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Chrysler Dodge Caravan 2002 User Manual
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SCHEMA
TICS
AND
DIAGRAMS
41TE
TRANSAXLE
HYDRAULIC
SCHEMA
TICS
Park/Neutral
(Speed
Under
8
MPH)
21
-
216
41TE
AUTOMA
TIC
TRANSAXLE
RS
41TE
AUTOMA
TIC
TRANSAXLE
(Continued)
1772
1774
Table of Contents
RG Service Manual
2398
GROUP TAB LOCATOR
1
in-INTRODUCTION
2
BODY CODE PLATE
2
DESCRIPTION
2
BODY CODE PLATE – LINE 3
2
BODY CODE PLATE LINE 2
3
BODY CODE PLATE LINE 1
3
IF TWO BODY CODE PLATES ARE REQUIRED
3
FASTENER IDENTIFICATION
3
DESCRIPTION
3
FASTENER USAGE
6
DESCRIPTION
6
DESCRIPTION - FASTENER USAGE
6
DESCRIPTION - THREADED HOLE REPAIR
6
INTERNATIONAL SYMBOLS
6
DESCRIPTION
6
METRIC SYSTEM
7
DESCRIPTION
7
TORQUE REFERENCES
9
DESCRIPTION
9
VEHICLE IDENTIFICATION NUMBER
10
DESCRIPTION
10
VEHICLE SAFETY CERTIFICATION LABEL
12
DESCRIPTION
12
E-MARK LABEL
12
DESCRIPTION
12
VECI LABEL
12
DESCRIPTION
12
MANUFACTURER PLATE
12
DESCRIPTION
12
0-LUBRICATION & MAINTENANCE
14
LUBRICATION & MAINTENANCE
14
SPECIFICATIONS - FLUID CAPACITIES
14
INTERNATIONAL SYMBOLS
15
DESCRIPTION
15
FLUID TYPES
15
DESCRIPTION
15
DESCRIPTION - ENGINE OIL AND LUBRICANTS
15
API SERVICE GRADE CERTIFIED
15
SAE VISCOSITY
15
ENERGY CONSERVING OIL
15
CONTAINER IDENTIFICATION
15
GEAR LUBRICANTS
16
LUBRICANTS AND GREASES
16
SPECIALIZED LUBRICANTS AND OILS
16
DESCRIPTION - ENGINE COOLANT
16
DESCRIPTION - FLEXIBLE FUEL ENGINE OIL
16
ETHANOL FUEL (E-85)
16
FUEL REQUIREMENTS
17
FFV STARTING
17
Engine Operating on E-85 Fuel
17
CRUISING RANGE
17
DESCRIPTION - AUTOMATIC TRANSMISSION FLUID
17
TRANSMISSION FLUID
17
DESCRIPTION - FUEL REQUIREMENTS
17
REFORMULATED GASOLINE
18
GASOLINE/OXYGENATE BLENDS
18
MMT IN GASOLINE
18
SULFUR IN GASOLINE
18
MATERIALS ADDED TO FUEL
18
FUEL SYSTEM CAUTIONS
18
DESCRIPTION - FUEL REQUIREMENTS - DIESEL ENGINE
19
DESCRIPTION - ENGINE OIL - DIESEL ENGINES
19
SAE VISCOSITY GRADE
19
FLUID FILL/CHECK LOCATIONS
19
DESCRIPTION
19
LUBRICATION POINTS
19
DESCRIPTION
19
MAINTENANCE SCHEDULES
19
DESCRIPTION
19
HOISTING
19
STANDARD PROCEDURE - HOISTING
19
JUMP STARTING
20
STANDARD PROCEDURE - JUMP STARTING
20
DISCONNECT CABLE CLAMPS AS FOLLOWS:
21
TOWING
21
STANDARD PROCEDURE - TOWING
21
WARNINGS AND CAUTIONS
21
RECOMMENDED TOWING EQUIPMENT
21
GROUND CLEARANCE
22
LOCKED VEHICLE TOWING
22
FLAT TOWING WITH TOW BAR
22
FLAT BED TOWING TIE DOWNS
22
TOWING – FRONT WHEEL LIFT
22
TOWING – REAR WHEEL LIFT
22
2-SUSPENSION
24
FRONT SUSPENSION
24
FRONT SUSPENSION
25
DESCRIPTION - FRONT SUSPENSION
25
OPERATION - FRONT SUSPENSION
25
STANDARD PROCEDURE - LUBRICATION
25
SPECIFICATIONS
26
FRONT SUSPENSION FASTENER TORQUE
26
SPECIAL TOOLS
26
FRONT SUSPENSION
26
BUSHINGS
27
REMOVAL - STABILIZER BAR CUSHION
27
INSTALLATION - STABILIZER BAR CUSHION
27
HUB / BEARING
27
DESCRIPTION
27
OPERATION
27
DIAGNOSIS AND TESTING - HUB AND BEARING
28
REMOVAL
28
INSTALLATION
29
KNUCKLE
29
DESCRIPTION
29
OPERATION
29
REMOVAL - STEERING KNUCKLE
30
INSPECTION - STEERING KNUCKLE
31
INSTALLATION - STEERING KNUCKLE
32
LOWER BALL JOINT
33
DESCRIPTION
33
OPERATION
33
DIAGNOSIS AND TESTING - LOWER BALL JOINT
33
LOWER BALL JOINT SEAL BOOT
33
DESCRIPTION - EXPORT
33
REMOVAL
34
REMOVAL - BALL JOINT SEAL BOOT
34
REMOVAL - EXPORT
34
INSTALLATION
34
INSTALLATION - BALL JOINT SEAL BOOT
34
INSTALLATION - EXPORT
35
LOWER CONTROL ARM
35
DESCRIPTION
35
OPERATION
35
REMOVAL - LOWER CONTROL ARM
35
DISASSEMBLY
36
DISASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - STANDARD)
36
DISASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - HYDRO)
36
INSPECTION - LOWER CONTROL ARM
37
ASSEMBLY
37
ASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - STANDARD)
37
ASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - HYDRO)
38
INSTALLATION - LOWER CONTROL ARM
38
STABILIZER BAR
39
DESCRIPTION
39
OPERATION
39
REMOVAL
40
INSPECTION
40
INSTALLATION
41
STRUT
42
DESCRIPTION - STRUT ASSEMBLY
42
OPERATION - STRUT ASSEMBLY
42
DIAGNOSIS AND TESTING - STRUT ASSEMBLY
43
REMOVAL - STRUT ASSEMBLY
43
DISASSEMBLY - STRUT ASSEMBLY
45
ASSEMBLY - STRUT ASSEMBLY
46
INSTALLATION - STRUT ASSEMBLY
48
REAR SUSPENSION
49
REAR SUSPENSION
49
DESCRIPTION - REAR SUSPENSION
49
OPERATION - REAR SUSPENSION
50
SPECIFICATIONS
51
REAR SUSPENSION FASTENER TORQUE
51
SPECIAL TOOLS
51
REAR SUSPENSION
51
BUSHINGS
52
REMOVAL - LEAF SPRING FRONT BUSHING
52
INSTALLATION - LEAF SPRING FRONT BUSHING
52
HUB / BEARING
53
DESCRIPTION
53
OPERATION
54
DIAGNOSIS AND TESTING - HUB AND BEARING
54
REMOVAL
54
FRONT-WHEEL-DRIVE VEHICLES
54
ALL-WHEEL-DRIVE VEHICLES
55
INSTALLATION
56
FRONT-WHEEL-DRIVE VEHICLES
56
ALL-WHEEL-DRIVE VEHICLES
56
JOUNCE BUMPER
59
DESCRIPTION
59
OPERATION
59
REMOVAL
59
REMOVAL - AWD AND HEAVY DUTY
59
REMOVAL - FRONT-WHEEL-DRIVE
59
INSTALLATION
59
INSTALLATION - AWD AND HEAVY DUTY
59
INSTALLATION - FRONT-WHEEL-DRIVE
59
SHOCK ABSORBER
60
DESCRIPTION
60
OPERATION
60
REMOVAL - SHOCK ABSORBER
60
DISASSEMBLY - SHOCK ABSORBER (UPPER BUSHING)
60
ASSEMBLY - SHOCK ABSORBER (UPPER BUSHING)
61
INSTALLATION - SHOCK ABSORBER
61
SPRING - AWD
61
DESCRIPTION
61
OPERATION
61
REMOVAL - AWD
61
INSTALLATION - AWD
62
SPRING - FWD
63
DESCRIPTION
63
OPERATION
63
REMOVAL - FWD
63
INSTALLATION - FWD
64
SPRING MOUNTS - FRONT
65
REMOVAL
65
INSTALLATION
66
SPRING MOUNTS - REAR
66
REMOVAL
66
INSTALLATION
67
STABILIZER BAR
67
DESCRIPTION
67
OPERATION
67
REMOVAL
67
REMOVAL - AWD
67
REMOVAL - FWD
67
INSTALLATION
67
INSTALLATION - AWD
67
INSTALLATION - FWD
68
TRACK BAR
68
DESCRIPTION
68
OPERATION
68
REMOVAL
68
INSTALLATION
68
WHEEL ALIGNMENT
69
WHEEL ALIGNMENT
69
DESCRIPTION - WHEEL ALIGNMENT
69
CAMBER
69
CROSS CAMBER
70
CASTER
70
CROSS CASTER
70
TOE
70
TOE-OUT ON TURNS
71
DYNAMIC TOE PATTERN
71
STEERING AXIS INCLINATION (S. A. I.)
71
INCLUDED ANGLE (I. A.)
71
THRUST ANGLE
72
DIAGNOSIS AND TESTING - SUSPENSION AND STEERING
72
STANDARD PROCEDURE
74
STANDARD PROCEDURE - WHEEL ALIGNMENT
74
PRE-WHEEL ALIGNMENT INSPECTION
74
WHEEL ALIGNMENT SETUP
74
CAMBER AND CASTER
75
TOE
76
STANDARD PROCEDURE - CURB HEIGHT MEASUREMENT
77
STANDARD PROCEDURE - CURB HEIGHT MEASUREMENT (EXPORT)
78
SPECIFICATIONS
79
WHEEL ALIGNMENT
79
3-DIFFERENTIAL & DRIVELINE
80
HALF SHAFT - FRONT
80
HALF SHAFT - FRONT
80
DESCRIPTION
80
DIAGNOSIS AND TESTING - HALF SHAFT
80
VEHICLE INSPECTION
80
NOISE AND/OR VIBRATION IN TURNS
80
CLUNKING NOISE DURING ACCELERATION
80
SHUDDER OR VIBRATION DURING ACCELERATION
81
VIBRATION AT HIGHWAY SPEEDS
81
REMOVAL
81
INSTALLATION
83
SPECIFICATIONS - HALF SHAFT - FRONT
85
CV BOOT - INNER
85
REMOVAL
85
INSTALLATION
85
CRIMP TYPE BOOT CLAMP
88
LATCHING TYPE BOOT CLAMP
89
CV BOOT - OUTER
89
REMOVAL
89
INSTALLATION
89
OUTER CV JOINT BEARING SHIELD
92
REMOVAL
92
INSTALLATION
92
HALF SHAFT - REAR
93
HALF SHAFT - REAR
93
DESCRIPTION
93
DIAGNOSIS AND TESTING - HALF SHAFT
93
VEHICLE INSPECTION
93
NOISE AND/OR VIBRATION IN TURNS
93
CLUNKING NOISE DURING ACCELERATION
93
SHUDDER OR VIBRATION DURING ACCELERATION
93
VIBRATION AT HIGHWAY SPEEDS
93
REMOVAL
94
INSTALLATION
94
SPECIFICATIONS - HALF SHAFT - FRONT
95
CV BOOT - INNER/OUTER
96
REMOVAL
96
INSTALLATION
97
CRIMP TYPE BOOT CLAMP
100
LATCHING TYPE BOOT CLAMP
100
PROPELLER SHAFT
101
PROPELLER SHAFT
101
DESCRIPTION
101
OPERATION
101
REMOVAL
102
INSTALLATION
102
SPECIFICATIONS - PROPELLER SHAFT
102
REAR DRIVELINE MODULE
103
REAR DRIVELINE MODULE
103
DESCRIPTION
103
OPERATION
103
DIAGNOSIS AND TESTING
104
DIAGNOSIS AND TESTING - REAR DRIVELINE MODULE NOISE
104
DRIVELINE MODULE ASSEMBLY NOISE
104
TIRE NOISE
105
GEAR NOISE (DRIVE PINION AND RING GEAR)
105
BEARING NOISE (DRIVE PINION AND DIFFERENTIAL)
105
ENGINE AND TRANSMISSION NOISE
105
DIAGNOSIS AND TESTING - REAR DRIVELINE MODULE OPERATION
106
REMOVAL
106
DISASSEMBLY
107
ASSEMBLY
109
INSTALLATION
113
SPECIFICATIONS - REAR DRIVELINE MODULE
114
SPECIAL TOOLS
114
BI-DIRECTIONAL OVERRUNNING CLUTCH
115
DESCRIPTION
115
OPERATION
117
STEADY STATE, LOW TO MODERATE SPEED, NO FRONT WHEEL SLIP, FORWARD DIRECTION
117
TRANSIENT CONDITION (BOC LOCKED), FRONT WHEEL SLIP, FORWARD DIRECTION
117
STEADY STATE, HIGH SPEED, NO WHEEL SLIP
118
DIFFERENTIAL ASSEMBLY
120
DESCRIPTION
120
OPERATION
120
FLUID - DIFFERENTIAL ASSEMBLY
121
STANDARD PROCEDURE - DIFFERENTIAL ASSEMBLY FLUID DRAIN AND FILL
121
FLUID
122
STANDARD PROCEDURE - OVERRUNNING CLUTCH HOUSING FLUID CHANGE
122
VISCOUS COUPLER
123
DESCRIPTION
123
OPERATION
123
TORQUE ARM
125
REMOVAL
125
INSTALLATION
125
INPUT FLANGE SEAL
125
REMOVAL
125
INSTALLATION
126
OUTPUT FLANGE SEAL
127
REMOVAL
127
INSTALLATION
128
5-BRAKES
130
BRAKES - BASE
130
BRAKES - BASE
132
DESCRIPTION
132
DESCRIPTION - BASE BRAKES
132
DESCRIPTION - BASE BRAKES (EXPORT)
132
OPERATION - BASE BRAKES
132
WARNING
133
CAUTION
133
DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM
133
RED BRAKE WARNING INDICATOR LAMP
134
BRAKE NOISE
134
OTHER BRAKE CONDITIONS
135
STANDARD PROCEDURE - BASE BRAKE BLEEDING
136
MANUAL BLEEDING PROCEDURE
137
PRESSURE BLEEDING PROCEDURE
137
SPECIFICATIONS
138
BRAKE FASTENER TORQUE
138
SPECIAL TOOLS
138
BASE BRAKE SYSTEM
138
BRAKE FLUID LEVEL SWITCH
139
DESCRIPTION
139
OPERATION
139
REMOVAL
139
INSTALLATION
139
ADJUSTABLE PEDAL SWITCH
140
DESCRIPTION
140
DIAGNOSIS AND TESTING - ADJUSTABLE PEDAL SWITCH
140
REMOVAL
140
INSTALLATION
141
PEDAL POSITION SENSOR
141
DESCRIPTION
141
DIAGNOSIS AND TESTING - PEDAL POSITION SENSOR
142
REMOVAL
142
INSTALLATION
142
HYDRAULIC/MECHANICAL
143
DESCRIPTION
143
DESCRIPTION - DISC BRAKES (FRONT)
143
DESCRIPTION - DISC BRAKES (REAR)
144
DESCRIPTION - DISC BRAKES (EXPORT)
144
DESCRIPTION - DRUM BRAKES (REAR)
145
OPERATION
145
OPERATION - DISC BRAKES (FRONT)
145
OPERATION - DISC BRAKES (REAR)
145
DIAGNOSIS AND TESTING - DRUM BRAKE AUTOMATIC ADJUSTER
145
BRAKE LINES
146
DESCRIPTION - BRAKE TUBES AND HOSES
146
OPERATION - BRAKE TUBES AND HOSES
146
INSPECTION - BRAKE TUBES AND HOSES
146
BRAKE PADS/SHOES - FRONT
146
REMOVAL
146
REMOVAL - FRONT DISC BRAKE SHOES (DISC/DISC BRAKES)
146
REMOVAL - FRONT DISC BRAKE SHOES (DISC/DRUM BRAKES)
147
CLEANING - DISC BRAKE SHOES
147
INSPECTION - DISC BRAKE SHOES
147
INSTALLATION
148
INSTALLATION - FRONT DISC BRAKE SHOES
148
INSTALLATION - FRONT DISC BRAKE SHOES (DISC/DRUM BRAKES)
148
BRAKE PADS/SHOES - REAR DISC
148
REMOVAL - REAR DISC BRAKE SHOES
148
CLEANING - DISC BRAKE SHOES
150
INSPECTION - DISC BRAKE SHOES
150
INSTALLATION - REAR DISC BRAKE SHOES
150
BRAKE PADS/SHOES - REAR DRUM
151
REMOVAL - REAR DRUM BRAKE SHOES
151
INSPECTION - REAR DRUM BRAKE SHOE LINING
154
INSTALLATION - REAR DRUM BRAKE SHOES
154
ADJUSTMENTS
155
ADJUSTMENT - REAR DRUM BRAKE SHOES
155
DISC BRAKE CALIPER - FRONT
155
REMOVAL
155
REMOVAL - FRONT DISC BRAKE CALIPER (DISC/DISC BRAKES)
155
REMOVAL - FRONT DISC BRAKE CALIPER (DISC/DRUM BRAKES)
155
DISASSEMBLY
156
DISASSEMBLY - CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES)
156
DISASSEMBLY - CALIPER PISTON AND SEAL
156
CLEANING - CALIPER
157
INSPECTION - CALIPER
157
ASSEMBLY
157
ASSEMBLY - CALIPER GUIDE PIN BUSHINGS (DISC/DISC BRAKES)
157
ASSEMBLY - CALIPER PISTON AND SEAL
157
INSTALLATION
158
INSTALLATION - FRONT DISC BRAKE CALIPER (DISC/DISC BRAKES)
158
INSTALLATION - FRONT DISC BRAKE CALIPER (DISC/DRUM BRAKES)
159
DISC BRAKE CALIPER - REAR
159
REMOVAL - REAR DISC BRAKE CALIPER
159
DISASSEMBLY - CALIPER PISTON AND SEAL
160
CLEANING - CALIPER
161
INSPECTION - CALIPER
161
ASSEMBLY - CALIPER PISTON AND SEAL
161
INSTALLATION - REAR DISC BRAKE CALIPER
162
DISC BRAKE CALIPER ADAPTER
163
REMOVAL - FRONT DISC BRAKE CALIPER ADAPTER
163
INSTALLATION - FRONT DISC BRAKE CALIPER ADAPTER
163
DISC BRAKE CALIPER GUIDE PINS
163
REMOVAL - DISC BRAKE CALIPER GUIDE PINS (DISC/DRUM BRAKES)
163
INSTALLATION - DISC BRAKE CALIPER GUIDE PINS (DISC/DRUM BRAKES)
163
DRUM
164
REMOVAL
164
INSTALLATION
164
FLUID
164
DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION
164
STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING
164
SPECIFICATIONS
164
BRAKE FLUID
164
JUNCTION BLOCK
165
DESCRIPTION - NON-ABS JUNCTION BLOCK
165
OPERATION - NON-ABS JUNCTION BLOCK
165
REMOVAL - NON-ABS JUNCTION BLOCK
165
INSTALLATION - NON-ABS JUNCTION BLOCK
165
MASTER CYLINDER
166
DESCRIPTION
166
DESCRIPTION
166
DESCRIPTION - RHD
167
OPERATION
167
STANDARD PROCEDURE - MASTER CYLINDER BLEEDING
167
REMOVAL
168
REMOVAL - LHD
168
REMOVAL - RHD
169
DISASSEMBLY - MASTER CYLINDER (FLUID RESERVOIR)
169
ASSEMBLY - MASTER CYLINDER (FLUID RESERVOIR)
170
INSTALLATION
170
INSTALLATION - LHD
170
INSTALLATION - RHD
171
PEDAL - ADJUSTABLE
171
DESCRIPTION
171
OPERATION
171
DIAGNOSIS AND TESTING - ADJUSTABLE PEDAL SYSTEM
172
REMOVAL
172
INSTALLATION
174
PEDAL TORQUE SHAFT - RHD
176
REMOVAL
176
INSTALLATION
176
POWER BRAKE BOOSTER
177
DESCRIPTION
177
