2001-2003 Chrysler PT Cruiser Service Manual
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The most detailed 2001-2003 Chrysler PT Cruiser Service Manual.
Manual covers in great details all aspects of maintenance, repair and troubleshooting.
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Full list of manual chapters:
PT Service Manual
AIRBAGS and SEAT BELTS
RESTRAINTS
DESCRIPTION
FRONT AIRBAG SYSTEM
SIDE IMPACT AIRBAG SYSTEM
BELT TENSIONER SYSTEM
OPERATION
FRONT AIRBAG SYSTEM
SIDE IMPACT AIRBAG SYSTEM
BELT TENSIONER SYSTEM
WARNING
FRONT AIRBAG SYSTEM
SIDE IMPACT AIRBAG SYSTEM
DIAGNOSIS AND TESTING - AIRBAG SYSTEM
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING AIRBAGS
DEPLOYED AIRBAG
UNDEPLOYED AIRBAG
STANDARD PROCEDURE - SERVICE AFTER AN AIRBAG DEPLOYMENT
DRIVER AIRBAG
PASSENGER AIRBAG
SEAT AIRBAG
SEAT BELT TENSIONERS
CLEAN UP PROCEDURE
CLOCK SPRING
DESCRIPTION
OPERATION
STANDARD PROCEDURE - CLOCK SPRING CENTERING
REMOVAL
INSTALLATION
DRIVER AIRBAG
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
DRIVER AIRBAG COVER
REMOVAL
INSTALLATION
FRONT SEAT BELT and RETRACTOR
REMOVAL
INSTALLATION
FRONT SEAT BELT BUCKLE
REMOVAL
INSTALLATION
FRONT SEAT BELT HEIGHT ADJUSTER
REMOVAL
INSTALLATION
OCCUPANT RESTRAINT CONTROLLER
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
PASSENGER AIRBAG
DESCRIPTION
OPERATION
REMOVAL
NON-DEPLOYED AIRBAG
DEPLOYED AIRBAG
INSTALLATION
PASSENGER AIRBAG COVER
REMOVAL
INSTALLATION
REAR CENTER SEAT BELT and RETRACTOR
REMOVAL
INSTALLATION
REAR SEAT BELT and RETRACTOR
REMOVAL
INSTALLATION
REAR SEAT BELT BUCKLE
REMOVAL
SEAT AIRBAG
DESCRIPTION
OPERATION
REMOVAL
DEPLOYED SEAT AIRBAG
NONDEPLOYED SEAT AIRBAG
INSTALLATION
DEPLOYED SEAT AIRBAG
NONDEPLOYED SEAT AIRBAG
SIDE IMPACT AIRBAG CONTROL MODULE
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
AIR CONDITIONING and HEATING
HEATING and AIR COND. - LHD
HEATING and AIR COND. - LHD
DESCRIPTION
ENGINE COOLING SYSTEM REQUIREMENTS
SAFETY PRECAUTIONS AND WARNINGS
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HEATER PERFORMANCE TEST
PRE-DIAGNOSTIC PREPARATIONS
MAXIMUM HEATER OUTPUT: TEST AND ACTION
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT
TEMPERATURE CONTROL
DIAGNOSIS AND TESTING - A/C PERFORMANCE TEST
PERFORMANCE TEST PROCEDURE
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING TUBING AND FITTINGS
STANDARD PROCEDURE - SYSTEM CHARGE LEVEL TEST
STANDARD PROCEDURE - CHARGING A/C SYSTEM
PARTIAL CHARGE
EVACUATION
CHARGING A/C SYSTEM
STANDARD PROCEDURE - EVACUATING REFRIGERANT SYSTEM
STANDARD PROCEDURE - SYSTEM LEAK CHECKING
EMPTY REFRIGERANT SYSTEM LEAK TEST
LOW REFRIGERANT LEVEL LEAK TEST
STANDARD PROCEDURE - REFRIGERANT RECOVERY0 - 12 PT (Continued)
SPECIFICATIONS
A/C APPLICATION TABLE
TORQUE
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
A/C HEATER CONTROL
DESCRIPTION
DIAGNOSIS AND TESTING - VACUUM CONTROL SYSTEM
ONE-WAY CHECK VALVE
HEATER-A/C CONTROLS
LOCATING VACUUM LEAKS
LOCATING PINCHED VACUUM LINES
REMOVAL
INSTALLATION
A/C COMPRESSOR CLUTCH COIL
REMOVAL
INSTALLATION
CLUTCH BREAK-IN
A/C HIGH PRESSURE SWITCH
DESCRIPTION
REMOVAL
INSTALLATION
A/C LOW PRESSURE SWITCH
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - A/C LOW PRESSURE CLUTCH CYCLING SWITCH
REMOVAL
INSTALLATION
A/C PRESSURE TRANSDUCER
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - A/C PRESSURE TRANSDUCER
REMOVAL
INSTALLATION
BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION
REMOVAL
INSTALLATION
MODE DOOR CABLE
REMOVAL
INSTALLATION
ADJUSTMENT
RECIRCULATION DOOR ACTUATOR
DESCRIPTION
REMOVAL
INSTALLATION
TEMPERATURE CONTROL CABLES
REMOVAL
INSTALLATION
ADJUSTMENTS
DISTRIBUTION
DESCRIPTION
DESCRIPTION - SYSTEM AIRFLOW
DESCRIPTION - HEATER AND AIR CONDITIONING
AIR FILTER - EXPORT
DESCRIPTION
REMOVAL
INSTALLATION
AIR FLOW DISTRIBUTION
DESCRIPTION
OPERATION
AIR OUTLETS
DESCRIPTION
REMOVAL - CENTER AIR OUTLET DUCT
INSTALLATION - CENTER AIR OUTLET DUCT
BLOWER MOTOR
DESCRIPTION - BLOWER MOTOR WHEEL
OPERATION
DIAGNOSIS AND TESTING - BLOWER MOTOR
REMOVAL
WITH AIR CONDITIONING
WITHOUT AIR CONDITIONING
INSTALLATION
WITH AIR CONDITIONING
WITHOUT AIR CONDITIONING
HVAC HOUSING
REMOVAL
DISASSEMBLY
ASSEMBLY
INSTALLATION
A/C COMPRESSOR
DESCRIPTION
DESCRIPTION
DESCRIPTION - COMPRESSOR FRONT SHAFT SEAL
OPERATION
DIAGNOSIS AND TESTING - COMPRESSOR NOISE
REMOVAL
INSTALLATION
A/C CONDENSER
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
A/C DISCHARGE LINE
DESCRIPTION - DISCHARGE LINE
REMOVAL
INSTALLATION
A/C EVAPORATOR
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
A/C HIGH PRESSURE RELIEF VALVE
REMOVAL - HIGH PRESSURE RELIEF VALVE
INSTALLATION - HIGH PRESSURE RELIEF VALVE
A/C VARIABLE ORIFICE TUBE
DESCRIPTION
REMOVAL - INSTALLATION
ACCUMULATOR
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
CONDENSATION DRAIN TUBE
DESCRIPTION
REMOVAL
INSTALLATION
HEATER CORE
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
HEATER INLET HOSE
REMOVAL
INSTALLATION
HEATER RETURN HOSE
REMOVAL
INSTALLATION
LIQUID LINE
DESCRIPTION
REMOVAL
INSTALLATION
REFRIGERANT
DESCRIPTION
OPERATION
STANDARD PROCEDURE - REFRIGERANT
REFRIGERANT OIL
DESCRIPTION
OPERATION
STANDARD PROCEDURE
STANDARD PROCEDURE - SERVICING REFRIGERANT OIL LEVEL
STANDARD PROCEDURE - REFRIGERANT OIL LEVEL CHECK
SUCTION LINE
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
SUCTION AND LIQUID LINE ASSEMBLY
REMOVAL
INSTALLATION
SERVICE PORT VALVE CORE
DESCRIPTION
A/C SERVICE PORT VALVE CORES
REMOVAL– SERVICE PORT VALVE CORES
INSTALLATION - SERVICE PORT VALVE CORES
A/C VARIABLE ORIFICE TUBE
DESCRIPTION
REMOVAL - INSTALLATION
CABIN HEATER
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - DIESEL ENGINE CABIN HEATER
HEATING and AIR COND. - RHD
HEATING and AIR COND. - RHD
DESCRIPTION
ENGINE COOLING SYSTEM REQUIREMENTS
SAFETY PRECAUTIONS AND WARNINGS
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HEATER PERFORMANCE TEST
PRE-DIAGNOSTIC PREPARATIONS
MAXIMUM HEATER OUTPUT: TEST AND ACTION
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT
TEMPERATURE CONTROL
DIAGNOSIS AND TESTING - A/C PERFORMANCE TEST
PERFORMANCE TEST PROCEDURE
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING TUBING AND FITTINGS
STANDARD PROCEDURE - SYSTEM CHARGE LEVEL TEST
STANDARD PROCEDURE - EVACUATING REFRIGERANT SYSTEM
STANDARD PROCEDURE - CHARGING A/C SYSTEM
PARTIAL CHARGE
EVACUATION
CHARGING A/C SYSTEM
STANDARD PROCEDURE - SYSTEM LEAK CHECKING
EMPTY REFRIGERANT SYSTEM LEAK TEST
LOW REFRIGERANT LEVEL LEAK TEST
STANDARD PROCEDURE - REFRIGERANT RECOVERY
SPECIFICATIONS
A/C APPLICATION TABLE
TORQUE
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
A/C HEATER CONTROL
DESCRIPTION
DIAGNOSIS AND TESTING - VACUUM CONTROL SYSTEM
ONE-WAY CHECK VALVE
HEATER-A/C CONTROLS
LOCATING VACUUM LEAKS
LOCATING PINCHED VACUUM LINES
REMOVAL
INSTALLATION
A/C COMPRESSOR CLUTCH COIL
REMOVAL
INSTALLATION
CLUTCH BREAK-IN
A/C HIGH PRESSURE SWITCH
DESCRIPTION
REMOVAL
INSTALLATION
A/C LOW PRESSURE SWITCH
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - A/C LOW PRESSURE CLUTCH CYCLING SWITCH
REMOVAL
INSTALLATION
A/C PRESSURE TRANSDUCER
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - A/C PRESSURE TRANSDUCER
REMOVAL
INSTALLATION
BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION
REMOVAL
INSTALLATION
MODE DOOR CABLE
REMOVAL
INSTALLATION
ADJUSTMENT
RECIRCULATION DOOR ACTUATOR
DESCRIPTION
REMOVAL
INSTALLATION
TEMPERATURE CONTROL CABLES
REMOVAL
INSTALLATION
ADJUSTMENTS
DISTRIBUTION
DESCRIPTION
DESCRIPTION - SYSTEM AIRFLOW
DESCRIPTION - HEATER AND AIR CONDITIONING
AIR FILTER - EXPORT
DESCRIPTION
REMOVAL
INSTALLATION
AIR FLOW DISTRIBUTION
DESCRIPTION
OPERATION
AIR OUTLETS
DESCRIPTION
REMOVAL - CENTER AIR OUTLET DUCT
INSTALLATION - CENTER AIR OUTLET DUCT
BLOWER MOTOR
DESCRIPTION - BLOWER MOTOR WHEEL
OPERATION
DIAGNOSIS AND TESTING - BLOWER MOTOR
REMOVAL
WITH AIR CONDITIONING
WITHOUT AIR CONDITIONING
INSTALLATION
WITH AIR CONDITIONING
WITHOUT AIR CONDITIONING
HVAC HOUSING
REMOVAL
DISASSEMBLY
ASSEMBLY
INSTALLATION
A/C COMPRESSOR
DESCRIPTION
DESCRIPTION
DESCRIPTION - COMPRESSOR FRONT SHAFT SEAL
OPERATION
DIAGNOSIS AND TESTING - COMPRESSOR NOISE
REMOVAL
INSTALLATION
A/C CONDENSER
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
A/C DISCHARGE LINE
DESCRIPTION - DISCHARGE LINE
REMOVAL
INSTALLATION
A/C EVAPORATOR
REMOVAL
INSTALLATION
A/C HIGH PRESSURE RELIEF VALVE
REMOVAL - HIGH PRESSURE RELIEF VALVE
INSTALLATION - HIGH PRESSURE RELIEF VALVE
