HOAT COOLANT 221
COOLANT PERFORMANCE 221
COOLANT SELECTION AND ADDITIVES 221
DESCRIPTION – ENGINE COOLANT 222
ETHYLENE-GLYCOL MIXTURES 222
PROPYLENE-GLYCOL MIXTURES 222
OPERATION 222
COOLANT RECOVERY PRESS CONTAINER 222
DESCRIPTION 222
OPERATION 222
REMOVAL 223
INSTALLATION 223
ENGINE BLOCK HEATER 223
DESCRIPTION 223
OPERATION 223
REMOVAL 223
REMOVAL – 2 4L 223
REMOVAL – 3 7L 223
INSTALLATION 223
INSTALLATION – 2 4L 223
INSTALLATION – 3 7L 224
ENGINE COOLANT TEMPERATURE SENSOR 224
DESCRIPTION 224
OPERATION 224
REMOVAL 225
2 4L 225
3 7L 225
INSTALLATION 225
ENGINE COOLANT THERMOSTAT 225
DESCRIPTION – 3 7L ENGINE 225
OPERATION 226
DIAGNOSIS AND TESTING – THERMOSTAT 226
ON-BOARD DIAGNOSTICS 226
REMOVAL 226
REMOVAL – 3 7L ENGINE 226
REMOVAL 226
INSTALLATION 226
INSTALLATION – 3 7L ENGINE 226
INSTALLATION 227
FAN DRIVE VISCOUS CLUTCH 227
DESCRIPTION 227
OPERATION 227
DIAGNOSIS AND TESTING 228
VISCOUS FAN DRIVE 228
NOISE 228
LEAKS 229
TESTING 229
REMOVAL 229
INSTALLATION 230
RADIATOR 230
DESCRIPTION 230
REMOVAL 231
REMOVAL 231
REMOVAL 232
CLEANING 234
INSPECTION 234
INSTALLATION 234
INSTALLATION 234
INSTALLATION 234
RADIATOR PRESSURE CAP 235
DESCRIPTION 235
OPERATION 235
DIAGNOSIS AND TESTING – RADIATOR PRESSURE CAP 235
CLEANING 235
INSPECTION 235
RADIATOR FAN – ELECTRIC 236
DESCRIPTION 236
OPERATION 236
REMOVAL 236
REMOVAL 236
REMOVAL 237
INSTALLATION 237
INSTALLATION 237
INSTALLATION 237
RADIATOR – FAN – VISCOUS 237
DESCRIPTION 237
OPERATION 238
DIAGNOSIS AND TESTING – VISCOUS FAN DRIVE 238
REMOVAL 238
CLEANING0 – 2 KJ (Continued) 239
INSPECTION 239
INSTALLATION 239
THERMOSTAT HOUSING 239
REMOVAL 239
INSTALLATION 240
WATER PUMP – 2 4L 240
DESCRIPTION 240
OPERATION 240
REMOVAL – 2 4L ENGINE 240
INSPECTION 241
INSTALLATION – 2 4L ENGINE 241
WATER PUMP – 3 7L 242
DESCRIPTION 242
DESCRIPTION – WATER PUMP 242
DESCRIPTION – WATER PUMP BYPASS 242
OPERATION – WATER PUMP 242
REMOVAL 242
REMOVAL 242
REMOVAL — 2 4L 243
CLEANING 244
INSPECTION 244
INSTALLATION 244
INSTALLATION 244
INSTALLATION 245
TRANSMISSION 246
TRANS COOLER 246
DESCRIPTION 246
8a-AUDIO 248
AUDIO 248
DESCRIPTION 248
OPERATION 249
DIAGNOSIS AND TESTING – AUDIO 249
AMPLIFIER CHOKE AND RELAY 251
DESCRIPTION 251
OPERATION 251
DIAGNOSIS AND TESTING – AMPLIFIER CHOKE AND RELAY 251
REMOVAL 252
INSTALLATION 252
ANTENNA BODY & CABLE 252
DESCRIPTION 252
DOMESTIC 252
EXPORT 252
OPERATION 252
DIAGNOSIS AND TESTING – ANTENNA BODY AND CABLE 253
TEST 1 253
TEST 2 253
TEST 3 253
TEST 4 254
REMOVAL 254
DOMESTIC 254
EXPORT 254
INSTALLATION 255
DOMESTIC 255
EXPORT 255
ANTENNA MODULE 256
DESCRIPTION 256
OPERATION 256
DIAGNOSIS AND TESTING – ANTENNA MODULE 256
REMOVAL 257
INSTALLATION 257
CD CHANGER 257
DESCRIPTION 257
OPERATION 257
REMOVAL 258
INSTALLATION 258
INSTRUMENT PANEL ANTENNA CABLE 258
REMOVAL 258
DOMESTIC 258
EXPORT 259
INSTALLATION 259
DOMESTIC 259
EXPORT 260
QUARTER GLASS INTEGRAL ANTENNA 260
DESCRIPTION 260
OPERATION 260
DIAGNOSIS AND TESTING – QUARTER GLASS INTEGRAL ANTENNA 260
RADIO 260
DESCRIPTION 260
OPERATION 261
REMOVAL 261
INSTALLATION 261
RADIO NOISE SUPPRESSION GROUND STRAP 261
DESCRIPTION 261
OPERATION 262
REMOVAL 262
2 4L ENGINE 262
2 5L ENGINE 263
3 7L ENGINE 263
INSTALLATION 263
2 4L ENGINE 263
2 5L ENGINE 263
3 7L ENGINE 263
REMOTE SWITCHES 264
DESCRIPTION 264
OPERATION 264
DIAGNOSIS AND TESTING – REMOTE SWITCHES 264
REMOVAL 265
INSTALLATION 266
SPEAKER 266
DESCRIPTION 266
STANDARD 266
PREMIUM 266
OPERATION 266
DIAGNOSIS AND TESTING – SPEAKER 267
REMOVAL 267
FRONT DOOR 267
INSTRUMENT PANEL 268
REAR DOOR 268
INSTALLATION 268
FRONT DOOR 268
INSTRUMENT PANEL 268
REAR DOOR 268
8b-CHIME/BUZZER 270
CHIME WARNING SYSTEM 270
DESCRIPTION 270
OPERATION 270
DIAGNOSIS AND TESTING – CHIME WARNING SYSTEM 274
8e-ELECTRONIC CONTROL MODULES 276
ELECTRONIC CONTROL MODULES 276
STANDARD PROCEDURE – PCM/SKIM PROGRAMMING 276
PROGRAMMING THE PCM (JTEC) 276
PROGRAMMING THE SKIM 277
PROGRAMMING IGNITION KEYS TO THE SKIM 277
BODY CONTROL MODULE 277
DESCRIPTION 277
OPERATION 280
DIAGNOSIS AND TESTING – BODY CONTROL MODULE 282
REMOVAL 282
INSTALLATION 283
COMMUNICATION 283
DESCRIPTION 283
OPERATION 284
CONTROLLER ANTILOCK BRAKE 285
DESCRIPTION 285
OPERATION 285
REMOVAL 285
INSTALLATION 285
DATA LINK CONNECTOR 286
DESCRIPTION – DATA LINK CONNECTOR 286
OPERATION – DATA LINK CONNECTOR 286
POWERTRAIN CONTROL MODULE 286
DESCRIPTION 286
DESCRIPTION – PCM 286
DESCRIPTION – MODES OF OPERATION 286
288
DESCRIPTION – 5 VOLT SUPPLIES 289
DESCRIPTION – IGNITION CIRCUIT SENSE 289
DESCRIPTION – POWER GROUNDS 289
DESCRIPTION – SENSOR RETURN 289
OPERATION 289
OPERATION – PCM 289
OPERATION – 5 VOLT SUPPLIES 290
OPERATION – IGNITION CIRCUIT SENSE 290
REMOVAL 290
INSTALLATION 291
SENTRY KEY IMMOBILIZER MODULE 291
DESCRIPTION 291
OPERATION 291
REMOVAL 292
INSTALLATION 293
TRANSMISSION CONTROL MODULE 293
DESCRIPTION 293
OPERATION 294
BATTERY FEED 294
CLUTCH VOLUME INDEXES (CVI) 294
SHIFT SCHEDULES 295
STANDARD PROCEDURE 297
STANDARD PROCEDURE – TCM QUICK LEARN 297
STANDARD PROCEDURE – DRIVE LEARN – RFE TRANSMISSIONS ONLY 298
LEARN A SMOOTH 1ST NEUTRAL TO DRIVE SHIFT 298
LEARN A SMOOTH NEUTRAL TO DRIVE GARAGE SHIFT 298
LEARN THE 1ST 2-3 SHIFT AFTER A RESTART OR SHIFT TO REVERSE 298
LEARN A SMOOTH 2-3 AND 3-4 UPSHIFT 298
LEARN A SMOOTH 4-3 COASTDOWN AND PART THROTTLE 4-3 KICKDOWN 299
LEARN A SMOOTH 1-2 UPSHIFT AND 3-2 KICKDOWN 299
LEARN A SMOOTH MANUAL 2-1 PULLDOWN SHIFT AS WELL AS A NEUTRAL TO REVERSE SHIFT 299
LEARN A SMOOTH NEUTRAL TO REVERSE SHIFT 299
HEATED SEAT MODULE 299
DESCRIPTION 299
OPERATION 300
DIAGNOSIS AND TESTING – HEATED SEAT MODULE 300
RIGHT SEAT HEATER INOPERATIVE 300
LEFT SEAT HEATER INOPERATIVE 301
BOTH SEATS INOPERATIVE 302
REMOVAL 302
INSTALLATION 302
8f-ENGINE SYSTEMS 304
BATTERY SYSTEM 304
BATTERY SYSTEM 304
DESCRIPTION 304
OPERATION 305
DIAGNOSIS AND TESTING – BATTERY SYSTEM 305
MICRO 420 BATTERY TESTER 305
ABNORMAL BATTERY DISCHARGING 307
CLEANING 308
INSPECTION 308
SPECIFICATIONS 309
BATTERY 310
DESCRIPTION 310
OPERATION 310
DIAGNOSIS AND TESTING – BATTERY 311
STANDARD PROCEDURE 312
STANDARD PROCEDURE – BATTERY CHARGING 312
CHARGING A COMPLETELY DISCHARGED BATTERY 312
CHARGING TIME REQUIRED 313
STANDARD PROCEDURE – BUILT-IN INDICATOR TEST 313
STANDARD PROCEDURE – HYDROMETER TEST 314
STANDARD PROCEDURE – OPEN-CIRCUIT VOLTAGE TEST 315
STANDARD PROCEDURE – IGNITION-OFF DRAW TEST 316
STANDARD PROCEDURE – USING MICRO 420 BATTERY TESTER 317
BATTERY TESTING 317
REMOVAL 318
INSTALLATION 318
BATTERY HOLDDOWN 319
DESCRIPTION 319
OPERATION 319
REMOVAL 319
INSTALLATION 319
BATTERY CABLES 320
DESCRIPTION 320
OPERATION 320
DIAGNOSIS AND TESTING – BATTERY CABLES 320
VOLTAGE DROP TEST 321
THERMAL GUARD 322
DESCRIPTION 322
OPERATION 322
REMOVAL 322
INSTALLATION 323
BATTERY TRAY 323
DESCRIPTION 323
OPERATION 323
REMOVAL 323
INSTALLATION 323
CHARGING SYSTEM 324
CHARGING SYSTEM 324
DESCRIPTION 324
OPERATION 324
DIAGNOSIS AND TESTING – CHARGING SYSTEM 325
SPECIFICATIONS 325
TORQUE – EXCEPT DIESEL 325
GENERATOR RATINGS – GAS ENGINES 326
SPECIAL TOOLS 326
BATTERY TEMPERATURE SENSOR 326
DESCRIPTION 326
OPERATION 326
REMOVAL 326
INSTALLATION 326
GENERATOR 327
DESCRIPTION 327
OPERATION 327
REMOVAL 327
INSTALLATION 327
GENERATOR DECOUPLER PULLEY 329
DESCRIPTION 329
OPERATION 329
DIAGNOSIS AND TESTING – GENERATOR DECOUPLER 329
REMOVAL 329
INSTALLATION 331
VOLTAGE REGULATOR 333
DESCRIPTION 333
OPERATION 333
STARTING SYSTEM 334
STARTING SYSTEM 334
DESCRIPTION 334
OPERATION 334
DIAGNOSIS AND TESTING – STARTING SYSTEM 335
INSPECTION 336
TESTING 337
INSPECTION – STARTING SYSTEM 339
SPECIFICATIONS 340
TORQUE – GAS POWERED 340
STARTER MOTOR – GAS POWERED 341
STARTER MOTOR 341
DIAGNOSIS AND TESTING – STARTER MOTOR 341
REMOVAL 342
2 4L 4–Cylinder 342
3 7L V-6 342
INSTALLATION 343
2 4L 4–Cylinder 343
3 7L V-6 343
STARTER MOTOR RELAY 343
DESCRIPTION 343
OPERATION 344
DIAGNOSIS AND TESTING – STARTER RELAY 344
RELAY TEST 344
RELAY CIRCUIT TEST 344
REMOVAL 345
INSTALLATION 345
8g-HEATED SYSTEMS 346
HEATED MIRRORS 346
HEATED MIRRORS 346
DESCRIPTION 346
OPERATION 346
DIAGNOSIS AND TESTING – HEATED MIRRORS 346
WINDOW DEFOGGER 348
WINDOW DEFOGGER 348
DESCRIPTION – REAR WINDOW DEFOGGER 348
OPERATION – REAR WINDOW DEFOGGER 348
DIAGNOSIS AND TESTING – REAR WINDOW DEFOGGER SYSTEM 348
STANDARD PROCEDURE – REAR GLASS HEATING GRID REPAIR 349
REAR WINDOW DEFOGGER GRID 350
DESCRIPTION 350
OPERATION 350
DIAGNOSIS AND TESTING – REAR WINDOW DEFOGGER GRID 350
REAR WINDOW DEFOGGER RELAY 351
DESCRIPTION 351
OPERATION 351
DIAGNOSIS AND TESTING – REAR WINDOW DEFOGGER RELAY 351
RELAY TEST 351
RELAY CIRCUIT TEST 352
REMOVAL 352
INSTALLATION 352
REAR WINDOW DEFOGGER SWITCH 353
DESCRIPTION 353
OPERATION 353
DIAGNOSIS AND TESTING 353
DIAGNOSIS AND TESTING – REAR WINDOW DEFOGGER SWITCH 353
DIAGNOSIS AND TESTING – REAR HVAC CONTROL ASSEMBLY WINDOW DEFOGGER FUNCTION 354
REMOVAL 354
INSTALLATION 354
HEATED SEAT SYSTEM 355
HEATED SEAT SYSTEM 355
DESCRIPTION 355
OPERATION 355
DIAGNOSIS AND TESTING – HEATED SEAT SYSTEM 356
HEATED SEAT SYSTEM SELF-DIAGNOSIS 356
HEATED SEAT SYSTEM TESTING 356
DRIVER HEATED SEAT SWITCH 357
DESCRIPTION 357
OPERATION 357
DIAGNOSIS AND TESTING – DRIVER HEATED SEAT SWITCH 357
REMOVAL 358
INSTALLATION 358
PASSENGER HEATED SEAT SWITCH 358
DESCRIPTION 358
OPERATION 358
DIAGNOSIS AND TESTING – PASSENGER HEATED SEAT SWITCH 358
REMOVAL 359
INSTALLATION 359
HEATED SEAT ELEMENT 359
DESCRIPTION 359
OPERATION 359
DIAGNOSIS AND TESTING – HEATED SEAT ELEMENT 360
SEAT CUSHION ELEMENT 360
SEAT BACK ELEMENT 360
HEATED SEAT SENSOR 360
DESCRIPTION 360
OPERATION 360
DIAGNOSIS AND TESTING – HEATED SEAT SENSOR 360
REMOVAL 361
8h-HORN 362
HORN SYSTEM 362
DESCRIPTION 362
OPERATION 362
DIAGNOSIS AND TESTING – HORN SYSTEM 362
HORN 363
DIAGNOSIS AND TESTING – HORN 363
REMOVAL 364
INSTALLATION 364
HORN RELAY 364
DIAGNOSIS AND TESTING – HORN RELAY 364
REMOVAL 364
INSTALLATION 365
HORN SWITCH 365
DESCRIPTION 365
DIAGNOSIS AND TESTING – HORN SWITCH 365
8i-IGNITION CONTROL 366
IGNITION CONTROL 366
DESCRIPTION 366
OPERATION 366
2 4L 366
3 7L 367
SPECIFICATIONS 367
SPECIFICATIONS – IGNITION TIMING 367
ENGINE FIRING ORDER – 2 4L 4-CYLINDER 367
ENGINE FIRING ORDER – 3 7L V-6 367
IGNITION COIL RESISTANCE – 2 4L 367
