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DRIVELINE/AXLE

CONTENTS

SECTION 3B MANUAL TRANSAXLE DRIVE AXLE

Table of Contents

Section 1A General Engine Information11
- Default Chapter3
- Description and Operation12
  - Cleanliness and Care12
  - On-Engine Service12
- Component Locator13
  - Engine Compartment (Typical)13
  - Engine Compartment (Euro III)14
- Diagnoctic Information and Procedure 1A-515
- 1 A-222
- 1 A-323
- Specifications24
  - General Specifications24
  - Engine Performance Curve25
Section 1B Sohc Engine Mechanical26
- Description and Operation27
- Component Locator30
- Diagnostic Information and Procedure34
Section 1D Engine Cooling39
- Description and Operation40
- Component Locator43
  - Coolant Hose and Components43
  - Radiator/Fan44
- Diagnostic Information and Procedure45
- Repair Instructions47
- Repair Instructions47
  - On-Vehicle Service47
- 1 D-247
- 1 D-553
  - Engine Coolant Temperature Sensor53
  - Coolant Pump53
- Specifications55
  - General Specifications55
  - Fastener Tightening Specifications56
Section 1E Engine Electrical57
- Description and Operation58
- Component Locator62
- Diagnostic Information and Procedure66
- Repair Instructions70
  - Unit Repair75
- Schematic and Routing Diagrams93
- 1 E-6.96
  - Ignition System Circuit - Euro III96
- Specifications97
Section 1F Engine Controls99
- Description and Operation102
- Diagnostic Information and Procedures115
  - System Diagnosis115
- Diagnostic Trouble Code Diagnosis153
Section 1G Engine Exhaust423
- Description and Operation424
- Component Locator425
  - Exhaust System425
  - On-Vehicle Service426
- Repair Instruction426
- 1 G-3430
- Specifications431
  - Fastener Tightening Specifications431
Section 2B Wheel Alignment438
- Description and Operation439
- Diagnostic Information and Procedures441
- Specifications443
  - Wheel Alignment Specifications443
  - Fastener Tightening Specifications443
Section 2C Front Suspension444
- Description and Operation445
  - Front Suspension445
- Component Locator446
  - Front Suspension446
- Diagnostic Information and Procedures448
- Repair Instructions450
- 2 C-3.455
- 2 C-2455
  - Unit Repair459
    - Hub Bearing and Knuckle459
    - Front Strut463
- Specifications466
  - General Specifications466
  - Fastener Tightening Specifications466
- 2 C-7.466
- Special Tools and Equipment467
  - Special Tools Table467
Sectiond Rear Suspension468
- Description and Operation469
  - Rear Suspension469
- Component Locator470
  - Rear Suspension470
- Diagnostic Information and Procedures471
- Repair Instructions473
- 2 D-2474
- 2 D-3476
  - Unit Repair479
    - Hub and Bearing Assembly479
- Specifications482
  - General Specifications482
  - Fastener Tightening Specifications482
- Special Tools and Equipment483
  - Special Tools Table483
- 2 D-6.483
Section 2E Tires and Wheels484
- Description and Operation485
- Diagnostic Information and Procedures488
- Repair Instructions490
- Specifications493
Section 3B Manual Transaxle Drive Axle494
- Description and Operation495
  - Front Drive Axle495
- Component Locator496
  - Drive Axle Assembly496
- Diagnostic Information and Procedures497
  - On-Vehicle Service498
    - Drive Axle Assembly498
- Repair Instructions498
- 3 B-2502
  - Unit Repair502
    - Inner Joint502
    - Outer Joint503
- Specifications505
  - General Specifications505
  - Fastener Tightening Specifications505
- 3 B-3505
- Special Tools and Equipment506
  - Special Tools Table506
Section 4A Hydraulic Brakes507
- Description and Operation508
  - Warning Lamp Operation508
- Noted.508
- Component Locator509
  - Brake System (Non-ABS)509
- Diagnostic Information and Procedures 4A-4510
- Specifications513
  - On-Vehicle Service514
- Repair Instructions514
- 4 A-3515
- Schematic and Routing Diagrams520
  - Brake Lamp Warning Circuit520
  - Stoplamp Switch Circuit520
Section 4B Master Cylinder521
- Description and Operation522