ACCUMULATOR
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
CONDENSATION DRAIN TUBE
DESCRIPTION
REMOVAL
INSTALLATION
HEATER CORE - EXPORT
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
HEATER INLET HOSE
REMOVAL
INSTALLATION
HEATER RETURN HOSE
REMOVAL
INSTALLATION
LIQUID LINE
DESCRIPTION
REMOVAL
INSTALLATION
REFRIGERANT
DESCRIPTION
OPERATION
STANDARD PROCEDURE - REFRIGERANT
REFRIGERANT OIL
DESCRIPTION
OPERATION
STANDARD PROCEDURE
STANDARD PROCEDURE - SERVICING REFRIGERANT OIL LEVEL
STANDARD PROCEDURE - REFRIGERANT OIL LEVEL CHECK
SUCTION LINE
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
SUCTION AND LIQUID LINE ASSEMBLY
REMOVAL
INSTALLATION
SERVICE PORT VALVE CORE0 - 14 PT (Continued)
DESCRIPTION
A/C SERVICE PORT VALVE CORES
REMOVAL– SERVICE PORT VALVE CORES
INSTALLATION - SERVICE PORT VALVE CORES
A/C VARIABLE ORIFICE TUBE
DESCRIPTION
REMOVAL - INSTALLATION
CABIN HEATER
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - DIESEL ENGINE CABIN HEATER
HEATER UNIT
REMOVAL
INSTALLATION
AUDIO COMPONENTS
AUDIO
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - AUDIO
ANTENNA BODY and CABLE
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - ANTENNA BODY AND CABLE
TEST 1
TEST 2
TEST 3
TEST 4
REMOVAL
INSTALLATION
ANTENNA - SATELLITE RADIO
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
ANTENNA CABLE - SATELLITE RADIO
DESCRIPTION
REMOVAL
INSTALLATION
RADIO
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
RADIO NOISE SUPPRESSION COMPONENTS
DESCRIPTION
OPERATION
REMOVAL
ENGINE GROUND STRAP
HOOD HINGE GROUND STRAP
MUFFLER GROUND STRAP
RADIO NOISE SUPPRESSION CAPACITOR
STRUT BRACKET TO BODY GROUND STRAP
INSTALLATION
ENGINE GROUND STRAP
HOOD HINGE GROUND STRAP
MUFFLER GROUND STRAP
RADIO NOISE SUPPRESSION CAPACITOR
STRUT BRACKET TO BODY GROUND STRAP
SATELLITE RECEIVER MODULE
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
SPEAKER
REMOVAL
FRONT DOOR SPEAKER
INSTRUMENT PANEL SPEAKER
REAR SPEAKER
INSTALLATION
FRONT DOOR SPEAKER
INSTRUMENT PANEL SPEAKER
REAR SPEAKER
BATTERY, CHARGING and STARTING
BATTERY SYSTEM
BATTERY SYSTEM
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - BATTERY SYSTEM
MICRO 420 BATTERY TESTER
ABNORMAL BATTERY DISCHARGING
CLEANING
INSPECTION
SPECIFICATIONS
SPECIFICATIONS
TORQUE SPECIFICATIONS
SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS
BATTERY
DESCRIPTION
SPIRAL PLATE BATTERY - DIESEL ENGINE
CONVENTIONAL BATTERY - GASOLINE ENGINE
OPERATION
DIAGNOSIS AND TESTING - BATTERY
MICRO 420 BATTERY TESTER
STANDARD PROCEDURE
STANDARD PROCEDURE - SPIRAL PLATE BATTERY CHARGING
CHARGING A COMPLETELY DISCHARGED BATTERY – SPIRAL PLATE BATTERY
CHARGING TIME REQUIRED
STANDARD PROCEDURE - CONVENTIONAL BATTERY CHARGING
CHARGING A COMPLETELY DISCHARGED CONVENTIONAL BATTERY
CHARGING TIME REQUIRED
STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER
BATTERY TESTING
STANDARD PROCEDURE - OPEN-CIRCUIT VOLTAGE TEST
STANDARD PROCEDURE - IGNITION-OFF DRAW TEST
REMOVAL
REMOVAL - GASOLINE ENGINE
REMOVAL - DIESEL ENGINE
INSTALLATION
INSTALLATION - GASOLINE ENGINE
INSTALLATION - DIESEL ENGINE
BATTERY HOLDDOWN
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
BATTERY CABLES
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - BATTERY CABLES
VOLTAGE DROP TEST
REMOVAL
INSTALLATION
BATTERY TRAY
DESCRIPTION
OPERATION
REMOVAL
REMOVAL - GASOLINE ENGINE
REMOVAL - DIESEL ENGINE
INSTALLATION
INSTALLATION - GASOLINE ENGINE
INSTALLATION - DIESEL ENGINE
THERMAL GUARD
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
BATTERY TRAY SUPPORT BRACKET
REMOVAL
INSTALLATION
CHARGING
CHARGING
DESCRIPTION - CHARGING SYSTEM
OPERATION - CHARGING SYSTEM
DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTIC SYSTEM
BATTERY TEMPERATURE SENSOR
OPERATION
REMOVAL - 2.0, 2.4, and 2.4L TURBO
INSTALLATION - 2.0, 2.4, and 2.4L TURBO
GENERATOR
DESCRIPTION
OPERATION
REMOVAL
REMOVAL - 2.0/2.4L
REMOVAL - 2.4L TURBO
REMOVAL - 2.2 DIESEL
INSTALLATION
INSTALLATION - 2.0/2.4L
INSTALLATION - 2.4L TURBO
INSTALLATION - 2.2 DIESEL
VOLTAGE REGULATOR
DESCRIPTION
OPERATION
STARTING
STARTING
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING SYSTEM TEST
INSPECTION
DIAGNOSIS AND TESTING - CONTROL CIRCUIT TEST
STARTER SOLENOID
STARTER RELAY
RELAY TEST
RELAY CIRCUIT TEST
SAFETY SWITCHES
IGNITION SWITCH
BATTERY
ALL RELATED WIRING AND CONNECTORS
DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST
DIAGNOSIS AND TESTING - FEED CIRCUIT TEST
SPECIFICATIONS
STARTER MOTOR
TORQUE
STARTER MOTOR
REMOVAL
REMOVAL - 1.6L
REMOVAL - 2.2 DIESEL
REMOVAL - 2.0/2.4L
REMOVAL - STARTER 2.4L TURBO
INSTALLATION
INSTALLATION - 1.6L
INSTALLATION - 2.2L DIESEL
INSTALLATION - 2.0/2.4L
INSTALLATION - STARTER 2.4L TURBO
BODY
BODY
BODY
DESCRIPTION - VEHICLE IDENTIFICATION
WARNING
SAFETY PRECAUTIONS AND WARNINGS
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS
VISUAL INSPECTION BEFORE WATER LEAK TESTS
WATER LEAK TESTS
WATER LEAK DETECTION
DIAGNOSIS AND TESTING - WIND NOISE
VISUAL INSPECTION BEFORE TESTS
STANDARD PROCEDURE
STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR
Rigid Plastics:
Semi-Rigid Plastics:
Flexible Plastics:
Repair Procedure:
Adhesion Promoter/Surface Modifier:
SAFETY PRECAUTION AND WARNINGS
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES
PANEL SECTIONING
PANEL REINFORCEMENT
VISUAL INSPECTION
PANEL SURFACE PREPARATION
PATCHING PANELS
PANEL PATCH FABRICATIONS
PANEL PATCH INSTALLATION
PATCHED PANEL SURFACING
STANDARD PROCEDURE - HEAT STAKING
SPECIFICATIONS
BODY LUBRICATION
LUBRICATION REQUIREMENTS
LUBRICANT APPLICATION
LUBRICANT USAGE
SPECIFICATIONS - TORQUE
SPECIAL TOOLS
BODY
LIFTGATE
LIFTGATE CHMSL ACCESS PANEL
REMOVAL
INSTALLATION
LIFTGATE OUTSIDE HANDLE
REMOVAL
INSTALLATION
LIFTGATE HINGE
REMOVAL
INSTALLATION
LIFTGATE LATCH
REMOVAL
INSTALLATION
LIFTGATE INNER CONTROL ASSEMBLY PANEL
REMOVAL
INSTALLATION
LATCH STRIKER
REMOVAL
INSTALLATION
LIFTGATE
REMOVAL
INSTALLATION
LIFTGATE LOCK CYLINDER
REMOVAL
INSTALLATION
LIFTGATE SUPPORT ROD
REMOVAL
INSTALLATION
LIFTGATE TRIM PANEL
REMOVAL
INSTALLATION
DOOR - FRONT
FRONT DOOR APPLIQUE
REMOVAL
INSTALLATION
FRONT DOOR CHECK STRAP
REMOVAL
INSTALLATION
FRONT DOOR
REMOVAL
INSTALLATION
FRONT DOOR GLASS
REMOVAL
INSTALLATION
FRONT DOOR OUTSIDE HANDLE
REMOVAL
INSTALLATION
FRONT DOOR HINGE
REMOVAL
INSTALLATION
FRONT DOOR INSIDE HANDLE ACTUATOR
REMOVAL
INSTALLATION
FRONT DOOR LATCH
REMOVAL
INSTALLATION
ADJUSTMENTS
FRONT DOOR LATCH ADJUSTMENT
FRONT DOOR LATCH STRIKER
REMOVAL
INSTALLATION
FRONT DOOR LOCK CYLINDER
REMOVAL
INSTALLATION
FRONT DOOR VERTICAL GUIDE BAR
REMOVAL
INSTALLATION
SIDE VIEW MIRROR TRIM BEZEL
REMOVAL
INSTALLATION
FRONT DOOR TRIM PANEL
REMOVAL
INSTALLATION
FRONT DOOR WATER DAM
REMOVAL
INSTALLATION
FRONT DOOR WINDOW REGULATOR
REMOVAL
INSTALLATION
DOORS-REAR
REAR DOOR APPLIQUE
REMOVAL
INSTALLATION
REAR DOOR CHECK STRAP
REMOVAL
INSTALLATION
REAR DOOR
REMOVAL
INSTALLATION
REAR DOOR GLASS
REMOVAL0 - 10 PT (Continued)
INSTALLATION
REAR DOOR OUTSIDE HANDLE
REMOVAL
INSTALLATION
REAR DOOR HINGE
REMOVAL
INSTALLATION
REAR DOOR LATCH
REMOVAL
INSTALLATION
ADJUSTMENTS
REAR DOOR LATCH ADJUSTMENT
REAR DOOR LATCH STRIKER
REMOVAL
INSTALLATION
REAR DOOR TRIM PANEL
REMOVAL
INSTALLATION
REAR DOOR WATER DAM
REMOVAL
INSTALLATION
REAR DOOR WINDOW REGULATOR
REMOVAL
INSTALLATION
EXTERIOR
COWL GRILLE SCREEN
REMOVAL
INSTALLATION
EXTERIOR NAME PLATES
REMOVAL
REMOVAL - EXTERIOR BADGING
REMOVAL - BADGING/TAPE
INSTALLATION
INSTALLATION - EXTERIOR BADGING
INSTALLATION - BADGING/TAPE
FRONT WHEELHOUSE SPLASH SHIELDS
REMOVAL
INSTALLATION
FRONT FENDER
REMOVAL
INSTALLATION
FUEL FILL DOOR
REMOVAL
INSTALLATION
GRILLE
REMOVAL
INSTALLATION
FRONT SIDE RAIL ACCESS PULLEY SPLASH SHIELD
REMOVAL
INSTALLATION
LUGGAGE RACK CROSSBAR
REMOVAL
INSTALLATION
LUGGAGE RACK SIDE RAIL
REMOVAL
INSTALLATION
RADIATOR CLOSURE PANEL
REMOVAL
INSTALLATION
SIDE VIEW MIRROR
REMOVAL
INSTALLATION
SIDE VIEW MIRROR GLASS
REMOVAL
INSTALLATION
BODY SIDE MOLDINGS
REMOVAL
INSTALLATION
WOOD GRAIN/FLAME DECALS
REMOVAL
INSTALLATION
Surface Preparation
Application
HOOD
HOOD HINGE
REMOVAL
INSTALLATION
HOOD
REMOVAL
INSTALLATION
HOOD LATCH
REMOVAL
INSTALLATION
HOOD LATCH RELEASE CABLE
REMOVAL
INSTALLATION
HOOD LATCH STRIKER
REMOVAL
INSTALLATION
SILENCER PAD
REMOVAL
INSTALLATION
INSTRUMENT PANEL
ACCESSORY SWITCH BEZEL
REMOVAL
INSTALLATION
CLUSTER BEZEL
REMOVAL
INSTALLATION
GLOVE BOX
REMOVAL
INSTALLATION
GLOVE BOX LATCH
REMOVAL
INSTALLATION
GLOVE BOX LOCK CYLINDER
REMOVAL
INSTALLATION