OPERATION
178
DIAGNOSIS AND TESTING - POWER BRAKE BOOSTER
178
BASIC TEST
178
VACUUM LEAK TEST
178
REMOVAL
179
REMOVAL - LHD
179
REMOVAL - RHD
181
INSTALLATION
182
INSTALLATION - LHD
182
INSTALLATION - RHD
184
PROPORTIONING VALVE
185
DESCRIPTION - PROPORTIONING VALVE (HEIGHT SENSING)
185
OPERATION - PROPORTIONING VALVE (HEIGHT SENSING)
186
DIAGNOSIS AND TESTING - PROPORTIONING VALVE (HEIGHT SENSING)
186
REMOVAL - PROPORTIONING VALVE (HEIGHT SENSING)
187
INSTALLATION - PROPORTIONING VALVE (HEIGHT SENSING)
188
ROTOR
188
DIAGNOSIS AND TESTING - BRAKE ROTOR
188
BRAKING SURFACE INSPECTION
188
ROTOR MINIMUM THICKNESS
188
ROTOR THICKNESS VARIATION
188
ROTOR RUNOUT
189
STANDARD PROCEDURE - BRAKE ROTOR MACHINING
190
REMOVAL - FRONT BRAKE ROTOR
191
INSTALLATION - FRONT BRAKE ROTOR
191
SPECIFICATIONS
192
BRAKE ROTOR
192
BRAKE ROTOR - EXPORT
192
SUPPORT PLATE - DRUM BRAKE
193
REMOVAL
193
INSTALLATION
193
WHEEL CYLINDERS
194
REMOVAL
194
INSPECTION
194
INSTALLATION
194
PARKING BRAKE
194
DESCRIPTION
194
DESCRIPTION
194
DESCRIPTION - EXPORT
195
OPERATION
195
STANDARD PROCEDURE
195
STANDARD PROCEDURE - PARKING BRAKE AUTOMATIC ADJUSTER TENSION RELEASE
195
STANDARD PROCEDURE - PARKING BRAKE AUTOMATIC ADJUSTER TENSION RESET
196
CABLES - PARKING BRAKE
196
REMOVAL
196
REMOVAL - PARKING BRAKE CABLE (FRONT)
196
REMOVAL - PARKING BRAKE CABLE (INTERMEDIATE)
197
REMOVAL - PARKING BRAKE CABLE (RIGHT REAR)
198
REMOVAL - PARKING BRAKE CABLE (LEFT REAR)
199
INSTALLATION
200
INSTALLATION - PARKING BRAKE CABLE (FRONT)
200
INSTALLATION - PARKING BRAKE CABLE (INTERMEDIATE)
200
INSTALLATION - PARKING BRAKE CABLE (RIGHT REAR)
201
INSTALLATION - PARKING BRAKE CABLE (LEFT REAR)
201
ADJUSTMENTS
201
ADJUSTMENT - PARKING BRAKE CABLES
201
CABLES - PARKING BRAKE (EXPORT)
201
REMOVAL - FRONT CABLE
201
INSTALLATION - FRONT CABLE
201
LEVER - PARKING BRAKE
201
REMOVAL
201
INSTALLATION
202
LEVER - PARKING BRAKE (EXPORT)
203
REMOVAL - PARKING BRAKE LEVER AND FRONT CABLE
203
INSTALLATION - PARKING BRAKE LEVER AND FRONT CABLE
204
SHOES - PARKING BRAKE
204
REMOVAL
204
INSTALLATION
210
ADJUSTMENTS
212
ADJUSTMENT - PARKING BRAKE SHOES
212
BRAKES - ABS
214
BRAKES - ABS
214
DESCRIPTION
214
DESCRIPTION - ANTILOCK BRAKE SYSTEM
214
DESCRIPTION - ANTILOCK BRAKE SYSTEM (EXPORT)
214
DESCRIPTION - ELECTRONIC VARIABLE BRAKE PROPORTIONING
215
DESCRIPTION - TRACTION CONTROL SYSTEM
215
HYDRAULIC SHUTTLE VALVES
215
TRACTION CONTROL LAMP
215
OPERATION
215
OPERATION - ANTILOCK BRAKE SYSTEM
215
NORMAL BRAKING
215
ABS BRAKING
215
NOISE AND BRAKE PEDAL FEEL
215
TIRE NOISE AND MARKS
215
START-UP CYCLE
216
PREMATURE ABS CYCLING
216
OPERATION - ELECTRONIC VARIABLE BRAKE PROPORTIONING
216
OPERATION - TRACTION CONTROL SYSTEM
216
CAUTION
217
CAUTIONS
217
STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING
217
BLEEDING
218
SPECIFICATIONS
218
ABS FASTENER TORQUE
218
TONE WHEEL RUNOUT
218
WHEEL SPEED SENSOR AIR GAP
218
FRONT WHEEL SPEED SENSOR
218
REMOVAL
218
INSTALLATION
218
REAR WHEEL SPEED SENSOR - AWD
219
REMOVAL
219
INSTALLATION
219
REAR WHEEL SPEED SENSOR - FWD
220
REMOVAL
220
INSTALLATION
220
TONE WHEEL
221
INSPECTION - TONE WHEEL
221
TRACTION CONTROL SWITCH
221
DIAGNOSIS AND TESTING - TRACTION CONTROL SWITCH
221
HYDRAULIC/MECHANICAL
222
OPERATION - HYDRAULIC CIRCUITS AND VALVES
222
NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION
222
ABS PRIMARY HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL)
223
ABS SECONDARY HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL)
224
HCU (HYDRAULIC CONTROL UNIT)
228
DESCRIPTION
228
OPERATION
228
VALVES AND SOLENOIDS
228
BRAKE FLUID ACCUMULATORS
228
PUMP/MOTOR
228
ICU (INTEGRATED CONTROL UNIT)
229
DESCRIPTION
229
OPERATION
229
REMOVAL
229
REMOVAL - LHD
229
REMOVAL - RHD
230
DISASSEMBLY - ICU
232
ASSEMBLY - ICU
232
INSTALLATION
233
INSTALLATION - LHD
233
INSTALLATION - RHD
234
6-CLUTCH
236
CLUTCH
236
DESCRIPTION
236
CLUTCH COMPONENTS
236
RELEASE SYSTEM
237
DIAGNOSIS AND TESTING
238
DIAGNOSIS AND TESTING - CLUTCH SYSTEM
238
DIAGNOSIS AND TESTING - DRIVE PLATE MISALIGNMENT
240
DIAGNOSIS AND TESTING - CLUTCH COVER AND DISC RUNOUT
241
DIAGNOSIS AND TESTING - CLUTCH CHATTER COMPLAINTS
241
SPECIAL TOOLS - T850 TRANSAXLE
241
CLUTCH RELEASE LEVER AND BEARING
241
REMOVAL
241
INSTALLATION
242
MASTER CYLINDER - RHD
243
REMOVAL
243
INSTALLATION
243
MASTER CYLINDER - LHD
244
REMOVAL
244
INSTALLATION
245
MODULAR CLUTCH ASSY - 2.4L GAS
246
REMOVAL
246
INSTALLATION
246
SLAVE CYLINDER
246
REMOVAL
246
INSTALLATION
246
CLUTCH DISC AND PRESSURE PLATE - 2.5L TD
247
REMOVAL
247
INSTALLATION
247
FLYWHEEL
248
REMOVAL
248
INSTALLATION
248
7-COOLING
250
COOLING
250
DESCRIPTION
250
DESCRIPTION - COOLING SYSTEM
250
DESCRIPTION - HOSE CLAMPS
250
OPERATION
251
OPERATION - COOLING SYSTEM
251
OPERATION - HOSE CLAMPS
251
DIAGNOSIS AND TESTING
251
DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TEST
251
DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK
252
PREFERRED METHOD
252
ALTERNATIVE METHOD
252
DIAGNOSIS AND TESTING - COOLING SYSTEM AERATION
253
DIAGNOSIS AND TESTING - COOLING SYSTEM DEAERATION
253
STANDARD PROCEDURE
253
STANDARD PROCEDURE - COOLING SYSTEM DRAINING
253
STANDARD PROCEDURE - COOLING SYSTEM FILLING
253
STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT
253
STANDARD PROCEDURE - COOLANT LEVEL CHECK
254
SPECIFICATIONS
255
COOLING SYSTEM CAPACITY
255
ACCESSORY DRIVE BELT TENSION
255
TORQUE
255
SPECIAL TOOLS
256
COOLING SYSTEM
256
ACCESSORY DRIVE
257
BELT TENSIONER - 2.4L
257
REMOVAL
257
INSTALLATION
257
BELT TENSIONER - 3.3/3.8L
257
REMOVAL
257
INSTALLATION
257
DRIVE BELTS
258
DESCRIPTION
258
OPERATION
258
DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT
258
DRIVE BELTS - 2.4L
259
STANDARD PROCEDURE - CHECKING POWER STEERING BELT TENSION
259
REMOVAL
259
GENERATOR AND AIR CONDITIONING BELT
259
POWER STEERING PUMP
259
CLEANING
260
INSPECTION
260
INSTALLATION
260
GENERATOR AND AIR CONDITIONING BELT
260
POWER STEERING PUMP
261
ADJUSTMENTS
261
DRIVE BELTS - 3.3/3.8L
261
REMOVAL
261
CLEANING
262
INSPECTION
262
INSTALLATION
262
ENGINE
263
ENGINE
264
DIAGNOSIS AND TESTING - ENGINE COOLING SYSTEM
264
DRIVING TECHNIQUES
264
TRAILER TOWING
264
VISUAL INSPECTION
264
CLEANING
268
INSPECTION
268
COOLANT
268
DIAGNOSIS AND TESTING - COOLANT CONCENTRATION TESTING
268
STANDARD PROCEDURE - COOLANT SERVICE
269
COOLANT RECOVERY CONTAINER
269
DESCRIPTION
269
OPERATION
269
DIAGNOSIS AND TESTING - COOLANT RECOVERY SYSTEM
269
REMOVAL
269
INSTALLATION
269
ENGINE BLOCK HEATER
270
DESCRIPTION
270
OPERATION
270
DIAGNOSIS AND TESTING - ENGINE BLOCK HEATER TESTING
270
REMOVAL
270
INSTALLATION
270
ENGINE COOLANT TEMPERATURE SENSOR - 2.4L
270
DESCRIPTION
270
REMOVAL
270
INSTALLATION
270
ENGINE COOLANT TEMPERATURE SENSOR - 3.3/3.8L
271
DESCRIPTION
271
REMOVAL
271
INSTALLATION
271
ENGINE COOLANT THERMOSTAT
272
DESCRIPTION
272
OPERATION
272
DIAGNOSIS AND TESTING - ENGINE COOLANT THERMOSTAT
272
ENGINE COOLANT THERMOSTAT - 2.4L
272
REMOVAL
272
INSTALLATION
272
ENGINE COOLANT THERMOSTAT - 3.3/3.8L
273
REMOVAL
273
INSTALLATION
273
RADIATOR
274
DESCRIPTION
274
OPERATION
274
REMOVAL
274
INSTALLATION
275
RADIATOR DRAINCOCK
276
REMOVAL
276
INSTALLATION
276
RADIATOR PRESSURE CAP
276
DESCRIPTION
276
OPERATION
276
DIAGNOSIS AND TESTING
277
DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP TESTING
277
DIAGNOSIS AND TESTING - RADIATOR CAP TO FILLER NECK SEAL
277
CLEANING
278
INSPECTION
278
RADIATOR FAN
278
DESCRIPTION
278
OPERATION
278
DIAGNOSIS AND TESTING - RADIATOR FAN MOTOR
279
REMOVAL
279
INSTALLATION
279
RADIATOR FAN RELAY
280
DESCRIPTION
280
OPERATION
280
REMOVAL
280
INSTALLATION
280
WATER PUMP - 2.4L
281
DESCRIPTION
281
OPERATION
281
REMOVAL
281
CLEANING
281
INSPECTION
281
INSTALLATION
281
WATER PUMP - 3.3/3.8L
283
DESCRIPTION
283
OPERATION
283
REMOVAL
283
CLEANING
284
INSPECTION
284
INSTALLATION
284
WATER PUMP INLET TUBE - 2.4L
285
DESCRIPTION
285
REMOVAL
285
INSTALLATION
285
WATER PUMP INLET TUBE - 3.3/3.8L
285
REMOVAL
285
INSTALLATION
285
TRANSMISSION
287
TRANSMISSION
287
STANDARD PROCEDURE - FLUSHING COOLERS AND TUBES
287
TRANSMISSION OIL COOLER
287
DESCRIPTION
287
REMOVAL
287
CLEANING
288
INSPECTION
288
INSTALLATION
288
TRANSMISSION OIL COOLER LINES
288
REMOVAL
288
INSTALLATION
289
7a-COOLING 2.5L TURBO DIESEL
290
COOLING 2.5L TURBO DIESEL
290
DESCRIPTION - COOLING SYSTEM
290
COOLING SYSTEM COMPONENTS
290
DIAGNOSIS AND TESTING
290
DIAGNOSIS AND TESTING - COOLING SYSTEM
290
DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TEST
295
DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK
296
DIAGNOSIS AND TESTING - COOLING SYSTEM AERATION
296
CLEANING
296
INSPECTION
296
SPECIFICATIONS
297
SPECIFICATIONS - TORQUE
297
SPECIFICATIONS - COOLING SYSTEM CAPACITY
297
ACCESSORY DRIVE
298
ACCESSORY DRIVE
298
SPECIFICATIONS - ACCESSORY BELT TENSION
298
BELT TENSIONER
298
REMOVAL
298
INSTALLATION
298
IDLER PULLEY
299
REMOVAL
299
INSTALLATION
299
DRIVE BELTS
299
DESCRIPTION
299
DESCRIPTION - ACCESSORY DRIVE BELT
299
DESCRIPTION - POWER STEERING BELT
299
OPERATION
299
OPERATION-ACCESSORY DRIVE BELT
299
OPERATION-POWER STEERING BELT
299
DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT
300
REMOVAL
300
REMOVAL-ACCESSORY DRIVE BELT
300
REMOVAL
300
INSTALLATION
302
INSTALLATION-ACCESSORY DRIVE BELT
302
INSTALLATION-POWER STEERING BELT
302
ENGINE
303
COOLANT
304
DESCRIPTION
304
DIAGNOSIS AND TESTING - COOLANT CONCENTRATION TESTING
304
STANDARD PROCEDURE
305
STANDARD PROCEDURE - COOLANT SERVICE
305
STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT
305
STANDARD PROCEDURE - COOLANT LEVEL CHECK
305
STANDARD PROCEDURE - COOLING SYSTEM FILLING
305
STANDARD PROCEDURE - COOLING SYSTEM DRAINING
306
COOLANT RECOVERY PRESS CONTAINER
306
DESCRIPTION
306
OPERATION
306
REMOVAL
307
INSTALLATION
307
ENGINE COOLANT TEMP SENSOR
308
DESCRIPTION
308
OPERATION
308
REMOVAL
308
INSTALLATION
308
ENGINE COOLANT THERMOSTAT
309
DESCRIPTION
309
OPERATION
309
REMOVAL
309
INSTALLATION
309
RADIATOR
310
DESCRIPTION
310
OPERATION
310
REMOVAL
310
INSTALLATION
311
RADIATOR DRAINCOCK
311
REMOVAL
311
INSTALLATION
311
WATER PUMP
312
DESCRIPTION
312
OPERATION
312
REMOVAL
312
REMOVAL - WATER PUMP
312
REMOVAL - WATER PUMP HOUSING
312
CLEANING
312
INSTALLATION
312
INSTALLATION - WATER PUMP
312
INSTALLATION - WATER PUMP HOUSING
313
RADIATOR PRESSURE CAP
314
DESCRIPTION
314
OPERATION
314
DIAGNOSIS AND TESTING
314
DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP
314
DIAGNOSIS AND TESTING - PRESSURE RELIEF TEST
315
CLEANING
315
INSPECTION
315
RADIATOR FAN
315
DESCRIPTION
315
OPERATION
316
DIAGNOSIS AND TESTING - RADIATOR FAN MOTOR
316
REMOVAL
317
INSTALLATION
317
HOSE CLAMPS
317
DESCRIPTION - HOSE CLAMPS
317
OPERATION - HOSE CLAMPS
317
RADIATOR FAN RELAY
318
DESCRIPTION
318
OPERATION
318
COOLANT SYSTEM HOSES
318
REMOVAL
318
REMOVAL - UPPER RADIATOR HOSE
318
REMOVAL - LOWER RADIATOR HOSE
318
REMOVAL - COOLANT BYPASS HOSE
319
INSTALLATION
319
INSTALLATION - UPPER RADIATOR HOSE
319
INSTALLATION - LOWER RADIATOR HOSE
319
INSTALLATION - COOLANT BYPASS HOSE
319
8a-AUDIO
320
AUDIO
320
DESCRIPTION
320
OPERATION
320
DIAGNOSIS AND TESTING - AUDIO
320
ANTENNA BODY AND CABLE
323
DESCRIPTION
323
OPERATION
323
DIAGNOSIS AND TESTING - ANTENNA BODY AND CABLE
323
TEST 1
323
TEST 2
323
TEST 3
323
REMOVAL
323
INSTALLATION
324
ANTENNA MODULE - EXPORT
325
DESCRIPTION
325
OPERATION
325
DIAGNOSIS AND TESTING - ANTENNA MODULE - EXPORT
325
REMOVAL
326
INSTALLATION
326
CD CHANGER
326
DESCRIPTION
326
OPERATION
326
REMOVAL
326
INSTALLATION
326
INSTRUMENT PANEL ANTENNA CABLE
327
REMOVAL
327
INSTALLATION
327
QUARTER GLASS INTEGRAL ANTENNA - EXPORT
327
DESCRIPTION
327
OPERATION
327
DIAGNOSIS AND TESTING - QUARTER GLASS INTEGRAL ANTENNA - EXPORT
327
RADIO
328
DIAGNOSIS AND TESTING - RADIO
328
REMOVAL
328
INSTALLATION
329
RADIO NOISE SUPPRESSION COMPONENTS
329
DESCRIPTION
329
OPERATION
329
REMOTE SWITCHES
330
DESCRIPTION
330
OPERATION
330
DIAGNOSIS AND TESTING - REMOTE SWITCHES
330
REMOVAL
331
INSTALLATION
331
SPEAKER
331
DIAGNOSIS AND TESTING - SPEAKER
331
REMOVAL
332
D-PILLAR SPEAKER
332
FRONT DOOR SPEAKER
332
INSTRUMENT PANEL SPEAKER
333
QUARTER PANEL SPEAKER
333
INSTALLATION
333
D-PILLAR SPEAKER
333
FRONT DOOR SPEAKER
333
INSTRUMENT PANEL SPEAKER
333
QUARTER PANEL SPEAKER
333
8b-CHIME/BUZZER
334
CHIME/BUZZER
334
DESCRIPTION
334
HIGH SPEED WARNING - EXPORT
334
OPERATION
334
HIGH SPEED WARNING - EXPORT
334
WARNING
334
DIAGNOSIS AND TESTING
334
DIAGNOSIS AND TESTING - CHIME SYSTEM
334
NO TONE WHEN IGNITION SWITCH IS TURNED ON AND DRIVER'S SEAT BELT IS NOT BUCKLED.
334
NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS TURNED ON.
335
NO TONE WHEN PARK OR HEADLAMPS ARE ON AND DRIVER'S DOOR IS OPEN.