IGNITION COIL RESISTANCE – 3 7L V-6 367
SPARK PLUGS 368
SPARK PLUG CABLE RESISTANCE – 2 4L 368
TORQUE – IGNITION SYSTEM 368
AUTO SHUT DOWN RELAY 369
DESCRIPTION – PCM OUTPUT 369
OPERATION 369
OPERATION – ASD SENSE – PCM INPUT 369
OPERATION – PCM OUTPUT 369
DIAGNOSIS AND TESTING – ASD AND FUEL PUMP RELAYS 369
REMOVAL 370
INSTALLATION 370
CAMSHAFT POSITION SENSOR 370
DESCRIPTION 370
DESCRIPTION – 2 4L 370
DESCRIPTION-3 7L 370
OPERATION 370
OPERATION – 2 4L 370
OPERATION – 3 7L 371
REMOVAL 371
2 4L 371
3 7L 372
INSTALLATION 372
2 4L 372
3 7L 373
IGNITION COIL 374
DESCRIPTION 374
2 4L 374
3 7L 374
OPERATION 374
2 4L 374
3 7L 375
REMOVAL 375
2 4L 375
3 7L 375
INSTALLATION 376
2 4L 376
3 7L 376
KNOCK SENSOR 376
DESCRIPTION 376
OPERATION 376
REMOVAL 376
INSTALLATION 377
SPARK PLUG 377
DESCRIPTION 377
OPERATION 377
DIAGNOSIS AND TESTING – SPARK PLUG CONDITIONS 378
REMOVAL 380
2 4L 380
3 7L 380
CLEANING 380
CLEANING SPARK PLUGS 380
INSTALLATION 380
2 4L 380
3 7L 380
IGNITION COIL CAPACITOR 381
DESCRIPTION 381
OPERATION 381
REMOVAL 381
INSTALLATION 381
8j-INSTRUMENT CLUSTER 382
INSTRUMENT CLUSTER 383
DESCRIPTION 383
OPERATION 386
INPUT AND OUTPUT CIRCUITS 389
DIAGNOSIS AND TESTING – INSTRUMENT CLUSTER 389
REMOVAL 391
DISASSEMBLY 391
ASSEMBLY 393
INSTALLATION 393
ABS INDICATOR 394
DESCRIPTION 394
OPERATION 394
AIRBAG INDICATOR 394
DESCRIPTION 394
OPERATION 395
BRAKE/PARK BRAKE INDICATOR 395
DESCRIPTION 395
OPERATION 395
DIAGNOSIS AND TESTING – BRAKE INDICATOR 396
CHARGING INDICATOR 397
DESCRIPTION 397
OPERATION 397
COOLANT LOW INDICATOR 398
DESCRIPTION 398
OPERATION 398
CRUISE INDICATOR 399
DESCRIPTION 399
OPERATION 399
DOOR AJAR INDICATOR 399
DESCRIPTION 399
OPERATION 400
ENGINE TEMPERATURE GAUGE 400
DESCRIPTION 400
OPERATION 400
FRONT FOG LAMP INDICATOR 401
DESCRIPTION 401
OPERATION 401
FUEL GAUGE 402
DESCRIPTION 402
OPERATION 402
GATE AJAR INDICATOR 403
DESCRIPTION 403
OPERATION 403
GLASS AJAR INDICATOR 403
DESCRIPTION 403
OPERATION 404
HIGH BEAM INDICATOR 404
DESCRIPTION 404
OPERATION 404
LIGHT BAR LAMP INDICATOR 405
DESCRIPTION 405
OPERATION 405
LOW FUEL INDICATOR 406
DESCRIPTION 406
OPERATION 406
LOW OIL PRESSURE INDICATOR 407
DESCRIPTION 407
OPERATION 407
MALFUNCTION INDICATOR LAMP (MIL) 407
DESCRIPTION 407
OPERATION 408
ODOMETER 408
DESCRIPTION 408
OPERATION 409
OVERDRIVE OFF INDICATOR 409
DESCRIPTION 409
OPERATION 410
REAR FOG LAMP INDICATOR 410
DESCRIPTION 410
OPERATION 410
SEATBELT INDICATOR 411
DESCRIPTION 411
OPERATION 411
SECURITY INDICATOR 412
DESCRIPTION 412
OPERATION 412
SHIFT INDICATOR (TRANSFER CASE) 412
DESCRIPTION 412
DESCRIPTION – PART TIME INDICATOR 412
DESCRIPTION – FULL TIME INDICATOR 412
DESCRIPTION – FOUR LOW MODE INDICATOR 413
OPERATION 413
OPERATION – PART TIME INDICATOR 413
OPERATION – FULL TIME INDICATOR 413
OPERATION – FOUR LOW MODE INDICATOR 414
SKIS INDICATOR 414
DESCRIPTION 414
OPERATION 415
SPEEDOMETER 415
DESCRIPTION 415
OPERATION 416
TACHOMETER 416
DESCRIPTION 416
OPERATION 416
TRANS TEMP INDICATOR 417
DESCRIPTION 417
OPERATION 417
TURN SIGNAL INDICATOR 418
DESCRIPTION 418
OPERATION 418
WAIT-TO-START INDICATOR 418
DESCRIPTION 418
OPERATION 418
WASHER FLUID INDICATOR 419
DESCRIPTION 419
OPERATION 419
DIAGNOSIS AND TESTING – WASHER FLUID INDICATOR 420
WATER-IN-FUEL INDICATOR 420
DESCRIPTION 420
OPERATION 421
8l-LAMPS 422
LAMPS/LIGHTING – EXTERIOR 422
LAMPS/LIGHTING – EXTERIOR 423
DESCRIPTION 423
OPERATION 426
DIAGNOSIS AND TESTING – LAMPS/LIGHTING – EXTERIOR 428
SPECIFICATIONS – LAMPS/LIGHTING – EXTERIOR 435
BACKUP LAMP SWITCH 435
DESCRIPTION 435
OPERATION 436
DIAGNOSIS AND TESTING – BACKUP LAMP SWITCH 436
BRAKE LAMP SWITCH 436
DESCRIPTION 436
OPERATION 436
DIAGNOSIS AND TESTING – BRAKE LAMP SWITCH 437
REMOVAL 437
INSTALLATION 438
CENTER HIGH MOUNTED STOP LAMP BULB 438
REMOVAL 438
INSTALLATION 439
CENTER HIGH MOUNTED STOP LAMP UNIT 439
REMOVAL 439
INSTALLATION 439
COMBINATION FLASHER 439
DESCRIPTION 439
OPERATION 439
DAYTIME RUNNING LAMP RELAY 440
DESCRIPTION 440
OPERATION 440
REMOVAL 440
INSTALLATION 441
FRONT FOG LAMP BULB 441
REMOVAL 441
INSTALLATION 441
FRONT FOG LAMP RELAY 442
DESCRIPTION 442
OPERATION 442
DIAGNOSIS AND TESTING – FRONT FOG LAMP RELAY 442
REMOVAL 443
INSTALLATION 443
FRONT FOG LAMP UNIT 444
REMOVAL 444
INSTALLATION 444
ADJUSTMENTS 445
ADJUSTMENT – FRONT FOG LAMP UNIT 445
FRONT LAMP BULB 445
REMOVAL 445
INSTALLATION 445
FRONT LAMP UNIT 445
REMOVAL 445
INSTALLATION 447
FRONT POSITION LAMP BULB 447
REMOVAL 447
INSTALLATION 447
HAZARD SWITCH 448
DESCRIPTION 448
OPERATION 448
REMOVAL 448
INSTALLATION 449
HEADLAMP BULB 449
REMOVAL 449
INSTALLATION 451
HEADLAMP HIGH BEAM RELAY 451
DESCRIPTION 451
OPERATION 452
DIAGNOSIS AND TESTING – HEADLAMP HIGH BEAM RELAY 452
REMOVAL 453
INSTALLATION 453
HEADLAMP LEVELING MOTOR 453
DESCRIPTION 453
OPERATION 454
REMOVAL 454
INSTALLATION 454
HEADLAMP LEVELING SWITCH 455
DESCRIPTION 455
OPERATION 455
DIAGNOSIS AND TESTING – HEADLAMP LEVELING SWITCH 456
REMOVAL 456
INSTALLATION 457
HEADLAMP LOW BEAM RELAY 457
DESCRIPTION 457
OPERATION 457
DIAGNOSIS AND TESTING – HEADLAMP LOW BEAM RELAY 458
REMOVAL 458
INSTALLATION 459
HEADLAMP UNIT 459
REMOVAL 459
INSTALLATION 460
ADJUSTMENTS 460
ADJUSTMENT – HEADLAMP UNIT 460
LAMP BAR 462
DESCRIPTION 462
OPERATION 462
DIAGNOSIS AND TESTING – LAMP BAR 462
STANDARD PROCEDURE – LAMP BAR AIMING 463
REMOVAL 463
REMOVAL – LAMP BAR 463
REMOVAL – LAMP 463
INSTALLATION 463
INSTALLATION – LAMP BAR 463
INSTALLATION – LAMP 463
LAMP BAR SWITCH 464
DESCRIPTION 464
REMOVAL 464
INSTALLATION 464
LICENSE PLATE LAMP BULB 464
REMOVAL 464
INSTALLATION 465
LICENSE PLATE LAMP UNIT 466
REMOVAL 466
INSTALLATION 466
MULTI-FUNCTION SWITCH 467
DESCRIPTION 467
OPERATION 468
DIAGNOSIS AND TESTING – MULTI-FUNCTION SWITCH 470
REMOVAL 472
INSTALLATION 473
PARK LAMP RELAY 473
DESCRIPTION 473
OPERATION 474
DIAGNOSIS AND TESTING – PARK LAMP RELAY 474
REMOVAL 475
INSTALLATION 475
REAR FOG LAMP RELAY 475
DESCRIPTION 475
OPERATION 476
DIAGNOSIS AND TESTING – REAR FOG LAMP RELAY 476
REMOVAL 477
INSTALLATION 477
REAR LAMP BULB 478
REMOVAL0 – 4 KJ (Continued) 478
INSTALLATION 478
REAR LAMP UNIT 478
REMOVAL 478
INSTALLATION 479
REPEATER LAMP BULB 479
REMOVAL 479
INSTALLATION 479
REPEATER LAMP UNIT 479
REMOVAL 479
INSTALLATION 479
TRAILER TOW CONNECTOR 480
REMOVAL 480
INSTALLATION 480
TRAILER TOW RELAY 480
DESCRIPTION 480
OPERATION 481
DIAGNOSIS AND TESTING – TRAILER TOW RELAY 481
REMOVAL 481
INSTALLATION 482
TRAILER TOW WIRING 483
DESCRIPTION 483
LAMPS/LIGHTING – INTERIOR 484
LAMPS/LIGHTING – INTERIOR 484
DESCRIPTION 484
OPERATION 486
DIAGNOSIS AND TESTING – LAMPS/LIGHTING – INTERIOR 487
SPECIFICATIONS – LAMPS/LIGHTING – INTERIOR 489
ASH RECEIVER LAMP BULB 489
REMOVAL 489
INSTALLATION 490
ASH RECEIVER LAMP UNIT 490
REMOVAL 490
INSTALLATION 491
CARGO LAMP BULB 491
REMOVAL 491
INSTALLATION 491
CARGO LAMP SWITCH 492
REMOVAL 492
INSTALLATION 492
CARGO LAMP UNIT 492
REMOVAL 492
INSTALLATION 492
COMPASS MINI-TRIP ILLUMINATION BULB 493
REMOVAL 493
INSTALLATION 493
COURTESY LAMP BULB 494
REMOVAL 494
INSTALLATION 494
COURTESY LAMP UNIT 495
REMOVAL 495
INSTALLATION 495
DOOR AJAR SWITCH 496
DESCRIPTION 496
OPERATION 496
FLIP-UP GLASS AJAR SWITCH 496
DESCRIPTION 496
OPERATION 496
HEATER-A/C CONTROL ILLUMINATION BULB 496
REMOVAL 496
INSTALLATION 497
READING LAMP BULB 497
REMOVAL 497
INSTALLATION 498
READING LAMP SWITCH 498
REMOVAL 498
INSTALLATION 499
READING LAMP UNIT 499
REMOVAL 499
INSTALLATION 500
TAILGATE AJAR SWITCH 500
DESCRIPTION 500
OPERATION 500
TRANSMISSION RANGE INDICATOR ILLUMINATION BULB 501
REMOVAL 501
INSTALLATION 501
VANITY LAMP BULB 502
REMOVAL 502
INSTALLATION 502
8m-MESSAGE SYSTEMS 504
OVERHEAD CONSOLE 504
DESCRIPTION 504
OPERATION 504
STANDARD PROCEDURE 504
STANDARD PROCEDURE – MODULE LENS REPLACEMENT 504
STANDARD PROCEDURE – MODULE LAMP REPLACEMENT 505
STANDARD PROCEDURE – COURTESY LAMP REPLACEMENT 505
STANDARD PROCEDURE – COMPASS CALIBRATION 505
STANDARD PROCEDURE – COMPASS DEMAGNETIZING 506
STANDARD PROCEDURE – COMPASS VARIATION ADJUSTMENT 507
STANDARD PROCEDURE – ELECTRONIC VEHICLE INFORMATION CENTER PROGRAMMING 507
EVIC PROGRAMMING MODE 507
PROGRAMMABLE FEATURES 507
REMOVAL 509
OVERHEAD CONSOLE – REMOVAL 509
INSTALLATION 509
COMPASS MINI/TRIP COMPUTER 509
DESCRIPTION 509
DESCRIPTION – COMPASS 510
DESCRIPTION – THERMOMETER 510
OPERATION 510
DIAGNOSIS AND TESTING – COMPASS MINI-TRIP COMPUTER 511
TEMPERATURE 511
TRIP ODOMETER 511
COMPASS DISPLAY 511
COMPASS MINI-TRIP COMPUTER – SELF DIAGNOSTIC TEST 511
REMOVAL 512
INSTALLATION 512
ELECTRONIC VEHICLE INFO CENTER 512
DESCRIPTION – ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) 512
DESCRIPTION – COMPASS 513
DESCRIPTION – TEMPERATURE 513
OPERATION 513
DIAGNOSIS AND TESTING – ELECTRONIC VEHICLE INFORMATION CENTER 514
SELF-DIAGNOSTIC TEST 514
REMOVAL 515
INSTALLATION 515
UNIVERSAL TRANSMITTER 515
DESCRIPTION 515
OPERATION 516
DIAGNOSIS AND TESTING – UNIVERSAL TRANSMITTER 516
STANDARD PROCEDURE 516
STANDARD PROCEDURE – ERASING TRANSMITTER CODES 516
STANDARD PROCEDURE – SETTING TRANSMITTER CODES 516
AMBIENT TEMP SENSOR 517
DESCRIPTION 517
OPERATION 517
DIAGNOSIS AND TESTING 517
DIAGNOSIS AND TESTING – AMBIENT TEMPERATURE SENSOR 517
DIAGNOSIS AND TESTING – AMBIENT TEMPERATURE SENSOR CIRCUIT 517
REMOVAL 518
INSTALLATION 518
8n-POWER SYSTEMS 520
POWER LOCKS 520
POWER LOCKS 520
DESCRIPTION 520
POWER LOCKS 520
REMOTE KEYLESS ENTRY 521
TAILGATE / FLIP-UP GLASS POWER RELEASE SYSTEM 521
COMBINATION FLASHER 522
HORN RELAY 522
LOW BEAM HEADLAMP RELAY 522
OPERATION 522
POWER LOCKS 522
AUTOMATIC DOOR LOCKS 522
DOOR LOCK INHIBIT 522
DOOR LOCK CIRCUIT PROTECTION 522
REMOTE KEYLESS ENTRY 522
DIAGNOSIS AND TESTING – POWER LOCKS 523
PRELIMINARY DIAGNOSIS 523
DOOR LOCK / UNLOCK SWITCH 523
DIAGNOSIS AND TESTING – DOOR LOCK/UNLOCK SWITCH 523
REMOVAL 524
INSTALLATION 524
DOOR LOCK MOTOR 524
DESCRIPTION 524
OPERATION 524
DIAGNOSIS AND TESTING – DOOR LOCK MOTOR 524
FLIP-UP GLASS RELEASE SWITCH 525
DIAGNOSIS AND TESTING – FLIP-UP GLASS RELEASE SWITCH 525
DOOR LOCK RELAY 525
DESCRIPTION 525
OPERATION 525
DIAGNOSIS AND TESTING – DOOR LOCK RELAY 525
REMOVAL 526
INSTALLATION 526
REMOTE KEYLESS ENTRY MODULE 526
DESCRIPTION 526
OPERATION 526