INSTRUMENT PANEL ASSEMBLY
REMOVAL
INSTALLATION
INSTRUMENT PANEL CENTER BEZEL
REMOVAL
INSTALLATION
INSTRUMENT PANEL CENTER BEZEL CONTROL KNOBS
REMOVAL
INSTALLATION
INSTRUMENT PANEL END CAP
REMOVAL
LEFT END CAP
RIGHT END CAP
INSTALLATION
LEFT END CAP
RIGHT END CAP
INSTRUMENT PANEL TOP COVER
REMOVAL
INSTALLATION
STEERING COLUMN OPENING COVER
REMOVAL
INSTALLATION
INTERIOR
A-PILLAR TRIM
REMOVAL
INSTALLATION
B-PILLAR TRIM
REMOVAL
INSTALLATION
BODY VENT
REMOVAL
INSTALLATION
FLOOR CARPET
REMOVAL
INSTALLATION
SIDE COWL TRIM PANEL
REMOVAL
INSTALLATION
UPPER C-PILLAR TRIM
REMOVAL
INSTALLATION
DOOR SILL TRIM
REMOVAL
INSTALLATION
UPPER D-PILLAR TRIM
REMOVAL
INSTALLATION
HEADLINER
REMOVAL
INSTALLATION
LOWER QUARTER TRIM PANEL
REMOVAL
INSTALLATION
INSIDE REAR VIEW MIRROR
REMOVAL
INSTALLATION
SUN VISOR
REMOVAL
INSTALLATION
PAINT
PAINT
SPECIFICATIONS - COLOR CODES
BASECOAT/CLEARCOAT FINISH
DESCRIPTION
PAINT CODE
DESCRIPTION
PAINT TOUCH-UP
DESCRIPTION
TOUCH UP PROCEDURE
FINESSE SANDING/BUFFING and POLISHING
DESCRIPTION
SEATS
FRONT SEAT
REMOVAL
INSTALLATION
FRONT SEAT BACK
REMOVAL
INSTALLATION
FRONT SEAT BACK COVER
REMOVAL
INSTALLATION
FRONT SEAT CUSHION
REMOVAL
INSTALLATION
FRONT SEAT CUSHION COVER
REMOVAL
INSTALLATION
FRONT SEAT HEAD RESTRAINT
REMOVAL
INSTALLATION
REAR SEAT
REMOVAL
INSTALLATION
REAR SEAT BACK
REMOVAL
INSTALLATION
REAR SEAT BACK COVER
REMOVAL
INSTALLATION
REAR SEAT CUSHION
REMOVAL
INSTALLATION
REAR SEAT BACK CUSHION / COVER
REMOVAL
INSTALLATION
UNDER SEAT STORAGE BIN
REMOVAL
INSTALLATION
REAR SEAT PIVOT BEZEL
REMOVAL
INSTALLATION
CHILD SEAT TETHER ANCHOR BEZEL
REMOVAL
INSTALLATION
STATIONARY GLASS
BACKLITE
REMOVAL
INSTALLATION
QUARTER WINDOW
REMOVAL
INSTALLATION
WINDSHIELD
DESCRIPTION
RECOMMENDED TOOLS AND ADHESIVE
ADHESIVE, PRIMER AND CLEANER
RECOMMENDED TOOLS AND ADHESIVE
WARNING
WINDSHIELD SAFETY PRECAUTIONS
REMOVAL
REMOVAL - EXTERIOR METHOD
REMOVAL - INTERIOR METHOD
INSTALLATION
SUNROOF
SUNROOF
DESCRIPTION
DIAGNOSIS AND TESTING - SUNROOF
WATER DRAINAGE AND WIND NOISE DIAGNOSIS
SUNROOF MODULE ASSEMBLY
REMOVAL
INSTALLATION
ELECTRONIC CONTROL MODULE
REMOVAL
INSTALLATION
SUNROOF DRIVE MOTOR
REMOVAL
INSTALLATION
SUNROOF CONTROL SWITCH
REMOVAL
INSTALLATION
WIND DEFLECTOR
REMOVAL
INSTALLATION
GLASS PANEL
REMOVAL
INSTALLATION
ADJUSTMENTS
SUNROOF GLASS PANEL ADJUSTMENT
SUNROOF SUNSHADE
REMOVAL
INSTALLATION
SUNROOF GLASS PANEL SEAL
REMOVAL
INSTALLATION
OPENING TRIM LACE
REMOVAL
INSTALLATION
SUNROOF TROUGH GUIDE ASSEMBLY
REMOVAL
INSTALLATION
DRAIN TUBE
REMOVAL
FRONT HOSES
REAR HOUSING HOSE
INSTALLATION
FRONT HOSES
REAR HOUSING HOSE
WEATHERSTRIP/SEALS
FRONT AND REAR DOOR OPENING WEATHERSTRIP
REMOVAL
INSTALLATION
FRONT AND REAR DOOR UPPER SECONDARY WEATHERSTRIP
REMOVAL
INSTALLATION
FRONT DOOR GLASS RUN WEATHERSTRIP
REMOVAL
INSTALLATION
FRONT DOOR INNER BELT WEATHERSTRIP
REMOVAL
INSTALLATION
FRONT DOOR OUTER BELT WEATHERSTRIP
REMOVAL
INSTALLATION
LIFTGATE WEATHERSTRIP
REMOVAL
INSTALLATION
REAR DOOR GLASS RUN WEATHERSTRIP
REMOVAL
INSTALLATION
REAR DOOR INNER BELT WEATHERSTRIP
REMOVAL
INSTALLATION
SILL SECONDARY WEATHERSTRIP
REMOVAL
INSTALLATION
BODY STRUCTURE
GAP AND FLUSH
SPECIFICATIONS - BODY GAP AND FLUSH MEASUREMENTS
OPENING DIMENSIONS
SPECIFICATIONS - BODY OPENING DIMENSION
SEALER LOCATIONS
SPECIFICATIONS - BODY SEALING LOCATIONS
STRUCTURAL ADHESIVE LOCATIONS
SPECIFICATIONS - STRUCTURAL ADHESIVES
WELD LOCATIONS
SPECIFICATIONS - WELD LOCATIONS
BRAKES
BRAKES - BASE
BRAKES - BASE
DESCRIPTION - BASE BRAKE SYSTEM
OPERATION - BASE BRAKE SYSTEM
WARNING
CAUTION
CAUTIONS
DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM DIAGNOSIS CHARTS
RED BRAKE WARNING INDICATOR
BRAKE NOISE
OTHER BRAKE CONDITIONS
STANDARD PROCEDURE - BASE BRAKE BLEEDING
MANUAL BLEEDING
PRESSURE BLEEDING
SPECIFICATIONS
BRAKE ACTUATION SYSTEM
BRAKE FASTENER TORQUE
SPECIAL TOOLS
BASE BRAKE SYSTEM
BRAKE FLUID LEVEL SWITCH
REMOVAL
INSTALLATION
HYDRAULIC/MECHANICAL
DESCRIPTION
DESCRIPTION - DISC BRAKES (FRONT)
DESCRIPTION - DISC BRAKES (REAR)
DESCRIPTION - DRUM BRAKES (REAR)
DIAGNOSIS AND TESTING - DRUM BRAKE AUTOMATIC ADJUSTER
BRAKE LINES
DESCRIPTION - BRAKE TUBES AND HOSES
OPERATION - BRAKE TUBES AND HOSES
INSPECTION - BRAKE TUBES AND HOSES
BRAKE PADS/SHOES - FRONT
REMOVAL
CLEANING - DISC BRAKE SHOES
INSPECTION - DISC BRAKE SHOES
INSTALLATION
BRAKE PADS/SHOES - REAR DISC
REMOVAL
CLEANING - DISC BRAKE SHOES
INSPECTION - DISC BRAKE SHOES
INSTALLATION
BRAKE PADS/SHOES - REAR DRUM
REMOVAL
CLEANING - DRUM BRAKE SHOES
INSPECTION - DRUM BRAKE SHOES
INSTALLATION
ADJUSTMENTS
ADJUSTMENT - DRUM BRAKE SHOES
DISC BRAKE CALIPER - FRONT
REMOVAL
DISASSEMBLY
CLEANING - DISC BRAKE CALIPER
INSPECTION - DISC BRAKE CALIPER
ASSEMBLY
INSTALLATION
DISC BRAKE CALIPER - REAR
REMOVAL
DISASSEMBLY
DISASSEMBLY - DISC BRAKE CALIPER (GUIDE PIN BUSHINGS)
DISASSEMBLY - DISC BRAKE CALIPER (PISTON AND SEAL)
CLEANING - DISC BRAKE CALIPER
INSPECTION - DISC BRAKE CALIPER
ASSEMBLY
ASSEMBLY - DISC BRAKE CALIPER (GUIDE PIN BUSHINGS)
ASSEMBLY - DISC BRAKE CALIPER (PISTON AND SEAL)
INSTALLATION
DISC BRAKE CALIPER ADAPTER - FRONT
REMOVAL
INSTALLATION
DISC BRAKE CALIPER GUIDE PINS
REMOVAL
INSTALLATION
DRUM
DIAGNOSIS AND TESTING - BRAKE DRUM
STANDARD PROCEDURE - BRAKE DRUM MACHINING
REMOVAL
INSTALLATION
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION
STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING
SPECIFICATIONS
BRAKE FLUID
FLUID RESERVOIR
REMOVAL
INSTALLATION
MASTER CYLINDER
DESCRIPTION
OPERATION
STANDARD PROCEDURE - MASTER CYLINDER BLEEDING
REMOVAL
REMOVAL - LHD WITH ABS
REMOVAL - LHD WITHOUT ABS
REMOVAL - RHD
INSTALLATION
INSTALLATION - LHD WITH ABS
INSTALLATION - LHD WITHOUT ABS
INSTALLATION - RHD
PEDAL - WITH AUTOMATIC TRANSAXLE
REMOVAL
INSTALLATION
PEDAL - WITH MANUAL TRANSAXLE
REMOVAL
INSTALLATION
POWER BRAKE BOOSTER
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - POWER BRAKE BOOSTER
BASIC TEST
VACUUM LEAK TEST
REMOVAL
REMOVAL - LHD
REMOVAL - RHD
INSTALLATION
INSTALLATION - LHD
INSTALLATION - RHD
PROPORTIONING VALVE
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - PROPORTIONING VALVE
PROPORTIONING VALVE TEST
REMOVAL
INSTALLATION
ROTOR
DESCRIPTION
DIAGNOSIS AND TESTING - BRAKE ROTOR
BRAKING SURFACE INSPECTION
ROTOR MINIMUM THICKNESS
ROTOR THICKNESS VARIATION
ROTOR RUNOUT
STANDARD PROCEDURE - BRAKE ROTOR MACHINING
REMOVAL
REMOVAL - FRONT BRAKE ROTOR
REMOVAL - REAR BRAKE ROTOR
INSTALLATION
INSTALLATION - FRONT BRAKE ROTOR
INSTALLATION - REAR BRAKE ROTOR
SPECIFICATIONS
BRAKE ROTOR LIMITS/SPECIFICATIONS
SUPPORT PLATE - DRUM BRAKES
REMOVAL
INSTALLATION
WHEEL CYLINDER - DRUM BRAKE
REMOVAL
INSPECTION
INSTALLATION
PARKING BRAKE
DESCRIPTION
OPERATION
STANDARD PROCEDURE - PARKING BRAKE AUTOMATIC ADJUSTER LOCKOUT
LOCKING AUTOMATIC ADJUSTER OUT
UNLOCKING AUTOMATIC ADJUSTER (UNLOADING)
CABLE - PARKING BRAKE
REMOVAL
INSTALLATION
LEVER - PARKING BRAKE
REMOVAL
INSTALLATION
SHOES - PARKING BRAKE
REMOVAL
INSTALLATION
ADJUSTMENTS
ADJUSTMENT
BRAKES - ABS
BRAKES - ABS
DESCRIPTION
DESCRIPTION - ANTILOCK BRAKE SYSTEM
DESCRIPTION - ELECTRONIC VARIABLE BRAKE PROPORTIONING
DESCRIPTION - TRACTION CONTROL SYSTEM
OPERATION
OPERATION - ANTILOCK BRAKE SYSTEM
NORMAL BRAKING
ABS BRAKING
NOISE AND BRAKE PEDAL FEEL
TIRE NOISE AND MARKS
START-UP CYCLE
DRIVE-OFF CYCLE
PREMATURE ABS CYCLING
OPERATION - ELECTRONIC VARIABLE BRAKE PROPORTIONING
OPERATION - TRACTION CONTROL SYSTEM
CAUTION
CAUTIONS
DIAGNOSIS AND TESTING - INSPECTION AND ROAD TEST
STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING
SPECIFICATIONS
SPECIFICATIONS - ABS FASTENER TORQUE
TONE WHEEL RUNOUT
WHEEL SPEED SENSOR AIR GAP
FRONT WHEEL SPEED SENSOR
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
REAR WHEEL SPEED SENSOR
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
TONE WHEEL
DESCRIPTION
OPERATION
INSPECTION
TRACTION CONTROL SWITCH
REMOVAL
INSTALLATION
HCU - HYDRAULIC CONTROL UNIT
DESCRIPTION - HYDRAULIC CONTROL UNIT (HCU)
VALVES AND SOLENOIDS
BRAKE FLUID ACCUMULATORS
PUMP/MOTOR
OPERATION - HYDRAULIC CIRCUITS AND VALVES
NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL)
ABS HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL)
NORMAL BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL)
ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL)
ABS TRACTION CONTROL HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL)
ICU - INTEGRATED CONTROL UNIT
DESCRIPTION
OPERATION
REMOVAL
DISASSEMBLY - ICU
ASSEMBLY - ICU
INSTALLATION
BUMPERS and FRAME
FRONT BUMPER REINFORCEMENT