335
DIAGNOSIS AND TESTING - DOME LAMP ON CHIME
335
DIAGNOSIS AND TESTING - ENGINE TEMPERATURE CRITICAL CHIME
335
DIAGNOSIS AND TESTING - EXTERIOR LAMPS ON CHIME
335
DIAGNOSIS AND TESTING - KEY-IN IGNITION CHIME
335
DIAGNOSIS AND TESTING - LOW OIL PRESSURE CHIME
336
DIAGNOSIS AND TESTING - SEAT BELT CHIME
336
DIAGNOSIS AND TESTING - SEAT BELT LAMP
336
DIAGNOSIS AND TESTING - TIRE PRESSURE MONITOR
336
DIAGNOSIS AND TESTING - TURN SIGNAL ON CHIME
336
DIAGNOSIS AND TESTING - WARNING LAMP ANNOUNCEMENT CHIME
337
8e-ELECTRONIC CONTROL MODULES
338
ELECTRONIC CONTROL MODULES
339
STANDARD PROCEDURE - PCM/SKIM PROGRAMMING
339
PROGRAMMING THE PCM (SBEC)
339
PROGRAMMING THE SKIM
339
PROGRAMMING IGNITION KEYS TO THE SKIM
339
ADJUSTABLE PEDAL MODULE
340
DIAGNOSIS AND TESTING - ADJUSTABLE PEDAL MODULE
340
REMOVAL
340
INSTALLATION
340
BODY CONTROL MODULE
340
DESCRIPTION
340
OPERATION
340
REMOVAL
342
INSTALLATION
342
CONTROLLER ANTILOCK BRAKE
342
DESCRIPTION
342
OPERATION
342
CAB INPUTS
343
CAB OUTPUTS
343
REMOVAL
343
INSTALLATION
343
DATA LINK CONNECTOR
344
DESCRIPTION
344
OPERATION
344
FRONT CONTROL MODULE
344
DESCRIPTION
344
OPERATION
344
DIAGNOSIS AND TESTING - FRONT CONTROL MODULE
345
REMOVAL
345
INSTALLATION
345
HEATED SEAT MODULE
346
DESCRIPTION
346
OPERATION
346
DIAGNOSIS AND TESTING - HEATED SEAT MODULE
346
REMOVAL
347
INSTALLATION
347
POWER LIFTGATE MODULE
347
DESCRIPTION
347
OPERATION
347
REMOVAL
347
INSTALLATION
348
POWERTRAIN CONTROL MODULE
348
DESCRIPTION
348
DESCRIPTION
348
DIAGNOSTIC TROUBLE CODE
350
DESCRIPTION
350
OPERATION - SENSOR RETURN - PCM INPUT
362
OPERATION - SCI RECEIVE - PCM INPUT
362
OPERATION - IGNITION SENSE - PCM INPUT
362
OPERATION - PCM GROUND
362
OPERATION
362
OPERATION - 8-VOLT SUPPLY - PCM OUTPUT
362
OPERATION - 5 VOLT SUPPLY - PCM OUTPUT
362
STANDARD PROCEDURE - OBTAINING DIAGNOSTIC TROUBLE CODES
362
BULB CHECK
362
OBTAINING DTC'S USING DRB SCAN TOOL
362
OBTAINING DTC'S USING IGNITION KEY
363
REMOVAL
363
INSTALLATION
363
SENTRY KEY IMMOBILIZER MODULE
363
DESCRIPTION
363
OPERATION
364
REMOVAL
364
INSTALLATION
364
TRANSMISSION CONTROL MODULE
365
DESCRIPTION
365
OPERATION
365
CLUTCH VOLUME INDEX (CVI)
366
SHIFT SCHEDULES
367
STANDARD PROCEDURE
368
STANDARD PROCEDURE - PINION FACTOR SETTING
368
STANDARD PROCEDURE - QUICK LEARN PROCEDURE
368
REMOVAL
368
INSTALLATION
369
MEMORY SEAT/MIRROR MODULE
370
DESCRIPTION
370
OPERATION
370
DIAGNOSIS AND TESTING - MEMORY SEAT/MIRROR MODULE
370
REMOVAL
370
INSTALLATION
370
SLIDING DOOR CONTROL MODULE
370
DESCRIPTION
370
OPERATION
371
REMOVAL
371
INSTALLATION
371
8ea-ELECTRONIC CONTROL MODULES
372
ENGINE CONTROL MODULE
372
DESCRIPTION
372
OPERATION
372
ECM OPERATING MODES
372
MONITORED CIRCUITS
373
DIAGNOSTIC TROUBLE CODES
373
STANDARD PROCEDURE - PCM/ECM/SKIM PROGRAMMING - DIESEL
373
PCM/SKIM PROGRAMMING
374
ECM/SKIM PROGRAMMING
374
PROGRAMMING THE ECM (Bosch)
374
PROGRAMMING THE PCM (JTEC)
374
PROGRAMMING THE SKIM
374
PROGRAMMING IGNITION KEYS TO THE SKIM
374
REMOVAL
375
INSTALLATION
375
8f-ENGINE SYSTEMS
376
BATTERY SYSTEM
376
BATTERY SYSTEM
376
DESCRIPTION
376
OPERATION
377
DIAGNOSIS AND TESTING - BATTERY SYSTEM
377
MICRO 420 ELECTRICAL SYSTEM TESTER
377
ABNORMAL BATTERY DISCHARGING
379
CLEANING
380
INSPECTION
380
SPECIFICATIONS
381
SPECIAL TOOLS
382
BATTERY SYSTEM SPECIAL TOOLS
382
BATTERY
382
DESCRIPTION
382
SPIRAL PLATE BATTERY - DIESEL ENGINE
382
CONVENTIONAL BATTERY - GASOLINE ENGINE
383
OPERATION
384
DIAGNOSIS AND TESTING - BATTERY
384
MICRO 420 ELECTRICAL SYSTEM TESTER
384
STANDARD PROCEDURE
385
STANDARD PROCEDURE - SPIRAL PLATE BATTERY CHARGING
385
CHARGING A COMPLETELY DISCHARGED BATTERY – SPIRAL PLATE BATTERY
385
CHARGING TIME REQUIRED
386
STANDARD PROCEDURE - CONVENTIONAL BATTERY CHARGING
386
CHARGING A COMPLETELY DISCHARGED BATTERY
387
CHARGING TIME REQUIRED
387
STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST
388
STANDARD PROCEDURE - IGNITION-OFF DRAW TEST
388
STANDARD PROCEDURE - CHECKING BATTERY ELECTROLYTE LEVEL
389
REMOVAL - BATTERY
389
INSTALLATION
390
BATTERY HOLDDOWN
390
DESCRIPTION
390
OPERATION
390
REMOVAL
390
INSTALLATION
391
BATTERY CABLES
391
DESCRIPTION
391
OPERATION
391
DIAGNOSIS AND TESTING - BATTERY CABLE
391
VOLTAGE DROP TEST
392
REMOVAL
393
INSTALLATION
393
BATTERY TRAY
393
DESCRIPTION
393
OPERATION
394
REMOVAL
394
INSTALLATION
394
THERMOWRAP
394
DESCRIPTION
394
OPERATION
395
REMOVAL
395
INSTALLATION
395
CHARGING
396
CHARGING
396
DESCRIPTION - CHARGING SYSTEM
396
OPERATION - CHARGING SYSTEM
396
DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTIC SYSTEM
397
SPECIFICATIONS
398
GENERATOR
398
TORQUE
398
SPECIAL TOOLS
398
BATTERY TEMPERATURE SENSOR
399
DESCRIPTION
399
OPERATION
399
REMOVAL
399
GENERATOR
399
DESCRIPTION
399
OPERATION
399
REMOVAL
399
REMOVAL - 2.4L
399
REMOVAL - 3.3/3.8L
399
INSTALLATION
400
INSTALLATION - 2.4L
400
INSTALLATION - 3.3/3.8L
400
GENERATOR DECOUPLER PULLEY
400
DESCRIPTION
400
OPERATION
401
DIAGNOSIS AND TESTING - GENERATOR DECOUPLER PULLEY
401
REMOVAL
401
INSTALLATION
401
VOLTAGE REGULATOR
402
DESCRIPTION
402
OPERATION
402
STARTING
403
STARTING
403
DESCRIPTION
403
OPERATION
403
DIAGNOSIS AND TESTING
403
DIAGNOSIS AND TESTING - STARTING SYSTEM TEST
403
INSPECTION
403
DIAGNOSIS AND TESTING - CONTROL CIRCUIT TEST
406
STARTER SOLENOID
406
STARTER RELAY
406
RELAY TEST
406
RELAY CIRCUIT TEST
407
SAFETY SWITCHES
408
IGNITION SWITCH
408
BATTERY
408
ALL RELATED WIRING AND CONNECTORS
408
DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST
408
DIAGNOSIS AND TESTING - FEED CIRCUIT TEST
408
SPECIFICATIONS
409
STARTER
409
Torques
409
STARTER MOTOR
410
REMOVAL
410
REMOVAL - 2.4L
410
REMOVAL - 3.3/3.8L
411
INSTALLATION
411
INSTALLATION - 2.4L
411
INSTALLATION - 3.3/3.8L
411
8fa-ENGINE SYSTEMS
412
BATTERY SYSTEM
412
BATTERY SYSTEM
412
DESCRIPTION
412
OPERATION
413
DIAGNOSIS AND TESTING - BATTERY SYSTEM
413
MICRO 420 ELECTRICAL SYSTEM TESTER
413
ABNORMAL BATTERY DISCHARGING
416
CLEANING
416
INSPECTION
417
SPECIFICATIONS
417
SPECIAL TOOLS
418
BATTERY SYSTEM SPECIAL TOOLS
418
BATTERY
418
DESCRIPTION
418
SPIRAL PLATE BATTERY - DIESEL ENGINE
418
CONVENTIONAL BATTERY - GASOLINE ENGINE
419
OPERATION
420
DIAGNOSIS AND TESTING - BATTERY
420
MICRO 420 ELECTRICAL SYSTEM TESTER
420
STANDARD PROCEDURE
421
STANDARD PROCEDURE - SPIRAL PLATE BATTERY CHARGING
421
CHARGING A COMPLETELY DISCHARGED BATTERY – SPIRAL PLATE BATTERY
421
CHARGING TIME REQUIRED
422
STANDARD PROCEDURE - CONVENTIONAL BATTERY CHARGING
422
CHARGING A COMPLETELY DISCHARGED BATTERY
423
CHARGING TIME REQUIRED
423
STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST
424
STANDARD PROCEDURE - IGNITION-OFF DRAW TEST
424
STANDARD PROCEDURE - CHECKING BATTERY ELECTROLYTE LEVEL
425
REMOVAL - BATTERY
426
INSTALLATION
426
BATTERY HOLDDOWN
426
DESCRIPTION
426
OPERATION
426
REMOVAL
427
INSTALLATION
427
BATTERY CABLES
427
DESCRIPTION
427
OPERATION
427
DIAGNOSIS AND TESTING - BATTERY CABLE
427
VOLTAGE DROP TEST
428
REMOVAL
429
INSTALLATION
429
BATTERY TRAY
429
DESCRIPTION
429
OPERATION
430
REMOVAL
430
INSTALLATION
430
THERMOWRAP
430
DESCRIPTION
430
OPERATION
430
REMOVAL
430
INSTALLATION
430
CHARGING
431
CHARGING
431
DESCRIPTION - CHARGING SYSTEM
431
OPERATION - CHARGING SYSTEM
431
DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTIC SYSTEM
432
SPECIFICATIONS
433
GENERATOR
433
TORQUE
433
SPECIAL TOOLS
433
BATTERY TEMPERATURE SENSOR
434
DESCRIPTION
434
OPERATION
434
REMOVAL
434
GENERATOR
434
DESCRIPTION
434
OPERATION
434
REMOVAL
434
REMOVAL - 2.4L
434
REMOVAL - 2.5L
435
REMOVAL - 3.3/3.8L
436
REMOVAL - 3.5L
437
INSTALLATION
438
INSTALLATION - 2.4L
438
INSTALLATION - 2.5L
439
INSTALLATION - 3.3/3.8L
439
INSTALLATION - 3.5L
439
GENERATOR DECOUPLER PULLEY
439
DESCRIPTION
439
OPERATION
439
DIAGNOSIS AND TESTING - GENERATOR DECOUPLER PULLEY
440
REMOVAL
440
INSTALLATION
441
VOLTAGE REGULATOR
441
DESCRIPTION
441
OPERATION
441
STARTING
442
STARTING
442
DESCRIPTION
442
OPERATION
442
DIAGNOSIS AND TESTING
442
DIAGNOSIS AND TESTING - STARTING SYSTEM TEST
442
INSPECTION
443
DIAGNOSIS AND TESTING - CONTROL CIRCUIT TEST
445
STARTER SOLENOID
445
STARTER RELAY
445
RELAY TEST
445
RELAY CIRCUIT TEST
446
SAFETY SWITCHES
447
IGNITION SWITCH
447
BATTERY
447
ALL RELATED WIRING AND CONNECTORS
447
DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST
447
DIAGNOSIS AND TESTING - FEED CIRCUIT TEST
447
SPECIFICATIONS
448
STARTER
448
Torques
448
STARTER MOTOR
449
REMOVAL
449
REMOVAL - 2.4L
449
REMOVAL - 3.3/3.8L
450
REMOVAL - 3.5L
450
REMOVAL - 2.5L
451
INSTALLATION
452
INSTALLATION - 2.4L
452
INSTALLATION - 3.3/3.8L
452
INSTALLATION - 3.5L
452
INSTALLATION - 2.5L
452
8g-HEATED SYSTEMS
454
HEATED GLASS
454
HEATED GLASS
454
DESCRIPTION
454
OPERATION
455
DEFOGGER RELAY
455
DESCRIPTION
455
REAR WINDOW DEFOGGER GRID
455
STANDARD PROCEDURE - GRID LINE REPAIR REAR
455
REAR WINDOW DEFOGGER SWITCH
455
DESCRIPTION
455
OPERATION
455
WINDSHIELD GRID
456
DIAGNOSIS AND TESTING - SYSTEM TEST
456
STANDARD PROCEDURE - GRID LINE AND TERMINAL REPAIR
456
HEATED MIRRORS
458
HEATED MIRRORS
458
DESCRIPTION
458
OPERATION
458
DIAGNOSIS AND TESTING - HEATED MIRROR TEST
458
MIRROR SWITCH
458
DESCRIPTION
458
OPERATION
459
HEATED MIRROR GRID
459
STANDARD PROCEDURE - HEATED MIRROR
459
RELAY
459
DESCRIPTION
459
HEATED SEAT SYSTEM
460
HEATED SEAT SYSTEM
460
DESCRIPTION
460
OPERATION
461
DIAGNOSIS AND TESTING - HEATED SEAT SYSTEM
461
DRIVER HEATED SEAT SWITCH
462
DESCRIPTION
462
OPERATION
462
DIAGNOSIS AND TESTING - DRIVER HEATED SEAT SWITCH
462
CHECKING SWITCH SIGNAL AND WIRING AT THE MODULE
462
CHECKING SWITCH ONLY
463
REMOVAL
463
INSTALLATION
463
HEATED SEAT ELEMENT
464
DESCRIPTION
464
OPERATION
464
DIAGNOSIS AND TESTING - HEATED SEAT ELEMENTS
464
SEAT CUSHION ELEMENT
464
SEAT BACK ELEMENT
464
REMOVAL
465
INSTALLATION
465
HEATED SEAT SENSOR
465
DESCRIPTION
465
OPERATION
465
DIAGNOSIS AND TESTING - HEATED SEAT SENSOR
465
PASSENGER HEATED SEAT SWITCH
466
DESCRIPTION
466
OPERATION
466
DIAGNOSIS AND TESTING - PASSENGER HEATED SEAT SWITCH
466
CHECKING SWITCH SIGNAL AND WIRING AT THE MODULE
466
CHECKING SWITCH ONLY
467
REMOVAL
467
INSTALLATION
468
8h-HORN
470
HORN SYSTEM
470
DESCRIPTION
470
OPERATION
470
DIAGNOSIS AND TESTING - HORN SYSTEM
470
HORN
472
DIAGNOSIS AND TESTING - HORN
472
HORN
472
HORNS SOUND CONTINUOUSLY
472
HORNS WILL NOT SOUND
472
FUSE BLOWN
473
FUSE OK
473
REMOVAL
473
INSTALLATION
473
HORN RELAY
474
DIAGNOSIS AND TESTING - HORN RELAY
474
REMOVAL
474
INSTALLATION
474
HORN SWITCH
474
DESCRIPTION
474
8i-IGNITION CONTROL
476
IGNITION CONTROL
476
DESCRIPTION - IGNITION SYSTEM
476
OPERATION - IGNITION SYSTEM
476
SPECIFICATIONS
477
TORQUE
477
SPARK PLUG CABLE RESISTANCE
477
SPARK PLUG
477
FIRING ORDER
478
AUTO SHUT DOWN RELAY
478
DESCRIPTION
478
OPERATION
478
CAMSHAFT POSITION SENSOR
478
DESCRIPTION
478
OPERATION
479
REMOVAL
479
REMOVAL - 2.4L
479
REMOVAL - 3.3/3.8L
479
INSTALLATION
481
INSTALLATION - 2.4L
481
INSTALLATION - 3.3/3.8L
481
IGNITION COIL
481
DESCRIPTION
481
OPERATION
481
REMOVAL
482
REMOVAL - 2.4L
482
REMOVAL - 3.3/3.8L
482
INSTALLATION
482
INSTALLATION - 2.4L
482
INSTALLATION - 3.3/3.8L
483
KNOCK SENSOR
483
DESCRIPTION
483
OPERATION
483
REMOVAL
483
REMOVAL - 2.4L
483
REMOVAL - 3.8L
483
INSTALLATION
483
INSTALLATION - 2.4L
483
INSTALLATION - 3.8L
483
SPARK PLUG
484
DESCRIPTION
484
DESCRIPTION - STANDARD 4 CYLINDER
484
DESCRIPTION - PLATINUM PLUGS
484
REMOVAL
484
INSTALLATION
485
SPARK PLUG CABLE
485
DESCRIPTION
485
REMOVAL
485
INSTALLATION
485
8ia-IGNITION CONTROL
486
GLOW PLUG
486
DESCRIPTION
486
OPERATION
486
GLOW PLUG RELAY
486
DESCRIPTION
486
OPERATION
486
CAMSHAFT POSITION SENSOR
487
DESCRIPTION
487
OPERATION
487
REMOVAL
487
INSTALLATION
487
8j-INSTRUMENT CLUSTER
488
INSTRUMENT CLUSTER
488
DESCRIPTION
488
WATER IN FUEL LAMP - EXPORT
488
OPERATION
488
WATER IN FUEL LAMP - EXPORT
488
DIAGNOSIS AND TESTING
489
DIAGNOSIS AND TESTING - SELF-DIAGNOSTICS
489
CALIBRATION TEST
489
ODOMETER SEGMENT TEST
489
ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST
489
DIAGNOSIS AND TESTING - CLUSTER DIAGNOSIS
489
CONDITIONS
489
REMOVAL
498
WITH ELECTRONIC TRANSMISSION RANGE INDICATOR
498
WITH MECHANICAL TRANSMISSION RANGE INDICATOR
498
INSTALLATION
499
WITH ELECTRONIC TRANSMISSION RANGE INDICATOR
499
WITH MECHANICAL TRANSMISSION RANGE INDICATOR
499
CLUSTER LENS
499
REMOVAL
499
INSTALLATION
499
MECHANICAL TRANSMISSION RANGE INDICATOR
499
REMOVAL
499
INSTALLATION
499
RED BRAKE WARNING INDICATOR
500
DESCRIPTION
500
OPERATION
500
8l-LAMPS
502
LAMPS/LIGHTING - EXTERIOR
502
LAMPS/LIGHTING - EXTERIOR
503
DESCRIPTION
503
LAMP SYSTEMS
503
AUTOMATIC HEADLAMP SYSTEM
503
DAYTIME RUNNING LAMPS
503
HEADLAMPS ON WITH WINDSHIELD WIPERS
503
HEADLAMP SYSTEM
503
HEADLAMP TIME DELAY SYSTEM
503
OPERATION
504
AUTOMATIC HEADLAMP SYSTEM
504
DAYTIME RUNNING LAMPS
504
HEADLAMP SYSTEM
504
HEADLAMP TIME DELAY SYSTEM
504
OPTICAL HORN/HIGH BEAMS
504
WARNING
504
SPECIFICATIONS
505
EXTERIOR LAMPS
505
BRAKE LAMP SWITCH
505
DESCRIPTION
505
OPERATION
505
DIAGNOSIS AND TESTING - BRAKE LAMP SWITCH
505
REMOVAL
506
INSTALLATION
507
CENTER HIGH MOUNTED STOP LAMP
507
REMOVAL
507
INSTALLATION
507
CENTER HIGH MOUNTED STOP LAMP UNIT
507
REMOVAL
507
INSTALLATION
507
FOG LAMP
508
DIAGNOSIS AND TESTING - FOG LAMP
508
REMOVAL
510
INSTALLATION
510
FOG LAMP - EXPORT
510
REMOVAL
510
INSTALLATION
510
FOG LAMP UNIT
511
STANDARD PROCEDURE
511
STANDARD PROCEDURE - FOG LAMP UNIT ALIGNMENT
511
FOG LAMP UNIT ALIGNMENT
511
STANDARD PROCEDURE - FOG LAMP UNIT ALIGNMENT - EXPORT
511
REMOVAL
512
INSTALLATION
512
FRONT POSITION LAMP - EXPORT
512
REMOVAL
512
INSTALLATION
512
HEADLAMP
513
DIAGNOSIS AND TESTING - HEADLAMP
513
REMOVAL
515
INSTALLATION
515
HEADLAMP - EXPORT
515
REMOVAL
515
INSTALLATION
515
HEADLAMP LEVELING MOTOR - EXPORT
516
DIAGNOSIS AND TESTING - HEADLAMP LEVELING MOTOR - EXPORT
516
REMOVAL
516
INSTALLATION
516
HEADLAMP LEVELING SWITCH - EXPORT
517
DESCRIPTION
517
DIAGNOSIS AND TESTING - HEADLAMP LEVELING SWITCH - EXPORT
517
HEADLAMP SWITCH
517
DIAGNOSIS AND TESTING
517
DIAGNOSIS AND TESTING - HEADLAMP SWITCH
517
DIAGNOSIS AND TESTING - HEADLAMP SWITCH - EXPORT
518
REMOVAL
518
INSTALLATION
518
HEADLAMP UNIT
518
STANDARD PROCEDURE
518
STANDARD PROCEDURE - HEADLAMP UNIT ALIGNMENT
518
HEADLAMP UNIT ALIGNMENT PREPARATION
518
ALIGNMENT SCREEN PREPARATION
519
HEADLAMP ADJUSTMENT
520
STANDARD PROCEDURE - HEADLAMP UNIT ALIGNMENT - EXPORT
520
HEADLAMP UNIT ALIGNMENT PREPARATION
520
ALIGNMENT SCREEN PREPARATION
520
HEADLAMP UNIT ADJUSTMENT
520
REMOVAL
520
INSTALLATION
521
LICENSE LAMP
522
REMOVAL
522
INSTALLATION
522
MULTI-FUNCTION SWITCH
522
DESCRIPTION - TURN SIGNAL SYSTEM
522
OPERATION - TURN SIGNAL SYSTEM
522
DIAGNOSIS AND TESTING - MULTI-FUNCTION SWITCH
523
REMOVAL
523
INSTALLATION
523
PARK/TURN SIGNAL LAMP
523
REMOVAL
523
INSTALLATION
523
PARK/TURN SIGNAL LAMP - EXPORT
523
REMOVAL
523
INSTALLATION
524
REAR FOG LAMP - EXPORT
524
DESCRIPTION
524
REPEATER LAMP - EXPORT
524
REMOVAL
524
INSTALLATION
524
TAIL LAMP
524
REMOVAL
524