DIAGNOSIS AND TESTING – REMOTE KEYLESS ENTRY MODULE 526
REMOVAL 526
INSTALLATION 526
REMOTE KEYLESS ENTRY TRANSMITTER 527
DIAGNOSIS AND TESTING – REMOTE KEYLESS ENTRY TRANSMITTER 527
STANDARD PROCEDURE 527
STANDARD PROCEDURE – RKE TRANSMITTER CUSTOMER PREFERENCES 527
AUTOMATIC (ROLLING) LOCKS 527
HORN CHIRP DISABLING / ENABLING 527
OPTICAL CHIRP (FLASH) DISABLING / ENABLING 527
TAIL GATE RELEASE DELAY 527
UNLOCK SEQUENCE 528
STANDARD PROCEDURE – RKE TRANSMITTER PROGRAMING 528
STANDARD PROCEDURE – RKE TRANSMITTER BATTERIES 528
SPECIFICATIONS – REMOTE KEYLESS ENTRY TRANSMITTER 528
RANGE 528
TAILGATE CYLINDER LOCK SWITCH 528
DESCRIPTION 528
OPERATION 528
DIAGNOSIS AND TESTING – TAILGATE CYLINDER LOCK SWITCH 529
REMOVAL 529
INSTALLATION 529
POWER MIRRORS 530
POWER MIRRORS 530
DESCRIPTION 530
OPERATION 530
DIAGNOSIS AND TESTING – POWER MIRRORS 530
WIRING VOLTAGE TEST 530
POWER MIRROR MOTOR TEST 531
AUTOMATIC DAY / NIGHT MIRROR 531
DESCRIPTION 531
DESCRIPTION – REAR VIEW MIRROR 531
DESCRIPTION – OUTSIDE REAR VIEW MIRROR 531
OPERATION 532
OPERATION – REAR VIEW MIRROR 532
OPERATION – OUTSIDE REAR VIEW MIRROR 532
DIAGNOSIS AND TESTING – AUTOMATIC DAY / NIGHT MIRROR 532
POWER FOLDAWAY MIRROR SWITCH – EXPORT 533
DESCRIPTION 533
OPERATION 533
DIAGNOSIS AND TESTING – POWER FOLDAWAY MIRROR SWITCH – EXPORT 533
REMOVAL 534
POWER MIRROR SWITCH 534
DIAGNOSIS AND TESTING – POWER MIRROR SWITCH 534
REMOVAL 535
INSTALLATION 535
SIDEVIEW MIRROR 535
REMOVAL 535
POWER SEATS 536
POWER SEATS 536
DESCRIPTION 536
OPERATION 537
DIAGNOSIS AND TESTING – POWER SEATS 537
LEFT POWER SEAT SWITCH 537
DESCRIPTION 537
OPERATION 538
DIAGNOSIS AND TESTING – LEFT POWER SEAT SWITCH 538
REMOVAL 539
INSTALLATION 539
RIGHT POWER SEAT SWITCH 539
DESCRIPTION 539
OPERATION 539
DIAGNOSIS AND TESTING – RIGHT POWER SEAT SWITCH 540
REMOVAL 541
INSTALLATION 541
POWER SEAT TRACK 541
DESCRIPTION 541
OPERATION 542
DIAGNOSIS AND TESTING – POWER SEAT TRACK 542
REMOVAL 542
INSTALLATION 542
POWER WINDOWS 543
POWER WINDOWS 543
DESCRIPTION 543
OPERATION 543
WINDOW SWITCH 543
WINDOW MOTOR 543
DIAGNOSIS AND TESTING – POWER WINDOWS 543
WIRING VOLTAGE TEST 543
POWER WINDOW MOTOR TEST 543
WINDOW MOTOR 544
REMOVAL 544
WINDOW SWITCH 544
DIAGNOSIS AND TESTING – WINDOW SWITCH 544
REMOVAL 545
FRONT 545
REAR 545
INSTALLATION 545
FRONT 545
REAR 545
8o-RESTRAINTS 570
RESTRAINTS 571
DESCRIPTION 571
ACTIVE RESTRAINTS 572
PASSIVE RESTRAINTS 572
OPERATION 573
ACTIVE RESTRAINTS 573
PASSIVE RESTRAINTS 573
WARNING 574
WARNINGS – RESTRAINT SYSTEM 574
DIAGNOSIS AND TESTING – SUPPLEMENTAL RESTRAINT SYSTEM 575
STANDARD PROCEDURE 575
STANDARD PROCEDURE – HANDLING NON-DEPLOYED SUPPLEMENTAL RESTRAINTS 575
SUPPLEMENTAL RESTRAINT STORAGE 575
STANDARD PROCEDURE – SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT 576
AIRBAG SQUIB STATUS 576
CLEANUP PROCEDURE 577
STANDARD PROCEDURE – VERIFICATION TEST 578
AIRBAG CONTROL MODULE 579
DESCRIPTION 579
OPERATION 579
REMOVAL 581
INSTALLATION 582
CHILD RESTRAINT ANCHOR 582
DESCRIPTION 582
OPERATION 584
CLOCKSPRING 584
DESCRIPTION 584
OPERATION 585
STANDARD PROCEDURE – CLOCKSPRING CENTERING 586
REMOVAL 586
INSTALLATION 587
DRIVER AIRBAG 588
DESCRIPTION 588
OPERATION 589
REMOVAL 590
INSTALLATION 590
FRONT IMPACT SENSOR 592
DESCRIPTION 592
OPERATION 592
REMOVAL 593
INSTALLATION 593
FRONT SEAT BELT & RETRACTOR 594
REMOVAL 594
INSTALLATION 595
FRONT SEAT BELT BUCKLE 596
REMOVAL 596
INSTALLATION 598
PASSENGER AIRBAG 598
DESCRIPTION 598
OPERATION 599
REMOVAL 600
INSTALLATION 600
PASSENGER AIRBAG DOOR 601
REMOVAL 601
INSTALLATION 602
PASSENGER AIRBAG MOUNTING BRACKET 603
REMOVAL 603
INSTALLATION 603
REAR CENTER SEAT BELT & RETRACTOR 604
REMOVAL 604
INSTALLATION 605
REAR OUTBOARD SEAT BELT & RETRACTOR 605
REMOVAL 605
INSTALLATION 606
REAR SEAT BELT BUCKLE 607
REMOVAL 607
INSTALLATION 607
SEAT BELT SWITCH 607
DESCRIPTION 607
OPERATION 608
SEAT BELT TENSIONER 608
DESCRIPTION 608
OPERATION 609
SEAT BELT TURNING LOOP ADJUSTER 609
REMOVAL 609
INSTALLATION 610
SIDE CURTAIN AIRBAG 611
DESCRIPTION 611
OPERATION 611
REMOVAL 611
INSTALLATION 614
SIDE IMPACT AIRBAG CONTROL MODULE 615
DESCRIPTION 615
OPERATION 615
REMOVAL 616
INSTALLATION 617
8p-SPEED CONTROL 618
SPEED CONTROL 618
DESCRIPTION 618
OPERATION 618
DIAGNOSIS AND TESTING – ROAD TEST 619
SPECIFICATIONS 619
TORQUE – SPEED CONTROL 619
CABLE 620
DESCRIPTION 620
OPERATION 620
REMOVAL – 3 7L 620
INSTALLATION – 3 7L 621
SERVO 621
DESCRIPTION 621
OPERATION 621
REMOVAL 622
INSTALLATION 622
SWITCH 622
DESCRIPTION 622
OPERATION 622
Multiplexing 623
REMOVAL 623
INSTALLATION 623
VACUUM RESERVOIR 624
DESCRIPTION 624
OPERATION 624
DIAGNOSIS AND TESTING – VACUUM RESERVOIR 624
REMOVAL 624
INSTALLATION 625
8q-VEHICLE THEFT SECURITY 626
VEHICLE THEFT SECURITY 626
DESCRIPTION 626
OPERATION 628
DIAGNOSIS AND TESTING – VEHICLE THEFT SECURITY SYSTEM 630
VEHICLE THEFT ALARM 631
SENTRY KEY IMMOBILIZER SYSTEM 631
STANDARD PROCEDURE 632
STANDARD PROCEDURE – SKIS INITIALIZATION 632
STANDARD PROCEDURE – SENTRY KEY TRANSPONDER PROGRAMMING 633
DOOR CYLINDER LOCK SWITCH 634
DESCRIPTION 634
OPERATION 634
DIAGNOSIS AND TESTING – DOOR CYLINDER LOCK SWITCH 634
REMOVAL 634
INSTALLATION 635
HOOD AJAR SWITCH 635
DESCRIPTION 635
OPERATION 635
DIAGNOSIS AND TESTING – HOOD AJAR SWITCH 636
REMOVAL 636
INSTALLATION 636
HOOD AJAR SWITCH BRACKET 636
REMOVAL 636
INSTALLATION 637
HOOD AJAR SWITCH STRIKER 637
REMOVAL 637
INSTALLATION 637
INTRUSION TRANSCEIVER MODULE 638
DESCRIPTION 638
OPERATION 638
REMOVAL 639
INSTALLATION 640
SIREN 640
DESCRIPTION 640
OPERATION 640
REMOVAL 641
INSTALLATION 641
TRANSPONDER KEY 642
DESCRIPTION 642
OPERATION 642
8r-WIPERS/WASHERS 644
FRONT WIPERS/WASHERS 644
FRONT WIPERS/WASHERS 645
DESCRIPTION 645
OPERATING MODES 646
OPERATION 647
OPERATING MODES 647
DIAGNOSIS AND TESTING – FRONT WIPER & WASHER SYSTEM 649
WIPER SYSTEM 649
WASHER SYSTEM 649
CLEANING – FRONT WIPER & WASHER SYSTEM 650
WIPER SYSTEM 650
WASHER SYSTEM 650
INSPECTION – FRONT WIPER & WASHER SYSTEM 650
WIPER SYSTEM 650
WASHER SYSTEM 651
FRONT CHECK VALVE 651
DESCRIPTION 651
OPERATION 652
REMOVAL 652
INSTALLATION 653
FRONT WASHER HOSES/TUBES 653
DESCRIPTION 653
OPERATION 654
FRONT WASHER NOZZLE 654
DESCRIPTION 654
OPERATION 654
REMOVAL 654
INSTALLATION 654
FRONT WIPER ARM 655
DESCRIPTION 655
OPERATION 655
REMOVAL 655
INSTALLATION 656
FRONT WIPER BLADE 656
DESCRIPTION 656
OPERATION 657
REMOVAL 657
INSTALLATION 657
FRONT WIPER MODULE 658
DESCRIPTION 658
OPERATION 658
REMOVAL 659
INSTALLATION 659
FRONT WIPER/WASHER SWITCH 659
DESCRIPTION 659
OPERATION 659
WASHER FLUID LEVEL SWITCH 660
DESCRIPTION 660
OPERATION 660
REMOVAL 660
INSTALLATION 661
WASHER PUMP/MOTOR 661
DESCRIPTION 661
OPERATION 662
REMOVAL 662
INSTALLATION 663
WASHER RESERVOIR 664
DESCRIPTION 664
OPERATION 664
REMOVAL 664
INSTALLATION 665
WIPER HIGH/LOW RELAY 666
DESCRIPTION 666
OPERATION 666
DIAGNOSIS AND TESTING – WIPER HIGH/LOW RELAY 667
REMOVAL 667
INSTALLATION 668
WIPER ON/OFF RELAY 668
DESCRIPTION 668
OPERATION 668
DIAGNOSIS AND TESTING – WIPER ON/OFF RELAY 669
REMOVAL 669
INSTALLATION 669
REAR WIPERS/WASHERS 670
REAR WIPERS/WASHERS 670
DESCRIPTION 670
OPERATING MODES 672
OPERATION 672
OPERATING MODES 673
DIAGNOSIS AND TESTING – REAR WIPER & WASHER SYSTEM 673
WIPER SYSTEM 673
WASHER SYSTEM 675
CLEANING – REAR WIPER & WASHER SYSTEM 675
WIPER SYSTEM 675
WASHER SYSTEM 675
INSPECTION – REAR WIPER & WASHER SYSTEM 676
WIPER SYSTEM 676
WASHER SYSTEM 676
REAR WASHER HOSES/TUBES 677
DESCRIPTION 677
OPERATION 677
REAR WASHER NOZZLE 678
DESCRIPTION 678
OPERATION 678
REMOVAL 678
INSTALLATION 678
REAR WIPER ARM 679
DESCRIPTION 679
OPERATION 679
REMOVAL 679
INSTALLATION 680
REAR WIPER BLADE 681
DESCRIPTION 681
OPERATION 681
REMOVAL 681
INSTALLATION 682
REAR WIPER MOTOR 682
DESCRIPTION 682
OPERATION 683
REMOVAL 683
INSTALLATION 684
REAR WIPER/WASHER SWITCH 684
DESCRIPTION 684
OPERATION 684
WIPER ARM PARK RAMP 685
REMOVAL 685
INSTALLATION 685
8w-WIRING 686
8W-01 WIRING DIAGRAM INFORMATION 688
WIRING DIAGRAM INFORMATION 688
DESCRIPTION 688
DESCRIPTION – HOW TO USE WIRING DIAGRAMS 688
SYMBOLS 688
TERMINOLOGY 692
DESCRIPTION – CIRCUIT INFORMATION 692
DESCRIPTION – CIRCUIT FUNCTIONS 693
DESCRIPTION – SECTION IDENTIFICATION AND INFORMATION 693
DESCRIPTION – CONNECTOR, GROUND AND SPLICE INFORMATION 694
IDENTIFICATION 694
LOCATIONS 694
WARNING 694
WARNINGS – GENERAL 694
DIAGNOSIS AND TESTING – WIRING HARNESS 694
TROUBLESHOOTING TOOLS 694
INTERMITTENT AND POOR CONNECTIONS 695
TROUBLESHOOTING WIRING PROBLEMS 695
STANDARD PROCEDURE 695
STANDARD PROCEDURE – ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES 695
STANDARD PROCEDURE – TESTING OF VOLTAGE POTENTIAL 696
STANDARD PROCEDURE – TESTING FOR CONTINUITY 696
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND 696
STANDARD PROCEDURE – TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 697
STANDARD PROCEDURE – TESTING FOR A VOLTAGE DROP 697
SPECIAL TOOLS 697
WIRING/TERMINAL 697
CONNECTOR 698
REMOVAL 698
INSTALLATION 698
DIODE 701
REMOVAL 701
INSTALLATION 701
TERMINAL 701
REMOVAL 701
INSTALLATION 701
WIRE 702
STANDARD PROCEDURE – WIRE SPLICING 702
8W-02 COMPONENT INDEX 704
8W-10 POWER DISTRIBUTION 706
8W-12 JUNCTION BLOCK 736
8W-15 GROUND DISTRIBUTION 770
8W-18 BUS COMMUNICATIONS 790
8W-20 CHARGING SYSTEM 796
8W-21 STARTING SYSTEM 800
8W-30 FUEL/IGNITION SYSTEM 808
8W-31 TRANSMISSION CONTROL SYSTEM 846
8W-33 VEHICLE SPEED CONTROL 862
8W-35 ANTILOCK BRAKES 868
8W-39 VEHICLE THEFT SECURITY SYSTEM 872
8W-40 INSTRUMENT CLUSTER 884
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 892
8W-42 AIR CONDITIONING-HEATER 896
8W-43 AIRBAG SYSTEM 904
8W-44 INTERIOR LIGHTING 908
8W-45 BODY CONTROL MODULE 912
8W-47 AUDIO SYSTEM 924
8W-48 REAR WINDOW DEFOGGER 934
8W-49 OVERHEAD CONSOLE 936
8W-50 FRONT LIGHTING 942
8W-51 REAR LIGHTING 960
8W-52 TURN SIGNALS 966
8W-53 WIPERS 974
8W-54 TRAILER TOW 980
8W-60 POWER WINDOWS 986
8W-61 POWER DOOR LOCKS 990
8W-62 POWER MIRRORS 998
8W-63 POWER SEAT 1004
8W-64 POWER SUNROOF 1010
8W-70 SPLICE INFORMATION 1012
8W-80 CONNECTOR PIN-OUTS 1020
8W-91 CONNECTOR/GROUND/SPLICE LOCATION 1126
CONNECTOR/GROUND/SPLICE LOCATION 1126
DESCRIPTION 1126
8W-97 POWER DISTRIBUTION 1188
POWER DISTRIBUTION 1188
DESCRIPTION 1188