- Diagnostic Information and Procedures523
  - Checking the Brake Fluid Level523
  - On-Vehicle Service524
- Repair Instructions524
- 4 B-2525
  - Unit Repair528
    - Master Cylinder528
- Specifications529
  - Fastener Tightening Specifications529
- 4 B-4.529
Section 4C Power Booster530
- Description and Operation531
  - Power Booster531
- Diagnostic Information and Procedures532
  - Power Booster Functional Check532
  - Check Valve Functional Check532
- Repair Instructions533
- 4 C-2533
  - On-Vehicle Service533
    - Vacuum Hose and Check Valve533
    - Power Booster Assembly534
- Specifications537
  - General Specifications537
  - Fastener Tightening Specifications537
Section 4D Front Disc Brakes538
- Description and Operation539
  - Disc Brake Caliper Assembly539
  - Clearance Calibration539
- Component Locator540
  - Front Disc Brakes540
- Diagnostic Information and Procedures541
- Repair Instructions543
- 4 D-2543
  - On-Vehicle Service543
- 4 D-3545
  - Unit Repair545
    - Caliper Overhaul545
- Specifications548
  - General Specifications548
  - Fastener Tightening Specifications559
Section 4F Antilock Brake System560
- Description and Operation562
- Visual Identification571
  - EBCM Connector Face View571
- Component Locator572
  - Abs572
- Diagnostic Information and Procedures575
- 4 F-3602
Section 5B Five-Speed Manual Transaxle626
- Description and Operation627
- Component Locators628
- Diagnostic Information and Procedure633
- Repair Instruction635
- 5 B-2635
  - On-Vehicle Service635
- 5 B-3.647
  - Unit Repair649
- Specifications677
  - General Specifications677
  - Fastener Tightening Specifications678
- Special Tools679
  - Special Tools Table679
Section 5C Clutch681
- Description and Operation682
- Component Locator683
  - Clutch Components683
- Diagnostic Information and Procedures684
- Repair Instruction686
  - On-Vehicle Service686
    - Pressure Plate, Clutch Disc and Input Shaft Bearing686
- 5 C-2688
- 5 C-3.692
  - Clutch Pedal692
- Specifications693
  - General Specifications693
  - Fastener Tightening Specifications693
- Special Tools694
  - Special Tools Table694
Section 6B Power Steering Pump695
- Default Chapter696
  - Power Steering Pump696
- Description and Operation705
- Diagnostic Information and Procedures720
  - Steering Gear722
  - On-Vehicle Service723
- Repair Instructions723
  - Unit Repair727
- Specifications733
  - General Specifications733
  - Fastener Tightening Specifications733
- Special Tools and Equipment734
  - Special Tools Table734
Section 6E Steering Wheel and Column735
- Default Chapter741
  - Steering Wheel741
  - Wiper Switch and Lever742
- 6 E-3.746
- 6 E-7.747
  - Unit Repair747
    - Standard Steering Column747
    - General Specifications749
- Specifications749
  - Special Tools and Equipment750
    - Special Tools Table750
Section 7A Heating and Ventilation System751
- Description and Operation752
  - Heating and Ventilation Systems752
- Component Locator753
- Diagnostic Informatin and Procedures 7A-6756
  - Heater System756
  - On-Vehicle Service768
- Repair Instructions768
- 7 A-2770
- 7 A-3.772
  - Unit Repair778
    - Heater Core778
- Specifications780
- Special Tools and Equipment780
  - Special Tools Table780
- Schematic and Routing Diagrams781
  - Non-A/C Diagrams781
- 7 A-18.781
Section 7B Manual Control Heating, Ventilation, and Air Conditioning System783
- Description and Operation784
  - System Components -Functional784
- Component Locator785
  - A/C System785
- Diagnostic Information and Procedures787
- Repair Instructions795
  - On-Vehicle Service795
  - General A/C System Service Procedures795
- 7 B-3799
- 7 B-2799
- Specifications812
  - General Specifications812
    - Fastener Tightening Specifications812
- 7 B-13.812
- Special Tools and Equipment813
  - Special Tools Table813
- Schematic and Routing Diagrams814
Section 8A Seat Belts816
- Description and Operation817