INSTALLATION
524
TAIL LAMP - EXPORT
524
REMOVAL
524
INSTALLATION
525
TAIL LAMP UNIT
525
REMOVAL
525
INSTALLATION
525
LAMPS/LIGHTING - INTERIOR
526
LAMPS/LIGHTING - INTERIOR
526
SPECIFICATIONS
526
INTERIOR LAMPS
526
CENTER CONSOLE LAMP SWITCH
527
REMOVAL
527
INSTALLATION
527
CLUSTER ILLUMINATION LAMPS
527
REMOVAL
527
INSTALLATION
527
COURTESY LAMP
527
REMOVAL
527
INSTALLATION
527
DOME LAMP
527
REMOVAL
527
INSTALLATION
527
GLOVE BOX LAMP SWITCH
527
REMOVAL
527
INSTALLATION
528
LIFTGATE LAMP
528
REMOVAL
528
INSTALLATION
528
READING LAMP
528
REMOVAL
528
INSTALLATION
529
VANITY LAMP
529
REMOVAL
529
INSTALLATION
529
8m-MESSAGE SYSTEMS
530
OVERHEAD CONSOLE
530
DESCRIPTION
530
DESCRIPTION - COMPASS
530
DESCRIPTION - TEMPERATURE
530
OPERATION
531
DIAGNOSIS AND TESTING - OVERHEAD CONSOLE
531
SELF-DIAGNOSTIC TEST
531
STANDARD PROCEDURE
532
STANDARD PROCEDURE - READING/COURTESY LAMP REPLACEMENT
532
STANDARD PROCEDURE - COMPASS CALIBRATION
532
STANDARD PROCEDURE - COMPASS DEMAGNETIZING
533
STANDARD PROCEDURE - COMPASS VARIATION ADJUSTMENT
533
REMOVAL - OVERHEAD CONSOLE
534
INSTALLATION
534
ELECTRONIC VEHICLE INFO CENTER
535
DESCRIPTION
535
OPERATION
535
DIAGNOSIS AND TESTING - ELECTRONIC VEHICLE INFORMATION CENTER
535
STANDARD PROCEDURE - ELECTRONIC VEHICLE INFORMATION CENTER PROGRAMMING
536
EVIC PROGRAMMING MODE
536
PROGRAMMABLE FEATURES
536
REMOVAL
537
INSTALLATION
537
COMPASS/MINI-TRIP COMPUTER
538
DESCRIPTION
538
OPERATION
538
DIAGNOSIS AND TESTING - COMPASS MINI-TRIP COMPUTER
538
REMOVAL
538
INSTALLATION
538
UNIVERSAL TRANSMITTER
538
DESCRIPTION
538
OPERATION
539
DIAGNOSIS AND TESTING - UNIVERSAL TRANSMITTER
539
AMBIENT TEMP SENSOR
539
DESCRIPTION
539
OPERATION
539
DIAGNOSIS AND TESTING
540
DIAGNOSIS AND TESTING - AMBIENT TEMPERATURE SENSOR
540
DIAGNOSIS AND TESTING - AMBIENT TEMPERATURE SENSOR CIRCUIT
540
REMOVAL
540
INSTALLATION
540
8n-POWER SYSTEMS
542
POWER LIFTGATE SYSTEM
542
POWER LIFTGATE SYSTEM
543
DESCRIPTION
543
OPERATION
544
POWER LIFTGATE SYSTEM INHIBITORS
545
POWER LIFTGATE SYSTEM CAUTIONS AND WARNINGS
545
DIAGNOSIS AND TESTING - POWER LIFTGATE SYSTEM
545
STANDARD PROCEDURE
549
STANDARD PROCEDURE - LIFTGATE ADJUSTMENT
549
STANDARD PROCEDURE - POWER LIFTGATE LEARN CYCLE
550
PINCH SENSOR
550
DESCRIPTION
550
OPERATION
550
REMOVAL
550
INSTALLATION
550
FULL OPEN SWITCH
551
DESCRIPTION
551
OPERATION
551
REMOVAL
551
INSTALLATION
551
LIFTGATE MOTOR
551
DESCRIPTION
551
OPERATION
552
REMOVAL
552
INSTALLATION
552
ENGAGE ACTUATOR
552
DESCRIPTION
552
OPERATION
552
REMOVAL
553
INSTALLATION
553
TRANSVERSE BRACKET
553
DESCRIPTION
553
OPERATION
553
REMOVAL
554
INSTALLATION
554
LIFT GEAR & LINK ROD
554
DESCRIPTION
554
OPERATION
555
REMOVAL
555
INSTALLATION
555
LATCH
555
DESCRIPTION
555
OPERATION
556
REMOVAL
556
INSTALLATION
556
LATCH ACTUATOR
556
DESCRIPTION
556
OPERATION
556
REMOVAL
556
INSTALLATION
557
EXTERIOR HANDLE SWITCH
557
DESCRIPTION
557
OPERATION
557
REMOVAL
557
INSTALLATION
557
CHIME/THERMISTOR
558
DESCRIPTION
558
OPERATION
558
REMOVAL
558
INSTALLATION
558
POWER SLIDING DOOR SYSTEM
559
POWER SLIDING DOOR SYSTEM
559
DESCRIPTION
559
OPERATION
561
POWER SLIDING DOOR SYSTEM INHIBITORS
561
POWER SLIDING DOOR SYSTEM WARNINGS
562
DIAGNOSIS AND TESTING - POWER SLIDING DOOR SYSTEM
562
STANDARD PROCEDURE
568
STANDARD PROCEDURE - WELLNUT REPLACEMENT
568
STANDARD PROCEDURE - POWER DOOR LEARN CYCLE
568
STANDARD PROCEDURE - SLIDING DOOR ADJUSTMENT
568
LATCH
569
DESCRIPTION
569
OPERATION
569
REMOVAL
569
INSTALLATION
570
SLIDING DOOR MOTOR
570
DESCRIPTION
570
OPERATION
570
REMOVAL
570
INSTALLATION
571
FULL OPEN SWITCH
571
DESCRIPTION
571
OPERATION
571
LEFT B-PILLAR SWITCH
572
DESCRIPTION
572
OPERATION
572
REMOVAL
572
INSTALLATION
572
RIGHT B-PILLAR SWITCH
572
DESCRIPTION
572
OPERATION
572
REMOVAL
572
INSTALLATION
572
LOWER DRIVE UNIT
572
DESCRIPTION
572
OPERATION
572
REMOVAL
573
INSTALLATION
573
LOWER DRIVE UNIT TRACK & RACK
574
DESCRIPTION
574
OPERATION
574
REMOVAL
574
INSTALLATION
574
WIRING HARNESS
575
DESCRIPTION
575
OPERATION
575
REMOVAL
575
INSTALLATION
576
FLEX DRIVE
576
DESCRIPTION
576
OPERATION
577
REMOVAL
577
INSTALLATION
577
SLIDING DOOR MODULE
578
DESCRIPTION
578
OPERATION
578
REMOVAL
579
INSTALLATION
579
POWER LOCKS
580
POWER LOCKS
580
DESCRIPTION
580
POWER DOOR LOCK SYSTEM
580
AUTOMATIC DOOR LOCK
580
AUTOMATIC DOOR UNLOCK
580
DOOR LOCK INHIBIT
580
CENTRAL LOCKING
580
DOOR LOCK CIRCUIT PROTECTION
580
REMOTE KEYLESS ENTRY SYSTEM
581
OPERATION
581
POWER DOOR LOCK SYSTEM
581
AUTOMATIC DOOR LOCKS
581
DOOR LOCK INHIBIT
581
CENTRAL LOCKING
581
DOOR LOCK CIRCUIT PROTECTION
582
REMOTE KEYLESS ENTRY SYSTEM
582
DOOR CYLINDER LOCK SWITCH
582
DESCRIPTION
582
OPERATION
582
DIAGNOSIS AND TESTING - DOOR CYLINDER LOCK SWITCH
582
REMOVAL
583
INSTALLATION
583
DOOR LOCK MOTOR
583
DIAGNOSIS AND TESTING - DOOR LOCK MOTOR
583
DOOR LOCK SWITCH
583
DIAGNOSIS AND TESTING - DOOR LOCK SWITCH
583
REMOVAL
584
INSTALLATION
584
KEYLESS ENTRY TRANSMITTER
584
STANDARD PROCEDURE
584
STANDARD PROCEDURE - HORN CHIRP PREFERENCE
584
DISABLING
584
ENABLING
584
STANDARD PROCEDURE - BATTERY REPLACEMENT
584
SPECIFICATIONS
584
RANGE
584
BATTERY
584
REMOTE KEYLESS ENTRY MODULE
585
DESCRIPTION
585
OPERATION
585
DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY MODULE
585
STANDARD PROCEDURE - PROGRAMMING RKE MODULE
585
REMOVAL
585
INSTALLATION
586
SLIDING DOOR LOCK MOTOR
586
REMOVAL
586
INSTALLATION
586
POWER MIRRORS
587
POWER MIRRORS
587
DESCRIPTION
587
OPERATION
587
DIAGNOSIS AND TESTING - POWER MIRRORS
587
AUTOMATIC DAY / NIGHT MIRROR
588
DESCRIPTION
588
OPERATION
588
DIAGNOSIS AND TESTING - AUTOMATIC DAY / NIGHT MIRROR
589
REMOTE SWITCH
590
DIAGNOSIS AND TESTING - REMOTE SWITCH
590
REMOVAL
590
INSTALLATION
590
SIDEVIEW MIRROR
590
REMOVAL
590
POWER FOLDAWAY MIRROR SWITCH - EXPORT
590
DESCRIPTION
590
OPERATION
591
REMOVAL
591
INSTALLATION
591
POWER SEAT SYSTEM
592
POWER SEAT SYSTEM
592
DESCRIPTION
592
DESCRIPTION
592
DESCRIPTION - MEMORY SYSTEM
593
OPERATION
594
OPERATION - POWER SEAT SYSTEM
594
OPERATION - MEMORY SYSTEM
594
ELECTRONIC VEHICLE INFORMATION CENTER
594
DIAGNOSIS AND TESTING
594
DIAGNOSIS AND TESTING - POWER SEAT SYSTEM
594
DIAGNOSIS AND TESTING - MEMORY SYSTEM
595
DRIVER SEAT SWITCH
595
DESCRIPTION
595
OPERATION
596
DIAGNOSIS AND TESTING - DRIVER SEAT SWITCH
596
REMOVAL
596
INSTALLATION
597
MEMORY SET SWITCH
597
DESCRIPTION
597
OPERATION
597
DIAGNOSIS AND TESTING - MEMORY SWITCH
598
REMOVAL
598
INSTALLATION
598
PASSENGER SEAT SWITCH
598
DESCRIPTION
598
OPERATION
598
DIAGNOSIS AND TESTING - PASSENGER SEAT SWITCH
599
REMOVAL
599
INSTALLATION
600
MEMORY MIRROR/SEAT MODULE
600
DESCRIPTION
600
OPERATION
600
DIAGNOSIS AND TESTING - MEMORY MIRROR/SEAT MODULE
600
REMOVAL
600
INSTALLATION
600
DRIVER POWER SEAT TRACK
601
DESCRIPTION
601
OPERATION
601
DIAGNOSIS AND TESTING - DRIVER POWER SEAT TRACK
601
TESTING POWER SEAT TRACK MOTORS
601
REMOVAL
602
INSTALLATION
602
PASSENGER POWER SEAT TRACK
602
DESCRIPTION
602
OPERATION
603
DIAGNOSIS AND TESTING - POWER SEAT TRACK
603
REMOVAL
603
INSTALLATION
604
POWER WINDOWS
605
POWER WINDOWS
605
DESCRIPTION
605
OPERATION
605
DIAGNOSIS AND TESTING - POWER WINDOWS
605
POWER WINDOW MOTOR TEST
605
WIRING VOLTAGE TEST
606
VENT WINDOW MOTOR
606
DIAGNOSIS AND TESTING - VENT WINDOW MOTOR
606
REMOVAL
606
INSTALLATION
606
WINDOW MOTOR
607
REMOVAL
607
WINDOW SWITCH
607
DIAGNOSIS AND TESTING - WINDOW SWITCH
607
REMOVAL
608
INSTALLATION
608
8o-RESTRAINTS
610
RESTRAINTS
611
DESCRIPTION
611
OPERATION
611
WARNING
611
DIAGNOSIS AND TESTING - AIRBAG SYSTEM
611
CLOCK SPRING
612
DESCRIPTION
612
OPERATION
612
STANDARD PROCEDURE - CLOCK SPRING CENTERING
612
REMOVAL
612
INSTALLATION
612
DRIVER AIRBAG
612
DESCRIPTION
612
OPERATION
612
CARE OF UNDEPLOYED AIRBAGS
613
STANDARD PROCEDURE - CLEAN UP
613
REMOVAL
613
DEPLOYED AIRBAG
613
UNDEPLOYED AIRBAG
613
INSTALLATION
613
DEPLOYED AIRBAG
613
UNDEPLOYED AIRBAG
613
DRIVER AIRBAG TRIM COVER
613
REMOVAL
613
INSTALLATION
614
OCCUPANT RESTRAINT CONTROLLER
614
DESCRIPTION
614
OPERATION
614
REMOVAL
614
INSTALLATION
614
PASSENGER AIRBAG
615
DESCRIPTION
615
OPERATION
615
CARE OF UNDEPLOYED AIRBAGS
615
STANDARD PROCEDURE - CLEAN UP
615
REMOVAL
615
DEPLOYED AIRBAG
615
UNDEPLOYED AIRBAG
615
INSTALLATION
615
DEPLOYED AIRBAG
615
UNDEPLOYED AIRBAG
616
SEAT AIRBAG
616
DESCRIPTION
616
OPERATION
616
SEAT BELT OUTBOARD FRONT
616
REMOVAL
616
INSTALLATION
616
SEAT BELT FIRST ROW ANCHOR BRACKET - LWB
617
REMOVAL
617
INSTALLATION
617
SEAT BELT LEFT FIRST ROW OUTBOARD - SWB THREE DOOR
617
REMOVAL
617
INSTALLATION
617
SEAT BELT FIRST ROW OUTBOARD - SWB FOUR DOOR
618
REMOVAL
618
INSTALLATION
618
SEAT BELT FIRST ROW OUTBOARD - LWB FOUR DOOR
619
REMOVAL
619
INSTALLATION
619
SEAT BELT SECOND RIGHT ROW OUTBOARD - LWB
619
REMOVAL
619
INSTALLATION
619
SEAT BELT SECOND RIGHT ROW OUTBOARD - LBW WITH REAR HVAC
620
REMOVAL
620
INSTALLATION
620
SEAT BELT SECOND ROW OUTBOARD - SWB
621
REMOVAL
621
INSTALLATION
621
SEAT BELT BUCKLE - FRONT INBOARD
622
REMOVAL
622
INSTALLATION
622
SEAT BELT BUCKLE FIRST ROW QUAD BUCKET
622
REMOVAL
622
INSTALLATION
622
SEAT BELT BUCKLE FIRST ROW - TWO PASSENGER BENCH
623
REMOVAL
623
INSTALLATION
623
SEAT BELT BUCKLE SECOND ROW - THREE PASSENGER BENCH
623
REMOVAL
623
INSTALLATION
623
SEAT BELT TENSIONER
623
DESCRIPTION
623
OPERATION
623
SHOULDER BELT HEIGHT ADJUSTER
624
REMOVAL
624
INSTALLATION
624
SHOULDER BELT HEIGHT ADJUSTER KNOB
624
REMOVAL
624
INSTALLATION
624
SIDE IMPACT AIRBAG CONTROL MODULE
625
DESCRIPTION
625
OPERATION
625
REMOVAL
625
INSTALLATION
625
8p-SPEED CONTROL
626
SPEED CONTROL
626
DESCRIPTION
626
OPERATION
626
OPERATION
626
OPERATION - INTERACTIVE SPEED CONTROL (4 Speed EATX Only)
627
CLIMBING A GRADE
627
GRADE HUNTING
627
AUTOMATIC SPEED CONTROL OVERSPEED REDUCTION
627
DIAGNOSIS AND TESTING - ROAD TEST
628
SPECIFICATIONS - TORQUE
628
CABLE
629
DESCRIPTION
629
OPERATION
629
REMOVAL
629
INSTALLATION
629
SERVO
629
DESCRIPTION
629
OPERATION
629
REMOVAL
629
INSTALLATION
630
SWITCH
630
DESCRIPTION
630
OPERATION
630
REMOVAL
630
INSTALLATION
631
VACUUM RESERVOIR
631
DESCRIPTION
631
OPERATION
631
REMOVAL
631
INSTALLATION
631
8q-VEHICLE THEFT SECURITY
632
VEHICLE THEFT SECURITY
632
DESCRIPTION
632
VEHICLE THEFT SECURITY SYSTEM
632
SENTRY KEY IMMOBILIZER SYSTEM
632
OPERATION
632
VEHICLE THEFT SECURITY SYSTEM
632
ARMING THE VTSS - METHOD A
633
ARMING THE VTSS - METHOD B
633
TRIGGERING THE VTSS
633
SENTRY KEY IMMOBILIZER SYSTEM
633
DIAGNOSIS AND TESTING
634
DIAGNOSIS AND TESTING - SENTRY KEY IMMOBILIZER SYSTEM
634
DIAGNOSIS AND TESTING - VEHICLE THEFT SECURITY SYSTEM
634
HOOD AJAR SWITCH
634
REMOVAL
634
INSTALLATION
634
TRANSPONDER KEY
634
DESCRIPTION
634
OPERATION
634
STANDARD PROCEDURE - TRANSPONDER PROGRAMMING
635
USING A DRB III SCAN TOOL
635
“CUSTOMER LEARN” MODE
635
VTSS/SKIS INDICATOR LAMP
636
DESCRIPTION
636
OPERATION
636
8r-WIPERS/WASHERS
638
WIPERS/WASHERS
638
DESCRIPTION
638
FRONT WIPER/WASHER SYSTEM
638
REAR WIPER/WASHER SYSTEM
638
OPERATION
639
FRONT WIPER/WASHER SYSTEM
639
REAR WIPER/WASHER SYSTEM
639
DIAGNOSIS AND TESTING
639
DIAGNOSIS AND TESTING - FRONT WIPER SYSTEM
639
DIAGNOSIS AND TESTING - FRONT WIPER/WASHER SWITCH
639
DIAGNOSIS AND TESTING - FAILED PARK SWITCH
640
DIAGNOSIS AND TESTING - REAR WIPER SYSTEM
642
DIAGNOSIS AND TESTING - WASHER SYSTEM
642
FRONT WASHER PUMP MOTOR
646
REMOVAL
646
INSTALLATION
646
FRONT WIPER ARMS
646
STANDARD PROCEDURE - FRONT WIPER ARM ALIGNMENT
646
REMOVAL
647
INSTALLATION
647
FRONT WIPER MOTOR
647
REMOVAL
647
INSTALLATION
647
HEADLAMP WASHERS - EXPORT
648
DESCRIPTION
648
OPERATION
648
DIAGNOSIS AND TESTING - HEADLAMP WASHERS - EXPORT
648
REMOVAL
650
INSTALLATION
650
HEADLAMP WASHER HOSE - EXPORT
650
REMOVAL
650
INSTALLATION
650
HEADLAMP WASHER PUMP MOTOR - EXPORT
650
REMOVAL
650
INSTALLATION
651
REAR WASHER PUMP MOTOR
651
REMOVAL
651
INSTALLATION
652
REAR WIPER ARM
652
REMOVAL
652
INSTALLATION
652
REAR WIPER MOTOR
653
REMOVAL
653
INSTALLATION
653
REAR WIPER/WASHER SWITCH
653
DESCRIPTION
653
OPERATION
653
WASHER FLUID LEVEL SWITCH
653
REMOVAL
653
INSTALLATION
654
WASHER HOSES
654
REMOVAL
654
INSTALLATION
654
WASHER RESERVOIR
655
REMOVAL
655
INSTALLATION
655
WIPER BLADES
655
REMOVAL
655
CLEANING
656
INSTALLATION
656
WIPER LINKAGE
656
REMOVAL
656
INSTALLATION
656
WIPER MODULE
656
REMOVAL
656
INSTALLATION
657
8w-WIRING
658
8W-01 WIRING DIAGRAM INFORMATION
660
WIRING DIAGRAM INFORMATION
660
DESCRIPTION
660
DESCRIPTION - HOW TO USE WIRING DIAGRAMS
660
SYMBOLS
660
TERMINOLOGY
664
DESCRIPTION - CIRCUIT INFORMATION
664
DESCRIPTION - CIRCUIT FUNCTIONS
665
DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION
665
DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION
666
IDENTIFICATION
666
LOCATIONS
666
WARNING
666
WARNINGS - GENERAL
666
DIAGNOSIS AND TESTING - WIRING HARNESS
666
TROUBLESHOOTING TOOLS
666
INTERMITTENT AND POOR CONNECTIONS
667
TROUBLESHOOTING WIRING PROBLEMS
667
STANDARD PROCEDURE
667
STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES
667
STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL
668
STANDARD PROCEDURE - TESTING FOR CONTINUITY
668
STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND
668
STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS
669
STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP
669
SPECIAL TOOLS
669
WIRING/TERMINAL
669
CONNECTOR
670
REMOVAL
670
INSTALLATION
670
DIODE
673
REMOVAL
673
INSTALLATION
673
TERMINAL
673
REMOVAL
673
INSTALLATION
673
WIRE
674
STANDARD PROCEDURE - WIRE SPLICING
674
8W-02 COMPONENT INDEX
676
8W-10 POWER DISTRIBUTION
678
8W-15 GROUND DISTRIBUTION
746
8W-18 BUS COMMUNICATIONS
772
8W-20 CHARGING SYSTEM
778
8W-21 STARTING SYSTEM
782
8W-30 FUEL/IGNITION SYSTEM
786
8W-31 TRANSMISSION CONTROL SYSTEM
818
8W-33 VEHICLE SPEED CONTROL
828
8W-35 ANTILOCK BRAKES
832
8W-39 VEHICLE THEFT SECURITY SYSTEM
836
8W-40 INSTRUMENT CLUSTER
852
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
864
8W-42 AIR CONDITIONING-HEATER
868
8W-43 AIRBAG SYSTEM
886
8W-44 INTERIOR LIGHTING
894
8W-45 BODY CONTROL MODULE
902
8W-46 MESSAGE CENTER
922
8W-47 AUDIO SYSTEM
924
8W-48 REAR WINDOW DEFOGGER
936
8W-49 OVERHEAD CONSOLE
940
8W-50 FRONT LIGHTING
944
8W-51 REAR LIGHTING
956
8W-52 TURN SIGNALS
962
8W-53 WIPERS
968
8W-54 TRAILER TOW
974
8W-60 POWER WINDOWS
978
8W-61 POWER DOOR LOCKS
986
8W-62 POWER MIRRORS
1006
8W-63 POWER SEATS
1016
8W-70 SPLICE INFORMATION
1026
8W-80 CONNECTOR PIN-OUTS
1032
8W-91 CONNECTOR/GROUND/SPLICE LOCATION
1148
CONNECTOR/GROUND/SPLICE LOCATION
1148
DESCRIPTION
1148
8W-97 POWER DISTRIBUTION SYSTEM
1196
POWER DISTRIBUTION SYSTEM
1196
DESCRIPTION
1196
OPERATION
1196
SPECIAL TOOLS
1197
POWER DISTRIBUTION SYSTEMS
1197
ACCESSORY RELAY
1197
DESCRIPTION
1197
OPERATION
1197
DIAGNOSIS AND TESTING
1197
DIAGNOSIS & TESTING - ACCESSORY RELAY
1197
DIAGNOSIS & TESTING - RELAY CIRCUIT TEST
1197
REMOVAL
1198
INSTALLATION
1198
INTEGRATED POWER MODULE
1198
DESCRIPTION
1198
OPERATION
1198
REMOVAL
1199
INSTALLATION
1199
IOD FUSE
1199
DESCRIPTION
1199
OPERATION