OPERATION 1188
SPECIAL TOOLS 1189
POWER DISTRIBUTION SYSTEMS 1189
CIGAR LIGHTER OUTLET 1189
DESCRIPTION 1189
OPERATION 1189
DIAGNOSIS AND TESTING – CIGAR LIGHTER OUTLET 1189
IOD FUSE 1190
DESCRIPTION 1190
CIRCUITS INCLUDED WITH IOD FUSE 1190
OPERATION 1190
REMOVAL 1190
INSTALLATION 1190
JUNCTION BLOCK 1191
DESCRIPTION 1191
OPERATION 1191
DIAGNOSIS AND TESTING – JUNCTION BLOCK 1191
REMOVAL 1192
REMOVAL – LHD 1192
REMOVAL – RHD 1192
INSTALLATION 1193
INSTALLATION – LHD 1193
INSTALLATION – RHD 1193
POWER DISTRIBUTION CENTER 1193
DESCRIPTION 1193
OPERATION 1193
REMOVAL 1194
DISASSEMBLY 1194
POWER DISTRIBUTION CENTER DISASSEMBLY 1194
PDC HOUSING LOWER COVER 1194
PDC B+ TERMINAL MODULE 1195
PDC RELAY WEDGE 1195
PDC RELAY CASSETTE 1195
ASSEMBLY 1196
POWER DISTRIBUTION CENTER ASSEMBLY 1196
PDC B(+) TERMINAL MODULE 1196
RELAY WEDGE 1196
RELAY CASSETTE 1197
PDC LOWER COVER 1197
INSTALLATION 1197
POWER OUTLET 1198
DESCRIPTION 1198
OPERATION 1198
DIAGNOSIS AND TESTING – POWER OUTLET 1198
REMOVAL 1198
INSTALLATION 1199
RELAY 1199
DESCRIPTION 1199
OPERATION 1200
DIAGNOSIS AND TESTING – RELAY 1200
DIAGNOSIS & TESTING – RELAY CIRCUIT TEST 1200
REMOVAL 1200
INSTALLATION 1200
MICRO-RELAY 1200
DESCRIPTION 1200
OPERATION 1201
DIAGNOSIS AND TESTING – MICRO-RELAY 1201
REMOVAL 1201
INSTALLATION 1201
9-ENGINE 1202
ENGINE – 2 4L 1202
ENGINE – 2 4L 1204
DESCRIPTION 1204
DIAGNOSIS AND TESTING 1204
DIAGNOSIS AND TESTING – CYLINDER COMBUSTION PRESSURE LEAKAGE TEST 1204
DIAGNOSIS AND TESTING – CYLINDER COMPRESSION PRESSURE TEST 1205
DIAGNOSIS AND TESTING – ENGINE OIL LEAK INSPECTION0 – 6 KJ (Continued) 1205
INSPECTION FOR REAR SEAL AREA LEAKS 1206
DIAGNOSIS AND TESTING – ENGINE 1206
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – PERFORMANCE 1207
DIAGNOSIS AND TESTING – ENGINE MECHANICAL 1209
STANDARD PROCEDURE 1211
STANDARD PROCEDURE – ENGINE CORE AND OIL GALLERY PLUGS 1211
STANDARD PROCEDURE – REPAIR OF DAMAGED OR WORN THREADS 1211
STANDARD PROCEDURE – HYDROSTATIC LOCKED ENGINE 1211
STANDARD PROCEDURE – FORM-IN-PLACE GASKETS AND SEALERS 1212
SEALER APPLICATION 1212
STANDARD PROCEDURE – ENGINE GASKET SURFACE PREPARATION 1213
STANDARD PROCEDURE – MEASURING BEARING CLEARANCE USING PLASTIGAGE 1213
REMOVAL – ENGINE ASSEMBLY 1214
INSTALLATION – ENGINE ASSEMBLY 1214
SPECIFICATIONS 1215
SPECIFICATIONS – 2 4L ENGINE 1215
SPECIFICATIONS – TORQUE 1218
SPECIAL TOOLS 1219
2 4L ENGINE 1219
AIR CLEANER ELEMENT 1221
REMOVAL – 2 4L 1221
INSTALLATION – 2 4L 1221
CYLINDER HEAD 1221
DESCRIPTION 1221
OPERATION 1221
DIAGNOSIS AND TESTING – CYLINDER HEAD GASKET 1221
CYLINDER-TO-CYLINDER LEAKAGE TEST 1222
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1222
REMOVAL – CYLINDER HEAD 1222
CLEANING 1222
INSPECTION 1223
INSTALLATION – CYLINDER HEAD 1223
CAMSHAFT OIL SEAL(S) 1224
REMOVAL 1224
INSTALLATION 1224
CAMSHAFT(S) 1225
DESCRIPTION 1225
OPERATION 1225
STANDARD PROCEDURE – CAMSHAFT END-PLAY 1225
REMOVAL 1225
CLEANING 1226
INSPECTION 1226
INSTALLATION 1227
CYLINDER HEAD COVER 1227
REMOVAL 1227
CLEANING 1228
INSPECTION 1228
INSTALLATION 1228
INTAKE/EXHAUST VALVES & SEATS 1229
DESCRIPTION 1229
CLEANING 1229
VALVE SPRINGS 1229
REMOVAL 1229
REMOVAL – CYLINDER HEAD ON 1229
REMOVAL – CYLINDER HEAD OFF 1229
INSPECTION 1229
INSTALLATION 1229
INSTALLATION – CYLINDER HEAD ON 1229
INSTALLATION – CYLINDER HEAD OFF 1230
HYDRAULIC LIFTERS 1230
DIAGNOSIS AND TESTING – LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS 1230
REMOVAL 1231
INSTALLATION 1231
ROCKER ARMS 1231
REMOVAL 1231
INSPECTION 1231
INSTALLATION 1232
ENGINE BLOCK 1232
DESCRIPTION 1232
STANDARD PROCEDURE 1232
STANDARD PROCEDURE – PISTON TO CYLINDER BORE FITTING 1232
STANDARD PROCEDURE – CYLINDER BORE HONING 1232
CLEANING 1233
INSPECTION 1233
ENGINE BLOCK 1233
CYLINDER BORE 1234
CONNECTING ROD BEARINGS 1234
STANDARD PROCEDURE 1234
CONNECTING ROD – FITTING 1234
CRANKSHAFT 1234
DESCRIPTION 1234
OPERATION 1234
STANDARD PROCEDURE – CRANKSHAFT END PLAY 1234
REMOVAL 1235
INSPECTION 1235
INSTALLATION 1236
CRANKSHAFT MAIN BEARINGS 1237
STANDARD PROCEDURE – MAIN BEARING – FITTING 1237
CRANKSHAFT MAIN BEARINGS 1237
MAIN BEARING INSTALLATION 1237
CRANKSHAFT OIL SEAL – FRONT 1238
REMOVAL 1238
INSTALLATION 1239
CRANKSHAFT OIL SEAL – REAR 1240
REMOVAL 1240
INSTALLATION 1240
PISTON & CONNECTING ROD 1241
DESCRIPTION 1241
OPERATION 1241
REMOVAL 1242
INSTALLATION 1242
PISTON RINGS 1243
STANDARD PROCEDURE 1243
PISTON RING – FITTING 1243
PISTON RINGS – INSTALLATION 1243
VIBRATION DAMPER 1244
REMOVAL 1244
INSTALLATION 1244
STRUCTURAL COLLAR 1245
REMOVAL 1245
INSTALLATION 1245
ENGINE MOUNTING 1245
DESCRIPTION 1245
FRONT MOUNT 1245
REMOVAL 1245
INSTALLATION 1245
REAR MOUNT 1246
REMOVAL 1246
MANUAL TRANSMISSION 1246
AUTOMATIC TRANSMISSION 1246
INSTALLATION 1246
MANUAL TRANSMISSION: 1246
AUTOMATIC TRANSMISSION: 1246
LUBRICATION 1247
DESCRIPTION 1247
OPERATION 1247
DIAGNOSIS AND TESTING – ENGINE OIL PRESSURE CHECKING 1248
OIL 1248
STANDARD PROCEDURE 1248
ENGINE OIL LEVEL CHECK 1248
STANDARD PROCEDURE – ENGINE OIL AND FILTER CHANGE 1248
OIL FILTER 1249
DESCRIPTION 1249
REMOVAL 1249
INSTALLATION 1249
OIL PAN 1249
REMOVAL 1249
INSTALLATION 1249
OIL PRESSURE SENSOR/SWITCH 1250
DESCRIPTION 1250
OPERATION 1250
OIL PUMP 1250
REMOVAL 1250
DISASSEMBLY 1251
CLEANING 1251
INSPECTION 1251
ASSEMBLY 1251
INSTALLATION 1252
INTAKE MANIFOLD 1253
DESCRIPTION 1253
OPERATION 1254
DIAGNOSIS AND TESTING – INTAKE MANIFOLD LEAKS 1254
REMOVAL 1254
REMOVAL — UPPER 1254
REMOVAL — LOWER 1254
INSPECTION 1254
INSTALLATION 1254
INSTALLATION — UPPER 1254
INSTALLATION — LOWER 1255
EXHAUST MANIFOLD 1255
DESCRIPTION 1255
OPERATION 1255
REMOVAL 1255
CLEANING 1256
INSPECTION 1256
INSTALLATION 1256
TIMING BELT COVER(S) 1256
REMOVAL 1256
FRONT COVER 1256
REAR COVER 1256
INSTALLATION 1256
REAR COVER 1256
FRONT COVER 1256
TIMING BELT AND SPROCKET(S) 1257
REMOVAL 1257
REMOVAL – TIMING BELT 1257
REMOVAL – CRANKSHAFT SPROCKET 1257
CLEANING 1257
INSTALLATION 1258
INSTALLATION – CRANKSHAFT SPROCKET 1258
INSTALLATION – TIMING BELT 1259
TIMING BELT TENSIONER & PULLEY 1261
REMOVAL 1261
INSTALLATION 1261
BALANCE SHAFT 1261
DESCRIPTION 1261
OPERATION 1261
REMOVAL 1262
BALANCE SHAFTS 1262
BALANCE SHAFT CARRIER 1262
INSTALLATION 1264
BALANCE SHAFT TIMING 1264
BALANCE SHAFT INSTALLATION 1264
BALANCE SHAFT CARRIER 1265
REMOVAL 1265
INSTALLATION 1265
BALANCE SHAFT CHAIN 1265
REMOVAL 1265
INSTALLATION 1265
ENGINE – 3 7L 1266
ENGINE – 3 7L 1268
DESCRIPTION 1268
DIAGNOSIS AND TESTING 1269
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – INTRODUCTION 1269
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – PERFORMANCE 1269
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – MECHANICAL 1271
DIAGNOSIS AND TESTING – ENGINE DIAGNOSIS – LUBRICATION 1272
DIAGNOSIS AND TESTING – CYLINDER COMPRESSION PRESSURE 1273
DIAGNOSIS AND TESTING – CYLINDER COMBUSTION PRESSURE LEAKAGE 1273
STANDARD PROCEDURE 1274
STANDARD PROCEDURE – ENGINE GASKET SURFACE PREPARATION 1274
STANDARD PROCEDURE – REPAIR DAMAGED OR WORN THREADS 1274
STANDARD PROCEDURE – ENGINE CORE AND OIL GALLERY PLUGS 1275
REMOVAL 1275
INSTALLATION 1276
SPECIFICATIONS 1277
TORQUE 1277
SPECIFICATIONS – 3 7L ENGINE 1277
SPECIAL TOOLS 1280
3 7L ENGINE 1280
AIR CLEANER ELEMENT 1284
REMOVAL – 3 7L 1284
INSTALLATION – 3 7L 1284
CYLINDER HEAD – LEFT 1284
DESCRIPTION – VALVE GUIDES 1284
DIAGNOSIS AND TESTING 1284
DIAGNOSIS AND TESTING – HYDRAULIC LASH ADJUSTER 1284
DIAGNOSIS AND TESTING – CYLINDER HEAD GASKET 1284
CYLINDER-TO-CYLINDER LEAKAGE TEST 1285
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1285
REMOVAL 1285
CLEANING 1287
INSTALLATION 1287
CAMSHAFT(S) 1288
DESCRIPTION 1288
REMOVAL 1288
INSTALLATION 1289
CYLINDER HEAD COVER(S) 1290
DESCRIPTION 1290
REMOVAL 1290
INSTALLATION 1291
INTAKE/EXHAUST VALVES & SEATS 1291
DESCRIPTION 1291
STANDARD PROCEDURE – REFACING 1291
REMOVAL 1291
TESTING VALVE SPRINGS 1292
INSTALLATION 1292
ROCKER ARM 1293
DESCRIPTION 1293
REMOVAL 1293
VALVE GUIDE SEALS 1294
DESCRIPTION 1294
VALVE SPRINGS 1294
DESCRIPTION 1294
REMOVAL 1294
INSTALLATION 1294
CYLINDER HEAD – RIGHT 1295
DESCRIPTION 1295
DESCRIPTION – CYLINDER HEAD 1295
DESCRIPTION – VALVE GUIDES 1295
DESCRIPTION 1295
DIAGNOSIS AND TESTING 1295
DIAGNOSIS AND TESTING – HYDRAULIC LASH ADJUSTER 1295
DIAGNOSIS AND TESTING – CYLINDER HEAD GASKET 1295
CYLINDER-TO-CYLINDER LEAKAGE TEST 1295
CYLINDER-TO-WATER JACKET LEAKAGE TEST 1296
REMOVAL 1296
CLEANING 1297
INSPECTION 1297
INSTALLATION 1297
CAMSHAFT(S) 1298
DESCRIPTION 1298
REMOVAL 1298
INSTALLATION 1299
CYLINDER HEAD COVER(S) 1300
REMOVAL 1300
INSTALLATION 1300
INTAKE/EXHAUST VALVES & SEATS 1300
STANDARD PROCEDURE – REFACING 1300
REMOVAL 1300
TESTING VALVE SPRINGS 1301
INSTALLATION 1301
ROCKER ARM 1302
DESCRIPTION 1302
REMOVAL 1302
INSTALLATION 1303
VALVE GUIDE SEALS 1303
DESCRIPTION 1303
VALVE SPRINGS 1303
DESCRIPTION 1303
REMOVAL 1303
INSTALLATION 1304
ENGINE BLOCK 1304
DESCRIPTION 1304
STANDARD PROCEDURE – CYLINDER BORE HONING 1304
CLEANING 1305
INSPECTION 1305
CRANKSHAFT 1306
DESCRIPTION 1306
REMOVAL 1306
INSPECTION 1307
INSTALLATION 1307
CRANKSHAFT MAIN BEARINGS 1308
STANDARD PROCEDURE 1308
MAIN BEARING – FITTING 1308
SELECT FIT IDENTIFICATION 1308
INSPECTION 1308
MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED) 1308
CRANKSHAFT MAIN BEARING SELECTION 1310
CRANKSHAFT OIL SEAL – FRONT 1310
REMOVAL 1310
INSTALLATION 1311
CRANKSHAFT OIL SEAL – REAR 1312
REMOVAL 1312
INSTALLATION 1312
FLEX PLATE 1313
REMOVAL 1313
INSTALLATION 1313
PISTON & CONNECTING ROD 1313
DESCRIPTION 1313
STANDARD PROCEDURE 1313
CONNECTING ROD BEARING FITTING 1313
STANDARD PROCEDURE – PISTON FITTING 1316
REMOVAL 1316
CLEANING 1317
INSPECTION 1317
INSTALLATION 1317
PISTON RINGS 1318
STANDARD PROCEDURE – PISTON RING FITTING 1318
VIBRATION DAMPER 1320
REMOVAL 1320
INSTALLATION 1320
STRUCTURAL COVER 1321
DESCRIPTION 1321
OPERATION 1321
REMOVAL 1321
INSTALLATION 1321
FRONT MOUNT 1322
REMOVAL 1322
INSTALLATION 1322
REAR MOUNT 1323
REMOVAL 1323
MANUAL TRANSMISSION 1323
AUTOMATIC TRANSMISSION 1323
INSTALLATION 1323
MANUAL TRANSMISSION: 1323
AUTOMATIC TRANSMISSION: 1323
LUBRICATION 1324
DESCRIPTION 1324
OPERATION 1324
DIAGNOSIS AND TESTING 1325
DIAGNOSIS AND TESTING – ENGINE OIL LEAK 1325