REMOVAL
INSTALLATION
FRONT BUMPER FASCIA
REMOVAL
INSTALLATION
REAR BUMPER FASCIA
REMOVAL
INSTALLATION
REAR BUMPER REINFORCEMENT
REMOVAL
INSTALLATION
FRAME
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS
VEHICLE PREPARATION
SPECIFICATIONS - TORQUE
FRONT CROSSMEMBER
REMOVAL
INSTALLATION
FRONT EMERGENCY TOW EYE
REMOVAL
INSTALLATION
REAR EMERGENCY TOW EYE
REMOVAL
INSTALLATION
BUZZER and CHIME
CHIME/BUZZER
DESCRIPTION
OPERATION
FASTEN SEAT BELT
HEADLAMPS REMINDER
KEY IN IGNITION REMINDER
DOOR AJAR CHIME
TURN SIGNAL ON
PARK BRAKE REMINDER
LOW FUEL REMINDER
REVERSE CHIME (DIESEL and TURBO ONLY EQUIPPED WITH THE GETRAG MANUAL TRANSMISSION)
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - BRAKE/PARK BRAKE INDICATOR
To test the system:
If lamp fails to light inspect for:
DIAGNOSIS AND TESTING - CHIME CONDITIONS
NO TONE WHEN IGNITION SWITCH IS TURNED ON AND DRIVERS SEAT BELT IS UNBUCKLED
NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS ON
NO TONE WHEN HEADLAMPS ARE ON AND DRIVERS DOOR IS OPEN
NO TONE WHEN KEY IS LEFT IN IGNITION AND DRIVERS DOOR IS OPEN
DIAGNOSIS AND TESTING - FASTEN SEAT BELTS
DIAGNOSIS AND TESTING - KEY IN IGNITION
CLUTCH
CLUTCH
DESCRIPTION
FLUID
OPERATION
T350-Equipped Models
G288-Equipped Models
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING—CLUTCH SYSTEM DIAGNOSIS
DIAGNOSIS AND TESTING - CLUTCH CHATTER COMPLAINTS
DIAGNOSIS AND TESTING - DRIVE PLATE MISALIGNMENT
DIAGNOSIS AND TESTING - CLASH-INTO-REVERSE COMPLAINTS
STANDARD PROCEDURE—BLEEDING CLUTCH HYDRAULIC CIRCUIT
1.6/2.0/2.4L MODELS (Except Turbo)
DIESEL AND TURBO MODELS
SPECIFICATIONS
CLUTCH/HYDRAULICS/PEDALS
CLUTCH DISC AND PRESSURE PLATE
REMOVAL
REMOVAL—1.6L
REMOVAL—2.2L TD
INSTALLATION
INSTALLATION—1.6L
INSTALLATION—2.2L TD
CLUTCH INTERLOCK/UPSTOP SWITCH
DESCRIPTION
OPERATION
CLUTCH INTERLOCK SWITCH
CLUTCH PEDAL UPSTOP SWITCH
DIAGNOSIS AND TESTING—CLUTCH INTERLOCK/UPSTOP SWITCH
LHD
RHD
CLUTCH INTERLOCK SWITCH
UPSTOP SWITCH
REMOVAL
REMOVAL - LHD
REMOVAL - RHD
INSTALLATION
INSTALLATION - LHD
INSTALLATION - RHD
CLUTCH RELEASE BEARING
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
FLYWHEEL
DESCRIPTION
1.6L Equipped Models
2.2L Turbo Diesel Equipped Models
OPERATION
REMOVAL
INSTALLATION
MASTER CYLINDER - LHD
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
MASTER CYLINDER - RHD
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
MODULAR CLUTCH
DESCRIPTION
2.0/2.4L MODELS (Except Turbo)
2.4L TURBO MODELS
OPERATION
REMOVAL
INSPECTION
OIL CONTAMINATION
GREASE CONTAMINATION
ROAD SPLASH/WATER CONTAMINATION
INSTALLATION
SLAVE CYLINDER
DESCRIPTION
1.6/2.0L/2.4L MODELS (Except Diesel and Turbo)
DIESEL AND TURBO MODELS
REMOVAL
REMOVAL—1.6/2.0/2.4L (Except Diesel and Turbo)
REMOVAL—DIESEL AND TURBO MODELS
INSTALLATION
INSTALLATION—1.6/2.0/2.4L MODELS (Except Diesel and Turbo)
INSTALLATION—DIESEL AND TURBO MODELS
COOLING SYSTEM
COOLING
COOLING
WARNING
COOLING SYSTEM WARNINGS
SPECIFICATIONS
TORQUE - 1.6L SOHC
TORQUE - 2.0/2.4L
SPECIAL TOOLS
COOLING SYSTEM
ACCESSORY DRIVE - 1.6L SOHC
ACCESSORY DRIVE - 1.6L SOHC
DESCRIPTION
DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT DIAGNOSIS
ACCESSORY DRIVE BELT
REMOVAL
CLEANING
INSPECTION
INSTALLATION
ACCESSORY DRIVE BELT TENSIONER
REMOVAL
INSTALLATION
IDLER PULLEY
REMOVAL
INSTALLATION
ACCESSORY DRIVE - 2.0/2.4L DOHC
DRIVE BELTS
DESCRIPTION
DIAGNOSIS AND TESTING
ACCESSORY DRIVE BELTS
REMOVAL
POWER STEERING PUMP/AIR CONDITIONING COMPRESSOR BELT
GENERATOR BELT
CLEANING
INSPECTION
INSTALLATION
GENERATOR BELT
POWER STEERING PUMP/AIR CONDITIONING COMPRESSOR BELT
ADJUSTMENTS
BELT TENSION
AUTOMATIC BELT TENSIONER AND PULLEY
DESCRIPTION
REMOVAL
INSTALLATION
ENGINE - 1.6L SOHC
ENGINE - 1.6L SOHC
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM AERATION
DIAGNOSIS AND TESTING - COOLING SYSTEM DEAERATION
DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK
DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TESTING
STANDARD PROCEDURE
STANDARD PROCEDURE - DRAINING COOLING SYSTEM
STANDARD PROCEDURE - FILLING COOLING SYSTEM
CLEANING
INSPECTION
COOLANT
DESCRIPTION
DIAGNOSIS AND TESTING - COOLANT CONCENTRATION TESTING
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLANT SERVICE
STANDARD PROCEDURE - ROUTINE COOLANT LEVEL CHECK
STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT
HOSE CLAMPS
DESCRIPTION - HOSE CLAMPS
COOLANT RECOVERY CONTAINER
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
ENGINE BLOCK HEATER
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - ENGINE BLOCK HEATER TESTING
REMOVAL
INSTALLATION
ENGINE COOLANT TEMP SENSOR
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
ENGINE COOLANT THERMOSTAT AND HOUSING
REMOVAL
INSTALLATION
RADIATOR PRESSURE CAP
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE RELIEF TESTING
CLEANING
INSPECTION
RADIATOR DRAINCOCK
REMOVAL
INSTALLATION
RADIATOR FAN
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - RADIATOR FAN
REMOVAL
INSTALLATION
RADIATOR
REMOVAL
CLEANING
INSPECTION
INSTALLATION
HEATER RETURN TUBE
REMOVAL
INSTALLATION
WATER PUMP/POWER STEERING PUMP ASSEMBLY
DESCRIPTION
REMOVAL
DISASSEMBLY
ASSEMBLY
INSTALLATION
ENGINE - 2.0/2.4L DOHC
ENGINE - 2.0/2.4L DOHC
DESCRIPTION
Non-Turbo
Turbo
OPERATION
DIAGNOSIS AND TESTING
COOLING SYSTEM
DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK
PREFERRED METHOD
ALTERNATIVE METHOD
COOLING SYSTEM AERATION
DIAGNOSIS AND TESTING - COOLING SYSTEM DEAERATION
STANDARD PROCEDURE
STANDARD PROCEDURE - DRAINING COOLING SYSTEM
STANDARD PROCEDURE - FILLING COOLING SYSTEM
CLEANING
INSPECTION
COOLANT
DESCRIPTION
DIAGNOSIS AND TESTING - COOLANT CONCENTRATION TESTING
STANDARD PROCEDURE
STANDARD PROCEDURE - ROUTINE COOLANT LEVEL CHECK0 - 2 PT (Continued)
STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT
STANDARD PROCEDURE - COOLANT LEVEL SERVICING
COOLANT RECOVERY CONTAINER
DESCRIPTION
OPERATION
REMOVAL
Non - Turbo
Turbo
INSTALLATION
Non - Turbo
Turbo
COOLING SYSTEM PRESSURE CAP
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE RELIEF TESTING
CLEANING
INSPECTION
ENGINE BLOCK HEATER
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING
ENGINE BLOCK HEATER
REMOVAL
INSTALLATION
ENGINE COOLANT TEMPERATURE SENSOR
DESCRIPTION
OPERATION
REMOVAL
Non-Turbo
Turbo
INSTALLATION
Non-Turbo
Turbo
ENGINE COOLANT THERMOSTAT
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - ENGINE COOLANT THERMOSTAT
REMOVAL
INSTALLATION
HOSE CLAMPS
DESCRIPTION - HOSE CLAMPS
OPERATION
RADIATOR FAN
DESCRIPTION
Non-Turbo
Turbo
OPERATION
Non-Turbo
Turbo
DIAGNOSIS AND TESTING
RADIATOR FAN MOTOR TEST
REMOVAL
INSTALLATION
RADIATOR
REMOVAL
CLEANING
INSPECTION
INSTALLATION
RADIATOR DRAINCOCK
REMOVAL
INSTALLATION
THERMOSTAT HOUSING
REMOVAL
INSTALLATION
WATER PUMP
DIAGNOSIS AND TESTING
WATER PUMP
REMOVAL
INSPECTION
INSTALLATION
WATER PUMP INLET TUBE
REMOVAL
INSTALLATION
TRANSMISSION
TRANSMISSION COOLER HOSES
DESCRIPTION
AUTOMATIC TRANSMISSION OIL COOLER
DESCRIPTION
Non - Turbo
Turbo
REMOVAL
Non - Turbo
Turbo
CLEANING
INSPECTION
INSTALLATION
Non - Turbo
Turbo
DRIVELINE and DIFFERENTIAL
HALF SHAFT
HALF SHAFT
DESCRIPTION
All Models Except Diesel and Turbo
Diesel and Turbo Models
OPERATION
DIAGNOSIS AND TESTING - HALFSHAFT DIAGNOSIS
VEHICLE INSPECTION
NOISE AND/OR VIBRATION IN TURNS
CLUNKING NOISE DURING ACCELERATION
SHUDDER OR VIBRATION DURING ACCELERATION
VIBRATION AT HIGHWAY SPEEDS
REMOVAL
REMOVAL—EXCEPT DIESEL AND TURBO MODELS
REMOVAL—DIESEL AND TURBO MODELS
INSTALLATION
INSTALLATION—EXCEPT DIESEL AND TURBO MODELS
INSTALLATION—DIESEL AND TURBO MODELS
SPECIFICATIONS - TORQUE
SPECIAL TOOLS
HALFSHAFT
CV BOOT - INNER
REMOVAL
INSTALLATION
CV BOOT - OUTER
REMOVAL
INSTALLATION
ELECTRONIC CONTROLS
CONTROLLER ANTILOCK BRAKE
DESCRIPTION
OPERATION
CONTROLLER ANTILOCK BRAKE INPUTS
CONTROLLER ANTILOCK BRAKE OUTPUTS
REMOVAL
INSTALLATION
DATA LINK CONNECTOR
DESCRIPTION
OPERATION
HEATED SEAT MODULE
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - HEATED SEAT MODULE
REMOVAL
INSTALLATION
POWERTRAIN CONTROL MODULE
DESCRIPTION
OPERATION - SENSOR RETURN - PCM INPUT
OPERATION - DATA BUS COMMUNICATION RECEIVE - PCM INPUT
OPERATION - IGNITION SENSE - PCM INPUT
OPERATION - PCM GROUND
OPERATION
OPERATION
Powertrain Control Module Connectors
TRANSMISSION CONTROL
OPERATION - 5 VOLT SUPPLY - PCM OUTPUT
STANDARD PROCEDURE
STANDARD PROCEDURE - OBTAINING DIAGNOSTIC TROUBLE CODES
BULB CHECK
OBTAINING DTC'S USING DRB SCAN TOOL
STANDARD PROCEDURE - PINION FACTOR SETTING