1200
REMOVAL
1200
INSTALLATION
1200
POWER OUTLET
1200
DESCRIPTION
1200
OPERATION
1200
DIAGNOSIS AND TESTING
1200
DIAGNOSIS & TESTING - POWER OUTLET
1200
REMOVAL
1201
INSTALLATION
1201
9-ENGINE
1202
ENGINE 2.4L
1202
ENGINE 2.4L
1204
DESCRIPTION
1204
DIAGNOSIS AND TESTING
1204
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION
1204
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
1205
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
1207
DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION
1209
INSPECTION FOR REAR SEAL AREA LEAKS
1209
DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST
1210
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST
1210
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
1212
STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE
1213
REMOVAL - ENGINE ASSEMBLY
1213
INSTALLATION - ENGINE ASSEMBLY
1217
SPECIFICATIONS
1218
SPECIFICATIONS - 2.4L ENGINE
1218
SPECIFICATIONS - TORQUE
1221
SPECIAL TOOLS
1222
2.4L ENGINE
1222
AIR CLEANER ELEMENT
1225
REMOVAL
1225
INSTALLATION
1225
AIR CLEANER HOUSING
1225
REMOVAL
1225
INSTALLATION
1225
CYLINDER HEAD
1225
DESCRIPTION
1225
OPERATION
1225
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET
1225
CYLINDER-TO-CYLINDER LEAKAGE TEST
1226
CYLINDER-TO-WATER JACKET LEAKAGE TEST
1226
REMOVAL - CYLINDER HEAD
1226
CLEANING
1227
INSPECTION
1227
INSTALLATION - CYLINDER HEAD
1227
CAMSHAFT OIL SEAL(S)
1229
REMOVAL
1229
INSTALLATION
1229
CAMSHAFT(S)
1230
DESCRIPTION
1230
OPERATION
1230
STANDARD PROCEDURE - MEASURING CAMSHAFT END PLAY
1230
REMOVAL
1230
CLEANING
1230
INSPECTION
1231
INSTALLATION
1231
CYLINDER HEAD COVER
1232
REMOVAL
1232
CLEANING
1232
INSPECTION
1232
INSTALLATION
1232
INTAKE/EXHAUST VALVES & SEATS
1233
DESCRIPTION
1233
CLEANING
1233
VALVE SPRINGS & SEALS
1233
REMOVAL
1233
REMOVAL - CYLINDER HEAD ON
1233
REMOVAL - CYLINDER HEAD OFF
1234
INSPECTION
1234
INSTALLATION
1234
INSTALLATION - CYLINDER HEAD ON
1234
INSTALLATION - CYLINDER HEAD OFF
1234
HYDRAULIC LASH ADJUSTERS
1235
DIAGNOSIS AND TESTING - HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS
1235
REMOVAL
1235
INSTALLATION
1235
ROCKER ARMS
1236
REMOVAL
1236
INSPECTION
1236
INSTALLATION
1236
ENGINE BLOCK
1236
DESCRIPTION
1236
STANDARD PROCEDURE
1237
STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING
1237
STANDARD PROCEDURE - CYLINDER BORE HONING
1237
CLEANING
1238
INSPECTION
1238
ENGINE BLOCK
1238
CYLINDER BORE
1238
CONNECTING ROD BEARINGS
1238
STANDARD PROCEDURE
1238
CONNECTING ROD - FITTING
1238
CRANKSHAFT
1239
DESCRIPTION
1239
OPERATION
1239
STANDARD PROCEDURE - CRANKSHAFT END PLAY
1239
REMOVAL
1239
INSPECTION
1240
INSTALLATION
1240
CRANKSHAFT MAIN BEARINGS
1242
STANDARD PROCEDURE - MAIN BEARING - FITTING
1242
CRANKSHAFT MAIN BEARINGS
1242
MAIN BEARING INSTALLATION
1242
CRANKSHAFT OIL SEAL - FRONT
1243
REMOVAL
1243
INSTALLATION
1244
CRANKSHAFT OIL SEAL - REAR
1244
REMOVAL
1244
INSTALLATION
1245
PISTON & CONNECTING ROD
1246
DESCRIPTION
1246
OPERATION
1246
REMOVAL
1246
INSTALLATION
1247
PISTON RINGS
1248
STANDARD PROCEDURE
1248
PISTON RING - FITTING
1248
PISTON RINGS - INSTALLATION
1248
VIBRATION DAMPER
1249
REMOVAL
1249
INSTALLATION
1249
STRUCTURAL COLLAR
1250
REMOVAL
1250
INSTALLATION
1250
ENGINE MOUNTING
1250
DESCRIPTION
1250
FRONT MOUNT
1250
REMOVAL
1250
INSTALLATION
1251
LEFT MOUNT
1251
REMOVAL
1251
INSTALLATION
1251
REAR MOUNT
1252
REMOVAL
1252
INSTALLATION
1252
RIGHT MOUNT
1253
REMOVAL
1253
INSTALLATION
1253
LUBRICATION
1254
DESCRIPTION
1254
OPERATION
1254
DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE
1254
OIL
1254
STANDARD PROCEDURE
1254
ENGINE OIL LEVEL CHECK
1254
STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE
1255
OIL FILTER
1255
DESCRIPTION
1255
REMOVAL
1255
INSTALLATION
1256
OIL PAN
1256
REMOVAL
1256
INSTALLATION
1256
OIL PRESSURE SWITCH
1256
REMOVAL
1256
INSTALLATION
1256
OIL PUMP
1256
REMOVAL
1256
DISASSEMBLY
1257
CLEANING
1258
INSPECTION
1258
ASSEMBLY
1259
INSTALLATION
1259
INTAKE MANIFOLD
1260
DESCRIPTION
1260
OPERATION
1260
DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS
1260
INTAKE MANIFOLD - UPPER
1261
REMOVAL
1261
INSPECTION
1262
INSTALLATION
1262
INTAKE MANIFOLD - LOWER
1262
REMOVAL
1262
INSPECTION
1262
INSTALLATION
1262
EXHAUST MANIFOLD
1263
DESCRIPTION
1263
OPERATION
1263
REMOVAL
1263
CLEANING
1263
INSPECTION
1263
INSTALLATION
1263
TIMING BELT COVER(S)
1264
REMOVAL
1264
FRONT COVER
1264
REAR COVER
1264
INSTALLATION
1264
REAR COVER
1264
FRONT COVER
1264
TIMING BELT AND SPROCKET(S)
1265
REMOVAL
1265
REMOVAL - TIMING BELT
1265
REMOVAL - CRANKSHAFT SPROCKET
1267
CLEANING
1267
INSTALLATION
1267
INSTALLATION - CRANKSHAFT SPROCKET
1267
INSTALLATION - TIMING BELT
1268
TIMING BELT TENSIONER & PULLEY
1269
REMOVAL
1269
INSTALLATION
1270
BALANCE SHAFTS AND CARRIER ASSEMBLY
1270
DESCRIPTION
1270
OPERATION
1271
REMOVAL
1271
BALANCE SHAFTS/CHAIN/SPROCKETS
1271
BALANCE SHAFT CARRIER
1271
INSTALLATION
1272
BALANCE SHAFT INSTALLATION/TIMING
1272
ENGINE 3.3/3.8L
1275
ENGINE 3.3/3.8L
1277
DESCRIPTION
1277
DIAGNOSIS AND TESTING
1278
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION
1278
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
1279
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
1281
DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION
1283
INSPECTION FOR REAR SEAL AREA LEAKS
1283
DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST
1284
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST
1284
STANDARD PROCEDURE
1285
STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE
1285
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
1285
SEALER APPLICATION
1286
STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION
1286
STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE
1287
STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS
1287
STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS
1287
REMOVAL - ENGINE ASSEMBLY
1288
INSTALLATION - ENGINE ASSEMBLY
1291
SPECIFICATIONS
1293
3.3/3.8L ENGINE
1293
SPECIFICATIONS - TORQUE
1296
SPECIAL TOOLS
1297
3.3/3.8L ENGINE
1297
AIR CLEANER ELEMENT
1300
REMOVAL
1300
INSTALLATION
1300
AIR CLEANER HOUSING
1300
REMOVAL
1300
INSTALLATION
1301
CYLINDER HEAD
1301
DESCRIPTION
1301
OPERATION
1301
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET
1301
CYLINDER-TO-CYLINDER LEAKAGE TEST
1301
CYLINDER-TO-WATER JACKET LEAKAGE TEST
1301
REMOVAL - CYLINDER HEAD
1301
CLEANING
1302
INSPECTION
1302
INSTALLATION - CYLINDER HEAD
1303
CYLINDER HEAD COVER(S)
1304
DESCRIPTION
1304
CYLINDER HEAD COVER - RIGHT
1304
REMOVAL
1304
INSTALLATION
1304
CYLINDER HEAD COVER - LEFT
1306
REMOVAL
1306
INSTALLATION
1306
INTAKE/EXHAUST VALVES & SEATS
1306
DESCRIPTION
1306
OPERATION
1306
STANDARD PROCEDURE - REFACING VALVES AND VALVE SEATS
1306
VALVES
1306
VALVE SEATS
1306
REMOVAL
1307
CLEANING
1307
INSPECTION
1307
VALVES
1307
VALVE GUIDES
1308
INSTALLATION
1308
VALVE SPRINGS
1308
DESCRIPTION
1308
OPERATION
1308
REMOVAL
1309
REMOVAL - CYLINDER HEAD OFF
1309
REMOVAL - CYLINDER HEAD ON
1309
INSPECTION
1310
INSTALLATION
1310
INSTALLATION - CYLINDER HEAD OFF
1310
INSTALLATION - CYLINDER HEAD ON
1310
ROCKER ARMS
1311
DESCRIPTION
1311
DESCRIPTION - ROCKER ARMS
1311
DESCRIPTION - PUSHRODS
1311
OPERATION
1311
OPERATION - ROCKER ARMS
1311
OPERATION - PUSHRODS
1311
REMOVAL - ROCKER ARMS AND SHAFT
1311
DISASSEMBLY - ROCKER ARMS AND SHAFT
1311
ASSEMBLY - ROCKER ARMS AND SHAFT
1312
INSTALLATION - ROCKER ARMS AND SHAFT
1312
VALVE STEM SEALS
1313
DESCRIPTION
1313
REMOVAL
1314
INSTALLATION
1314
ENGINE BLOCK
1314
DESCRIPTION
1314
STANDARD PROCEDURE - CYLINDER BORE HONING
1314
CLEANING
1314
INSPECTION
1314
ENGINE BLOCK
1314
CYLINDER BORE
1314
CAMSHAFT & BEARINGS (IN BLOCK)
1315
DESCRIPTION
1315
OPERATION
1315
REMOVAL
1315
INSPECTION
1316
INSTALLATION
1316
CONNECTING ROD BEARINGS
1316
STANDARD PROCEDURE - MEASURING CONNECTING ROD BEARING CLEARANCE
1316
CRANKSHAFT
1317
DESCRIPTION
1317
DESCRIPTION - 3.3L
1317
DESCRIPTION - 3.8L
1318
OPERATION
1318
STANDARD PROCEDURE - MEASURING CRANKSHAFT END PLAY
1318
REMOVAL
1318
INSPECTION
1319
INSTALLATION
1319
CRANKSHAFT MAIN BEARINGS
1320
STANDARD PROCEDURE - MAIN BEARING FITTING
1320
CRANKSHAFT BEARING OIL CLEARANCE
1321
REMOVAL - CRANKSHAFT MAIN BEARINGS
1322
INSTALLATION - CRANKSHAFT MAIN BEARINGS
1322
CRANKSHAFT OIL SEAL - FRONT
1323
REMOVAL
1323
INSTALLATION
1324
CRANKSHAFT OIL SEAL - REAR
1324
REMOVAL
1324
INSTALLATION
1324
CRANKSHAFT REAR OIL SEAL RETAINER
1325
REMOVAL
1325
INSTALLATION
1325
FLEX PLATE
1325
REMOVAL
1325
INSTALLATION
1325
HYDRAULIC LIFTERS (CAM IN BLOCK)
1326
DESCRIPTION
1326
DIAGNOSIS AND TESTING - HYDRAULIC LIFTERS
1326
HYDRAULIC LIFTERS DIAGNOSIS - PRELIMINARY STEP
1326
OIL LEVEL TOO HIGH
1326
OIL LEVEL TOO LOW
1326
VALVE TRAIN NOISE
1326
REMOVAL
1327
INSTALLATION
1327
PISTON & CONNECTING ROD
1327
DESCRIPTION
1327
OPERATION
1327
STANDARD PROCEDURE
1328
STANDARD PROCEDURE - FITTING CONNECTING RODS
1328
STANDARD PROCEDURE - FITTING PISTONS
1328
REMOVAL
1328
INSTALLATION
1329
PISTON RINGS
1331
STANDARD PROCEDURE - PISTON RING FITTING
1331
REMOVAL
1332
INSTALLATION
1332
VIBRATION DAMPER
1333
REMOVAL
1333
INSTALLATION
1333
ENGINE MOUNTING
1334
DESCRIPTION
1334
FRONT MOUNT
1334
REMOVAL
1334
INSTALLATION
1334
LEFT MOUNT
1335
REMOVAL
1335
INSTALLATION
1335
REAR MOUNT
1336
REMOVAL
1336
INSTALLATION
1337
RIGHT MOUNT
1338
REMOVAL
1338
INSTALLATION
1338
LUBRICATION
1338
DESCRIPTION
1338
OPERATION
1338
DIAGNOSIS AND TESTING - ENGINE OIL PRESSURE
1338
OIL
1339
STANDARD PROCEDURE
1339
STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE
1339
STANDARD PROCEDURE - ENGINE OIL LEVEL CHECK
1340
OIL COOLER & LINES
1341
DESCRIPTION
1341
OPERATION
1341
REMOVAL
1341
INSTALLATION
1341
OIL FILTER
1341
REMOVAL
1341
INSTALLATION
1341
OIL FILTER ADAPTER
1342
REMOVAL
1342
INSTALLATION
1342
OIL PAN
1342
REMOVAL
1342
CLEANING
1342
INSPECTION
1343
INSTALLATION
1343
OIL PRESSURE RELIEF VALVE
1343
REMOVAL
1343
INSTALLATION
1344
OIL PRESSURE SWITCH
1344
DESCRIPTION
1344
OPERATION
1344
REMOVAL
1344
INSTALLATION
1344
OIL PUMP
1344
DESCRIPTION
1344
REMOVAL
1344
DISASSEMBLY
1345
CLEANING
1345
INSPECTION
1345
ASSEMBLY
1347
INSTALLATION
1347
INTAKE MANIFOLD
1347
DESCRIPTION
1347
OPERATION
1347
DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS
1347
INTAKE MANIFOLD - UPPER
1347
STANDARD PROCEDURE
1347
STANDARD PROCEDURE - MANIFOLD STRIPPED THREAD REPAIR
1347
STANDARD PROCEDURE - INTAKE MANIFOLD VACUUM PORT REPAIR
1348
REMOVAL - UPPER INTAKE MANIFOLD
1348
CLEANING
1349
INSPECTION
1350
INSTALLATION - UPPER INTAKE MANIFOLD
1350
INTAKE MANIFOLD - LOWER
1351
REMOVAL - LOWER INTAKE MANIFOLD
1351
CLEANING
1351
INSPECTION
1351
INSTALLATION - LOWER INTAKE MANIFOLD
1351
EXHAUST MANIFOLD
1353
DESCRIPTION
1353
OPERATION
1353
EXHAUST MANIFOLD - RIGHT
1353
REMOVAL
1353
CLEANING
1353
INSPECTION
1354
INSTALLATION
1354
EXHAUST MANIFOLD - LEFT
1355
REMOVAL
1355
CLEANING
1355
INSPECTION
1355
INSTALLATION
1355
VALVE TIMING
1356
STANDARD PROCEDURE
1356
STANDARD PROCEDURE - VALVE TIMING VERIFICATION
1356
STANDARD PROCEDURE - MEASURING TIMING CHAIN WEAR
1356
TIMING CHAIN COVER
1356
REMOVAL
1356
INSTALLATION
1357
TIMING CHAIN AND SPROCKETS
1360
REMOVAL
1360
REMOVAL - TIMING CHAIN AND CAMSHAFT SPROCKET
1360
REMOVAL - CRANKSHAFT SPROCKET
1360
INSTALLATION
1360
INSTALLATION - CRANKSHAFT SPROCKET
1360
INSTALLATION - TIMING CHAIN AND CAMSHAFT SPROCKET
1360
9a-ENGINE
1362
ENGINE 2.5L TURBO DIESEL
1363
DESCRIPTION
1363
DESCRIPTION - 2.5L COMMON RAIL DIESEL ENGINE
1363
DESCRIPTION - ENGINE COVER
1364
REMOVAL
1364
REMOVAL - 2.5L DIESEL ENGINE
1364
REMOVAL - ENGINE COVER
1367
INSTALLATION
1368
INSTALLATION - 2.5L TURBO DIESEL ENGINE
1368
INSTALLATION - ENGINE COVER
1368
SPECIFICATIONS
1369
SPECIFICATIONS - 2.5L COMMON RAIL DIESEL ENGINE
1369
SPECIFICATIONS - TORQUE
1371
SPECIAL TOOLS
1373
CYLINDER HEAD
1378
STANDARD PROCEDURE
1378
STANDARD PROCEDURE - VALVE SERVICE
1378
DISASSEMBLY
1378
VALVE CLEANING
1378
INSPECTION
1378
VALVE REFACING
1378
VALVE SEAT REFACING
1378
VALVE STAND DOWN
1378
VALVE GUIDES
1378
VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT
1378
STANDARD PROCEDURE - MEASURING PISTON PROTRUSION
1379
REMOVAL
1380
CLEANING
1382
INSPECTION
1382
INSTALLATION
1382
Cylinder Head Bolt Torquing Procedure
1382
CAMSHAFT(S)
1383
DESCRIPTION
1383
OPERATION
1383
REMOVAL
1383
INSTALLATION
1384
CHECKING CAMSHAFT ENDPLAY
1384
CYLINDER HEAD COVER(S)
1385
DESCRIPTION
1385
REMOVAL
1385
INSTALLATION
1386
CYLINDER HEAD COVER/INTAKE MANIFOLD TIGHTENING PROCEDURE
1387
CAMSHAFT OIL SEAL(S)
1388
REMOVAL
1388
INSTALLATION
1388
ROCKER ARMS
1388
DESCRIPTION
1388
OPERATION
1388
REMOVAL
1388
INSTALLATION
1389
HYDRAULIC LIFTERS
1390
DESCRIPTION
1390
REMOVAL
1390
INSPECTION
1391
INSTALLATION
1391
ENGINE BLOCK
1391
DESCRIPTION
1391
CRANKSHAFT
1391
DESCRIPTION
1391
OPERATION
1391
STANDARD PROCEDURE - CHECKING CRANKSHAFT END PLAY
1392
REMOVAL
1392
INSTALLATION
1393
CYLINDER LINERS
1394
DESCRIPTION
1394
REMOVAL
1394
INSPECTION
1395
INSTALLATION
1395
INTERNAL VACUUM PUMP
1396
DESCRIPTION
1396
REMOVAL
1396
INSTALLATION
1396
PISTON & CONNECTING ROD
1397
DESCRIPTION
1397
STANDARD PROCEDURE - PISTON RING FITTING
1397
REMOVAL
1397
PISTON PIN - REMOVAL
1398
PISTON RING - REMOVAL
1399
INSPECTION
1399
PISTONS
1399
CONNECTING RODS
1399
PISTON PINS
1399
INSTALLATION
1400
PISTON PIN INSTALLATION
1400
PISTON RINGS - INSTALLATION
1400
INSTALLATION
1401
CRANKSHAFT OIL SEAL - FRONT
1402
REMOVAL
1402
INSTALLATION
1402
VIBRATION DAMPER
1403
REMOVAL
1403
INSTALLATION
1403
ENGINE COVER - FRONT
1404
DESCRIPTION
1404
REMOVAL
1404
INSTALLATION
1404
CRANKSHAFT MAIN BEARINGS
1405
REMOVAL
1405
CRANKSHAFT MAIN BEARINGS
1405
CRANKSHAFT FRONT MAIN BEARING
1405
INSTALLATION
1406
CRANKSHAFT MAIN BEARINGS
1406
FRONT CRANKSHAFT MAIN BEARING
1406
CRANKSHAFT OIL SEAL - REAR
1407
REMOVAL
1407
INSTALLATION
1407
OIL PAN
1407
REMOVAL
1407
INSTALLATION
1407
OIL PUMP
1408
REMOVAL
1408
REMOVAL
1408
REMOVAL
1408
INSTALLATION
1408
INSTALLATION
1408
INSTALLATION
1409
OIL PRESSURE SENSOR/SWITCH
1409
DESCRIPTION
1409
REMOVAL
1409
INSTALLATION
1409
OIL TEMPERATURE SENSOR
1409
DESCRIPTION
1409
REMOVAL
1409
INSTALLATION
1409
OIL PRESSURE RELIEF VALVE
1410
DESCRIPTION
1410
REMOVAL
1410
INSTALLATION
1410
OIL COOLER & LINES
1411
REMOVAL
1411
INSTALLATION
1411
OIL FILTER
1412
DESCRIPTION
1412
REMOVAL
1412
INSTALLATION
1412
OIL JET
1413
DESCRIPTION
1413
REMOVAL
1413
INSTALLATION
1413
INTAKE MANIFOLD
1413
DESCRIPTION
1413
REMOVAL
1413
INSTALLATION
1413
VALVE TIMING
1414
STANDARD PROCEDURE - LOCKING ENGINE 90° AFTER TDC
1414
BALANCE SHAFT
1415
DESCRIPTION
1415
OPERATION
1415
REMOVAL
1416
INSTALLATION
1416
TIMING BELT / CHAIN COVER(S)
1417
REMOVAL
1417
REMOVAL - TIMING BELT OUTER COVER
1417
REMOVAL - TIMING BELT INNER COVER
1417
INSTALLATION
1417
INSTALLATION - TIMING BELT OUTER COVER
1417
INSTALLATION - TIMING BELT INNER COVER
1418
TIMING BELT IDLER PULLEY
1419
REMOVAL
1419
INSTALLATION
1419
TMNG BELT/CHAIN TENSIONER
1420
REMOVAL