Air Leak Detection Test Method 1325
INSPECTION FOR REAR SEAL AREA LEAKS 1327
DIAGNOSIS AND TESTING – CHECKING ENGINE OIL PRESSURE 1327
DIAGNOSIS AND TESTING – REAR SEAL AREA LEAKS 1327
OIL 1328
STANDARD PROCEDURE – ENGINE OIL 1328
ENGINE OIL SPECIFICATION 1328
API SERVICE GRADE CERTIFIED 1328
SAE VISCOSITY 1328
ENERGY CONSERVING OIL 1328
CONTAINER IDENTIFICATION 1328
OIL LEVEL INDICATOR (DIPSTICK) 1328
CRANKCASE OIL LEVEL INSPECTION 1329
ENGINE OIL CHANGE 1329
USED ENGINE OIL DISPOSAL 1329
OIL FILTER 1329
REMOVAL 1329
INSTALLATION 1330
OIL PAN 1330
DESCRIPTION 1330
REMOVAL 1330
REMOVAL 1330
REMOVAL – 4×4 1331
CLEANING 1331
INSPECTION 1331
INSTALLATION 1332
INSTALLATION 1332
INSTALLATION – 4×4 1332
OIL PRESSURE SENSOR/SWITCH 1332
DESCRIPTION 1332
OPERATION 1333
REMOVAL 1333
INSTALLATION 1333
OIL PUMP 1333
REMOVAL 1333
DISASSEMBLY 1333
INSPECTION 1333
ASSEMBLY 1334
INSTALLATION 1334
INTAKE MANIFOLD 1336
DESCRIPTION 1336
DIAGNOSIS AND TESTING – INTAKE MANIFOLD LEAKS 1336
REMOVAL 1336
INSTALLATION 1336
EXHAUST MANIFOLD 1337
DESCRIPTION 1337
REMOVAL 1337
RIGHT EXHAUST MANIFOLD 1337
LEFT EXHAUST MANIFOLD 1338
INSTALLATION 1339
RIGHT EXHAUST MANIFOLD 1339
LEFT EXHAUST MANIFOLD 1339
VALVE TIMING 1339
DESCRIPTION 1339
OPERATION 1339
STANDARD PROCEDURE 1341
MEASURING TIMING CHAIN WEAR 1341
SERVICE PROCEDURE – TIMING VERIFICATION 1341
COUNTER BALANCE SHAFT TIMING 1341
TIMING – SINGLE CAMSHAFT 1341
BALANCE SHAFT 1343
REMOVAL 1343
INSTALLATION 1343
TIMING BELT / CHAIN COVER(S) 1344
REMOVAL 1344
INSTALLATION 1344
IDLER SHAFT 1345
REMOVAL 1345
INSTALLATION 1346
TIMING BELT/CHAIN AND SPROCKET(S) 1346
REMOVAL 1346
INSPECTION 1348
INSTALLATION 1348
11-EXHAUST SYSTEM 1352
EXHAUST SYSTEM 1352
DESCRIPTION 1352
DIAGNOSIS AND TESTING – EXHAUST SYSTEM 1353
CATALYTIC CONVERTER 1353
DESCRIPTION – CATALYTIC CONVERTER 1353
REMOVAL 1353
2 4L ENGINES 1353
3 7L ENGINES 1354
INSPECTION 1354
INSTALLATION 1354
CROSS-OVER PIPE 1355
REMOVAL 1355
INSTALLATION 1355
EXHAUST PIPE-2 4L 1355
REMOVAL 1355
INSTALLATION 1356
HEAT SHIELDS 1356
DESCRIPTION 1356
MUFFLER 1356
DESCRIPTION 1356
REMOVAL 1356
INSTALLATION 1357
13-FRAMES & BUMPERS 1360
FRONT FASCIA 1360
REMOVAL 1360
INSTALLATION 1361
REAR FASCIA 1361
REMOVAL 1361
INSTALLATION 1361
REAR FASCIA SUPPORT 1361
REMOVAL 1361
INSTALLATION 1362
REAR FASCIA – STEP PAD 1362
REMOVAL 1362
INSTALLATION 1362
REAR FASCIA – RAIN DIVERTER 1362
REMOVAL 1362
INSTALLATION 1362
FRAME 1362
SPECIFICATIONS 1362
SPECIFICATIONS – FRAME DIMENSIONS 1362
VEHICLE PREPARATION 1362
DIMENSION ILLUSTRATIONS 1362
SPECIFICATIONS – TORQUE 1364
FRONT SKID PLATE 1365
REMOVAL 1365
INSTALLATION 1365
ENGINE CRADLE CROSSMEMBER 1365
REMOVAL 1365
INSTALLATION 1365
TRANSFER CASE SKID PLATE 1365
REMOVAL 1365
INSTALLATION 1365
REAR CROSSMEMBER 1366
REMOVAL 1366
INSTALLATION 1366
FRONT TOW HOOK 1366
REMOVAL 1366
INSTALLATION 1366
REAR TOW HOOK 1367
REMOVAL 1367
INSTALLATION 1367
TRAILER HITCH 1367
REMOVAL 1367
INSTALLATION 1367
FUEL TANK SKID PLATE 1367
REMOVAL 1367
INSTALLATION 1367
14-FUEL SYSTEM 1368
FUEL DELIVERY 1368
FUEL DELIVERY 1369
DESCRIPTION 1369
OPERATION 1369
STANDARD PROCEDURE – FUEL SYSTEM PRESSURE RELEASE 1369
SPECIFICATIONS 1369
FUEL SYSTEM PRESSURE 1369
TORQUE 1371
SPECIAL TOOLS 1372
FUEL SYSTEM 1372
FLOW MANAGEMENT VALVE 1372
DESCRIPTION 1372
OPERATION 1372
REMOVAL 1373
INSTALLATION 1373
FUEL FILTER 1373
DESCRIPTION 1373
REMOVAL 1373
INSTALLATION 1374
FUEL LEVEL SENDING UNIT / SENSOR 1375
DESCRIPTION 1375
OPERATION 1375
REMOVAL 1375
INSTALLATION 1376
FUEL LINES 1376
DESCRIPTION 1376
QUICK CONNECT FITTING 1376
DESCRIPTION 1376
STANDARD PROCEDURE – QUICK-CONNECT FITTINGS 1377
DISCONNECTING 1377
CONNECTING 1380
FUEL PRESSURE REGULATOR 1380
DESCRIPTION 1380
OPERATION 1380
REMOVAL 1380
INSTALLATION 1381
FUEL PUMP 1381
DESCRIPTION 1381
OPERATION 1381
FUEL PUMP MODULE 1381
DESCRIPTION 1381
OPERATION 1381
REMOVAL 1381
INSTALLATION 1382
FUEL RAIL 1384
DESCRIPTION 1384
OPERATION 1385
REMOVAL 1385
INSTALLATION 1387
FUEL TANK 1388
DESCRIPTION 1388
OPERATION 1388
REMOVAL 1388
Fuel Tank Draining 1388
Tank Removal 1389
INSTALLATION 1390
FUEL TANK CHECK VALVE 1391
DESCRIPTION 1391
OPERATION 1391
REMOVAL 1391
INSTALLATION 1391
INLET FILTER 1392
REMOVAL 1392
INSTALLATION 1392
FUEL INJECTION 1393
FUEL INJECTION 1393
DESCRIPTION 1393
ACCELERATOR PEDAL 1393
REMOVAL 1393
INSTALLATION 1393
CRANKSHAFT POSITION SENSOR 1394
DESCRIPTION 1394
2 4L 1394
3 7L 1394
OPERATION 1394
2 4L 1394
3 7L 1395
REMOVAL 1395
2 4L 1395
3 7L 1396
INSTALLATION 1396
2 4L 1396
3 7L 1396
FUEL INJECTOR 1396
DESCRIPTION 1396
OPERATION 1396
OPERATION – FUEL INJECTOR 1396
OPERATION – PCM OUTPUT 1397
REMOVAL 1397
INSTALLATION 1397
FUEL PUMP RELAY 1398
DESCRIPTION 1398
OPERATION 1398
REMOVAL 1398
INSTALLATION 1398
IDLE AIR CONTROL MOTOR 1398
DESCRIPTION 1398
OPERATION 1398
REMOVAL 1399
2 4L 1399
3 7L 1399
INSTALLATION 1400
2 4L 1400
3 7L 1400
INTAKE AIR TEMPERATURE SENSOR 1400
DESCRIPTION 1400
OPERATION 1400
REMOVAL 1400
2 4L 1400
3 7L 1401
INSTALLATION 1401
2 4L 1401
3 7L 1401
MAP SENSOR 1401
DESCRIPTION 1401
2 4L 1401
3 7L 1401
OPERATION 1401
REMOVAL 1402
2 4L 1402
3 7L 1402
INSTALLATION 1403
2 4L 1403
3 7L 1403
OXYGEN SENSOR 1403
DESCRIPTION 1403
OPERATION 1404
REMOVAL 1405
INSTALLATION 1406
THROTTLE BODY 1406
DESCRIPTION 1406
OPERATION 1406
REMOVAL 1407
2 4L 1407
3 7L 1407
INSTALLATION 1407
2 4L 1407
3 7L 1407
THROTTLE CONTROL CABLE 1408
REMOVAL 1408
2 4L 1408
3 7L 1409
INSTALLATION 1410
THROTTLE POSITION SENSOR 1410
DESCRIPTION 1410
OPERATION 1410
REMOVAL 1410
2 4L 1410
3 7L 1411
INSTALLATION 1411
2 4L 1411
3 7L 1411
19-STEERING 1412
STEERING 1412
DESCRIPTION 1412
OPERATION 1412
DIAGNOSIS AND TESTING 1412
DIAGNOSIS AND TESTING – POWER STEERING SYSTEM 1412
DIAGNOSIS AND TESTING – POWER STEERING FLOW AND PRESSURE 1415
FLOW AND PRESSURE TEST 1415
COLUMN 1416
COLUMN 1416
DESCRIPTION 1416
OPERATION – SERVICE PRECAUTIONS 1416
REMOVAL 1416
INSTALLATION 1418
SPECIFICATIONS 1419
TORQUE CHART 1419
SPECIAL TOOLS 1419
STEERING COLUMN 1419
IGNITION SWITCH 1419
DESCRIPTION 1419
DIAGNOSIS AND TESTING – IGNITION SWITCH 1419
ELECTRICAL DIAGNOSIS 1419
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE) 1419
REMOVAL 1420
IGNITION SWITCH REMOVAL 1420
INSTALLATION 1420
IGNITION SWITCH INSTALLATION 1420
KEY-IN IGNITION SWITCH 1421
DESCRIPTION 1421
DIAGNOSIS AND TESTING – KEY-IN IGNITION SWITCH 1421
KEY CYLINDER0 – 8 KJ (Continued) 1421
REMOVAL 1421
INSTALLATION 1422
INTERMEDIATE SHAFT 1422
REMOVAL 1422
INSTALLATION 1422
STEERING WHEEL 1423
REMOVAL 1423
INSTALLATION 1423
GEAR 1424
GEAR 1424
DESCRIPTION 1424
OPERATION 1424
REMOVAL 1424
REMOVAL – 4WD 1424
REMOVAL – 2WD 1425
REMOVAL – 2 5L DIESEL 1425
REMOVAL – RHD – 4X2 & 4X4 1426
INSTALLATION 1426
INSTALLATION – 4WD 1426
INSTALLATION – 2WD 1427
INSTALLATION – 2 5L DIESEL 1427
INSTALLATION – RHD – 4X2 & 4X4 1427
SPECIFICATIONS 1428
TORQUE CHART 1428
SPECIAL TOOLS 1428
OUTER TIE ROD END REMOVAL TOOL 1428
LINKAGE 1429
LINKAGE 1429
STANDARD PROCEDURE – STEERING LINKAGE 1429
TIE ROD END 1429
REMOVAL 1429
INSTALLATION 1429
PUMP 1430
PUMP 1430
DESCRIPTION 1430
DESCRIPTION 1430
DESCRIPTION 1430
OPERATION 1430
STANDARD PROCEDURE – POWER STEERING PUMP – INITIAL OPERATION 1431
REMOVAL 1431
REMOVAL 1431
REMOVAL – 3 7L 1432
REMOVAL – 2 4L 1432
INSTALLATION 1432
INSTALLATION 1432
INSTALLATION – 3 7L 1433
INSTALLATION – 2 4L 1433
SPECIFICATIONS 1433
TORQUE CHART 1433
SPECIAL TOOLS 1434
POWER STEERING PUMP 1434
FLUID COOLER 1434
DESCRIPTION 1434
OPERATION 1434
REMOVAL 1434
INSTALLATION 1434
HOSES 1435
REMOVAL 1435
REMOVAL 1435
REMOVAL – PRESSURE HOSE 1435
REMOVAL – RETURN HOSE (GEAR TO THE COOLER) 1435
REMOVAL – RETURN HOSE (RESERVOIR TO THE COOLER) 1435
INSTALLATION 1435
INSTALLATION 1435
INSTALLATION – PRESSURE HOSE 1436
INSTALLATION – RETURN HOSE (GEAR TO THE COOLER) 1436
INSTALLATION – RETURN HOSE (RESERVOIR TO THE COOLER) 1437
POWER STEERING PRESSURE SWITCH 1437
DESCRIPTION 1437
OPERATION 1437
REMOVAL 1437
INSTALLATION 1437
PULLEY 1437
REMOVAL 1437
REMOVAL – DIESEL 1437
REMOVAL 1437
INSTALLATION 1438
INSTALLATION – DIESEL 1438
INSTALLATION 1438
RESERVOIR 1438
REMOVAL 1438
REMOVAL – DIESEL 1438
REMOVAL – 3 7L 1439
REMOVAL – 2 4L 1439
INSTALLATION 1439
INSTALLATION – DIESEL 1439
INSTALLATION – 3 7L 1439
INSTALLATION – 2 4L 1439
21-TRANSMISSION AND TRANSFER CASE 1440
MANUAL – NV1500 1440
MANUAL – NV1500 1440
DESCRIPTION 1440
OPERATION 1440
DIAGNOSIS AND TESTING 1441
LOW LUBRICANT LEVEL 1441
HARD SHIFTING 1441
TRANSMISSION NOISE 1442
REMOVAL 1442
DISASSEMBLY 1443
CLEANING 1450
INSPECTION 1450
SHIFT LEVER ASSEMBLY 1450
SHIFT SHAFT AND FORKS 1450
FRONT/REAR HOUSINGS AND BEARING RETAINERS 1450
COUNTERSHAFT BEARINGS AND RACES 1451
REVERSE IDLER COMPONENTS 1451
Shift Socket 1452
Output Shaft And Geartrain 1452
ASSEMBLY 1452
INSTALLATION 1469
SPECIFICATIONS 1470
SPECIAL TOOLS 1470
EXTENSION HOUSING SEAL 1472
REMOVAL 1472
INSTALLATION 1472
MANUAL – NV3550 1473
MANUAL – NV3550 1473
DESCRIPTION 1473
OPERATION 1473
DIAGNOSIS AND TESTING 1473
LOW LUBRICANT LEVEL 1473
HARD SHIFTING 1474
TRANSMISSION NOISE 1474
REMOVAL 1474
DISASSEMBLY 1475
FRONT HOUSING 1475
SHIFT/FORK SHAFTS AND REVERSE IDLER SEGMENT 1478
REAR HOUSING – 2WD 1481
REAR ADAPTER HOUSING – 4WD 1483
GEARTRAIN FROM FIXTURE 1484
OUTPUT SHAFT 1484
REVERSE IDLER 1487
CLEANING 1487
INSPECTION 1488
SHIFT LEVER ASSEMBLY 1488
SHIFT SHAFT AND FORKS 1488
FRONT/REAR HOUSINGS AND BEARING RETAINERS 1488
COUNTERSHAFT BEARINGS AND RACES 1489
REVERSE IDLER COMPONENTS 1489
Shift Socket 1489
Output Shaft And Geartrain 1489
ASSEMBLY 1489
SYNCHRONIZER 1489
OUTPUT SHAFT 1490
REVERSE IDLER ASSEMBLY 1497
SHIFT SHAFT AND BUSHINGS/BEARINGS 1498
DETENT PLUNGER BUSHING 1498
GEARTRAIN ASSEMBLY 1499
REAR HOUSING – 2WD 1501
ADAPTER HOUSING – 4WD 1503
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET 1504
FRONT HOUSING AND INPUT SHAFT BEARING RETAINER 1507
SHIFT TOWER AND LEVER 1510
INSTALLATION 1510
SPECIFICATIONS 1511
SPECIAL TOOLS 1512
EXTENSION HOUSING BUSHING 1514
REMOVAL 1514
INSTALLATION 1514
EXTENSION HOUSING SEAL 1514
REMOVAL 1514
INSTALLATION 1514
AUTOMATIC TRANSMISSION – 42RLE 1515
AUTOMATIC TRANSMISSION – 42RLE 1516
DESCRIPTION 1516
TRANSMISSION IDENTIFICATION 1518