STANDARD PROCEDURE - QUICK LEARN PROCEDURE
REMOVAL
REMOVAL - 1.6L
REMOVAL - 2.0, 2.4, and 2.4L Turbo
INSTALLATION
INSTALLATION - 1.6L
INSTALLATION - 2.0, 2.4, and 2.4L TURBO
SENTRY KEY IMMOBILIZER MODULE
DESCRIPTION
OPERATION
STANDARD PROCEDURE - SENTRY KEY IMMOBILIZER SYSTEM INITIALIZATION
REMOVAL
INSTALLATION
TRANSMISSION CONTROL MODULE
DESCRIPTION
OPERATION
CLUTCH VOLUME INDEX (CVI)
SHIFT SCHEDULES
REMOVAL
INSTALLATION
EMISSIONS and EVAPORATIVE SYSTEMS
EMISSIONS CONTROL
EMISSIONS CONTROL
DESCRIPTION
DESCRIPTION - MONITORED COMPONENT
DESCRIPTION - VEHICLE EMISSION CONTROL INFORMATION LABEL
DESCRIPTION - TRIP DEFINITION
OPERATION - NON-MONITORED CIRCUITS
DESCRIPTION - MONITORED SYSTEMS
DESCRIPTION - HIGH AND LOW LIMITS
OPERATION
OPERATION - SYSTEM
DRB III STATE DISPLAY TEST MODE
OPERATION
EVAPORATIVE EMISSIONS
EVAPORATIVE EMISSIONS
OPERATION - EVAPORATION CONTROL SYSTEM
EVAP/PURGE SOLENOID
DESCRIPTION
OPERATION
REMOVAL
REMOVAL
REMOVAL - 2.4L TURBO
INSTALLATION
INSTALLATION
INSTALLATION - 2.4L TURBO
FUEL FILLER CAP
DESCRIPTION
OPERATION
NATURAL VAC LEAK DETECTION ASSY
REMOVAL
INSTALLATION
ORVR
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - VEHICLE DOES NOT FILL
PCV VALVE
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - PCV SYSTEM
REMOVAL - 1.6L
INSTALLATION - 1.6L
VAPOR CANISTER
DESCRIPTION
OPERATION
Purge Free Cells
REMOVAL
INSTALLATION
ON-BOARD DIAGNOSTICS
TASK MANAGER
DESCRIPTION
OPERATION
ENGINE-1.6L, 2.0L and 2.4L
ENGINE 1.6L SOHC
ENGINE 1.6L SOHC
DESCRIPTION
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - INTRODUCTION
DIAGNOSIS AND TESTING - ENGINE PERFORMANCE
DIAGNOSIS AND TESTING - ENGINE MECHANICAL
DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET
CYLINDER-TO-CYLINDER LEAKAGE TEST
CYLINDER-TO-WATER JACKET LEAKAGE TEST
DIAGNOSIS AND TESTING - LASH ADJUSTER NOISE DIAGNOSIS
DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION
INSPECTION FOR REAR SEAL AREA LEAKS
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS
STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
SEALER APPLICATION
STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION
STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE
STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS
REMOVAL - ENGINE ASSEMBLY
INSTALLATION - ENGINE ASSEMBLY
SPECIFICATIONS
1.6L SOHC ENGINE
TORQUE
SPECIAL TOOLS
1.6L SOHC ENGINE
AIR CLEANER ELEMENT
REMOVAL
INSTALLATION
AIR CLEANER HOUSING
REMOVAL
INSTALLATION
CYLINDER HEAD
REMOVAL - CYLINDER HEAD
CLEANING
INSPECTION
INSTALLATION - CYLINDER HEAD
CYLINDER HEAD COVER
REMOVAL
CLEANING
INSPECTION
INSTALLATION
SPARK PLUG TUBE SEAL
DESCRIPTION
REMOVAL
INSTALLATION
SPARK PLUG TUBE
REMOVAL
INSTALLATION
ROCKER ARM SHAFT / ROCKER ARM / LASH ADJUSTER
DESCRIPTION
REMOVAL
INSTALLATION
CAMSHAFT
REMOVAL
INSPECTION
INSTALLATION
VALVE SPRINGS AND SEALS (ON VEHICLE SERVICE)
STANDARD PROCEDURE - VALVE SPRINGS AND SEALS (ON VEHICLE SERVICE)
VALVE SPRINGS AND SEALS (CYLINDER HEAD REMOVED)
STANDARD PROCEDURE - VALVE SPRINGS AND SEALS (CYLINDER HEAD REMOVED)
INSPECTION
INTAKE/EXHAUST VALVES and SEATS
STANDARD PROCEDURE - VALVE AND VALVE SEAT REFACING
ENGINE BLOCK
DESCRIPTION
STANDARD PROCEDURE - CYLINDER BORE HONING
CLEANING
INSPECTION
ENGINE BLOCK
CYLINDER BORE
CRANKSHAFT MAIN BEARINGS
DESCRIPTION
CRANKSHAFT
DESCRIPTION
STANDARD PROCEDURE - CRANKSHAFT END PLAY
REMOVAL
INSPECTION
INSTALLATION
CRANKSHAFT OIL SEAL - FRONT
REMOVAL
INSTALLATION
CRANKSHAFT OIL SEAL - REAR
REMOVAL
INSTALLATION
PISTON and CONNECTING ROD
DESCRIPTION
STANDARD PROCEDURE
STANDARD PROCEDURE - CONNECTING ROD AND BEARING - FITTING
STANDARD PROCEDURE - CYLINDER BORE AND PISTON - FITTING
REMOVAL
INSTALLATION
PISTON RINGS
STANDARD PROCEDURE - PISTON RING - FITTING
REMOVAL
INSTALLATION
VIBRATION DAMPER
REMOVAL
INSTALLATION
ENGINE MOUNTING
DESCRIPTION
TORQUE STRUTS
REMOVAL
UPPER TORQUE STRUT
LOWER TORQUE STRUT
INSTALLATION
UPPER TORQUE STRUT
LOWER TORQUE STRUT
ADJUSTMENTS
ADJUSTMENT
RIGHT ENGINE MOUNT BRACKET
REMOVAL
INSTALLATION
RIGHT MOUNT
REMOVAL
INSTALLATION
LEFT MOUNT
REMOVAL
INSTALLATION
LUBRICATION
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE
OIL FILTER CARTRIDGE
REMOVAL
INSTALLATION
OIL FILTER CARTRIDGE HOUSING
DESCRIPTION
REMOVAL
INSTALLATION
OIL PAN
REMOVAL
INSTALLATION
OIL PUMP
REMOVAL
INSTALLATION
OIL PUMP PICK-UP
REMOVAL
INSTALLATION
INTAKE MANIFOLD
REMOVAL
REMOVAL - UPPER INTAKE MANIFOLD
REMOVAL - LOWER INTAKE MANIFOLD
INSTALLATION
INSTALLATION - UPPER INTAKE MANIFOLD
INSTALLATION - LOWER INTAKE MANIFOLD
EXHAUST MANIFOLD
REMOVAL
CLEANING
INSPECTION
INSTALLATION
VALVE TIMING
DESCRIPTION
STANDARD PROCEDURE - VALVE TIMING VERIFICATION
TIMING CHAIN COVER
REMOVAL
INSTALLATION
TIMING CHAIN/GUIDES/SPROCKETS
REMOVAL
REMOVAL - TIMING CHAIN AND GUIDES
REMOVAL - CAMSHAFT SPROCKET
REMOVAL - CRANKSHAFT SPROCKET
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
INSTALLATION - CAMSHAFT SPROCKET
INSTALLATION - TIMING CHAIN AND GUIDES
ENGINE 2.0L DOHC
ENGINE 2.0L DOHC
DESCRIPTION
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST
DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST
DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION
INSPECTION FOR REAR SEAL AREA LEAKS
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS
STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
SEALER APPLICATION
STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION
STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS
STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE
REMOVAL - ENGINE ASSEMBLY
INSTALLATION - ENGINE ASSEMBLY
SPECIFICATIONS
2.0L DOHC ENGINE
TORQUE
SPECIAL TOOLS
2.0L DOHC ENGINE
AIR CLEANER ELEMENT
REMOVAL
INSTALLATION
AIR CLEANER HOUSING
REMOVAL
INSTALLATION
CYLINDER HEAD
DESCRIPTION
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET
CYLINDER-TO-CYLINDER LEAKAGE TEST
CYLINDER-TO-WATER JACKET LEAKAGE TEST
REMOVAL
CLEANING
INSPECTION
INSTALLATION
CAMSHAFT OIL SEAL(S)
REMOVAL
INSTALLATION
CAMSHAFT(S)
DESCRIPTION
OPERATION
STANDARD PROCEDURE - MEASURING CAMSHAFT END PLAY
REMOVAL
CLEANING
INSPECTION
INSTALLATION
CYLINDER HEAD COVER
REMOVAL
INSTALLATION
HYDRAULIC LASH ADJUSTERS
DIAGNOSIS AND TESTING
HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS
REMOVAL
INSTALLATION
INTAKE/EXHAUST VALVES and SEATS
DESCRIPTION
OPERATION
CLEANING
ROCKER ARMS
REMOVAL
INSPECTION
INSTALLATION
VALVE SPRINGS AND SEALS
REMOVAL
REMOVAL - CYLINDER HEAD ON
REMOVAL - CYLINDER HEAD OFF
INSPECTION
INSTALLATION
INSTALLATION - CYLINDER HEAD ON
INSTALLATION - CYLINDER HEAD OFF
ENGINE BLOCK
DESCRIPTION
STANDARD PROCEDURE - CYLINDER BORE HONING
CLEANING
INSPECTION
ENGINE BLOCK
CYLINDER BORE
CRANKSHAFT
STANDARD PROCEDURE - CRANKSHAFT END PLAY
REMOVAL - CRANKSHAFT
INSPECTION
INSTALLATION - CRANKSHAFT
CRANKSHAFT MAIN BEARING LOCATION
CRANKSHAFT OIL SEAL - FRONT
REMOVAL
INSTALLATION
CRANKSHAFT OIL SEAL - REAR
REMOVAL
INSTALLATION0 - 6 PT (Continued)
PISTON and CONNECTING ROD
DESCRIPTION
STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING
REMOVAL
INSTALLATION
CONNECTING ROD BEARINGS
STANDARD PROCEDURE
CONNECTING ROD - FITTING
PISTON RINGS
STANDARD PROCEDURE - PISTON RING - FITTING
REMOVAL
INSTALLATION
STRUCTURAL COLLAR
REMOVAL
INSTALLATION
VIBRATION DAMPER
REMOVAL
INSTALLATION
ENGINE MOUNTING
DESCRIPTION
OPERATION
LEFT MOUNT
REMOVAL
INSTALLATION
RIGHT MOUNT
REMOVAL
INSTALLATION
TORQUE STRUT
REMOVAL
REMOVAL - UPPER
REMOVAL - LOWER
INSTALLATION
INSTALLATION - UPPER
INSTALLATION - LOWER
ADJUSTMENTS
ENGINE TORQUE STRUT ADJUSTMENT
LUBRICATION
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE
OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK
STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE
OIL FILTER SPECIFICATION
USED ENGINE OIL DISPOSAL
OIL FILTER
REMOVAL
INSTALLATION
OIL FILTER ADAPTER
REMOVAL
INSTALLATION
OIL PAN
REMOVAL
INSTALLATION
OIL PRESSURE SENSOR/SWITCH
REMOVAL
INSTALLATION
OIL PUMP
REMOVAL
DISASSEMBLY
INSPECTION
ASSEMBLY
INSTALLATION
INTAKE MANIFOLD
DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS
REMOVAL
REMOVAL - UPPER INTAKE MANIFOLD
REMOVAL - LOWER INTAKE MANIFOLD
CLEANING
INSPECTION
INSTALLATION
INSTALLATION - UPPER INTAKE MANIFOLD
INSTALLATION - LOWER INTAKE MANIFOLD
EXHAUST MANIFOLD
REMOVAL
CLEANING
INSPECTION
INSTALLATION
VALVE TIMING
STANDARD PROCEDURE - VALVE TIMING VERIFICATION
TIMING BELT COVER(S)
REMOVAL
FRONT COVER
REAR COVER
INSTALLATION
REAR COVER
FRONT COVER
TIMING BELT AND SPROCKETS
REMOVAL
REMOVAL - TIMING BELT