1420
INSTALLATION
1420
ADJUSTMENTS
1421
ADJUSTMENT - TIMING BELT TENSIONER
1421
TIMING BELT/CHAIN AND SPROCKETS
1421
REMOVAL
1421
INSTALLATION
1422
11-EXHAUST SYSTEM
1424
EXHAUST SYSTEM
1424
DESCRIPTION
1424
OPERATION
1425
DIAGNOSIS AND TESTING
1425
DIAGNOSIS AND TESTING - EXCESSIVE EXHAUST SYSTEM NOISE
1425
DIAGNOSIS AND TESTING - EXHAUST SYSTEM RESTRICTION CHECK
1425
INSPECTION
1426
ADJUSTMENTS
1426
SPECIFICATIONS
1426
TORQUE
1426
SPECIAL TOOLS
1427
EXHAUST SYSTEM
1427
CATALYTIC CONVERTER
1427
DESCRIPTION
1427
OPERATION
1427
REMOVAL
1428
INSPECTION
1429
INSTALLATION
1429
CROSS-OVER PIPE - 3.3/3.8L
1429
REMOVAL
1429
INSTALLATION
1429
HEAT SHIELDS
1429
DESCRIPTION
1429
OPERATION
1430
REMOVAL
1430
INSTALLATION
1430
MUFFLER
1430
REMOVAL
1430
INSTALLATION
1431
RESONATOR
1432
REMOVAL
1432
INSTALLATION
1432
11a-EXHAUST SYSTEM AND TURBOCHARGER
1434
EXHAUST SYSTEM AND TURBOCHARGER
1434
DESCRIPTION
1434
SPECIFICATIONS - TORQUE
1434
TURBOCHARGER SYSTEM
1435
DESCRIPTION
1435
OPERATION
1435
TURBOCHARGER
1437
REMOVAL
1437
CLEANING
1438
INSTALLATION
1438
HEAT SHIELDS
1438
REMOVAL
1438
INSTALLATION
1439
13-FRAME & BUMPERS
1440
BUMPERS
1440
SPECIFICATIONS - TORQUE
1440
FRONT FASCIA
1440
REMOVAL
1440
INSTALLATION
1440
FRONT BUMPER REINFORCEMENT
1441
REMOVAL
1441
INSTALLATION
1441
REAR FASCIA
1442
REMOVAL
1442
INSTALLATION
1442
REAR BUMPER REINFORCEMENT
1442
REMOVAL
1442
INSTALLATION
1442
REAR FASCIA - SCUFF PAD
1443
REMOVAL
1443
INSTALLATION
1443
FRAME
1443
SPECIFICATIONS
1443
FRAME DIMENSIONS
1443
VEHICLE PREPARATION
1443
SPECIFICATIONS - TORQUE
1448
FRONT CRADLE CROSSMEMBER
1448
DESCRIPTION
1448
DESCRIPTION - FRONT CRADLE CROSSMEMBER
1448
DESCRIPTION - FRONT CRADLE CROSSMEMBER THREAD REPAIR
1448
TOOL REQUIREMENT FOR M8x1.25 Thread
1448
TOOL REQUIREMENT FOR M10x1.5 Thread
1448
REMOVAL
1449
REMOVAL
1449
INSTALLATION
1451
FRONT CROSSMEMBER MOUNT BUSHINGS
1451
REMOVAL
1451
INSTALLATION
1451
14-FUEL SYSTEM
1452
FUEL DELIVERY
1452
FUEL DELIVERY
1453
DESCRIPTION
1453
DESCRIPTION
1453
DESCRIPTION - FFV REPLACEMENT PARTS
1453
OPERATION
1453
DIAGNOSIS AND TESTING - FUEL DELIVERY SYSTEM
1453
STANDARD PROCEDURE
1453
STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE
1453
STANDARD PROCEDURE - DRAINING FUEL TANK
1453
SPECIFICATIONS
1454
FUEL SYSTEM PRESSURE
1454
TORQUE
1454
SPECIAL TOOLS
1454
FUEL
1454
FUEL FILTER
1455
REMOVAL
1455
INSTALLATION
1455
FUEL LEVEL SENDING UNIT / SENSOR
1455
DESCRIPTION
1455
OPERATION
1455
REMOVAL
1455
INSTALLATION
1457
FUEL LINES
1457
DESCRIPTION - FUEL LINES/HOSES AND CLAMPS
1457
STANDARD PROCEDURE - HOSES AND CLAMP
1457
FUEL PRESSURE REGULATOR
1458
OPERATION
1458
REMOVAL
1458
INSTALLATION
1458
FUEL PUMP
1458
DESCRIPTION
1458
OPERATION
1458
FUEL PUMP MODULE
1459
DESCRIPTION
1459
OPERATION
1459
FUEL PUMP ELECTRICAL CONTROL
1459
ELECTRICAL PUMP REPLACEMENT
1459
REMOVAL
1459
INSTALLATION
1460
FUEL RAIL
1460
REMOVAL
1460
REMOVAL - 2.4L
1460
REMOVAL - 3.3/3.8L
1460
INSTALLATION
1461
INSTALLATION - 2.4L
1461
INSTALLATION - 3.3/3.8L
1461
FUEL TANK
1461
DESCRIPTION
1461
OPERATION
1461
REMOVAL
1462
INSTALLATION
1462
FUEL TANK FILLER TUBE
1463
REMOVAL
1463
INSTALLATION
1463
INLET FILTER
1464
REMOVAL
1464
INSTALLATION
1464
QUICK CONNECT FITTING
1464
STANDARD PROCEDURE - QUICK-CONNECT FITTINGS
1464
REMOVAL
1464
INSTALLATION
1464
TWO-TAB TYPE FITTING
1465
PLASTIC RETAINER RING TYPE FITTING
1466
FUEL INJECTION
1467
FUEL INJECTION
1468
OPERATION
1468
OPERATION - INJECTION SYSTEM
1468
OPERATION - MODES OF OPERATION
1468
IGNITION SWITCH ON (ZERO RPM) MODE
1468
ENGINE START-UP MODE
1469
ENGINE WARM-UP MODE
1469
CRUISE OR IDLE MODE
1469
ACCELERATION MODE
1470
DECELERATION MODE
1470
WIDE-OPEN-THROTTLE MODE
1470
IGNITION SWITCH OFF MODE
1470
FUEL CORRECTION or ADAPTIVE MEMORIES
1470
DESCRIPTION
1470
OPERATION
1470
PROGRAMMABLE COMMUNICATIONS INTERFACE (PCI) BUS
1471
DESCRIPTION
1471
OPERATION
1471
SYSTEM DIAGNOSIS
1472
OPERATION
1472
SPECIFICATIONS
1472
TORQUE
1472
SPECIAL TOOLS
1473
FUEL
1473
ACCELERATOR PEDAL
1473
REMOVAL
1473
INSTALLATION
1474
CRANKSHAFT POSITION SENSOR
1474
DESCRIPTION
1474
OPERATION
1475
REMOVAL
1475
INSTALLATION - 2.4L
1475
ENGINE SPEED SENSOR
1475
DESCRIPTION
1475
OPERATION
1476
FUEL INJECTOR
1476
DESCRIPTION
1476
OPERATION
1476
REMOVAL
1476
REMOVAL - 2.4L
1476
REMOVAL - 3.3/3.8L
1477
INSTALLATION
1477
INSTALLATION - 2.4L
1477
INSTALLATION - 3.3/3.8L
1477
FUEL PUMP RELAY
1478
DESCRIPTION
1478
OPERATION
1478
IDLE AIR CONTROL MOTOR
1478
DESCRIPTION
1478
OPERATION
1478
Target Idle
1478
REMOVAL
1479
INSTALLATION
1479
INLET AIR TEMPERATURE SENSOR
1479
DESCRIPTION
1479
OPERATION
1479
Inlet/Intake Air Temperature
1479
Battery Temperature
1479
MAP SENSOR
1480
DESCRIPTION
1480
OPERATION
1480
REMOVAL
1481
REMOVAL - 2.4L
1481
REMOVAL - 3.3/3.8L
1481
INSTALLATION
1481
INSTALLATION - 2.4L
1481
INSTALLATION - 3.3/3.8L
1481
O2 SENSOR
1481
DESCRIPTION
1481
OPERATION
1482
UPSTREAM OXYGEN SENSOR
1482
DOWNSTREAM OXYGEN SENSOR
1482
REMOVAL
1483
REMOVAL - UPSTREAM 1/1 - 2.4L
1483
REMOVAL - UPSTREAM 1/1 - 3.3/3.8L
1483
REMOVAL - DOWNSTREAM 1/2 - 2.4/3.3/3.8L
1483
INSTALLATION
1483
INSTALLATION - UPSTREAM 1/1 - 2.4L
1483
INSTALLATION - UPSTREAM 1/1 - 3.3/3.8L
1484
INSTALLATION DOWNSTREAM 2/1 - 2.4/3.3/3.8L
1484
THROTTLE BODY
1484
DESCRIPTION
1484
OPERATION
1484
REMOVAL
1485
INSTALLATION
1485
THROTTLE CONTROL CABLE
1485
REMOVAL
1485
INSTALLATION
1485
THROTTLE POSITION SENSOR
1486
DESCRIPTION
1486
OPERATION
1486
REMOVAL - 3.3/3.8L
1486
INSTALLATION - 3.3/3.8L
1486
14a-FUEL SYSTEM
1488
FUEL SYSTEM 2.5L TURBO DIESEL
1488
DESCRIPTION - DIESEL FUEL DELIVERY SYSTEM
1488
WARNING - HIGH FUEL SYSTEM PRESSURE
1488
DIAGNOSIS AND TESTING
1488
DIAGNOSIS AND TESTING - AIR IN FUEL SYSTEM
1488
DIAGNOSIS AND TESTING - FUEL SUPPLY RESTRICTIONS
1488
LOW-PRESSURE LINES
1488
HIGH-PRESSURE LINES
1489
STANDARD PROCEDURE
1489
STANDARD PROCEDURES - DRAINING WATER FROM FUEL FILTER
1489
STANDARD PROCEDURE - FUEL SYSTEM AIR PURGE
1489
STANDARD PROCEDURES - CLEANING FUEL SYSTEM COMPONENTS
1489
SPECIFICATIONS - TORQUE
1490
FUEL DELIVERY
1491
FUEL RAIL
1491
DESCRIPTION
1491
OPERATION
1491
REMOVAL - FUEL RAIL
1491
INSTALLATION - FUEL RAIL
1492
FUEL FILTER / WATER SEPARATOR
1492
DESCRIPTION
1492
OPERATION
1492
FUEL LINES
1493
DESCRIPTION
1493
DESCRIPTION
1493
DESCRIPTION - HIGH PRESSURE FUEL LINES
1493
OPERATION - HIGH PRESSURE FUEL LINES
1493
DIAGNOSIS AND TESTING - HIGH PRESSURE FUEL LINES
1493
FUEL TRANSFER PUMP
1494
DESCRIPTION
1494
OPERATION
1494
FUEL INJECTION PUMP
1494
DESCRIPTION
1494
REMOVAL
1494
INSTALLATION
1496
WATER IN FUEL SENSOR
1497
DESCRIPTION
1497
OPERATION
1497
FUEL INJECTION
1498
FUEL INJECTOR
1498
DESCRIPTION
1498
FUEL INJECTOR
1498
OPERATION
1498
Injector closed (with high pressure applied)
1498
Injector opens (start of injection)
1499
Injector opens fully
1499
Injector closes (end of injection)
1499
REMOVAL
1499
INSTALLATION
1500
ACCELERATOR PEDAL POSITION SENSOR
1500
DESCRIPTION
1500
OPERATION
1500
REMOVAL
1501
REMOVAL - PEDAL POSITION SENSOR (LHD)
1501
REMOVAL - PEDAL POSITION SENSOR (RHD)
1501
INSTALLATION
1501
INSTALLATION - PEDAL POSITION SENSOR (LHD)
1501
INSTALLATION - PEDAL POSITION SENSOR (RHD)
1501
BOOST PRESSURE SENSOR
1501
DESCRIPTION
1501
OPERATION
1501
DIAGNOSIS AND TESTING - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR
1501
INTAKE AIR TEMPERATURE SENSOR
1502
DESCRIPTION
1502
OPERATION
1502
REMOVAL
1502
INSTALLATION
1502
CRANKSHAFT POSITION SENSOR
1502
DESCRIPTION
1502
OPERATION
1502
MASS AIR FLOW (MAF) SENSOR
1503
DESCRIPTION
1503
OPERATION
1503
REMOVAL
1503
INSTALLATION
1503
19-STEERING
1504
STEERING
1504
DESCRIPTION - POWER STEERING SYSTEM
1504
OPERATION - POWER STEERING SYSTEM
1504
DIAGNOSIS AND TESTING
1504
DIAGNOSIS AND TESTING - POWER STEERING SYSTEM FLOW AND PRESSURE TEST
1504
ALL ENGINES
1504
DIAGNOSIS AND TESTING - STEERING SYSTEM DIAGNOSIS CHARTS
1506
POWER STEERING NOISE
1506
STEERING WHEEL FEEL
1508
POWER STEERING FLUID
1511
SPECIFICATIONS
1512
POWER STEERING FASTENER TORQUE
1512
SPECIAL TOOLS
1512
POWER STEERING
1512
COLUMN
1513
COLUMN
1513
DESCRIPTION - STEERING COLUMN
1513
WARNING
1513
WARNINGS AND CAUTIONS
1513
DIAGNOSIS AND TESTING - STEERING COLUMN
1515
REMOVAL
1515
INSTALLATION
1516
SPECIFICATIONS
1517
COLUMN TORQUE
1517
IGNITION SWITCH
1518
REMOVAL
1518
INSTALLATION
1519
LOCK CYLINDER HOUSING
1520
DESCRIPTION - IGNITION INTERLOCK
1520
REMOVAL
1520
INSTALLATION
1523
KEY/LOCK CYLINDER
1524
DESCRIPTION
1524
OPERATION
1524
REMOVAL
1525
INSTALLATION
1525
GEAR SHIFT LEVER
1525
REMOVAL
1525
INSTALLATION
1525
SHROUD
1526
REMOVAL
1526
INSTALLATION
1526
STEERING WHEEL
1526
REMOVAL
1526
INSTALLATION
1528
GEAR
1529
GEAR
1529
DESCRIPTION
1529
OPERATION
1529
WARNING
1529
WARNINGS AND CAUTIONS
1529
REMOVAL
1529
REMOVAL - LHD GEAR
1529
REMOVAL - RHD GEAR
1532
INSTALLATION
1535
INSTALLATION - LHD GEAR
1535
INSTALLATION - RHD GEAR
1536
SPECIAL TOOLS
1537
POWER STEERING GEAR
1537
OUTER TIE ROD
1537
REMOVAL
1537
INSTALLATION
1537
PUMP
1539
PUMP
1539
DESCRIPTION
1539
DESCRIPTION - PUMP (2.4L/3.3L/3.8L ENGINE)
1539
DESCRIPTION - PUMP (2.5L DIESEL)
1540
OPERATION
1540
WARNING
1540
CAUTION
1540
STANDARD PROCEDURE - POWER STEERING PUMP INITIAL OPERATION
1540
REMOVAL
1541
REMOVAL - PUMP (2.4L ENGINE)
1541
REMOVAL - PUMP (3.3L/3.8L ENGINE)
1543
REMOVAL - PUMP (2.5L DIESEL)
1544
DISASSEMBLY - PUMP (PULLEY)
1544
ASSEMBLY - PUMP (PULLEY)
1545
INSTALLATION
1546
INSTALLATION - PUMP (2.4L ENGINE)
1546
INSTALLATION - PUMP (3.3L/3.8L ENGINE)
1546
INSTALLATION - PUMP (2.5L DIESEL)
1546
SPECIAL TOOLS
1547
POWER STEERING PUMP
1547
FLUID
1547
STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING
1547
FLUID COOLER
1548
DESCRIPTION
1548
OPERATION
1548
REMOVAL
1548
INSTALLATION
1548
HOSE - POWER STEERING PRESSURE
1548
REMOVAL
1548
REMOVAL - 2.4L ENGINE
1548
REMOVAL - 3.3L/3.8L ENGINE
1549
INSTALLATION
1549
INSTALLATION - 2.4L ENGINE
1549
INSTALLATION - 3.3L/3.8L ENGINE
1550
HOSE - POWER STEERING RETURN
1552
REMOVAL
1552
REMOVAL - 2.4L ENGINE
1552
REMOVAL - 3.3L/3.8L ENGINE
1552
INSTALLATION
1553
INSTALLATION - 2.4L ENGINE
1553
INSTALLATION - 3.3L/3.8L ENGINE
1553
HOSE - POWER STEERING SUPPLY
1554
REMOVAL
1554
REMOVAL - 2.4L ENGINE
1554
REMOVAL - 3.3L/3.8L ENGINE
1554
INSTALLATION
1554
INSTALLATION - 2.4L ENGINE
1554
INSTALLATION - 3.3L/3.8L ENGINE
1554
RESERVOIR - POWER STEERING FLUID
1554
DESCRIPTION
1554
DESCRIPTION - 2.4L/3.3L/3.8L ENGINE
1554
DESCRIPTION - 2.5L DIESEL
1555
OPERATION
1555
REMOVAL
1555
REMOVAL - 2.4L ENGINE
1555
REMOVAL - 3.3L/3.8L ENGINE
1555
REMOVAL - 2.5L DIESEL
1555
INSTALLATION
1556
INSTALLATION - 2.4L ENGINE
1556
INSTALLATION - 3.3L/3.8L ENGINE
1556
INSTALLATION - 2.5L DIESEL
1556
21-TRANSMISSION/TRANSAXLE
1558
POWER TRANSFER UNIT
1558
POWER TRANSFER UNIT
1558
DESCRIPTION
1558
OPERATION
1560
DIAGNOSIS AND TESTING
1560
SEAL IDENTIFICATION
1560
FLUID LEAK DIAGNOSIS
1561
STANDARD PROCEDURE
1562
STANDARD PROCEDURE - FLUID LEVEL INSPECTION
1562
STANDARD PROCEDURE - PTU FLUID CHANGE
1562
REMOVAL
1563
INSTALLATION
1564
ADJUSTMENTS
1564
OUTPUT FLANGE SHIM SELECTION
1564
SPECIFICATIONS
1565
TORQUE
1565
SPECIAL TOOLS
1565
SDP POWER TRANSFER UNIT
1565
DIFFERENTIAL CARRIER SEAL
1566
REMOVAL
1566
INSTALLATION
1566
END COVER BALL BEARING
1566
REMOVAL
1566
INSTALLATION
1567
END COVER SEAL
1568
REMOVAL
1568
INSTALLATION
1568
HALF SHAFT INNER SEAL
1569
REMOVAL
1569
INSTALLATION
1570
INPUT SHAFT COVER SEAL
1570
REMOVAL
1570
INSTALLATION
1571
INPUT SHAFT END SEAL
1573
REMOVAL
1573
INSTALLATION
1573
INPUT SHAFT SEAL
1574
REMOVAL
1574
INSTALLATION
1575
OUTER HALF SHAFT SEAL
1576
REMOVAL
1576
INSTALLATION
1576
REAR COVER O-RING
1576
REMOVAL
1576
INSTALLATION
1577
31TH AUTOMATIC TRANSAXLE
1578
31TH AUTOMATIC TRANSAXLE
1579
DESCRIPTION
1579
OPERATION
1581
DIAGNOSIS AND TESTING
1581
DIAGNOSIS AND TESTING - PRELIMINARY DIAGNOSIS
1581
TRANSAXLE DIAGNOSIS CHARTS
1582
DIAGNOSIS AND TESTING - ROAD TEST
1588
DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TESTS
1589
TEST ONE (SELECTOR IN 1)
1589
TEST TWO (SELECTOR IN 2)
1590
TEST THREE (SELECTOR IN D)
1591
TEST FOUR (SELECTOR IN REVERSE)
1591
TEST RESULT INDICATIONS
1591
GOVERNOR PRESSURE
1591
THROTTLE PRESSURE
1591
DIAGNOSIS AND TESTING - TORQUE CONVERTER HOUSING FLUID LEAKAGE
1592
TORQUE CONVERTER LEAKAGE
1592
DIAGNOSIS AND TESTING - CLUTCH AND SERVO AIR PRESSURE TESTS
1592
FRONT CLUTCH
1592
REAR CLUTCH
1593
KICKDOWN SERVO (FRONT)
1593
LOW AND REVERSE SERVO (REAR)
1593
STANDARD PROCEDURE - ALUMINUM THREAD REPAIR
1594
REMOVAL
1594
DISASSEMBLY
1597
ASSEMBLY
1608
INSTALLATION
1618
SCHEMATICS AND DIAGRAMS
1621
31TH TRANSAXLE HYDRAULIC SCHEMATICS
1621
SPECIFICATIONS
1629
31TH AUTOMATIC TRANSAXLE
1629
SPECIAL TOOLS
1632
31TH AUTOMATIC TRANSAXLE
1632
ACCUMULATOR
1636
DESCRIPTION
1636
OPERATION
1636
BANDS
1637
DESCRIPTION
1637
KICKDOWN (FRONT) BAND
1637
DESCRIPTION
1637
OPERATION
1637
OPERATION
1637
LOW/REVERSE (REAR) BAND
1637
DESCRIPTION
1637
OPERATION
1637
ADJUSTMENTS
1637
ADJUSTMENT - FRONT BAND
1637
ADJUSTMENTS - REAR BAND
1637
CLUTCH - FRONT
1639
DESCRIPTION
1639
OPERATION
1639
DISASSEMBLY
1639
ASSEMBLY
1641
CLUTCH - REAR
1643
DESCRIPTION
1643
OPERATION
1643
DISASSEMBLY
1644
ASSEMBLY
1646
FINAL DRIVE
1648
DISASSEMBLY
1648
ASSEMBLY
1651
ADJUSTMENTS
1654
ADJUSTMENT - DIFFERENTIAL BEARING
1654
FLUID
1656
STANDARD PROCEDURE
1656
STANDARD PROCEDURE - FLUID LEVEL AND CONDITION CHECK
1656
FLUID LEVEL CHECK
1656
FLUID CONDITION
1656
STANDARD PROCEDURE - FLUID AND FILTER CHANGE
1656
FLUID/FILTER SERVICE (RECOMMENDED)
1656
DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE)
1657
GEAR SHIFT CABLE
1658
REMOVAL
1658
INSTALLATION
1659
ADJUSTMENTS
1661
GEARSHIFT CABLE ADJUSTMENT
1661
GOVERNOR
1661
DESCRIPTION
1661
OPERATION
1661
CLEANING
1661
INSPECTION
1661
OIL PUMP
1662
DESCRIPTION
1662
OPERATION
1662
STANDARD PROCEDURE - OIL PUMP VOLUME CHECK
1662
DISASSEMBLY
1663
CLEANING
1663
INSPECTION
1663
ASSEMBLY
1664
PARK/NEUTRAL POSITION SWITCH
1664
DIAGNOSIS AND TESTING - PARK/NEUTRAL POSITION SWITCH
1664
REMOVAL
1664
INSTALLATION
1664
PLANETARY GEARTRAIN
1665
DISASSEMBLY
1665
ASSEMBLY
1666
SEAL - OIL PUMP
1667
REMOVAL
1667
INSTALLATION
1667
SERVO - KICKDOWN
1668
DESCRIPTION
1668
OPERATION
1668
DISASSEMBLY
1668
CLEANING
1669
INSPECTION
1670
ASSEMBLY
1670
SERVO - LOW/REVERSE
1670
DESCRIPTION
1670
OPERATION
1670
DISASSEMBLY
1671
CLEANING
1671
ASSEMBLY
1672
SHIFT INTERLOCK SOLENOID
1672
DESCRIPTION
1672
OPERATION
1672
DIAGNOSIS AND TESTING - BRAKE/TRANSMISSION SHIFT INTERLOCK SOLENOID
1674
REMOVAL
1674
INSTALLATION
1675
SOLENOID - TCC
1676
DESCRIPTION
1676
OPERATION
1676
REMOVAL
1676
INSTALLATION
1677
THROTTLE VALVE CABLE
1677
REMOVAL
1677
INSTALLATION
1678
ADJUSTMENTS
1679
THROTTLE VALVE LINKAGE ADJUSTMENT
1679
LINKAGE ADJUSTMENT PROCEDURE
1679
TORQUE CONVERTER
1679
DESCRIPTION
1679
IMPELLER
1680
TURBINE
1681
STATOR
1682
TORQUE CONVERTER CLUTCH (TCC)
1682
OPERATION
1683
TURBINE
1683
STATOR
1684
TORQUE CONVERTER CLUTCH (TCC)
1684
REMOVAL
1684
INSTALLATION
1684