OPERATION 1518
FIRST GEAR POWERFLOW 1519
SECOND GEAR POWERFLOW 1520
THIRD GEAR POWERFLOW 1521
FOURTH GEAR POWERFLOW 1522
REVERSE GEAR POWERFLOW 1523
DIAGNOSIS AND TESTING 1523
DIAGNOSIS AND TESTING – AUTOMATIC TRANSMISSION 1523
DIAGNOSIS AND TESTING – ROAD TEST 1524
DIAGNOSIS AND TESTING – HYDRAULIC PRESSURE TESTS 1525
TEST ONE-SELECTOR IN L (1st Gear) 1525
TEST TWO-SELECTOR IN DRIVE (Second Gear) 1525
TEST TWO A–SELECTOR IN OD (Fourth Gear) 1525
TEST THREE-SELECTOR IN OVERDRIVE (Third and Second Gear) 1525
TEST FOUR-SELECTOR IN OD (Fourth Gear) 1525
TEST FIVE-SELECTOR IN OVERDRIVE (Fourth Gear, CC on) 1526
TEST SIX-SELECTOR IN REVERSE 1526
TEST RESULT INDICATIONS 1526
DIAGNOSIS AND TESTING – CLUTCH AIR PRESSURE TESTS 1527
OVERDRIVE CLUTCH 1527
UNDERDRIVE CLUTCH 1527
REVERSE CLUTCH 1527
2/4 CLUTCH 1527
LOW/REVERSE CLUTCH 1527
DIAGNOSIS AND TESTING – FLUID LEAKAGE 1527
FLUID LEAKAGE – TORQUE CONVERTER HOUSING AREA 1527
TORQUE CONVERTER LEAKAGE 1528
STANDARD PROCEDURE – ALUMINUM THREAD REPAIR 1528
REMOVAL 1528
DISASSEMBLY 1530
ASSEMBLY 1547
INSTALLATION 1564
SCHEMATICS AND DIAGRAMS – 42RLE TRANSMISSION 1566
SPECIFICATIONS 1579
42RLE AUTOMATIC TRANSMISSION 1579
SPECIAL TOOLS 1581
42RLE AUTOMATIC TRANSMISSION 1581
ACCUMULATOR 1584
DESCRIPTION 1584
OPERATION 1584
ADAPTER HOUSING SEAL 1584
REMOVAL 1584
INSTALLATION 1584
BEARINGS 1585
ADJUSTMENTS 1585
BEARING ADJUSTMENT PROCEDURES 1585
BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM 1585
DESCRIPTION 1585
OPERATION 1585
DIAGNOSIS AND TESTING – BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM 1585
DRIVING CLUTCHES 1585
DESCRIPTION 1585
OPERATION 1585
UNDERDRIVE CLUTCH 1586
OVERDRIVE CLUTCH 1586
REVERSE CLUTCH 1586
EXTENSION HOUSING SEAL 1586
REMOVAL 1586
INSTALLATION 1586
FLUID AND FILTER 1587
DIAGNOSIS AND TESTING 1587
DIAGNOSIS AND TESTING – CAUSES OF BURNT FLUID 1587
DIAGNOSIS AND TESTING – EFFECTS OF INCORRECT FLUID LEVEL 1587
DIAGNOSIS AND TESTING – FLUID CONTAMINATION 1587
STANDARD PROCEDURE 1587
STANDARD PROCEDURE – FLUID LEVEL CHECK 1587
FLUID LEVEL CHECK 1587
FLUID LEVEL CHECK USING DRB 1587
STANDARD PROCEDURE – FLUID/FILTER SERVICE 1588
STANDARD PROCEDURE – TRANSMISSION FILL 1588
GEARSHIFT CABLE 1589
DIAGNOSIS AND TESTING – GEARSHIFT CABLE 1589
REMOVAL 1589
INSTALLATION 1590
ADJUSTMENTS – GEARSHIFT CABLE 1591
Gearshift Adjustment Procedure 1591
HOLDING CLUTCHES 1591
DESCRIPTION 1591
OPERATION 1591
2/4 CLUTCH 1591
LOW/REVERSE CLUTCH 1592
INPUT CLUTCH ASSEMBLY 1592
DISASSEMBLY 1592
ASSEMBLY 1599
INPUT SPEED SENSOR 1609
DESCRIPTION 1609
OPERATION 1609
REMOVAL 1610
INSTALLATION 1610
OIL PUMP 1610
DESCRIPTION 1610
OPERATION 1610
DISASSEMBLY 1610
ASSEMBLY 1611
OUTPUT SPEED SENSOR 1612
DESCRIPTION 1612
OPERATION 1612
REMOVAL 1612
INSTALLATION 1612
OVERDRIVE SWITCH 1612
DESCRIPTION 1612
OPERATION 1612
PARK – INTERLOCK CABLE 1613
REMOVAL 1613
INSTALLATION 1613
ADJUSTMENTS – PARK-INTERLOCK CABLE 1614
PLANETARY GEARTRAIN 1615
DESCRIPTION 1615
OPERATION 1615
SEAL – OIL PUMP 1615
REMOVAL 1615
INSTALLATION 1615
SHIFT MECHANISM 1615
DESCRIPTION 1615
OPERATION 1615
REMOVAL 1616
INSTALLATION 1616
SOLENOID 1616
DESCRIPTION 1616
OPERATION 1617
SOLENOID/PRESSURE SWITCH ASSY 1618
DESCRIPTION 1618
OPERATION 1618
SOLENOIDS 1618
PRESSURE SWITCHES 1618
REMOVAL 1619
INSTALLATION 1619
TORQUE CONVERTER 1620
DESCRIPTION 1620
IMPELLER 1621
TURBINE 1622
STATOR 1623
TORQUE CONVERTER CLUTCH (TCC) 1623
OPERATION 1624
TURBINE 1624
STATOR 1625
TORQUE CONVERTER CLUTCH (TCC) 1625
REMOVAL 1625
INSTALLATION 1625
TRANSMISSION CONTROL RELAY 1626
DESCRIPTION 1626
OPERATION 1626
TRANSMISSION RANGE SENSOR 1626
DESCRIPTION 1626
OPERATION 1626
REMOVAL 1627
INSTALLATION 1627
TRANSMISSION TEMPERATURE SENSOR 1627
DESCRIPTION 1627
OPERATION 1628
CALCULATED TEMPERATURE 1628
VALVE BODY 1628
DESCRIPTION 1628
OPERATION 1628
THERMAL VALVE 1628
REGULATOR VALVE 1628
SOLENOID SWITCH VALVE 1630
MANUAL VALVE 1630
CONVERTER CLUTCH SWITCH VALVE 1630
CONVERTER CLUTCH CONTROL VALVE 1630
T/C REGULATOR VALVE 1630
LOW/REVERSE SWITCH VALVE 1630
REMOVAL 1631
DISASSEMBLY 1633
ASSEMBLY 1639
INSTALLATION 1644
AUTOMATIC TRANSMISSION – 45RFE 1645
AUTOMATIC TRANSMISSION – 45RFE 1646
DESCRIPTION 1646
TRANSMISSION IDENTIFICATION 1647
GEAR RATIOS 1647
OPERATION 1647
DIAGNOSIS AND TESTING 1647
DIAGNOSIS AND TESTING – AUTOMATIC TRANSMISSION 1647
DIAGNOSIS AND TESTING – PRELIMINARY 1648
VEHICLE IS DRIVABLE 1648
VEHICLE IS DISABLED 1648
DIAGNOSIS AND TESTING – ROAD TESTING 1648
DIAGNOSIS AND TESTING – HYDRAULIC PRESSURE TEST 1649
Pressure Test Port Locations 1649
TEST PROCEDURE 1649
DIAGNOSIS AND TESTING – AIR CHECKING TRANSMISSION CLUTCH OPERATION 1650
DIAGNOSIS AND TESTING – CONVERTER HOUSING FLUID LEAK 1650
TORQUE CONVERTER LEAK POINTS 1650
STANDARD PROCEDURE – ALUMINUM THREAD REPAIR 1651
REMOVAL 1651
DISASSEMBLY 1653
CLEANING 1659
INSPECTION 1659
ASSEMBLY 1660
INSTALLATION 1666
SCHEMATICS AND DIAGRAMS 1670
HYDRAULIC SCHEMATICS 1670
SPECIFICATIONS 1689
TRANSMISSION 1689
SPECIAL TOOLS 1690
RFE TRANSMISSION 1690
4C RETAINER/BULKHEAD 1693
DISASSEMBLY 1693
ASSEMBLY 1693
ADAPTER HOUSING SEAL 1694
REMOVAL 1694
INSTALLATION 1694
BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM 1695
DESCRIPTION 1695
OPERATION 1695
DIAGNOSIS AND TESTING – BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM 1695
FLUID AND FILTER 1695
DIAGNOSIS AND TESTING 1695
DIAGNOSIS AND TESTING – EFFECTS OF INCORRECT FLUID LEVEL 1695
DIAGNOSIS AND TESTING – CAUSES OF BURNT FLUID 1695
DIAGNOSIS AND TESTING – FLUID CONTAMINATION 1695
STANDARD PROCEDURE 1696
STANDARD PROCEDURE – FLUID LEVEL CHECK 1696
STANDARD PROCEDURE – FLUID AND FILTER REPLACEMENT 1696
REMOVAL 1696
INSPECTION 1697
CLEANING 1697
INSTALLATION 1698
STANDARD PROCEDURE – TRANSMISSION FILL 1698
GEARSHIFT CABLE 1698
DIAGNOSIS AND TESTING – GEARSHIFT CABLE 1698
REMOVAL 1698
INSTALLATION 1699
ADJUSTMENTS – GEARSHIFT CABLE 1700
Gearshift Adjustment Procedure 1700
HOLDING CLUTCHES 1701
DESCRIPTION 1701
OPERATION 1702
2C CLUTCH 1702
4C CLUTCH 1702
LOW/REVERSE CLUTCH 1702
INPUT CLUTCH ASSEMBLY 1703
DESCRIPTION 1703
OPERATION 1703
UNDERDRIVE CLUTCH 1703
OVERDRIVE CLUTCH 1705
REVERSE CLUTCH 1705
DISASSEMBLY 1705
ASSEMBLY 1707
INPUT SPEED SENSOR 1712
DESCRIPTION 1712
OPERATION 1712
REMOVAL 1712
INSTALLATION 1713
LINE PRESSURE (LP) SENSOR 1713
DESCRIPTION 1713
OPERATION 1713
REMOVAL 1713
INSTALLATION 1713
LOW/REVERSE CLUTCH 1714
DISASSEMBLY 1714
CLEANING 1715
INSPECTION 1715
ASSEMBLY 1715
OIL PUMP 1716
DESCRIPTION 1716
OPERATION 1716
CONVERTER CLUTCH SWITCH VALVE 1716
CONVERTER CLUTCH REGULATOR VALVE 1717
TORQUE CONVERTER LIMIT VALVE 1717
STANDARD PROCEDURE – OIL PUMP VOLUME CHECK 1717
DISASSEMBLY 1718
CLEANING 1719
INSPECTION 1719
ASSEMBLY 1720
OIL PUMP FRONT SEAL 1721
REMOVAL 1721
INSTALLATION 1721
OUTPUT SPEED SENSOR 1721
DESCRIPTION 1721
OPERATION 1721
REMOVAL 1721
INSTALLATION 1721
OVERDRIVE SWITCH 1722
DESCRIPTION 1722
OPERATION 1722
PARK – INTERLOCK CABLE 1722
REMOVAL 1722
INSTALLATION 1722
ADJUSTMENTS – PARK-INTERLOCK CABLE 1723
PISTONS 1724
DESCRIPTION 1724
OPERATION 1724
PRESSURE 1724
PRESSURE ON A CONFINED FLUID 1724
FORCE MULTIPLICATION 1725
PISTON TRAVEL 1725
PLANETARY GEARTRAIN 1726
DESCRIPTION 1726
OPERATION 1726
REACTION PLANETARY GEARTRAIN 1726
REVERSE PLANETARY GEARTRAIN 1726
INPUT PLANETARY GEARTRAIN 1727
DISASSEMBLY 1727
CLEANING 1727
INSPECTION 1727
ASSEMBLY 1728
SHIFT MECHANISM 1729
DESCRIPTION 1729
OPERATION 1729
REMOVAL 1729
INSTALLATION 1730
SOLENOID SWITCH VALVE 1730
DESCRIPTION 1730
OPERATION 1730
SOLENOIDS 1730
DESCRIPTION 1730
OPERATION 1731
TORQUE CONVERTER 1731
DESCRIPTION 1731
IMPELLER 1732
TURBINE 1733
STATOR 1734
TORQUE CONVERTER CLUTCH (TCC) 1734
OPERATION 1735
TURBINE 1735
STATOR 1735
TORQUE CONVERTER CLUTCH (TCC) 1735
REMOVAL 1736
INSTALLATION 1736
TRANSMISSION CONTROL RELAY 1737
DESCRIPTION 1737
OPERATION 1737
TRANSMISSION RANGE SENSOR 1737
DESCRIPTION 1737
OPERATION 1737
TRANSMISSION SOLENOID/TRS ASSEMBLY 1738
DESCRIPTION 1738
OPERATION 1738
SOLENOIDS 1738
PRESSURE SWITCHES 1738
REMOVAL 1739
INSTALLATION 1739
TRANSMISSION TEMPERATURE SENSOR 1739
DESCRIPTION 1739
OPERATION 1739
Calculated Temperature 1739
VALVE BODY 1740
DESCRIPTION 1740
OPERATION 1740
SOLENOID SWITCH VALVE 1740
MANUAL VALVE 1741
LOW/REVERSE SWITCH VALVE 1741
REMOVAL 1741
DISASSEMBLY 1742
CLEANING 1744
INSPECTION 1745
ASSEMBLY 1746
INSTALLATION 1746
TRANSFER CASE – NV231 1747
TRANSFER CASE – NV231 1747
DESCRIPTION 1747
OPERATING RANGES 1747
SHIFT MECHANISM 1748
IDENTIFICATION 1748
OPERATION 1748
DIAGNOSIS AND TESTING – TRANSFER CASE – NV231 1749
REMOVAL 1750
DISASSEMBLY 1751
REAR RETAINER AND OIL PUMP 1751
COMPANION FLANGE AND RANGE LEVER 1752
FRONT OUTPUT SHAFT AND DRIVE CHAIN 1753
SHIFT FORKS AND MAINSHAFT 1754
MAINSHAFT 1756
INPUT GEAR AND LOW RANGE GEAR 1756
INPUT AND LOW RANGE GEAR 1757
CLEANING 1759
INSPECTION 1759
MAINSHAFT/SPROCKET/HUB 1759
INPUT GEAR AND PLANETARY CARRIER 1760
SHIFT FORKS/HUBS/SLEEVES 1760
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT 1761
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN 1762
LOW RANGE ANNULUS GEAR 1762
FRONT/REAR CASES AND FRONT RETAINER 1762
OIL PUMP/OIL PICKUP 1762
ASSEMBLY 1762
BEARINGS AND SEALS 1762
INPUT AND LOW RANGE GEAR 1766
MAINSHAFT 1767
SHIFT FORKS, SECTOR, AND MAINSHAFT 1767
FRONT OUTPUT SHAFT AND DRIVE CHAIN 1769
OIL PUMP AND REAR CASE 1770
COMPANION FLANGE AND RANGE LEVER 1771
REAR RETAINER 1771
INSTALLATION 1772
SPECIFICATIONS 1772
TRANSFER CASE – NV231 1772
SPECIAL TOOLS 1773
TRANSFER CASE – NV231 1773
FLUID 1775
STANDARD PROCEDURE – FLUID DRAIN AND FILL 1775
FRONT OUTPUT SHAFT SEAL 1775
REMOVAL 1775
INSTALLATION 1775
POSITION SENSOR 1775
DESCRIPTION 1775
OPERATION 1776
REMOVAL 1777
INSTALLATION 1777
REAR OUTPUT SHAFT SEAL 1777
REMOVAL 1777
INSTALLATION 1778
SHIFT LEVER 1779
REMOVAL 1779
INSTALLATION 1779
TRANSFER CASE – NV242 1780
TRANSFER CASE – NV242 1780
DESCRIPTION 1780
TRANSFER CASE IDENTIFICATION 1780
OPERATING RANGES 1780
SHIFT MECHANISM 1780
OPERATION 1781
DIAGNOSIS AND TESTING – TRANSFER CASE – NV242 1781
REMOVAL 1782
DISASSEMBLY 1783
REAR RETAINER 1783
COMPANION FLANGE AND RANGE LEVER 1785
FRONT OUTPUT SHAFT AND DRIVE CHAIN 1786
SHIFT FORKS AND MAINSHAFT 1787