REMOVAL - CAMSHAFT SPROCKET(S)
REMOVAL - CRANKSHAFT SPROCKET
CLEANING
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
INSTALLATION - CAMSHAFT SPROCKETS
INSTALLATION - TIMING BELT
TIMING BELT TENSIONER and PULLEY
REMOVAL
INSTALLATION
ENGINE 2.4L DOHC
ENGINE 2.4L DOHC
DESCRIPTION
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST
DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST
DIAGNOSIS AND TESTING - ENGINE OIL LEAK INSPECTION
INSPECTION FOR REAR SEAL AREA LEAKS
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS
STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
SEALER APPLICATION
STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION
STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS
STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING PLASTIGAGE
REMOVAL - ENGINE ASSEMBLY
INSTALLATION - ENGINE ASSEMBLY
SPECIFICATIONS
2.4L ENGINE
TORQUE
SPECIAL TOOLS
2.4L ENGINE
AIR CLEANER ELEMENT
REMOVAL
INSTALLATION
AIR CLEANER HOUSING
REMOVAL
INSTALLATION
CYLINDER HEAD
DESCRIPTION
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET
CYLINDER-TO-CYLINDER LEAKAGE TEST
CYLINDER-TO-WATER JACKET LEAKAGE TEST
REMOVAL - CYLINDER HEAD
CLEANING
INSPECTION
INSTALLATION - CYLINDER HEAD
CAMSHAFT OIL SEAL(S)
REMOVAL
INSTALLATION
CAMSHAFT(S)
DESCRIPTION
OPERATION
STANDARD PROCEDURE - MEASURING CAMSHAFT END PLAY
REMOVAL
CLEANING
INSPECTION
INSTALLATION
CYLINDER HEAD COVER
REMOVAL
INSTALLATION
HYDRAULIC LASH ADJUSTERS
DIAGNOSIS AND TESTING
HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS
REMOVAL
INSTALLATION
INTAKE/EXHAUST VALVES and SEATS
DESCRIPTION
OPERATION
CLEANING
ROCKER ARMS
REMOVAL
INSPECTION
INSTALLATION
VALVE SPRINGS and SEALS
REMOVAL
REMOVAL - CYLINDER HEAD ON
REMOVAL - CYLINDER HEAD OFF
INSPECTION
INSTALLATION
INSTALLATION - CYLINDER HEAD ON
INSTALLATION - CYLINDER HEAD OFF
ENGINE BLOCK
DESCRIPTION
STANDARD PROCEDURE - CYLINDER BORE HONING
CLEANING
INSPECTION
ENGINE BLOCK
CYLINDER BORE
CRANKSHAFT
STANDARD PROCEDURE - MEASURING CRANKSHAFT END PLAY
REMOVAL - CRANKSHAFT
INSPECTION
INSTALLATION - CRANKSHAFT
CRANKSHAFT MAIN BEARING LOCATION
CRANKSHAFT OIL SEAL - FRONT
REMOVAL
INSTALLATION
CRANKSHAFT OIL SEAL - REAR
REMOVAL
INSTALLATION
PISTON and CONNECTING ROD
DESCRIPTION
Non-Turbo
Turbo
STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING
REMOVAL
INSTALLATION
CONNECTING ROD BEARINGS
STANDARD PROCEDURE
CONNECTING ROD - FITTING
PISTON RINGS
STANDARD PROCEDURE
PISTON RING - FITTING
REMOVAL
INSTALLATION
STRUCTURAL COLLAR
REMOVAL
STRUCTURAL COLLAR—AUTOMATIC TRANSAXLE EQUIPPED
STRUCTURAL COLLAR—MANUAL TRANSAXLE EQUIPPED
INSTALLATION
STRUCTURAL COLLAR—AUTOMATIC TRANSAXLE EQUIPPED
STRUCTURAL COLLAR—MANUAL TRANSAXLE EQUIPPED
VIBRATION DAMPER
REMOVAL
INSTALLATION
ENGINE MOUNTING
DESCRIPTION
OPERATION
LEFT MOUNT
REMOVAL
INSTALLATION
RIGHT MOUNT
REMOVAL
INSTALLATION
TORQUE STRUT
REMOVAL
REMOVAL - UPPER
REMOVAL - LOWER
INSTALLATION
INSTALLATION - UPPER
INSTALLATION - LOWER
ADJUSTMENTS
ENGINE TORQUE STRUT ADJUSTMENT
LUBRICATION
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE
OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK
STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE
OIL FILTER SPECIFICATION
USED ENGINE OIL DISPOSAL
OIL FILTER
REMOVAL
INSTALLATION
OIL FILTER ADAPTER
REMOVAL
INSTALLATION
OIL PAN
REMOVAL
INSTALLATION
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
OIL PUMP
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION
ASSEMBLY
INSTALLATION
OIL JET - 2.4L TURBO
DESCRIPTION
REMOVAL
INSTALLATION
OIL COOLER and LINES - 2.4L TURBO
DESCRIPTION
REMOVAL
INSTALLATION
INTAKE MANIFOLD
DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS
REMOVAL
REMOVAL - UPPER INTAKE MANIFOLD
Non-Turbo
Turbo
REMOVAL - LOWER INTAKE MANIFOLD
CLEANING
INSPECTION
INSTALLATION
INSTALLATION - UPPER INTAKE MANIFOLD
Non-Turbo
Turbo
INSTALLATION - LOWER INTAKE MANIFOLD
EXHAUST MANIFOLD
REMOVAL
CLEANING
INSPECTION
INSTALLATION
TIMING BELT COVER(S)
REMOVAL
FRONT COVER—UPPER
FRONT COVER—LOWER
REAR COVER
INSTALLATION
FRONT COVER—UPPER
FRONT COVER—LOWER
REAR COVER
TIMING BELT AND SPROCKETS
REMOVAL
REMOVAL - TIMING BELT
REMOVAL - CAMSHAFT SPROCKET(S)
REMOVAL - CRANKSHAFT SPROCKET
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
INSTALLATION - CAMSHAFT SPROCKET(S)
INSTALLATION - TIMING BELT
TIMING BELT TENSIONER and PULLEY
REMOVAL
INSTALLATION
BALANCE SHAFTS AND CARRIER ASSEMBLY
DESCRIPTION
OPERATION
REMOVAL
BALANCE SHAFTS/CHAIN/SPROCKETS
BALANCE SHAFT CARRIER
INSTALLATION
BALANCE SHAFT INSTALLATION/TIMING
EXHAUST, CATALYTIC CONV. and TURBOCHARGER
EXHAUST SYSTEM AND TURBOCHARGER
DESCRIPTION - EXHAUST SYSTEM
DIAGNOSIS AND TESTING
EXHAUST SYSTEM DIAGNOSIS
DIAGNOSIS AND TESTING - EXHAUST SYSTEM RESTRICTION CHECK
INSPECTION
ADJUSTMENTS
EXHAUST SYSTEM ALIGNMENT
SPECIFICATIONS
EXHAUST SYSTEM CLEARANCE
TORQUE - EXHAUST SYSTEM COMPONENTS
TORQUE - TURBOCHARGER COMPONENTS
SPECIAL TOOLS
EXHAUST SYSTEM
MUFFLER
REMOVAL
INSTALLATION
INTERMEDIATE PIPE
REMOVAL
INSTALLATION
CATALYTIC CONVERTER
DESCRIPTION
OPERATION
REMOVAL
INSPECTION
INSTALLATION
SUPPORT BRACKETS AND ISOLATORS
REMOVAL
INSTALLATION
HEAT SHIELDS
DESCRIPTION
REMOVAL
INSTALLATION
TURBOCHARGER SYSTEM
DIAGNOSIS AND TESTING - TURBOCHARGER
TURBOCHARGER
DESCRIPTION
OPERATION
REMOVAL - TURBOCHARGER
INSTALLATION - TURBOCHARGER
CHARGE AIR COOLER AND HOSES
REMOVAL
REMOVAL - CHARGE AIR COOLER HOSES
HOSE - CHARGE AIR COOLER TO THROTTLE BODY
HOSE - TURBOCHARGER TO CHARGE AIR COOLER
REMOVAL - CHARGE AIR COOLER
INSTALLATION
INSTALLATION - CHARGE AIR COOLER HOSES
HOSE - CHARGE AIR COOLER TO THROTTLE BODY
HOSE - TURBOCHARGER TO CHARGE AIR COOLER
INSTALLATION - CHARGE AIR COOLER
LINES AND HOSES
REMOVAL - LINES AND HOSES
COOLANT SUPPLY LINE
COOLANT RETURN LINE
OIL SUPPLY LINE
OIL RETURN LINE
INSTALLATION - LINES AND HOSES
COOLANT SUPPLY LINE
COOLANT RETURN LINE
OIL SUPPLY LINE
OIL RETURN LINE
SOLENOIDS AND VACUUM HARNESS
DESCRIPTION
REMOVAL
INSTALLATION
FUEL - DELIVERY and INJECTION
FUEL DELIVERY
FUEL DELIVERY
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - FUEL DELIVERY SYSTEM
STANDARD PROCEDURE
STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE
STANDARD PROCEDURE - DRAINING FUEL TANK
SPECIFICATIONS
TORQUE
FUEL SYSTEM PRESSURE
SPECIAL TOOLS
FUEL
FUEL FILTER
DESCRIPTION
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
FUEL LINES
DESCRIPTION - FUEL LINES/HOSES AND CLAMPS
STANDARD PROCEDURE - HOSES AND CLAMP
FUEL PRESSURE REGULATOR
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
FUEL PUMP
DESCRIPTION
OPERATION
FUEL PUMP MODULE
DESCRIPTION
OPERATION
FUEL PUMP ELECTRICAL CONTROL
ELECTRICAL PUMP REPLACEMENT
REMOVAL
INSTALLATION
FUEL RAIL
DESCRIPTION
OPERATION
REMOVAL
REMOVAL
REMOVAL - 2.4L TURBO
REMOVAL - 1.6L
INSTALLATION
INSTALLATION
INSTALLATION - 2.4L TURBO
INSTALLATION - 1.6L
FUEL TANK
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
FUEL TANK FILLER TUBE
REMOVAL
INSTALLATION
INLET FILTER
DESCRIPTION
QUICK CONNECT FITTING
STANDARD PROCEDURE - QUICK-CONNECT FITTINGS
REMOVAL
INSTALLATION
TWO-TAB TYPE FITTING
PLASTIC RETAINER RING TYPE FITTING
FUEL INJECTION
FUEL INJECTION
OPERATION
OPERATION - INJECTION SYSTEM
OPERATION - MODES OF OPERATION
IGNITION SWITCH ON (ZERO RPM) MODE
ENGINE START-UP MODE
ENGINE WARM-UP MODE
CRUISE OR IDLE MODE
ACCELERATION MODE
DECELERATION MODE
WIDE-OPEN-THROTTLE MODE
IGNITION SWITCH OFF MODE
FUEL CORRECTION or ADAPTIVE MEMORIES
DESCRIPTION
OPERATION
PROGRAMMABLE COMMUNICATIONS INTERFACE (PCI) BUS
DESCRIPTION
OPERATION
SYSTEM DIAGNOSIS
OPERATION
SPECIFICATIONS
TORQUE
SPECIAL TOOLS
FUEL
ACCELERATOR PEDAL
REMOVAL
INSTALLATION
ACCELERATOR PEDAL POSITION SENSOR - 1.6L
DESCRIPTION
REMOVAL - LHD
INSTALLATION - LHD
CRANKSHAFT POSITION SENSOR
DESCRIPTION
OPERATION
REMOVAL
REMOVAL - 1.6L
REMOVAL - 2.0, 2.4, 2.4L TURBO
INSTALLATION
INSTALLATION - 1.6L
INSTALLATION - 2.0, 2.4, 2.4L Turbo
FUEL INJECTOR
DESCRIPTION
OPERATION
STANDARD PROCEDURE
REMOVAL - INJECTOR CONNECTOR
REMOVAL
REMOVAL - 2.0, 2.4L
REMOVAL - 1.6L
REMOVAL - 2.4L TURBO
INSTALLATION
INSTALLATION - 2.0, 2.4L
INSTALLATION - 1.6L
INSTALLATION - 2.4L TURBO
FUEL PUMP RELAY
DESCRIPTION
OPERATION
IDLE AIR CONTROL MOTOR
DESCRIPTION
OPERATION
Target Idle
REMOVAL
INSTALLATION
INLET AIR TEMPERATURE SENSOR
DESCRIPTION
OPERATION
Inlet/Intake Air Temperature (NGC)
Battery Temperature (SBEC Vehicles without Battery Temperature sensor)
REMOVAL
INSTALLATION
MAP SENSOR
DESCRIPTION
OPERATION
REMOVAL