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/BEARING
1685
REMOVAL
1685
INSTALLATION
1688
ADJUSTMENTS
1692
ADJUSTMENT - OUTPUT SHAFT BEARING
1692
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING
1694
REMOVAL
1694
INSTALLATION
1698
ADJUSTMENTS
1702
ADJUSTMENT - TRANSFER SHAFT BEARING
1702
VALVE BODY
1703
REMOVAL
1703
DISASSEMBLY
1705
CLEANING
1711
INSPECTION
1712
ASSEMBLY
1712
INSTALLATION
1715
ADJUSTMENTS
1717
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS
1717
LINE PRESSURE
1717
THROTTLE PRESSURE
1717
VEHICLE SPEED SENSOR/PINION GEAR
1717
REMOVAL
1717
INSTALLATION
1717
41TE AUTOMATIC TRANSAXLE
1718
41TE AUTOMATIC TRANSAXLE
1719
DESCRIPTION
1719
TRANSAXLE IDENTIFICATION
1721
OPERATION
1721
DIAGNOSIS AND TESTING
1721
DIAGNOSIS AND TESTING - 41TE TRANSAXLE GENERAL DIAGNOSIS
1721
DIAGNOSIS AND TESTING - ROAD TEST
1722
DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TESTS
1722
TEST ONE-SELECTOR IN LOW (1st GEAR)
1723
TEST TWO-SELECTOR IN DRIVE (2nd GEAR)
1723
TEST TWO A–SELECTOR IN OD (4th Gear)
1723
TEST THREE-OVERDRIVE CLUTCH CHECK (3rd and 2nd Gear)
1723
TEST FOUR-SELECTOR IN OVERDRIVE (4th Gear)
1723
TEST FIVE-SELECTOR IN OVERDRIVE (4th Gear-CC on)
1723
TEST SIX-SELECTOR IN REVERSE
1724
TEST RESULT INDICATIONS
1724
DIAGNOSIS AND TESTING - CLUTCH AIR PRESSURE TESTS
1725
OVERDRIVE CLUTCH
1725
REVERSE CLUTCH
1725
2/4 CLUTCH
1725
LOW/REVERSE CLUTCH
1725
UNDERDRIVE CLUTCH
1725
DIAGNOSIS AND TESTING - TORQUE CONVERTER HOUSING FLUID LEAKAGE
1725
TORQUE CONVERTER LEAKAGE
1726
REMOVAL
1726
DISASSEMBLY
1728
ASSEMBLY
1747
INSTALLATION
1770
SCHEMATICS AND DIAGRAMS
1773
41TE TRANSAXLE HYDRAULIC SCHEMATICS
1773
SPECIFICATIONS - 41TE TRANSAXLE
1785
SPECIAL TOOLS
1787
41TE AUTOMATIC TRANSAXLE
1787
ACCUMULATOR
1793
DESCRIPTION
1793
OPERATION
1793
AUTOSTICK SWITCH
1794
DESCRIPTION
1794
OPERATION
1794
DRIVING CLUTCHES
1794
DESCRIPTION
1794
OPERATION
1795
UNDERDRIVE CLUTCH
1795
OVERDRIVE CLUTCH
1795
REVERSE CLUTCH
1795
FINAL DRIVE
1795
DISASSEMBLY
1795
ASSEMBLY
1800
ADJUSTMENTS
1803
ADJUSTMENT - DIFFERENTIAL BEARING PRELOAD
1803
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING EXISTING SHIM
1803
PRELOAD ADJUSTMENT W/O SHIM
1805
FLUID
1806
STANDARD PROCEDURE
1806
FLUID LEVEL AND CONDITION CHECK
1806
FLUID LEVEL CHECK
1806
FLUID LEVEL CHECK USING DRB
1806
FLUID CONDITION
1807
STANDARD PROCEDURE - FLUID AND FILTER SERVICE
1807
FLUID/FILTER SERVICE (RECOMMENDED)
1807
DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE)
1808
GEAR SHIFT CABLE
1808
REMOVAL
1808
INSTALLATION
1810
ADJUSTMENTS
1811
GEARSHIFT CABLE ADJUSTMENT
1811
VERIFICATION
1811
ADJUSTMENT
1811
HOLDING CLUTCHES
1812
DESCRIPTION
1812
OPERATION
1812
2/4 CLUTCH
1812
LOW/REVERSE CLUTCH
1812
INPUT CLUTCH ASSEMBLY
1812
DISASSEMBLY
1812
ASSEMBLY
1820
OIL PUMP
1829
DESCRIPTION
1829
OPERATION
1829
STANDARD PROCEDURE - OIL PUMP VOLUME CHECK
1829
DISASSEMBLY
1830
ASSEMBLY
1831
PLANETARY GEARTRAIN
1831
DESCRIPTION
1831
OPERATION
1831
SEAL - OIL PUMP
1832
REMOVAL
1832
INSTALLATION
1832
SHIFT INTERLOCK SOLENOID
1832
DESCRIPTION
1832
OPERATION
1833
DIAGNOSIS AND TESTING - BRAKE/TRANSMISSION SHIFT INTERLOCK SOLENOID
1834
REMOVAL
1834
INSTALLATION
1835
SOLENOID/PRESSURE SWITCH ASSY
1836
DESCRIPTION
1836
OPERATION
1837
SOLENOIDS
1837
PRESSURE SWITCHES
1837
REMOVAL
1837
INSTALLATION
1838
SPEED SENSOR - INPUT
1838
DESCRIPTION
1838
OPERATION
1839
REMOVAL
1839
INSTALLATION
1840
SPEED SENSOR - OUTPUT
1840
DESCRIPTION
1840
OPERATION
1840
VEHICLE SPEED SIGNAL
1841
REMOVAL
1841
INSTALLATION
1841
TORQUE CONVERTER
1842
DESCRIPTION
1842
IMPELLER
1843
TURBINE
1844
STATOR
1845
TORQUE CONVERTER CLUTCH (TCC)
1845
OPERATION
1846
TURBINE
1846
STATOR
1846
TORQUE CONVERTER CLUTCH (TCC)
1846
REMOVAL
1847
INSTALLATION
1847
TRANSMISSION CONTROL RELAY
1848
DESCRIPTION
1848
OPERATION
1848
TRANSMISSION RANGE SENSOR
1848
DESCRIPTION
1848
OPERATION
1849
TRANSMISSION TEMPERATURE SENSOR
1849
CALCULATED TEMPERATURE
1849
REMOVAL
1849
INSTALLATION
1849
TRD LINK
1849
DESCRIPTION
1849
OPERATION
1849
VALVE BODY
1850
DESCRIPTION
1850
OPERATION
1850
REGULATOR VALVE
1850
SOLENOID SWITCH VALVE
1851
MANUAL VALVE
1851
CONVERTER CLUTCH SWITCH VALVE
1851
CONVERTER CLUTCH CONTROL VALVE
1851
T/C REGULATOR VALVE
1851
LOW/REVERSE SWITCH VALVE
1851
REMOVAL
1851
REMOVAL
1851
REMOVAL
1853
DISASSEMBLY
1854
ASSEMBLY
1858
INSTALLATION
1863
T850 MANUAL TRANSAXLE
1865
T850 MANUAL TRANSAXLE
1865
DESCRIPTION
1865
TRANSAXLE IDENTIFICATION
1867
OPERATION
1868
NEUTRAL
1868
1ST GEAR
1869
2ND GEAR
1870
3RD GEAR
1871
4TH GEAR
1872
5TH GEAR
1873
REVERSE GEAR
1874
DIAGNOSIS AND TESTING - COMMON PROBLEM CAUSES
1875
HARD SHIFTING
1875
NOISY OPERATION
1875
SLIPS OUT OF GEAR
1875
LOW LUBRICANT LEVEL
1875
CLUTCH PROBLEMS
1875
REMOVAL
1875
REMOVAL - 2.4L GAS
1875
REMOVAL - 2.5L TD
1877
DISASSEMBLY
1880
ASSEMBLY
1886
INSTALLATION
1895
INSTALLATION - 2.4L GAS
1895
INSTALLATION - 2.5L TD
1897
SPECIFICATIONS - T850 MANUAL TRANSAXLE
1900
SPECIAL TOOLS - T850 TRANSAXLE
1902
AXLE SEALS
1905
REMOVAL
1905
INSTALLATION
1905
BACK-UP LAMP SWITCH
1906
REMOVAL
1906
INSTALLATION
1906
DIFFERENTIAL
1906
DESCRIPTION
1906
OPERATION
1906
DISASSEMBLY
1907
ASSEMBLY
1910
ADJUSTMENTS
1913
ADJUSTMENT - DIFFERENTIAL TURNING TORQUE
1913
ADJUSTMENT - DIFFERENTIAL SIDE GEAR END PLAY
1915
FLUID
1915
STANDARD PROCEDURE
1915
STANDARD PROCEDURE - FLUID LEVEL CHECK
1915
STANDARD PROCEDURE - FLUID DRAIN AND FILL
1916
FLUID DRAIN
1916
FLUID FILL
1916
GEARSHIFT BOOT
1916
REMOVAL
1916
INSTALLATION
1917
GEARSHIFT CABLE - CROSSOVER
1917
REMOVAL
1917
INSTALLATION
1920
ADJUSTMENTS
1923
ADJUSTMENT
1923
GEARSHIFT CABLE - SELECTOR
1925
REMOVAL
1925
INSTALLATION
1928
GEARSHIFT KNOB
1931
REMOVAL
1931
INSTALLATION
1931
GEARSHIFT MECHANISM
1932
REMOVAL
1932
INSTALLATION
1934
INPUT SHAFT
1937
DESCRIPTION
1937
DISASSEMBLY
1937
ASSEMBLY
1940
INTERMEDIATE SHAFT
1944
DESCRIPTION
1944
DISASSEMBLY
1945
ASSEMBLY
1952
SHIFT COVER
1958
DESCRIPTION
1958
SHIFT FORK AND SHAFT
1959
DESCRIPTION
1959
SYNCHRONIZER
1959
DESCRIPTION
1959
DISASSEMBLY
1959
CLEANING
1959
CLEAN
1959
INSPECTION
1959
INSPECT
1959
ASSEMBLY
1960
VEHICLE SPEED SENSOR
1960
REMOVAL
1960
INSTALLATION
1960
22-TIRES/WHEELS
1962
TIRES/WHEELS
1962
DIAGNOSIS AND TESTING - TIRE AND WHEEL VIBRATION
1962
VISUAL INSPECTION
1962
ROAD TEST
1963
TIRE AND WHEEL BALANCE
1963
TIRE AND WHEEL RUNOUT/MATCH MOUNTING
1963
RADIAL FORCE VARIATION
1965
STANDARD PROCEDURE
1966
STANDARD PROCEDURE - TIRE AND WHEEL BALANCE
1966
STANDARD PROCEDURE - TIRE AND WHEEL MATCH MOUNTING
1966
STANDARD PROCEDURE - TIRE AND WHEEL ROTATION
1968
NON-DIRECTIONAL TREAD PATTERN TIRES
1968
DIRECTIONAL TREAD PATTERN TIRES
1968
REMOVAL
1968
REMOVAL - TIRE AND WHEEL ASSEMBLY (ALUMINUM WHEEL)
1968
REMOVAL - TIRE AND WHEEL ASSEMBLY (STEEL WHEEL)
1968
INSTALLATION
1969
INSTALLATION - TIRE AND WHEEL ASSEMBLY (ALUMINUM WHEEL)
1969
INSTALLATION - TIRE AND WHEEL ASSEMBLY (STEEL WHEEL)
1969
TIRE PRESSURE MONITORING (TPM)
1970
DESCRIPTION
1970
OPERATION
1970
SENSOR - TPM
1971
DESCRIPTION
1971
OPERATION
1971
CAUTION
1971
DIAGNOSIS AND TESTING - TIRE PRESSURE SENSOR
1971
STANDARD PROCEDURE - TIRE PRESSURE SENSOR RETRAIN
1971
REMOVAL
1972
INSTALLATION
1972
TIRES
1974
DESCRIPTION
1974
DESCRIPTION - TIRE
1974
TIRE IDENTIFICATION
1974
TIRE CHAINS
1974
DESCRIPTION - RADIAL-PLY TIRES
1974
DESCRIPTION - REPLACEMENT TIRES
1975
DESCRIPTION - SPARE TIRE (TEMPORARY)
1975
DIAGNOSIS AND TESTING
1975
DIAGNOSIS AND TESTING - TIRE NOISE
1975
DIAGNOSIS AND TESTING - TIRE/VEHICLE LEAD
1975
DIAGNOSIS AND TESTING - TIRE WEAR PATTERNS
1975
DIAGNOSIS AND TESTING - TREAD WEAR INDICATORS
1975
STANDARD PROCEDURE
1975
STANDARD PROCEDURE - TIRE INFLATION PRESSURES
1975
STANDARD PROCEDURE - TIRE PRESSURE FOR HIGH SPEED OPERATION
1978
STANDARD PROCEDURE - TIRE LEAK REPAIRING
1978
CLEANING - TIRES
1978
WHEELS
1978
DESCRIPTION - WHEEL
1978
DIAGNOSIS AND TESTING - WHEEL INSPECTION
1979
CLEANING - ALUMINUM WHEEL CARE
1979
SPECIFICATIONS
1980
WHEEL
1980
WHEEL COVER
1980
DESCRIPTION
1980
REMOVAL
1980
INSTALLATION
1980
WHEEL MOUNTING STUDS - FRONT
1981
REMOVAL
1981
INSTALLATION
1982
WHEEL MOUNTING STUDS - REAR
1982
REMOVAL
1982
INSTALLATION
1983
23-BODY
1984
BODY
1984
DESCRIPTION - VEHICLE IDENTIFICATION
1984
WARNING
1984
SAFETY PRECAUTIONS AND WARNINGS
1984
DIAGNOSIS AND TESTING
1984
DIAGNOSIS AND TESTING - WATER LEAKS
1984
VISUAL INSPECTION BEFORE WATER LEAK TESTS
1985
WATER LEAK TESTS
1985
WATER LEAK DETECTION
1985
DIAGNOSIS AND TESTING - WIND NOISE
1985
VISUAL INSPECTION BEFORE TESTS
1986
STANDARD PROCEDURE
1986
STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR
1986
Rigid Plastics:
1986
Semi-Rigid Plastics:
1986
Flexible Plastics:
1986
Repair Procedure:
1986
Adhesion Promoter/Surface Modifier:
1986
SAFETY PRECAUTION AND WARNINGS
1986
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES
1987
PANEL SECTIONING
1989
PANEL REINFORCEMENT
1989
VISUAL INSPECTION
1990
PANEL SURFACE PREPARATION
1990
PATCHING PANELS
1990
PANEL PATCH FABRICATIONS
1991
PANEL PATCH INSTALLATION
1991
PATCHED PANEL SURFACING
1993
STANDARD PROCEDURE - HEAT STAKING
1993
SPECIFICATIONS
1994
TORQUE
1994
BODY LUBRICATION
1995
LUBRICATION REQUIREMENTS
1995
LUBRICANT APPLICATION
1995
LUBRICANT USAGE
1995
SPECIAL TOOLS
1996
BODY
1996
DOOR - FRONT
1997
APPLIQUE
1997
REMOVAL
1997
INSTALLATION
1997
CHECK STRAP
1997
REMOVAL
1997
INSTALLATION
1997
DOOR
1998
REMOVAL
1998
INSTALLATION
1999
DOOR GLASS
1999
REMOVAL
1999
INSTALLATION
2000
FRAME CLOSEOUT MOLDING
2000
REMOVAL – A-PILLAR, HEADER, OR B-PILLAR
2000
INSTALLATION – A-PILLAR, HEADER, OR B-PILLAR
2000
HINGE
2001
REMOVAL
2001
INSTALLATION
2001
LATCH
2001
REMOVAL
2001
INSTALLATION
2001
LATCH STRIKER
2002
REMOVAL
2002
INSTALLATION
2002
LOCK CYLINDER
2002
REMOVAL
2002
INSTALLATION
2003
TRIM PANEL
2003
REMOVAL
2003
INSTALLATION
2004
WATERSHIELD
2004
REMOVAL
2004
INSTALLATION
2004
WINDOW CRANK
2004
REMOVAL
2004
INSTALLATION
2004
WINDOW REGULATOR
2005
REMOVAL
2005
INSTALLATION
2005
EXTERIOR HANDLE
2006
REMOVAL
2006
INSTALLATION
2006
DOORS - SLIDING
2007
CENTER HINGE
2007
REMOVAL
2007
INSTALLATION
2007
SLIDING DOOR STOP BUMPER BEZEL
2008
REMOVAL
2008
INSTALLATION
2008
STOP BUMPER
2008
REMOVAL
2008
INSTALLATION
2008
HOLD OPEN LATCH
2008
REMOVAL
2008
INSTALLATION
2008
HOLD OPEN LATCH STRIKER
2009
REMOVAL
2009
INSTALLATION
2009
LATCH / LOCK ASSEMBLY
2009
REMOVAL
2009
INSTALLATION
2009
CENTER STRIKER
2010
REMOVAL
2010
INSTALLATION
2010
LOWER HINGE
2011
REMOVAL
2011
INSTALLATION
2011
REAR LATCH STRIKER
2011
REMOVAL
2011
INSTALLATION
2011
SLIDING DOOR
2012
REMOVAL
2012
INSTALLATION
2012
ADJUSTMENTS
2013
SLIDING DOOR ADJUSTMENTS
2013
PRELIMINARY CHECKS
2013
DOOR FLUSHNESS ADJUSTMENT
2013
DOOR GAP ADJUSTMENT - UP/DOWN
2013
DOOR GAP ADJUSTMENT - FORE/AFT
2014
DOOR SEAL COMPRESSION
2015
STABILIZER ADJUSTMENT - UPPER/LOWER
2015
STABILIZER
2015
REMOVAL
2015
INSTALLATION
2015
STABILIZER SOCKET
2016
REMOVAL
2016
INSTALLATION
2016
TRIM PANEL
2016
REMOVAL
2016
INSTALLATION
2016
INSIDE LATCH HANDLE
2016
REMOVAL
2016
INSTALLATION
2017
BELLCRANK
2017
REMOVAL
2017
INSTALLATION
2017
OUTSIDE HANDLE
2018
REMOVAL
2018
INSTALLATION
2018
UPPER HINGE
2019
REMOVAL
2019
INSTALLATION
2019
OUTSIDE HANDLE CABLE
2019
REMOVAL
2019
INSTALLATION
2020
INSIDE HANDLE CABLE
2020
REMOVAL
2020
INSTALLATION
2020
HOLD OPEN LATCH CABLE
2021
REMOVAL
2021
INSTALLATION
2021
DECKLID/HATCH/LIFTGATE/TAILGATE
2022
EXTERIOR HANDLE
2022
REMOVAL
2022
INSTALLATION
2022
HINGE
2022
REMOVAL
2022
INSTALLATION
2022
LATCH
2023
REMOVAL
2023
INSTALLATION
2023
LATCH STRIKER
2023
REMOVAL
2023
INSTALLATION
2023
LIFTGATE
2023
REMOVAL
2023
INSTALLATION
2024
LIFTGATE SPOILER
2024
REMOVAL
2024
INSTALLATION
2024
LOCK CYLINDER
2025
REMOVAL
2025
INSTALLATION
2025
SUPPORT CYLINDER
2025
REMOVAL
2025
INSTALLATION
2025
TRIM PANEL
2025
REMOVAL
2025
INSTALLATION
2026
SLAM BUMPER
2026
REMOVAL
2026
REMOVAL
2026
REMOVAL - LIFTGATE SIDE
2026
INSTALLATION
2026
INSTALLATION
2026
INSTALLATION - LIFTGATE SIDE
2026
EXTERIOR
2027
BODY SIDE MOLDINGS
2027
REMOVAL
2027
INSTALLATION
2028
COWL GRILLE
2033
REMOVAL
2033
INSTALLATION
2033
EXTERIOR NAME PLATES - TAPE ATTACHED
2033
REMOVAL
2033
INSTALLATION
2034
EXTERIOR NAME PLATES - ADHESIVE ATTACHED
2034
REMOVAL
2034
INSTALLATION
2034
FRONT FENDER
2034
REMOVAL
2034
INSTALLATION
2034
FUEL FILL DOOR
2035
REMOVAL
2035
INSTALLATION
2035
FUEL FILL DOOR BLOCKER LATCH
2035
REMOVAL
2035
INSTALLATION
2035
FUEL FILL DOOR BLOCKER LATCH STRIKER
2036
REMOVAL
2036
INSTALLATION
2036
FUEL FILL DOOR BLOCKER LOCKOUT LINK
2036
REMOVAL
2036
INSTALLATION
2037
GRILLE OPENING REINFORCEMENT
2037
REMOVAL
2037
INSTALLATION
2037
FRONT WHEELHOUSE SPLASH SHIELD
2038
REMOVAL
2038
INSTALLATION
2038
LUGGAGE RACK RISER
2038
REMOVAL
2038
INSTALLATION
2039
LUGGAGE RACK CROSSBAR
2039
REMOVAL
2039
INSTALLATION
2040
REAR QUARTER PANEL/FENDER AIR EXHAUSTER
2040
DESCRIPTION
2040
REMOVAL
2040
INSTALLATION
2041
ROOF JOINT MOLDING
2041
REMOVAL
2041
INSTALLATION
2041
SIDE VIEW MIRROR
2041
REMOVAL
2041
INSTALLATION
2041
SIDE VIEW MIRROR GLASS
2042
REMOVAL
2042
INSTALLATION
2042
HOOD
2043
HINGE
2043
REMOVAL
2043
INSTALLATION
2043
HOOD
2043
REMOVAL
2043
INSTALLATION
2044
LATCH
2044
REMOVAL
2044
INSTALLATION
2044
LATCH RELEASE CABLE
2044
REMOVAL
2044
INSTALLATION
2045
LATCH STRIKER
2045
REMOVAL
2045
INSTALLATION
2045
INSTRUMENT PANEL
2046
CLUSTER BEZEL
2046
REMOVAL
2046
INSTALLATION
2046
CUP HOLDER
2047
REMOVAL
2047
INSTALLATION
2047
GLOVE BOX
2047
REMOVAL
2047
INSTALLATION
2047
GLOVE BOX LATCH
2047
REMOVAL
2047
INSTALLATION
2047
GLOVE BOX LATCH STRIKER
2047
REMOVAL
2047
INSTALLATION
2048
INSTRUMENT PANEL ASSEMBLY
2048
REMOVAL
2048
INSTALLATION
2050
INSTRUMENT PANEL CENTER BEZEL
2051
REMOVAL
2051
INSTALLATION
2051
INSTRUMENT PANEL END CAP
2051
REMOVAL
2051
INSTALLATION
2051
INSTRUMENT PANEL TOP COVER
2052
REMOVAL
2052
INSTALLATION
2052
LOWER CONSOLE
2052
REMOVAL
2052
INSTALLATION
2052
LOWER INSTRUMENT PANEL
2053
REMOVAL
2053
INSTALLATION
2053
LOWER STEERING COLUMN COVER
2053
REMOVAL
2053
INSTALLATION
2053
STEERING COLUMN COVER BACKING PLATE
2053
REMOVAL
2053
INSTALLATION
2054
OVER STEERING COLUMN COVER
2054
REMOVAL
2054
INSTALLATION
2054
INTERIOR
2055
A-PILLAR LOWER EXTENSION TRIM
2056
REMOVAL
2056
INSTALLATION
2056
A-PILLAR TRIM
2056
REMOVAL
2056
INSTALLATION
2056
ASSIST HANDLE
2056
REMOVAL
2056
INSTALLATION
2056
B-PILLAR LOWER TRIM
2056
REMOVAL
2056
INSTALLATION
2057
B-PILLAR UPPER TRIM
2057
REMOVAL
2057
INSTALLATION
2057
CARPETS AND FLOOR MATS
2057
REMOVAL
2057
INSTALLATION
2058
COWL TRIM
2058
REMOVAL
2058
INSTALLATION
2058
C-PILLAR TRIM
2058
REMOVAL
2058
INSTALLATION
2059
DOOR SILL TRIM PLATE
2059
REMOVAL
2059
INSTALLATION
2059
HEADLINER
2059
REMOVAL
2059
INSTALLATION
2059
LEFT D-PILLAR TRIM PANEL
2060
REMOVAL
2060
INSTALLATION
2060
LIFTGATE SILL PLATE
2060
REMOVAL
2060
INSTALLATION
2060
QUARTER TRIM BOLSTER
2060
REMOVAL
2060
INSTALLATION
2060
RIGHT QUARTER TRIM PANEL
2061
REMOVAL
2061
INSTALLATION
2061
LEFT QUARTER TRIM PANEL
2061
REMOVAL
2061
INSTALLATION
2061