INPUT GEAR/LOW RANGE ASSEMBLY 1790
DIFFERENTIAL 1792
CLEANING 1793
INSPECTION 1793
MAINSHAFT/SPROCKET/HUB 1793
INPUT GEAR AND PLANETARY CARRIER 1793
SHIFT FORKS/HUBS/SLEEVES 1794
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT 1794
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN 1794
LOW RANGE ANNULUS GEAR 1794
FRONT-REAR CASES AND FRONT RETAINER 1794
OIL PUMP/OIL PICKUP 1794
ASSEMBLY 1796
BEARINGS AND SEALS 1796
DIFFERENTIAL 1799
INPUT GEAR/LOW RANGE ASSEMBLY 1800
SHIFT FORKS, SECTOR, AND MAINSHAFT 1801
FRONT OUTPUT SHAFT AND DRIVE CHAIN 1806
OIL PUMP AND REAR CASE 1806
REAR RETAINER 1807
COMPANION FLANGE AND RANGE LEVER 1808
INSTALLATION 1809
SPECIFICATIONS 1809
NV242 TRANSFER CASE 1809
SPECIAL TOOLS 1810
TRANSFER CASE – NV242 1810
FLUID 1812
STANDARD PROCEDURE – FLUID DRAIN AND FILL 1812
FRONT OUTPUT SHAFT SEAL 1812
REMOVAL 1812
INSTALLATION 1812
POSITION SENSOR 1812
DESCRIPTION 1812
OPERATION 1813
REMOVAL 1814
INSTALLATION 1814
REAR OUTPUT SHAFT SEAL 1814
REMOVAL 1814
INSTALLATION 1815
SHIFT LEVER 1815
REMOVAL 1815
INSTALLATION 1816
22-TIRES/WHEELS 1818
TIRES/WHEELS 1818
DIAGNOSIS AND TESTING – TIRE AND WHEEL RUNOUT 1818
METHOD 1 (RELOCATE WHEEL ON HUB) 1818
METHOD 2 (RELOCATE TIRE ON WHEEL) 1818
STANDARD PROCEDURE 1819
STANDARD PROCEDURE – TIRE ROTATION 1819
STANDARD PROCEDURE – MATCH MOUNTING 1820
STANDARD PROCEDURE – WHEEL BALANCING 1821
SPARE TIRE 1822
DESCRIPTION 1822
DESCRIPTION – SPARE / TEMPORARY TIRE 1822
DESCRIPTION – FULL SIZE, SPARE WHEEL WITH MATCHING TIRE 1822
REMOVAL 1822
INSTALLATION 1822
TIRES 1822
DESCRIPTION 1822
DESCRIPTION – TIRES 1822
TIRE IDENTIFICATION 1823
TIRE CHAINS 1823
DESCRIPTION – RADIAL-PLY TIRES 1823
DESCRIPTION – SPARE TIRE &TEMPORARY 1823
DESCRIPTION – TIRE PRESSURE FOR HIGH SPEED 1823
DESCRIPTION – REPLACEMENT TIRES 1824
DIAGNOSIS AND TESTING 1824
DIAGNOSIS AND TESTING – TIRE INFLATION 1824
DIAGNOSIS AND TESTING – TREAD WEAR INDICATORS 1825
DIAGNOSIS AND TESTING – PRESSURE GAUGES 1825
DIAGNOSIS AND TESTING – TIRE/VEHICLE LEAD 1825
DIAGNOSIS AND TESTING – TIRE WEAR PATTERNS 1825
DIAGNOSIS AND TESTING – TIRE NOISE OR VIBRATION 1825
STANDARD PROCEDURE – REPAIRING LEAKS 1825
CLEANING 1825
SPECIFICATIONS 1827
WHEELS 1827
DESCRIPTION 1827
DIAGNOSIS AND TESTING – WHEELS 1828
STANDARD PROCEDURE 1828
STANDARD PROCEDURE – WHEEL REPLACEMENT 1828
STANDARD PROCEDURE – WHEEL MOUNTING 1828
SPECIFICATIONS 1829
SPECIFICATION 1829
STUDS 1829
REMOVAL 1829
INSTALLATION 1829
23-BODY 1838
BODY 1838
WARNING 1838
SAFETY PRECAUTIONS AND WARNINGS0 – 10 KJ (Continued) 1838
DIAGNOSIS AND TESTING 1838
DIAGNOSIS AND TESTING – WATER LEAKS 1838
VISUAL INSPECTION BEFORE WATER LEAK TESTS 1839
WATER LEAK TESTS 1839
WATER LEAK DETECTION 1839
DIAGNOSIS AND TESTING – WIND NOISE 1839
VISUAL INSPECTION BEFORE TESTS 1839
STANDARD PROCEDURE 1840
STANDARD PROCEDURE – BODY LUBRICATION 1840
STANDARD PROCEDURE – HEAT STAKING 1840
STANDARD PROCEDURE – PLASTIC BODY PANEL REPAIR 1840
Rigid Plastics: 1840
Semi-Rigid Plastics: 1841
Flexible Plastics: 1841
Repair Procedure: 1841
Adhesion Promoter/Surface Modifier: 1841
SAFETY PRECAUTION AND WARNINGS 1841
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES 1841
PANEL SECTIONING 1843
PANEL REINFORCEMENT 1843
VISUAL INSPECTION 1844
PANEL SURFACE PREPARATION 1844
PATCHING PANELS 1845
PANEL PATCH FABRICATIONS 1845
PANEL PATCH INSTALLATION 1845
PATCHED PANEL SURFACING 1847
STANDARD PROCEDURE – BUZZ, SQUEAK & RATTLE 1847
SPECIFICATIONS 1849
SPECIAL TOOLS 1850
BODY 1850
HOOD 1851
HINGE 1851
REMOVAL 1851
INSTALLATION 1851
HOOD 1851
REMOVAL 1851
INSTALLATION 1851
ADJUSTMENTS 1851
ADJUSTMENT 1851
LATCH 1851
REMOVAL 1851
INSTALLATION 1852
LATCH RELEASE CABLE 1852
REMOVAL 1852
INSTALLATION 1852
SUPPORT CYLINDER 1853
REMOVAL 1853
INSTALLATION 1853
LATCH RELEASE HANDLE 1853
REMOVAL 1853
INSTALLATION 1853
DOOR – FRONT 1854
CHECK STRAP 1854
REMOVAL 1854
INSTALLATION 1854
DOOR 1855
REMOVAL 1855
INSTALLATION 1855
ADJUSTMENTS 1855
ADJUSTMENT 1855
FORE/AFT 1855
UP/DOWN 1855
IN/OUT 1856
DOOR GLASS 1856
REMOVAL 1856
INSTALLATION 1856
EXTERIOR HANDLE 1857
REMOVAL 1857
INSTALLATION 1857
GLASS RUN CHANNEL 1857
REMOVAL 1857
INSTALLATION 1857
HINGE 1857
REMOVAL 1857
INSTALLATION 1857
LATCH 1858
REMOVAL 1858
INSTALLATION 1858
LATCH STRIKER 1858
REMOVAL 1858
INSTALLATION 1858
LOCK CYLINDER 1859
REMOVAL 1859
INSTALLATION 1859
TRIM PANEL 1859
REMOVAL 1859
INSTALLATION 1859
WATERDAM 1860
REMOVAL 1860
INSTALLATION 1860
WINDOW REGULATOR – MANUAL 1860
REMOVAL 1860
INSTALLATION 1861
WINDOW REGULATOR – POWER 1861
REMOVAL 1861
INSTALLATION 1862
DOORS – REAR 1863
CHECK STRAP 1863
REMOVAL 1863
INSTALLATION 1863
DOOR 1864
REMOVAL 1864
INSTALLATION 1864
ADJUSTMENTS 1864
ADJUSTMENT 1864
FORE/AFT 1864
UP/DOWN 1864
IN/OUT 1865
DOOR GLASS 1865
REMOVAL 1865
INSTALLATION 1866
EXTERIOR HANDLE 1866
REMOVAL 1866
INSTALLATION 1866
GLASS RUN CHANNEL 1867
REMOVAL 1867
INSTALLATION 1867
HINGE 1867
REMOVAL 1867
INSTALLATION 1867
LATCH 1867
REMOVAL 1867
INSTALLATION 1868
ADJUSTMENTS 1868
ADJUSTMENT 1868
LATCH STRIKER 1868
REMOVAL 1868
INSTALLATION 1868
TRIM PANEL 1868
REMOVAL 1868
INSTALLATION 1869
WATERDAM 1869
REMOVAL 1869
INSTALLATION 1869
WINDOW REGULATOR – MANUAL 1870
REMOVAL 1870
INSTALLATION 1870
WINDOW REGULATOR – POWER 1870
REMOVAL 1870
INSTALLATION 1871
SWING GATE 1872
FLIP-UP GLASS 1872
REMOVAL 1872
INSTALLATION 1872
ADJUSTMENTS 1872
ADJUSTMENT 1872
FLIP-UP GLASS LATCH 1873
REMOVAL 1873
INSTALLATION 1873
FLIP-UP GLASS – HINGE 1873
REMOVAL 1873
INSTALLATION 1874
FLIP-UP GLASS – HINGE COVER 1874
REMOVAL 1874
INSTALLATION 1874
FLIP-UP GLASS SUPPORT CYLINDER 1875
REMOVAL 1875
INSTALLATION 1875
TRIM PANEL 1876
REMOVAL 1876
INSTALLATION 1876
LATCH 1876
REMOVAL 1876
INSTALLATION 1876
LATCH STRIKER 1876
REMOVAL 1876
INSTALLATION 1876
ADJUSTMENTS 1876
ADJUSTMENT 1876
LATCH – ACCESS PANEL 1877
DESCRIPTION 1877
REMOVAL 1877
INSTALLATION 1877
EXTERIOR HANDLE 1877
REMOVAL 1877
INSTALLATION 1877
LOCK CYLINDER 1877
REMOVAL 1877
INSTALLATION 1877
CHECK STRAP 1878
REMOVAL 1878
INSTALLATION 1878
STABILIZER WEDGE/INSERT 1878
REMOVAL 1878
INSTALLATION 1878
ADJUSTMENTS 1878
ADJUSTMENT 1878
HINGE 1879
REMOVAL 1879
INSTALLATION 1879
SWING GATE 1880
REMOVAL 1880
INSTALLATION 1880
ADJUSTMENTS 1881
ADJUSTMENT 1881
IN/OUT 1881
UP/DOWN 1881
LEFT/RIGHT 1881
EXTERIOR 1882
BODY SIDE MOLDINGS 1882
REMOVAL 1882
INSTALLATION 1882
COWL GRILLE 1882
REMOVAL 1882
INSTALLATION 1882
EXTERIOR NAME PLATES 1883
REMOVAL 1883
INSTALLATION 1883
FRONT FENDER 1883
REMOVAL 1883
INSTALLATION 1883
FUEL FILL DOOR/HOUSING 1884
REMOVAL 1884
INSTALLATION 1884
GRILLE 1885
REMOVAL 1885
INSTALLATION 1885
GRILLE OPENING REINFORCEMENT 1885
REMOVAL 1885
INSTALLATION 1885
FRONT WHEELHOUSE SPLASH SHIELD 1886
REMOVAL 1886
INSTALLATION 1886
LUGGAGE RACK 1887
REMOVAL 1887
INSTALLATION 1887
REAR WHEELHOUSE SPLASH SHIELD 1887
REMOVAL 1887
INSTALLATION 1887
SIDE VIEW MIRROR 1888
REMOVAL 1888
INSTALLATION 1888
FRONT WHEEL OPENING FLARE MOLDINGS 1888
REMOVAL 1888
INSTALLATION 1888
REAR WHEEL OPENING FLARE MOLDINGS 1889
REMOVAL 1889
INSTALLATION 1889
RADIATOR CROSSMEMBER 1889
REMOVAL 1889
INSTALLATION 1890
SIDE VIEW MIRROR GLASS 1890
REMOVAL 1890
INSTALLATION 1890
INSTRUMENT PANEL 1891
CLUSTER BEZEL 1891
REMOVAL 1891
INSTALLATION 1891
GLOVE BOX 1892
REMOVAL 1892
INSTALLATION 1892
GLOVE BOX LATCH 1892
REMOVAL 1892
INSTALLATION 1892
GLOVE BOX LATCH STRIKER 1892
REMOVAL 1892
INSTALLATION 1893
INSTRUMENT PANEL ASSEMBLY 1893
REMOVAL 1893
INSTALLATION 1896
INSTRUMENT PANEL TOP COVER 1897
REMOVAL 1897
INSTALLATION 1898
INSTRUMENT PANEL END CAP 1898
REMOVAL 1898
INSTALLATION 1898
INSTRUMENT PANEL DRIVER SIDE BEZELS 1898
REMOVAL 1898
INSTALLATION 1899
INSTRUMENT PANEL CENTER BEZEL 1899
REMOVAL 1899
INSTALLATION 1899
INSTRUMENT PANEL PASSENGER SIDE BEZEL 1899
REMOVAL 1899
INSTALLATION 1900
KNEE BLOCKER 1900
REMOVAL 1900
INSTALLATION 1900
INTERIOR 1901
4WD FLOOR SHIFT BOOT 1901
REMOVAL 1901
INSTALLATION 1901
A-PILLAR TRIM AND GRAB HANDLE 1901
REMOVAL 1901
INSTALLATION 1901
COWL TRIM COVER 1902
REMOVAL 1902
INSTALLATION 1902
DOOR SILL SCUFF PLATE 1902
REMOVAL 1902
INSTALLATION 1902
ASSIST HANDLE 1902
REMOVAL 1902
INSTALLATION 1902
B-PILLAR LOWER TRIM 1902
REMOVAL 1902
INSTALLATION 1902
B-PILLAR UPPER TRIM 1903
REMOVAL 1903
INSTALLATION 1903
CARPETS AND FLOOR MATS 1903
REMOVAL 1903
Front Carpet 1903
Rear Cargo Carpet 1903
INSTALLATION 1903
Front Carpet 1903
Rear Cargo Carpet 1903
SHIFT BEZEL 1903
REMOVAL 1903
INSTALLATION 1903
FLOOR CONSOLE 1903
REMOVAL 1903
INSTALLATION 1904
FLOOR CONSOLE LID LATCH 1904
REMOVAL 1904
INSTALLATION 1904
HEADLINER 1904
REMOVAL 1904
INSTALLATION 1904
QUARTER TRIM PANEL 1905
REMOVAL 1905
INSTALLATION 1905
REAR DOOR SCUFF PLATE 1905
REMOVAL 1905
INSTALLATION 1905
SUN VISOR 1905
REMOVAL 1905
INSTALLATION 1905
SUN VISOR SUPPORT 1905
REMOVAL 1905
INSTALLATION 1905
REAR VIEW MIRROR 1906
REMOVAL 1906
INSTALLATION 1906
INSTALLATION 1906
INSTALLATION – REARVIEW MIRROR SUPPORT BRACKET 1906
PAINT 1907
PAINT 1907
SPECIFICATIONS – PAINT CODES 1907
PAINT CODE 1907
DESCRIPTION 1907
BASE COAT/CLEAR COAT FINISH 1908
DESCRIPTION 1908
PAINT TOUCH-UP 1908
DESCRIPTION 1908
OPERATION 1908
FINESSE SANDING/BUFFING & POLISHING 1908
DESCRIPTION 1908
SEATS 1909
HEADREST 1909
REMOVAL0 – 12 KJ (Continued) 1909
INSTALLATION 1909
HEADREST SLEEVE 1909
REMOVAL 1909
INSTALLATION 1909
SEAT – FRONT 1910
REMOVAL 1910
INSTALLATION 1910
SEAT BACK – FRONT 1911
REMOVAL 1911
INSTALLATION 1911
SEAT BACK RECLINER – FRONT 1911
REMOVAL 1911
INSTALLATION 1911
SEAT BACK COVER – FRONT 1911
REMOVAL 1911
INSTALLATION 1912
SEAT BACK CUSHION – FRONT 1912
REMOVAL 1912
INSTALLATION 1912
SEAT CUSHION – FRONT 1912
REMOVAL 1912
INSTALLATION 1912
SEAT CUSHION COVER – FRONT 1912
REMOVAL 1912
INSTALLATION 1912
SEAT CUSHION SIDE SHIELDS 1912
REMOVAL 1912
INSTALLATION 1912
MANUAL SEAT RISER 1912
REMOVAL 1912
INSTALLATION 1912
SEAT TRACK 1913
REMOVAL 1913
INSTALLATION 1913
SEAT – REAR 1913
REMOVAL 1913
INSTALLATION 1913
SEAT BACK – REAR 1914
REMOVAL 1914
60/40 Split Seat – Left 1914
60/40 Split Seat – Right 1914
INSTALLATION 1914
60/40 Split Seat – Left 1914
60/40 Split Seat – Right 1914
SEAT BACK COVER – REAR 1915
REMOVAL 1915
INSTALLATION 1915