REMOVAL - 2.0, 2.4, 2.4L TURBO
REMOVAL - 1.6L
INSTALLATION
INSTALLATION - 2.0, 2.4, 2.4L Turbo
INSTALLATION - 1.6L
O2 SENSOR
DESCRIPTION
OPERATION
UPSTREAM OXYGEN SENSOR
DOWNSTREAM OXYGEN SENSOR
REMOVAL
REMOVAL - 1/1 UPSTREAM
REMOVAL - 1/2 DOWNSTREAM
REMOVAL - 2.4L TURBO
INSTALLATION
INSTALLATION - 1/1 UPSTREAM
INSTALLATION - 1/2 DOWNSTREAM
INSTALLATION - 2.4L TURBO
THROTTLE BODY
DESCRIPTION
OPERATION
REMOVAL
REMOVAL - 2.0, 2.4L
REMOVAL - 1.6L
REMOVAL - 2.4L TURBO
INSTALLATION
INSTALLATION - 2.0, 2.4L
INSTALLATION - 1.6L
INSTALLATION - 2.4L TURBO
THROTTLE CONTROL CABLE
REMOVAL
INSTALLATION
THROTTLE POSITION SENSOR
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
HEATED - SEATS and WINDOWS
HEATED SEAT SYSTEM
HEATED SEAT SYSTEM
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - HEATED SEAT SYSTEM
SELF-DIAGNOSTICS - HEATED SEAT SYSTEM
DRIVER HEATED SEAT SWITCH
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - DRIVER HEATED SEAT SWITCH
REMOVAL
INSTALLATION
HEATED SEAT ELEMENT
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - HEATED SEAT ELEMENT
REMOVAL
INSTALLATION
HEATED SEAT RELAY
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - MICRO-RELAY
REMOVAL
INSTALLATION
HEATED SEAT SENSOR
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - HEATED SEAT SENSOR
REMOVAL
PASSENGER HEATED SEAT SWITCH
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - PASSENGER HEATED SEAT SWITCH
REMOVAL
INSTALLATION
HEATED WINDOW DEFOGGER
HEATED WINDOW DEFOGGER
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING
REAR WINDOW DEFOGGER SYSTEM
DEFOGGER SWITCH
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING
REAR WINDOW DEFOGGER SWITCH
IN-VEHICLE TESTING
BENCH TESTING
REAR WINDOW DEFOGGER GRID
DIAGNOSIS AND TESTING
GRID LINES
STANDARD PROCEDURE
GRID LINE AND TERMINAL REPAIR
REAR WINDOW DEFOGGER GRID LINES
HORN SYSTEM and SWITCH
HORN SYSTEM
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - HORN SYSTEM
HORN
DIAGNOSIS AND TESTING - HORN
REMOVAL
INSTALLATION
HORN RELAY
DIAGNOSIS AND TESTING - HORN RELAY
REMOVAL
INSTALLATION
HORN SWITCH
DESCRIPTION
OPERATION
REMOVAL
IDENTIFICATION, METRIC SYSTEM and TORQUE REFERENCES
BODY CODE PLATE
DESCRIPTION
BODY CODE PLATE LINE 2
BODY CODE PLATE LINE 1
IF TWO BODY CODE PLATES ARE REQUIRED
FASTENER IDENTIFICATION
DESCRIPTION
FASTENER USAGE
DESCRIPTION
DESCRIPTION - FASTENER USAGE
DESCRIPTION - THREADED HOLE REPAIR
INTERNATIONAL SYMBOLS
DESCRIPTION
METRIC SYSTEM
DESCRIPTION
TORQUE REFERENCES
DESCRIPTION
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION - VEHICLE IDENTIFICATION NUMBER
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION
E-MARK LABEL
DESCRIPTION
VECI LABEL
DESCRIPTION
MANUFACTURER PLATE
DESCRIPTION
IGNITION SYSTEM
IGNITION CONTROL
DESCRIPTION - IGNITION SYSTEM
OPERATION - IGNITION SYSTEM
SPECIFICATIONS
FIRING ORDER—1.6/2.0L
TORQUE
IGNITION COILS
SPARK PLUGS
SPARK PLUG CABLE RESISTANCE
SPECIAL TOOLS - EXPORT
AUTO SHUT DOWN RELAY
DESCRIPTION
OPERATION
CAMSHAFT POSITION SENSOR
DESCRIPTION
OPERATION
REMOVAL
REMOVAL - 2.0/2.4L
REMOVAL - 1.6L
INSTALLATION
INSTALLATION - 2.0/2.4L
INSTALLATION - 1.6L
IGNITION COIL
DESCRIPTION
OPERATION
REMOVAL
REMOVAL - 1.6L
REMOVAL - 2.0/2.4L
REMOVAL - 2.4L TURBO
INSTALLATION
INSTALLATION - 1.6L
INSTALLATION- 2.0/2.4L
INSTALLATION - 2.4L TURBO
IGNITION COIL CAPACITOR
REMOVAL - 2.4L TURBO
INSTALLATION - 2.4L TURBO
KNOCK SENSOR
DESCRIPTION
OPERATION
REMOVAL
REMOVAL - 1.6L
REMOVAL - 2.0/2.4L
INSTALLATION
INSTALLATION - 1.6L
INSTALLATION - 2.0/2.4L
SPARK PLUG
REMOVAL
REMOVAL - 1.6L
REMOVAL - 2.0/2.4L
REMOVAL - 2.4L TURBO
INSTALLATION
INSTALLATION - 1.6L
INSTALLATION - 2.0/2.4L
INSTALLATION - 2.4L TURBO
SPARK PLUG CABLE
DESCRIPTION
REMOVAL
REMOVAL - 1.6L
REMOVAL - 2.0/2.4L
INSTALLATION
INSTALLATION - 1.6L
INSTALLATION - 2.0/2.4L
INSTRUMENT INDICATORS
INSTRUMENT CLUSTER
DESCRIPTION
CHIME
KEY IN IGNITION SWITCH
INSTRUMENT CLUSTER - EXPORT
OPERATION
INSTRUMENT CLUSTER - EXPORT
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - INSTRUMENT CLUSTER WARNING/INDICATOR LAMPS
DIAGNOSIS AND TESTING - MULTIPLE/INDIVIDUAL GAUGES INOPERATIVE
STANDARD PROCEDURE - SELF-DIAGNOSTICS
REMOVAL
INSTALLATION
CLUSTER MASK/LENS
REMOVAL
INSTALLATION
LAMPS and LIGHTING
LAMPS/LIGHTTING - EXTERIOR
LAMPS/LIGHTING - EXTERIOR
SPECIFICATIONS
EXTERIOR LAMPS
BACK-UP LAMP
REMOVAL
INSTALLATION
BACK-UP LAMP UNIT
REMOVAL
INSTALLATION
BRAKE LAMP SWITCH
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - BRAKE LAMP SWITCH
REMOVAL
INSTALLATION
CENTER HIGH MOUNTED STOP LAMP
REMOVAL
INSTALLATION
CENTER HIGH MOUNTED STOP LAMP UNIT
REMOVAL
INSTALLATION
COMBINATION FLASHER
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
DAYTIME RUNNING LAMP MODULE
DESCRIPTION
OPERATION
FOG LAMP
DIAGNOSIS AND TESTING - FOG LAMP
REMOVAL
INSTALLATION
FOG LAMP UNIT
STANDARD PROCEDURE - FOG LAMP UNIT ALIGNMENT
REMOVAL
INSTALLATION
FRONT POSITION LAMP - EXPORT
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - FRONT POSITION LAMP - EXPORT
REMOVAL
INSTALLATION
HEADLAMP
DIAGNOSIS AND TESTING - HEADLAMPS
REMOVAL
INSTALLATION
HEADLAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - HEADLAMP UNIT ALIGNMENT
ALIGNMENT SCREEN PREPARATION
HEADLAMP UNIT ALIGNMENT
STANDARD PROCEDURE - HEADLAMP UNIT ALIGNMENT - EXPORT
VEHICLE PREPARATION FOR HEADLAMP UNIT ALIGNMENT
ALIGNMENT SCREEN PREPARATION
HEADLAMP UNIT ALIGNMENT
REMOVAL
INSTALLATION
HEADLAMP LEVELING MOTOR - EXPORT
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - HEADLAMP LEVELING MOTOR - EXPORT
REMOVAL
INSTALLATION
HEADLAMP LEVELING SWITCH - EXPORT
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - HEADLAMP LEVELING SWITCH - EXPORT
REMOVAL
INSTALLATION
HEADLAMP SWITCH
DESCRIPTION
OPERATION
LICENSE PLATE LAMP
REMOVAL
INSTALLATION
LICENSE PLATE LAMP UNIT
REMOVAL
INSTALLATION
MULTI-FUNCTION SWITCH
DESCRIPTION
MULTI-FUNCTION SWITCH
HAZARD WARNING SYSTEM
OPERATION
MULTI-FUNCTION SWITCH
HAZARD WARNING SYSTEM
DIAGNOSIS AND TESTING - MULTI-FUNCTION SWITCH
FLASHER DIAGNOSIS
SWITCH DIAGNOSIS
REMOVAL
INSTALLATION
PARK/TURN SIGNAL LAMP
REMOVAL
INSTALLATION
REAR FOG LAMP SWITCH - EXPORT
DESCRIPTION
OPERATION
SIDE REPEATER LAMP - EXPORT
DIAGNOSIS AND TESTING - SIDE REPEATER LAMP
REMOVAL
INSTALLATION
SIDE REPEATER LAMP UNIT - EXPORT
REMOVAL
INSTALLATION
TAIL LAMP
REMOVAL
INSTALLATION
TAIL LAMP UNIT
REMOVAL
INSTALLATION
LAMPS/LIGHTING - INTERIOR
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS
CENTER CONSOLE FLOOD LAMP
REMOVAL
INSTALLATION
CENTER CONSOLE FLOOD LAMP HOUSING
REMOVAL
INSTALLATION
COURTESY/READING LAMP
REMOVAL
INSTALLATION
DOME LAMP
REMOVAL
INSTALLATION
DOME LAMP UNIT
REMOVAL
INSTALLATION
DOME LAMP WITH INTRUSION SENSOR - EXPORT
REMOVAL
INSTALLATION
DOME LAMP UNIT WITH INTRUSION SENSOR - EXPORT
REMOVAL
INSTALLATION
CLUSTER ILLUMINATION LAMPS
REMOVAL
INSTALLATION
REAR CARGO LAMP
REMOVAL
INSTALLATION
REAR CARGO LAMP UNIT
REMOVAL
INSTALLATION
TRANS RANGE INDICATOR ILLUMINATION
REMOVAL
INSTALLATION
VANITY LAMP
REMOVAL
INSTALLATION
MAINTENANCE and LUBRICATION
INTERNATIONAL SYMBOLS
DESCRIPTION
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE OIL AND LUBRICANTS
API SERVICE GRADE CERTIFIED
SAE VISCOSITY
ENERGY CONSERVING OIL
CONTAINER IDENTIFICATION
SYNTHETIC ENGINE OILS
MATERIALS ADDED TO ENGINE OIL
GEAR LUBRICANTS
LUBRICANTS AND GREASES
SPECIALIZED LUBRICANTS AND OILS
DESCRIPTION - ENGINE COOLANT
DESCRIPTION - TRANSMISSION FLUID
TRANSMISSION FLUID
DESCRIPTION - FUEL REQUIREMENTS
REFORMULATED GASOLINE
GASOLINE/OXYGENATE BLENDS
MMT IN GASOLINE
SULFUR IN GASOLINE
MATERIALS ADDED TO FUEL
FUEL SYSTEM CAUTIONS
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
FLUID FILL/CHECK LOCATIONS
DESCRIPTION
LUBRICATION POINTS
DESCRIPTION
MAINTENANCE SCHEDULES
DESCRIPTION
SCHEDULE "B"—ALL ENGINES
SCHEDULE "A"—NON TURBO CHARGED ENGINES
SCHEDULE "A"—2.4L TURBO CHARGED ENGINES
HOISTING
STANDARD PROCEDURE - HOISTING
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
TO JUMP START A DISABLED VEHICLE:
TOWING
STANDARD PROCEDURE - TOWING
MESSAGING SYSTEMS
OVERHEAD CONSOLE
DESCRIPTION
OPERATION
AUTOMATIC COMPASS CALIBRATION
MANUAL COMPASS CALIBRATION
ZONE VARIANCE
OUTSIDE TEMPERATURE
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPASS CALIBRATION
STANDARD PROCEDURE - COMPASS VARIATION ADJUSTMENT
PROGRAMMING ZONE VARIATION
STANDARD PROCEDURE - COMPASS DEMAGNETIZING
REMOVAL
INSTALLATION
SPECIAL TOOLS
OVERHEAD CONSOLE
AMBIENT TEMP SENSOR
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - AMBIENT TEMPERATURE SENSOR