REAR HEADER TRIM
2062
REMOVAL
2062
INSTALLATION
2062
REAR HVAC LOUVER
2062
REMOVAL
2062
INSTALLATION
2062
REAR VIEW MIRROR
2063
REMOVAL
2063
INSTALLATION
2063
RIGHT D-PILLAR TRIM PANEL
2063
REMOVAL
2063
INSTALLATION
2063
SLIDING DOOR SILL PLATE
2063
REMOVAL
2063
INSTALLATION
2063
SUN VISOR
2064
REMOVAL
2064
INSTALLATION
2064
SUN VISOR SUPPORT
2064
REMOVAL
2064
INSTALLATION
2064
FLOOR CONSOLE TRAY
2065
REMOVAL
2065
INSTALLATION
2065
FLOOR CONSOLE TRAY - BRACKET ASSEMBLY
2065
REMOVAL
2065
INSTALLATION
2065
PAINT
2066
PAINT
2066
SPECIFICATIONS - COLOR CODE CHARTS
2066
BASE COAT/CLEARCOAT FINISH
2066
DESCRIPTION
2066
PAINT CODE
2067
DESCRIPTION
2067
PAINTED TOUCH-UP
2067
DESCRIPTION
2067
TOUCH UP PROCEDURE
2067
FINESSE SANDING/BUFFING & POLISHING
2067
DESCRIPTION
2067
SEATS
2068
CHILD SEAT MODULE
2069
REMOVAL
2069
INSTALLATION
2070
INSTALLATION
2070
SYNCHRONIZING CABLE ADJUSTMENT
2070
QUAD CHILD SEAT
2071
REMOVAL
2071
INSTALLATION
2071
HEADREST
2071
REMOVAL
2071
INSTALLATION
2071
HEADREST SLEEVE
2071
REMOVAL
2071
INSTALLATION
2072
RECLINER HANDLE
2072
REMOVAL
2072
INSTALLATION
2072
ARMREST
2072
REMOVAL
2072
INSTALLATION
2073
CENTER ARMREST 3 PASSENGER BENCH
2073
REMOVAL
2073
INSTALLATION
2073
FRONT SEAT
2073
REMOVAL
2073
INSTALLATION
2073
FRONT SEATBACK
2073
REMOVAL
2073
INSTALLATION
2074
FRONT SEATBACK ASSIST STRAP
2074
REMOVAL
2074
INSTALLATION
2075
FRONT SEATBACK PANEL
2075
REMOVAL
2075
INSTALLATION
2075
FRONT SEATBACK COVER
2075
REMOVAL
2075
INSTALLATION
2075
FRONT/QUAD SEAT CUSHION
2075
REMOVAL
2075
INSTALLATION
2076
FRONT SEAT CUSHION SIDE COVER
2076
REMOVAL
2076
INSTALLATION
2076
FRONT SEAT RISER - MANUAL TRACK
2077
REMOVAL
2077
INSTALLATION
2077
FRONT SEAT TRACK POWER ADJUSTER
2077
REMOVAL
2077
INSTALLATION
2077
FRONT SEAT TRACK MANUAL ADJUSTER
2077
REMOVAL
2077
INSTALLATION
2078
FRONT SEAT TRACK - FRONT COVER
2078
REMOVAL
2078
INSTALLATION
2078
FRONT SEAT TRACK - REAR COVER
2079
REMOVAL
2079
INSTALLATION
2079
QUAD BUCKET SEAT SIDE SHIELD/CUP HOLDER
2079
REMOVAL
2079
INSTALLATION
2079
QUAD BUCKET SEAT SIDE SHIELD - NO CUP HOLDER
2080
REMOVAL
2080
INSTALLATION
2080
QUAD BUCKET SEAT RISER
2080
REMOVAL
2080
INSTALLATION
2080
BUCKET SEAT BACK - QUAD BUCKET
2081
REMOVAL
2081
INSTALLATION
2081
BENCH SEATBACK PANEL
2082
REMOVAL
2082
INSTALLATION
2082
SEAT CUSHION COVER - QUAD BUCKET, 50/50 SPLIT, BENCH
2082
REMOVAL
2082
BENCH SEAT & 50/50 SPLIT
2082
QUAD BUCKET
2082
INSTALLATION
2083
BENCH SEAT & 50/50 SPLIT
2083
QUAD BUCKET
2083
BENCH SEAT RISER - 50/50 SPLIT
2083
REMOVAL
2083
INSTALLATION
2083
BENCH SEAT RISER - SECOND ROW
2083
REMOVAL
2083
INSTALLATION
2084
BENCH SEAT RISER - THIRD ROW
2084
REMOVAL
2084
INSTALLATION
2084
SEAT BACK HINGE COVERS - QUAD BUCKET, 50/50 SPLIT, BENCH
2084
REMOVAL
2084
INSTALLATION
2084
BENCH SEAT BACK HINGE
2084
REMOVAL
2084
INSTALLATION
2084
INSTALLATION
2084
SYNCHRONIZING CABLE ADJUSTMENT
2085
BENCH SEAT BACK
2085
REMOVAL
2085
INSTALLATION
2086
BENCH SEAT BACK COVER
2086
REMOVAL
2086
INSTALLATION
2086
BENCH SEAT TRACK
2086
REMOVAL
2086
INSTALLATION
2087
PLASTIC GROCERY BAG RETAINER
2087
REMOVAL
2087
3-PASS BENCH SEAT
2087
50/50 SPLIT BENCH SEAT
2087
INSTALLATION
2087
3-PASS BENCH SEAT
2087
50/50 SPLIT BENCH SEAT
2087
UNDER SEAT STORAGE BIN
2087
REMOVAL
2087
INSTALLATION
2088
UNDER SEAT STORAGE BIN GUIDE
2088
REMOVAL
2088
INSTALLATION
2088
UNDER SEAT STORAGE BIN LOCK/LATCH
2088
REMOVAL
2088
INSTALLATION
2088
LUMBAR SUPPORT
2089
REMOVAL
2089
INSTALLATION
2089
STATIONARY GLASS
2090
WINDSHIELD
2090
DESCRIPTION
2090
WARNING
2090
WINDSHIELD SAFETY PRECAUTIONS
2090
REMOVAL
2090
WINDSHIELD REMOVAL – EXTERIOR METHOD
2090
WINDSHIELD REMOVAL – INTERIOR METHOD
2091
INSTALLATION
2091
SLIDING DOOR GLASS
2092
REMOVAL
2092
INSTALLATION
2092
QUARTER WINDOW
2093
REMOVAL
2093
INSTALLATION
2093
REAR DOOR GLASS
2093
REMOVAL
2093
REAR WINDOW REMOVAL – EXTERIOR METHOD
2093
REAR WINDOW REMOVAL – INTERIOR METHOD
2093
INSTALLATION
2093
WEATHERSTRIP/SEALS
2095
FRONT DOOR GLASS RUN WEATHERSTRIP
2095
REMOVAL
2095
INSTALLATION
2095
FRONT DOOR OUTER BELT MOLDING
2096
REMOVAL
2096
INSTALLATION
2096
FRONT DOOR WEATHERSTRIP
2096
REMOVAL
2096
INSTALLATION
2096
SLIDING DOOR WEATHERSTRIP
2097
REMOVAL
2097
INSTALLATION
2097
FRONT DOOR INNER BELT MOLDING
2097
REMOVAL
2097
INSTALLATION
2097
BODY STRUCTURE
2098
GAP AND FLUSH
2098
SPECIFICATIONS
2098
GAP AND FLUSH MEASUREMENTS
2098
OPENING DIMENSIONS
2101
SPECIFICATIONS
2101
BODY OPENING DIMENSIONS
2101
SEALER LOCATIONS
2104
SPECIFICATIONS
2104
BODY SEALING LOCATIONS
2104
STUCTURAL ADHESIVE LOCATIONS
2130
SPECIFICATIONS
2130
STRUCTURAL ADHESIVE LOCATIONS
2130
WELD LOCATIONS
2139
SPECIFICATIONS
2139
WELD LOCATIONS
2139
24-HEATING & AIR CONDITIONING
2244
HEATING & AIR CONDITIONING
2244
DESCRIPTION
2244
DESCRIPTION - SINGLE ZONE
2244
DESCRIPTION - DUAL ZONE
2244
DESCRIPTION - MANUAL THREE ZONE
2244
FRONT CONTROL PANEL
2245
REAR CONTROL PANEL
2245
DESCRIPTION - THREE ZONE AUTOMATIC TEMPERATURE CONTROL
2245
FRONT CONTROL PANEL
2245
REAR CONTROL PANEL
2246
OPERATION
2246
OPERATION - DUAL ZONE
2246
OPERATION - MANUAL THREE ZONE
2246
FRONT CONTROL PANEL
2246
REAR CONTROL PANEL
2247
OPERATION - THREE ZONE ATC
2247
FRONT CONTROL PANEL
2247
REAR CONTROL PANEL
2247
DIAGNOSIS AND TESTING
2248
DIAGNOSIS AND TESTING - A/C COOL DOWN TEST
2248
DIAGNOSIS AND TESTING - A/C PERFORMANCE TEST
2248
DIAGNOSIS AND TESTING - HEATER PERFORMANCE TEST
2249
SPECIFICATIONS - HEATER-A/C SYSTEM
2250
CONTROLS - FRONT
2251
A/C HEATER CONTROL
2251
STANDARD PROCEDURE - HEATER-A/C CONTROL CALIBRATION
2251
REMOVAL
2252
INSTALLATION
2252
A/C PRESSURE TRANSDUCER
2253
DESCRIPTION - A/C PRESSURE TRANSDUCER
2253
OPERATION
2253
DIAGNOSIS AND TESTING - A/C PRESSURE TRANSDUCER
2253
REMOVAL
2254
INSTALLATION
2254
BLEND DOOR ACTUATOR
2254
DESCRIPTION
2254
OPERATION
2254
REMOVAL
2255
INSTALLATION
2255
BLOWER MOTOR RELAY
2256
DESCRIPTION
2256
OPERATION
2256
DIAGNOSIS AND TESTING - BLOWER MOTOR RELAY
2257
REMOVAL
2257
INSTALLATION
2257
BLOWER MOTOR RESISTOR
2258
DESCRIPTION
2258
OPERATION
2258
DIAGNOSIS AND TESTING - BLOWER MOTOR RESISTOR
2258
REMOVAL
2259
INSTALLATION
2259
COMPRESSOR CLUTCH
2259
DESCRIPTION
2259
OPERATION
2260
STANDARD PROCEDURE
2260
STANDARD PROCEDURE - COMPRESSOR CLUTCH AIR GAP
2260
STANDARD PROCEDURE - COMPRESSOR CLUTCH BREAK-IN
2260
REMOVAL
2260
INSPECTION - COMPRESSOR CLUTCH/COIL
2261
INSTALLATION
2262
COMPRESSOR CLUTCH COIL
2263
DIAGNOSIS AND TESTING - COMPRESSOR CLUTCH COIL
2263
COMPRESSOR CLUTCH RELAY
2264
DESCRIPTION
2264
OPERATION
2264
DIAGNOSIS AND TESTING - COMPRESSOR CLUTCH RELAY
2265
REMOVAL
2265
INSTALLATION
2265
EVAPORATOR TEMPERATURE SENSOR
2265
DESCRIPTION
2265
OPERATION
2266
REMOVAL
2266
INSTALLATION
2266
INFRARED TEMPERATURE SENSOR
2267
DESCRIPTION
2267
OPERATION
2267
MODE DOOR ACTUATOR
2267
DESCRIPTION
2267
OPERATION
2268
REMOVAL
2268
INSTALLATION
2268
POWER MODULE
2269
DESCRIPTION
2269
OPERATION
2269
REMOVAL
2269
INSTALLATION
2270
RECIRCULATION DOOR ACTUATOR
2270
DESCRIPTION
2270
OPERATION
2270
REMOVAL
2271
INSTALLATION
2271
CONTROLS - REAR
2272
A/C-HEATER CONTROL
2272
REMOVAL
2272
INSTALLATION
2272
BLEND DOOR ACTUATOR
2273
DESCRIPTION
2273
OPERATION
2273
REMOVAL
2274
INSTALLATION
2274
BLOWER MOTOR RELAY
2275
DESCRIPTION
2275
OPERATION
2275
DIAGNOSIS AND TESTING - BLOWER MOTOR RELAY
2276
REMOVAL
2276
INSTALLATION
2277
BLOWER MOTOR RESISTOR
2277
DESCRIPTION
2277
OPERATION
2277
DIAGNOSIS AND TESTING - BLOWER MOTOR RESISTOR
2278
REMOVAL
2278
INSTALLATION
2278
INFRARED TEMPERATURE SENSOR
2279
DESCRIPTION
2279
OPERATION
2279
MODE DOOR ACTUATOR
2279
REMOVAL
2279
INSTALLATION
2280
POWER MODULE
2280
DESCRIPTION
2280
OPERATION
2280
REMOVAL
2281
INSTALLATION
2281
DISTRIBUTION - FRONT
2282
AIR FILTER
2283
DESCRIPTION
2283
REMOVAL
2283
INSTALLATION
2283
AIR OUTLETS
2283
DESCRIPTION
2283
REMOVAL
2284
REMOVAL - CENTER BEZEL OUTLETS
2284
REMOVAL - DEMISTER OUTLET
2284
REMOVAL - FRONT DOOR REAR OUTLET
2284
REMOVAL - INSTRUMENT PANEL OUTLET
2285
INSTALLATION
2286
INSTALLATION - CENTER BEZEL OUTLETS
2286
INSTALLATION - DEMISTER OUTLET
2286
INSTALLATION - FRONT DOOR REAR OUTLET
2286
INSTALLATION - INSTRUMENT PANEL OUTLET
2286
BLOWER MOTOR
2286
DESCRIPTION
2286
OPERATION
2286
DIAGNOSIS AND TESTING - BLOWER MOTOR
2287
REMOVAL
2287
INSTALLATION
2289
DEFROSTER DUCT
2290
REMOVAL
2290
INSTALLATION
2290
DEMISTER DUCTS
2290
REMOVAL
2290
INSTALLATION
2291
FLOOR DISTRIBUTION DUCTS
2291
REMOVAL
2291
INSTALLATION
2291
HVAC HOUSING
2292
REMOVAL
2292
INSTALLATION
2293
PANEL DUCTS
2293
REMOVAL
2293
INSTALLATION
2293
DISTRIBUTION - REAR
2294
AIR OUTLETS
2294
DESCRIPTION
2294
REMOVAL
2294
INSTALLATION
2294
A/C DISTRIBUTION DUCT
2295
REMOVAL
2295
INSTALLATION
2295
BLOWER MOTOR
2295
DESCRIPTION
2295
OPERATION
2295
DIAGNOSIS AND TESTING - BLOWER MOTOR
2296
REMOVAL
2296
INSTALLATION
2298
REAR HEATER-A/C HOUSING
2298
REMOVAL
2298
INSTALLATION
2299
REAR HEATER DISTRIBUTION DUCT
2301
REMOVAL
2301
INSTALLATION
2301
PLUMBING - FRONT
2302
PLUMBING - FRONT
2303
WARNING
2303
WARNING
2303
WARNING
2303
WARNING - A/C PLUMBING
2303
CAUTION - A/C PLUMBING
2304
COMPRESSOR
2305
DESCRIPTION
2305
OPERATION
2305
DIAGNOSIS AND TESTING - COMPRESSOR NOISE DIAGNOSIS
2305
REMOVAL
2306
REMOVAL - COMPRESSOR
2306
REMOVAL - COMPRESSOR MOUNTING BRACKET - 2.4L ENGINE
2307
INSTALLATION
2307
INSTALLATION - COMPRESSOR
2307
INSTALLATION - COMPRESSOR MOUNTING BRACKET - 2.4L ENGINE
2308
CONDENSER
2308
DESCRIPTION
2308
OPERATION
2308
REMOVAL
2308
INSTALLATION
2309
DISCHARGE LINE
2310
REMOVAL
2310
INSTALLATION
2311
EVAPORATOR
2311
DESCRIPTION
2311
OPERATION
2311
REMOVAL
2312
INSTALLATION
2313
EXPANSION VALVE
2314
DESCRIPTION
2314
OPERATION
2314
DIAGNOSIS AND TESTING - EXPANSION VALVE
2314
REMOVAL
2315
INSTALLATION
2316
HEATER CORE
2316
DESCRIPTION
2316
OPERATION
2316
REMOVAL
2317
REMOVAL- HEATER CORE EXTENSION TUBES
2317
REMOVAL - HEATER CORE
2318
INSTALLATION
2319
INSTALLATION- HEATER CORE EXTENSION TUBES
2319
INSTALLATION - HEATER CORE
2320
HEATER HOSE
2321
REMOVAL
2321
INSTALLATION
2322
HEATER HOSES - DIESEL SUPPLEMENTAL HEATER - BUX
2323
REMOVAL
2323
INSTALLATION
2323
HEATER PIPES - DIESEL SUPPLEMENTAL HEATER - BUX
2323
REMOVAL
2323
INSTALLATION
2325
LIQUID LINE
2325
REMOVAL
2325
INSTALLATION
2327
RECEIVER/DRIER
2328
DESCRIPTION
2328
OPERATION
2328
REMOVAL
2328
INSTALLATION
2329
REFRIGERANT
2330
DESCRIPTION
2330
OPERATION
2330
DIAGNOSIS AND TESTING
2330
DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM CHARGE LEVEL
2330
DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM LEAKS
2331
DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM CHARGE LEVEL 2.5L DIESEL
2332
STANDARD PROCEDURE
2333
STANDARD PROCEDURE - REFRIGERANT SYSTEM SERVICE EQUIPMENT
2333
STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE
2334
STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE
2335
STANDARD PROCEDURE - REFRIGERANT RECOVERY
2336
REFRIGERANT OIL
2336
DESCRIPTION
2336
OPERATION
2336
STANDARD PROCEDURE - REFRIGERANT OIL LEVEL
2336
SUCTION LINE
2337
REMOVAL
2337
INSTALLATION
2338
SERVICE PORTS
2338
REMOVAL
2338
INSTALLATION
2339
PLUMBING - REAR
2340
EVAPORATOR
2340
DESCRIPTION
2340
OPERATION
2340
REMOVAL
2340
REMOVAL - REAR EVAPORATOR
2340
REMOVAL - EVAPORATOR LINE EXTENSION
2341
INSTALLATION
2342
INSTALLATION - REAR EVAPORATOR
2342
INSTALLATION - EVAPORATOR LINE EXTENSION
2342
EXPANSION VALVE
2342
DESCRIPTION
2342
OPERATION
2343
DIAGNOSIS AND TESTING - EXPANSION VALVE
2343
REMOVAL
2343
INSTALLATION
2344
HEATER CORE
2344
DESCRIPTION
2344
OPERATION
2344
STANDARD PROCEDURE - HEATER CORE FILLING
2344
REMOVAL
2345
INSTALLATION
2346
HEATER HOSE
2346
REMOVAL
2346
INSTALLATION
2346
SUCTION LINE
2347
REMOVAL
2347
INSTALLATION
2348
UNDERBODY LINES
2349
DESCRIPTION
2349
OPERATION
2349
REMOVAL
2350
REMOVAL - REAR HEATER LINES
2350
REMOVAL - REAR AIR CONDITIONING LINES
2350
INSTALLATION
2351
INSTALLATION - REAR HEATER LINES
2351
INSTALLATION - REAR AIR CONDITIONING LINES
2351
DIESEL SUPPLEMENTAL HEATER - DCHA - BUX
2352
DIESEL SUPPLEMENTAL HEATER - DCHA - BUX
2352
DESCRIPTION
2352
OPERATION
2352
DIAGNOSIS AND TESTING - DIESEL SUPPLEMENTAL HEATER - DCHA
2353
EXHAUST TUBE
2353
REMOVAL
2353
INSTALLATION
2353
FUEL DOSING PUMP
2354
DESCRIPTION
2354
OPERATION
2354
REMOVAL
2354
INSTALLATION
2354
FUEL LINE
2355
STANDARD PROCEDURE - CLEANING
2355
REMOVAL
2355
INSTALLATION
2355
HEATER UNIT
2357
REMOVAL
2357
INSTALLATION
2357
SUPPLEMENTAL DIESEL HEATER WIRING
2358
REMOVAL
2358
INSTALLATION
2358
AIR INTAKE PIPE
2358
REMOVAL
2358
INSTALLATION
2359
25-EMISSIONS CONTROL
2360
EMISSIONS CONTROL
2360
DESCRIPTION
2360
DESCRIPTION - VEHICLE EMISSION CONTROL INFORMATION LABEL
2360
DESCRIPTION - TRIP DEFINITION
2360
DESCRIPTION - MONITORED COMPONENT
2360
OPERATION - NON-MONITORED CIRCUITS
2364
DESCRIPTION - MONITORED SYSTEMS
2365
DESCRIPTION - HIGH AND LOW LIMITS
2368
OPERATION
2368
OPERATION - SYSTEM
2368
DRB III STATE DISPLAY TEST MODE
2369
OPERATION
2369
EVAPORATIVE EMISSIONS
2370
EVAPORATIVE EMISSIONS
2370
OPERATION - EVAPORATION CONTROL SYSTEM
2370
SPECIFICATIONS
2371
TORQUE
2371
EVAP/PURGE SOLENOID
2372
DESCRIPTION
2372
OPERATION
2372
REMOVAL
2372
INSTALLATION
2372
FUEL FILLER CAP
2372
DESCRIPTION
2372
OPERATION
2372
LEAK DETECTION PUMP
2373
REMOVAL
2373
INSTALLATION
2373
ORVR
2373
OPERATION
2373
DIAGNOSIS AND TESTING - VEHICLE DOES NOT FILL
2375
PCV VALVE
2376
DESCRIPTION
2376
OPERATION
2376
DIAGNOSIS AND TESTING - PCV SYSTEM
2376
VAPOR CANISTER
2377
DESCRIPTION
2377
OPERATION
2377
Purge Free Cells
2377
REMOVAL
2378
REMOVAL
2378
REMOVAL - REAR EVAP CANISTER
2378
INSTALLATION
2378
INSTALLATION
2378
INSTALLATION - REAR EVAP CANISTER
2378
EXHAUST GAS RECIRCULATION
2379
EXHAUST GAS RECIRCULATION
2379
SPECIFICATIONS
2379
TORQUE
2379
TUBE
2379
REMOVAL
2379
REMOVAL - 2.4L
2379
REMOVAL - FRONT TUBE- 3.5L
2379
REMOVAL - REAR TUBE - 3.5L
2380
INSTALLATION
2380
INSTALLATION - 2.4L
2380
INSTALLATION - FRONT TUBE - 3.5L
2380
INSTALLATION - REAR TUBE - 3.5L
2380
VALVE
2380
DESCRIPTION
2380
OPERATION
2380
REMOVAL
2382
REMOVAL - 2.4L
2382
REMOVAL - 3.5L
2382
INSTALLATION
2382
INSTALLATION - 2.4L
2382
INSTALLATION - 3.5L
2382
ON-BOARD DIAGNOSTICS
2383
TASK MANAGER
2383
DESCRIPTION
2383
OPERATION
2383
25a-EMISSIONS CONTROL 2.5L TURBO DIESEL
2388
EMISSIONS CONTROL 2.5L TURBO DIESEL
2388
DESCRIPTION
2388
ECM MONITORED SYSTEMS
2388
ECM NON–MONITORED SYSTEMS
2388
HIGH AND LOW LIMITS
2388
SPECIFICATIONS - TORQUE
2389
EXHAUST GAS RECIRCULATION
2390
EXHAUST GAS RECIRCULATION
2390
DESCRIPTION
2390
OPERATION
2390
VALVE
2391
DESCRIPTION
2391
OPERATION
2391
REMOVAL
2391
INSTALLATION
2391
VALVE COOLER
2392
DESCRIPTION
2392
REMOVAL
2392
INSTALLATION
2392
ON-BOARD DIAGNOSTICS
2393
ON-BOARD DIAGNOSTICS
2393
DESCRIPTION - DIAGNOSTIC TROUBLE CODES
2393
COMMENTS
2398
5
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Chrysler Dodge Caravan 2002 Specifications
General
Brand
Chrysler
Model
Dodge Caravan 2002
Category
Automobile
Language
English
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