- Component Locator818
  - Front and Rear Seat Belt818
- Diagnostic Information and Procedures819
  - Seat Belt Warning Lamp Is Inoperative819
- 8 A-2820
  - On-Vehicle Service820
- Specifications826
  - Fastener Tightening Specifications826
- Schematic and Routing Diagrams827
  - Driver Seat Belt Warning827
- 8 A-3827
Section 8B Supplemental Inflatable Restraints (Sir)828
- Noted.830
- Description and Operation830
- Component Locator834
  - SIR Component834
- Diagnostic Information and Procedures835
- 8 B-3862
- 8 B-7.872
- Special Tools905
  - Special Tools Table905
Section 9A Body Wiring System907
- Description and Operation908
  - How to Read Electrical Wiring Diagram908
  - How to Check Terminal Number of Connector . 9A-4910
- Special Tools and Equipment911
  - Special Tools Table911
- Schematic and Routing Diagrams912
  - Wire Color Chart912
  - Fuse Chart916
- 9 A-2917
- 9 A-5922
  - Airbag Harness Routing922
  - Body Harness Routing923
- 9 A-6925
Section 9B Lighting Systems928
- Noted.929
- Description and Operation929
- Diagnostic Information and Procedures930
- Repair Instructions935
- 9 B-2939
- Specifications943
  - Bulb Usage Chart943
- Schematic and Routing Diagrams944
- 9 B-7949
Section 9D Wipers / Washer Systems959
- Description and Operation960
  - Windshield Wiper System960
  - Windshield Washer System960
- Diagnostic Information and Procedures961
  - Windshield/Rear Window Wiper and Washer System961
- Repair Instructions964
  - On-Vehicle Service964
- 9 D-2968
- Specifications973
  - Fastener Tightening Specifications973
- 9 D-6.973
- Schematic and Routing Diagrams974
Section 9E Instrumentation/Driver Information975
- Description and Operation976
- Component Locator977
  - Instrument Panel Assembly977
  - Instrument Cluster978
- Diagnostic Information and Procedures979
- Repair Instructions982
  - On-Vehicle Service982
- Specifications996
  - Fastener Tightening Specifications996
  - Instrument Cluster Indicator Lamps Specifications996
- Schematic and Routing Diagrams997
  - Instrument Panel Illumination999
- 9 E-8.1000
  - Digital Clock1000
Section 9F Audio Systems1001
- Default Chapter1002
- Diagnostic Information and Procedures1004
  - On-Vehicle Service1006
    - Front Speaker Covers1009
- Specifications1011
  - Fastener Tightening Specifications1011
- Schematic and Routing Diagrams1012
  - Audio System Circuit1012
Section 9G Interior Trim1013
- Description and Operation1014
  - Interior Trim Panels1014
  - Pressure Relief Vent1014
    - Interior Trim1015
- Repair Instructions1016
- Component Locator1016
- 9 G-21022
- 9 G-31026
  - Rear Rocker Trim Panel1026
  - Luggage Compartment Wheelhouse Trim Panel1029
- Special Tools and Equipment1030
  - Special Tools Table1030
Section 9H Seats1031
- Description and Operation1031
  - Seats1031
  - Front Seat Cushion1037
- 9 H-21039
  - Front Seat Cushion Frame1039
- 9 H-31041
  - Rear Seat Cushion1041
  - Rear Seatback Latch1041
- 9 H-51042
  - Rear Seatback Hinge1042
  - Fastener Tightening Specifications1043
Section 9L Glass and Mirrors1056
- Description and System Operation 9L-21057
  - Inside Rearview Mirror1057
  - Outside Rearview Mirrors1057
- Components Locator1058
  - Glass and Mirror1058
- Diagnostic Information and Procedures1059
  - Testing Rear Window Defogger Grid Line1059
- Repair Instructions1060
- 9 L-3.1068
- Special Tools and Equipment1072
- 9 L-5.1072
  - Special Tools Table1072
- Schematic and Routing Diagrams1073
  - Rear Window Defogger1073
Section 9P Doors1093
- Description and Operation1094
  - Door Lock Striker1094
  - Childproof Rear Door Lock1094
- Component Locator1095
  - Front Door1095
  - Rear Door1097
- Repair Instructions1099
- 9 P-21110
- 9 P-31115
  - Tailgate Lock Cylinder1115
  - Door Hinge1115
- 9 P-71116
- Schematic and Routing Diagrams1122
  - Power Windows (Front Only)1126

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