SEAT BACK CUSHION – REAR 1915
REMOVAL 1915
INSTALLATION 1915
FOLDING REAR SEAT BACK LATCH / LOCK 1915
REMOVAL 1915
INSTALLATION 1915
REAR SEAT BACK LATCH STRIKER 1916
REMOVAL 1916
INSTALLATION 1916
SEAT BACK FRAME – REAR 1917
REMOVAL 1917
INSTALLATION 1917
SEAT CUSHION – REAR 1917
REMOVAL 1917
INSTALLATION 1917
STATIONARY GLASS 1918
DOOR GLASS 1918
REMOVAL 1918
INSTALLATION 1918
QUARTER WINDOW 1918
REMOVAL 1918
INSTALLATION 1918
WINDSHIELD 1919
WARNING 1919
WINDSHIELD SAFETY PRECAUTIONS 1919
REMOVAL 1919
INSTALLATION 1919
SUNROOF 1921
SUNROOF 1921
DESCRIPTION 1921
SUNROOF OPERATION INSTRUCTIONS 1922
DIAGNOSIS AND TESTING 1922
WATER DRAINAGE AND WIND NOISE DIAGNOSIS 1922
DIAGNOSTIC PROCEDURES 1922
GLASS PANEL 1924
REMOVAL 1924
INSTALLATION 1924
ADJUSTMENTS 1924
SUNROOF GLASS PANEL ADJUSTMENT 1924
GLASS PANEL SEAL 1924
REMOVAL 1924
INSTALLATION 1924
SUNSHADE 1925
REMOVAL 1925
INSTALLATION 1925
GUIDE ASSEMBLY 1925
REMOVAL 1925
INSTALLATION 1925
WIND DEFLECTOR 1926
REMOVAL 1926
INSTALLATION 1926
OPENING TRIM LACE 1926
REMOVAL 1926
INSTALLATION 1926
DRAIN TUBE 1926
REMOVAL 1926
FRONT DRAIN TUBES 1926
REAR DRAIN TUBES 1927
INSTALLATION 1927
FRONT DRAIN TUBES 1927
REAR DRAIN TUBES 1927
MODULE ASSEMBLY 1927
REMOVAL 1927
INSTALLATION 1927
DRIVE MOTOR 1928
REMOVAL 1928
INSTALLATION 1928
CONTROL MODULE 1928
REMOVAL 1928
INSTALLATION 1928
CONTROL SWITCH 1929
DESCRIPTION 1929
OPERATION 1929
DIAGNOSIS AND TESTING – CONTROL SWITCH 1930
REMOVAL 1930
INSTALLATION 1930
WEATHERSTRIP/SEALS 1931
A-PILLAR SEAL 1931
REMOVAL 1931
INSTALLATION 1931
COWL WEATHERSTRIP 1931
REMOVAL 1931
INSTALLATION 1931
DOOR PRIMARY WEATHERSTRIP 1931
REMOVAL 1931
INSTALLATION 1931
DOOR LOWER WEATHERSTRIP 1932
REMOVAL 1932
INSTALLATION 1932
FRONT DOOR OUTER BELT MOLDING 1932
REMOVAL 1932
INSTALLATION 1932
SWING GATE BELTLINE WEATHERSTRIP 1932
REMOVAL 1932
INSTALLATION 1932
SWING GATE OPENING WEATHERSTRIP 1932
REMOVAL 1932
INSTALLATION 1932
REAR DOOR OUTER BELT MOLDING 1933
REMOVAL 1933
INSTALLATION 1933
SIDE RAIL WEATHERSTRIP/RETAINER 1933
REMOVAL 1933
INSTALLATION 1933
WINDSHIELD A-PILLAR WEATHERSTRIP/RETAINER 1933
REMOVAL 1933
INSTALLATION 1933
COWL/PLENUM SEAL 1933
REMOVAL 1933
INSTALLATION 1933
COWL/PLENUM WINDOW BAFFLE SEAL 1934
REMOVAL 1934
INSTALLATION 1934
AIR INLET SEAL 1934
REMOVAL 1934
INSTALLATION 1934
FRONT DOOR INNER BELT WEATHERSTRIP 1934
REMOVAL 1934
INSTALLATION 1934
REAR DOOR INNER BELT WEATHERSTRIP 1934
REMOVAL 1934
INSTALLATION 1934
BODY STRUCTURE 1935
ASSEMBLY 1935
SPECIFICATIONS 1935
SPECIFICATION 1935
WELD AND STRUCTURAL ADHESIVE LOCATIONS 1938
SPECIFICATIONS 1938
FRONT END ASSEMBLY 1942
FRONT END ASSEMBLY/UNDERBODY 1959
REAR FRAME RAILS 1964
REAR FLOOR PAN ASSEMBLY 1970
FULL FLOOR PAN ASSEMBLY 1977
BODY SIDE PANELS AND SUB ASSEMBLIES 1983
BODY SIDE PANELS 1990
FENDER ASSEMBLIES 2002
ROOF PANEL ASSEMBLIES 2006
BODY SIDE PANELS & FLOOR PAN ASSEMBLIES 2010
SEALER LOCATIONS 2016
SPECIFICATIONS 2016
OPENING DIMENSIONS 2040
SPECIFICATIONS 2040
GAP AND FLUSH 2045
SPECIFICATIONS 2045
24-HEATING & AIR CONDITIONING 2048
HEATING & AIR CONDITIONING 2048
DESCRIPTION 2048
DESCRIPTION – HEATER AND AIR CONDITIONER 2048
DESCRIPTION – COOLING SYSTEM REQUIREMENTS 2048
DESCRIPTION – REFRIGERANT SYSTEM SERVICE PORT 2049
OPERATION 2049
OPERATION – HEATER AND AIR CONDITIONER 2049
OPERATION – REFRIGERANT SYSTEM SERVICE PORT 2049
DIAGNOSIS AND TESTING 2049
DIAGNOSIS AND TESTING – A/C PERFORMANCE 2049
DIAGNOSIS AND TESTING – HEATER PERFORMANCE 2053
MAXIMUM HEATER OUTPUT 2053
TEMPERATURE CONTROL 2053
DIAGNOSIS AND TESTING – VACUUM SYSTEM 2053
VACUUM CHECK VALVE 2054
A/C HEATER CONTROLS 2054
LOCATING VACUUM LEAKS 2054
STANDARD PROCEDURE – DIODE REPLACEMENT 2056
SPECIFICATIONS 2056
A/C APPLICATION TABLE 2056
SPECIFICATIONS 2057
CONTROLS 2058
A/C COMPRESSOR CLUTCH 2059
DESCRIPTION – 3 7L and 2 4L 2059
OPERATION – 3 7L and 2 4L 2059
DIAGNOSIS AND TESTING – A/C COMPRESSOR CLUTCH 2059
STANDARD PROCEDURE – A/C COMPRESSOR CLUTCH BREAK-IN 2060
REMOVAL 2060
INSPECTION 2061
INSTALLATION 2061
A/C COMPRESSOR CLUTCH RELAY 2062
DESCRIPTION 2062
OPERATION 2062
DIAGNOSIS AND TESTING – COMPRESSOR CLUTCH RELAY 2062
RELAY TEST 2062
RELAY CIRCUIT TEST 2063
REMOVAL 2063
INSTALLATION 2063
A/C HEATER CONTROL 2063
DESCRIPTION 2063
REMOVAL 2064
INSTALLATION 2064
A/C HIGH PRESSURE SWITCH 2064
DESCRIPTION 2064
OPERATION 2065
DIAGNOSIS AND TESTING – A/C HIGH PRESSURE SWITCH 2065
REMOVAL 2065
INSTALLATION 2065
A/C LOW PRESSURE SWITCH 2065
DESCRIPTION 2065
OPERATION 2065
DIAGNOSIS AND TESTING – A/C LOW PRESSURE SWITCH 2066
REMOVAL 2066
INSTALLATION 2066
BLEND DOOR ACTUATOR 2067
REMOVAL 2067
INSTALLATION 2067
BLOWER MOTOR RELAY 2067
DESCRIPTION 2067
OPERATION 2067
DIAGNOSIS AND TESTING – BLOWER MOTOR RELAY 2068
RELAY TEST 2068
RELAY CIRCUIT TEST 2068
REMOVAL 2068
INSTALLATION 2069
BLOWER MOTOR RESISTOR BLOCK 2069
DESCRIPTION 2069
OPERATION 2069
DIAGNOSIS AND TESTING – BLOWER MOTOR RESISTOR 2069
REMOVAL 2069
INSTALLATION 2069
BLOWER MOTOR SWITCH 2070
DESCRIPTION 2070
OPERATION 2070
DIAGNOSIS AND TESTING – BLOWER MOTOR SWITCH 2070
REMOVAL 2070
INSTALLATION 2070
MODE DOOR ACTUATOR 2071
REMOVAL 2071
REMOVAL – PANEL DOOR ACTUATOR 2071
REMOVAL – FLOOR – DEFROST DOOR ACTUATOR 2071
INSTALLATION 2072
INSTALLATION – PANEL DOOR ACTUATOR 2072
INSTALLATION – FLOOR – DEFROST DOOR ACTUATOR 2072
RECIRCULATION DOOR ACTUATOR 2073
REMOVAL 2073
INSTALLATION 2073
VACUUM CHECK VALVE 2074
DESCRIPTION 2074
OPERATION 2074
REMOVAL 2075
INSTALLATION 2075
DISTRIBUTION 2076
AIR OUTLETS 2076
DESCRIPTION – DEMISTER OUTLETS 2076
REMOVAL – PANEL OUTLET BARRELS 2076
INSTALLATION – PANEL OUTLET BARRELS 2076
BLEND DOOR 2077
REMOVAL 2077
INSTALLATION 2077
BLOWER MOTOR 2077
DESCRIPTION 2077
OPERATION 2077
DIAGNOSIS AND TESTING – BLOWER MOTOR 2078
VIBRATION 2078
NOISE 2078
REMOVAL 2078
INSTALLATION 2078
DEFROST – DEMISTER DUCT 2079
REMOVAL – DEFROST DUCT/DEMISTER ADAPTOR 2079
INSTALLATION – DEFROST/DEMISTER DUCT 2079
FLOOR CONSOLE DUCT 2080
REMOVAL 2080
INSTALLATION 2080
FLOOR DUCT 2080
REMOVAL 2080
INSTALLATION 2080
HVAC HOUSING 2080
REMOVAL 2080
DISASSEMBLY 2081
ASSEMBLY 2082
INSTALLATION 2082
MODE DOOR 2083
REMOVAL 2083
REMOVAL – DEFROST DOOR 2083
REMOVAL – FLOOR – DEFROST DOOR 2083
INSTALLATION 2084
INSTALLATION – PANEL DOOR 2084
INSTALLATION – FLOOR – DEFROST DOOR 2084
RECIRCULATION DOOR 2084
REMOVAL 2084
INSTALLATION 2085
PLUMBING 2086
PLUMBING 2086
DESCRIPTION – REFRIGERANT LINE 2086
WARNING 2087
SERVICE WARNINGS 2087
CAUTION 2087
SERVICE CAUTIONS 2087
CAUTION – REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS 2088
STANDARD PROCEDURE 2088
STANDARD PROCEDURE – REFRIGERANT SYSTEM SERVICE EQUIPMENT 2088
MANIFOLD GAUGE SET CONNECTIONS 2088
STANDARD PROCEDURE – REFRIGERANT RECOVERY 2089
STANDARD PROCEDURE – REFRIGERANT SYSTEM EVACUATE 2089
STANDARD PROCEDURE – REFRIGERANT SYSTEM CHARGE 2089
SPECIFICATIONS – CHARGE CAPACITY0 – 14 KJ (Continued) 2090
A/C COMPRESSOR 2090
DESCRIPTION 2090
DESCRIPTION 2090
DESCRIPTION – HIGH PRESSURE RELIEF VALVE 2090
OPERATION 2090
OPERATION 2090
OPERATION – HIGH PRESSURE RELIEF VALVE 2090
DIAGNOSIS AND TESTING – A/C COMPRESSOR NOISE 2090
REMOVAL 2091
INSTALLATION 2092
A/C CONDENSER 2093
DESCRIPTION 2093
OPERATION 2093
REMOVAL 2093
INSTALLATION 2094
A/C DISCHARGE LINE 2094
REMOVAL 2094
INSTALLATION 2095
A/C LIQUID LINE 2095
REMOVAL 2095
INSTALLATION 2095
A/C SUCTION LINE 2096
REMOVAL 2096
INSTALLATION 2097
A/C EVAPORATOR 2097
DESCRIPTION 2097
OPERATION 2097
REMOVAL 2097
INSTALLATION 2097
A/C ORIFICE TUBE 2098
DESCRIPTION 2098
OPERATION 2098
REMOVAL 2098
INSTALLATION 2098
ACCUMULATOR 2099
DESCRIPTION 2099
OPERATION 2099
REMOVAL 2099
INSTALLATION 2100
HEATER CORE 2100
DESCRIPTION 2100
OPERATION 2100
REMOVAL 2100
INSTALLATION 2101
REFRIGERANT 2101
DESCRIPTION 2101
OPERATION 2101
REFRIGERANT OIL 2101
DESCRIPTION 2101
OPERATION 2102
STANDARD PROCEDURE – REFRIGERANT OIL LEVEL 2102
25-EMISSIONS CONTROL 2104
EMISSIONS CONTROL 2104
DESCRIPTION 2104
DESCRIPTION – EMISSION CONTROL SYSTEM 2104
DESCRIPTION – STATE DISPLAY TEST MODE 2105
DESCRIPTION – CIRCUIT ACTUATION TEST MODE 2105
DESCRIPTION – DIAGNOSTIC TROUBLE CODES 2105
DESCRIPTION – TASK MANAGER 2105
DESCRIPTION – MONITORED SYSTEMS 2105
OXYGEN SENSOR (O2S) MONITOR 2105
OXYGEN SENSOR HEATER MONITOR 2106
LEAK DETECTION PUMP MONITOR (IF EQUIPPED) 2106
MISFIRE MONITOR 2107
FUEL SYSTEM MONITOR 2107
CATALYST MONITOR 2107
DESCRIPTION – TRIP DEFINITION 2107
DESCRIPTION – COMPONENT MONITORS 2108
DESCRIPTION – NON-MONITORED CIRCUITS 2108
DESCRIPTION – HIGH AND LOW LIMITS 2109
DESCRIPTION – LOAD VALUE 2109
OPERATION – TASK MANAGER 2109
Test Sequence 2109
MIL Illumination 2110
Diagnostic Trouble Codes (DTCs) 2110
DTC Self Erasure 2110
Trip Indicator 2110
Freeze Frame Data Storage 2111
Similar Conditions Window 2111
EVAPORATIVE EMISSIONS 2113
EVAPORATIVE EMISSIONS 2113
DESCRIPTION – EVAPORATION CONTROL SYSTEM 2113
SPECIFICATIONS 2115
TORQUE 2115
EVAP/PURGE SOLENOID 2116
DESCRIPTION 2116
OPERATION 2116
REMOVAL 2116
INSTALLATION 2116
FUEL FILLER CAP 2116
DESCRIPTION 2116
OPERATION 2116
LEAK DETECTION PUMP 2117
DESCRIPTION 2117
OPERATION 2117
REMOVAL 2117
INSTALLATION 2117
ORVR 2118
DESCRIPTION 2118
OPERATION 2118
PCV VALVE 2118
DESCRIPTION 2118
2 4L 2118
3 7L 2119
OPERATION 2119
DIAGNOSIS AND TESTING – PCV VALVE 2120
REMOVAL 2121
INSTALLATION 2121
VACUUM LINES 2121
DESCRIPTION 2121
VAPOR CANISTER 2122
DESCRIPTION 2122
OPERATION 2122
REMOVAL 2122
INSTALLATION 2122
INDEX 2124
COMMENTS 2158
DESCRIPTION:
Jeep Cherokee 2003 KJ Service Manual – PDF DOWNLOAD
FOREWORD:
- The information contained in this service manual has been prepared for the professional automotive technician
involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner’s Manual provided with the vehicle. - Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components. - To assist in locating a group title page, use the Group Tab Locator by clicking to the following page. The
first page of the group has a contents section that lists major topics within the group. - A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions. - Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed. - DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
S.V 16/03/2025