SENSOR TESTING
SENSOR CIRCUIT TESTING
REMOVAL
INSTALLATION
POWER LOCKS/MIRRORS/SEATS/WINDOWS
POWER LOCKS
POWER LOCKS
DESCRIPTION
POWER LOCKS
CHILD PROTECTION LOCKS
DOOR LOCK INHIBIT
REMOTE KEYLESS ENTRY
OPERATION
POWER LOCKS
CENTRAL LOCKING/UNLOCKING (IF EQUIPPED)0 - 4 PT (Continued)
REMOTE KEYLESS ENTRY
ROLLING DOOR LOCKS
DIAGNOSIS AND TESTING - POWER LOCKS
STANDARD PROCEDURE
STANDARD PROCEDURE - DOUBLE ACTIVATION UNLOCK
DRB lll PROGRAMMING
CUSTOMER PROGRAMMING
STANDARD PROCEDURE - ROLLING DOOR LOCKS
DRB lll PROGRAMMING
CUSTOMER PROGRAMMING
DOOR LOCK SWITCH
DIAGNOSIS AND TESTING - DOOR LOCK SWITCH
REMOVAL
INSTALLATION
DOOR LOCK MOTOR
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - DOOR LOCK MOTOR
LIFTGATE LOCK MOTOR
REMOVAL
INSTALLATION
REMOTE KEYLESS ENTRY MODULE
DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY MODULE
REMOVAL
INSTALLATION
REMOTE KEYLESS ENTRY TRANSMITTER
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY TRANSMITTER
STANDARD PROCEDURE
STANDARD PROCEDURE - HORN CHIRP TOGGLE
DRB lll PROGRAMMING
CUSTOMER PROGRAMMING
STANDARD PROCEDURE - TRANSMITTER PROGRAMING
DRB lll PROGRAMMING
CUSTOMER PROGRAMMING
STANDARD PROCEDURE - RKE TRANSMITTER BATTERIES
SPECIFICATIONS - TRANSMITTER RANGE
POWER MIRRORS
POWER MIRRORS
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - POWER MIRRORS
WIRING VOLTAGE TEST (LHD)
POWER MIRROR MOTOR TEST (LHD)
POWER MIRROR SWITCH - LHD
DIAGNOSIS AND TESTING - POWER MIRROR SWITCH - LHD
REMOVAL
INSTALLATION
POWER FOLDAWAY MIRROR SWITCH - RHD
DIAGNOSIS AND TESTING - POWER FOLDAWAY MIRROR SWITCH - RHD
EXTENDED MIRROR SWITCH CIRCUIT TEST
RETRACTED MIRROR SWITCH CIRCUIT TEST
REMOVAL
INSTALLATION
POWER SEAT SYSTEM
POWER SEAT SYSTEM
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - POWER SEAT SYSTEM
DRIVER SEAT SWITCH
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - DRIVER SEAT SWITCH
REMOVAL
INSTALLATION
POWER SEAT TRACK
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - POWER SEAT TRACK
REMOVAL
INSTALLATION
LUMBAR
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
POWER WINDOWS
POWER WINDOWS
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - POWER WINDOWS
WIRING VOLTAGE TEST
POWER WINDOW MOTOR TEST
POWER WINDOW SWITCH
DIAGNOSIS AND TESTING - POWER WINDOW SWITCH
REMOVAL
FRONT
REAR
INSTALLATION
FRONT
REAR
WINDOW MOTOR
REMOVAL
INSTALLATION
SPEED CONTROL
SPEED CONTROL
DESCRIPTION
OPERATION
OPERATION
OPERATION - INTERACTIVE SPEED CONTROL (4 Speed EATX Only)
CLIMBING A GRADE
GRADE HUNTING
AUTOMATIC SPEED CONTROL OVERSPEED REDUCTION
OPERATION - CHECKING FOR DIAGNOSTIC CODES
DIAGNOSIS AND TESTING - ROAD TEST
CABLE
DESCRIPTION
OPERATION
REMOVAL
REMOVAL
REMOVAL - 2.4L TURBO
INSTALLATION
INSTALLATION
INSTALLATION - 2.4L TURBO
SERVO
DESCRIPTION
OPERATION
REMOVAL
REMOVAL
REMOVAL - 2.4L TURBO
INSTALLATION
INSTALLATION
INSTALLATION - 2.4L TURBO
SWITCH
REMOVAL
INSTALLATION
VACUUM RESERVOIR
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
STEERING SYSTEM
STEERING
STEERING
DESCRIPTION - POWER STEERING SYSTEM
OPERATION - POWER STEERING SYSTEM
WARNING
WARNINGS AND CAUTIONS
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER STEERING FLOW AND PRESSURE TEST
TEST PROCEDURE
DIAGNOSIS AND TESTING - STEERING DIAGNOSIS CHARTS
POWER STEERING NOISE
STEERING WHEEL FEEL
POWER STEERING FLUID
SPECIFICATIONS - POWER STEERING FASTENER TORQUE
SPECIAL TOOLS
POWER STEERING
COLUMN
COLUMN
DESCRIPTION
OPERATION
WARNING
WARNINGS AND CAUTIONS
DIAGNOSIS AND TESTING - STEERING COLUMN
REMOVAL
REMOVAL
REMOVAL - RHD
INSTALLATION
INSTALLATION
INSTALLATION - RHD
SPECIFICATIONS - STEERING COLUMN FASTENER TORQUE
IGNITION SWITCH
REMOVAL
INSTALLATION
KEY/LOCK CYLINDER
REMOVAL
INSTALLATION
SHROUD - UPPER/LOWER
REMOVAL
INSTALLATION
STEERING COUPLING - LOWER
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - STEERING COLUMN LOWER COUPLING
REMOVAL
INSTALLATION
STEERING WHEEL
REMOVAL
INSTALLATION
GEAR
GEAR
DESCRIPTION
OPERATION
REMOVAL
REMOVAL
REMOVAL - RHD
INSTALLATION
INSTALLATION
INSTALLATION - RHD
POWER STEERING PRESSURE SWITCH
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
TIE ROD - OUTER
REMOVAL
INSTALLATION
PUMP
PUMP
DESCRIPTION
DESCRIPTION - 1.6L ENGINE
DESCRIPTION - 2.0L/2.4L/2.4L TURBO ENGINE
DESCRIPTION - 2.2L DIESEL
STANDARD PROCEDURE - POWER STEERING PUMP INITIAL OPERATION
REMOVAL
REMOVAL - 1.6L ENGINE
REMOVAL - 2.0L/2.4L ENGINE
REMOVAL - 2.4L TURBO
REMOVAL - 2.2L DIESEL
DISASSEMBLY
ASSEMBLY
INSTALLATION
INSTALLATION - 1.6L ENGINE
INSTALLATION - 2.0L/2.4L ENGINE
INSTALLATION - 2.4L TURBO
INSTALLATION - 2.2L DIESEL
FLUID
STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING0 - 8 PT (Continued)
1.6L GAS/2.2L DIESEL ENGINE
2.0L/2.4L ENGINE
2.4L TURBO ENGINE
FLUID COOLER
DESCRIPTION
REMOVAL - NON-TURBO ENGINES
INSTALLATION - NON-TURBO ENGINES
HOSE - POWER STEERING PRESSURE
REMOVAL
REMOVAL - 2.0L ENGINE
REMOVAL - 2.4L ENGINE
REMOVAL - 2.2L DIESEL
INSTALLATION
INSTALLATION - 2.0L ENGINE
INSTALLATION - 2.4L ENGINE
INSTALLATION - 2.2L DIESEL
HOSE - POWER STEERING PRESSURE/RETURN
REMOVAL - 2.4L TURBO
INSTALLATION - 2.4L TURBO
HOSE - POWER STEERING RETURN
REMOVAL
REMOVAL - 2.0L/2.4L ENGINE
REMOVAL - 2.4L TURBO
REMOVAL - 2.2L DIESEL
INSTALLATION
INSTALLATION - 2.0L/2.4L ENGINE
INSTALLATION - 2.4L TURBO
INSTALLATION - 2.2L DIESEL
HOSE - POWER STEERING SUPPLY
REMOVAL
REMOVAL - 2.0L/2.4L ENGINE
REMOVAL - 2.2L DIESEL
INSTALLATION
INSTALLATION - 2.0L/2.4L ENGINE
INSTALLATION - 2.2L DIESEL
PULLEY
REMOVAL - 2.2L DIESEL
INSTALLATION - 2.2L DIESEL
RESERVOIR
DESCRIPTION
REMOVAL
REMOVAL - 1.6L ENGINE
REMOVAL - 2.0L/2.4L ENGINE
REMOVAL - 2.2L DIESEL
INSTALLATION
INSTALLATION - 1.6L ENGINE
INSTALLATION - 2.0L/2.4L ENGINE
INSTALLATION - 2.2L DIESEL
SUSPENSION
FRONT SUSPENSION
FRONT SUSPENSION
DESCRIPTION - FRONT SUSPENSION
OPERATION - FRONT SUSPENSION
WARNING
WARNINGS AND CAUTIONS
STANDARD PROCEDURE - LUBRICATION
SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUE
SPECIAL TOOLS
FRONT SUSPENSION
HUB / BEARING
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - WHEEL BEARING AND HUB
REMOVAL
INSTALLATION
KNUCKLE
DESCRIPTION - STEERING KNUCKLE
OPERATION - STEERING KNUCKLE
DIAGNOSIS AND TESTING - STEERING KNUCKLE
REMOVAL - STEERING KNUCKLE
DISASSEMBLY - STEERING KNUCKLE (WHEEL BEARING AND HUB)
ASSEMBLY - STEERING KNUCKLE (WHEEL BEARING AND HUB)
INSTALLATION - STEERING KNUCKLE
LOWER BALL JOINT
DIAGNOSIS AND TESTING - BALL JOINT
LOWER BALL JOINT SEAL BOOT
REMOVAL
INSTALLATION
LOWER CONTROL ARM
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - LOWER CONTROL ARM
REMOVAL - LOWER CONTROL ARM
DISASSEMBLY
DISASSEMBLY - LOWER CONTROL ARM (BALL JOINT)
DISASSEMBLY - LOWER CONTROL ARM (REAR ISOLATOR BUSHING)
ASSEMBLY
ASSEMBLY - LOWER CONTROL ARM (BALL JOINT)
ASSEMBLY - LOWER CONTROL ARM (REAR ISOLATOR BUSHING)
INSTALLATION - LOWER CONTROL ARM
STABILIZER BAR
DESCRIPTION
OPERATION
REMOVAL
INSPECTION
INSTALLATION
STRUT ASSEMBLY
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - STRUT ASSEMBLY (FRONT)
REMOVAL
DISASSEMBLY
ASSEMBLY
INSTALLATION
REAR SUSPENSION
REAR SUSPENSION
DESCRIPTION - REAR SUSPENSION
OPERATION - REAR SUSPENSION
WARNING
WARNINGS AND CAUTIONS
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUE
SPECIAL TOOLS
REAR SUSPENSION
AXLE - FRONT WHEEL DRIVE REAR
DESCRIPTION
OPERATION
REMOVAL
INSPECTION
INSTALLATION
AXLE PIVOT BUSHING
REMOVAL
INSTALLATION
HUB / BEARING
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - HUB AND BEARING (REAR)
REMOVAL
INSTALLATION
JOUNCE BUMPER
REMOVAL
INSTALLATION
SHOCK ABSORBER
DESCRIPTION
DIAGNOSIS AND TESTING - SHOCK ABSORBER
REMOVAL
INSTALLATION
SPINDLE
REMOVAL
INSTALLATION
SPRING
DESCRIPTION
REMOVAL
INSTALLATION
STABILIZER BAR
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
STABILIZER BAR CUSHIONS
REMOVAL
INSTALLATION
STABILIZER BAR LINK
REMOVAL
INSTALLATION
WATTS LINK ASSEMBLY
DESCRIPTION
OPERATION
DIAGNOSIS AND TESTING - WATTS LINK ASSEMBLY
WATTS BELL CRANK
REMOVAL
INSTALLATION
WATTS LINK
REMOVAL
INSTALLATION
WHEEL ALIGNMENT
DESCRIPTION - WHEEL ALIGNMENT
CAMBER
CROSS CAMBER
CASTER
CROSS CASTER
TOE
TOE-OUT ON TURNS
DYNAMIC TOE PATTERN
STEERING AXIS INCLINATION (S.A.I.)
INCLUDED ANGLE (I.A.)
THRUST ANGLE
DIAGNOSIS AND TESTING - SUSPENSION AND STEERING
STANDARD PROCEDURE
STANDARD PROCEDURE - CURB HEIGHT MEASUREMENT
STANDARD PROCEDURE - WHEEL ALIGNMENT
PRE-WHEEL ALIGNMENT INSPECTION
WHEEL ALIGNMENT SETUP
REAR CAMBER AND TOE
FRONT CAMBER AND CASTER
FRONT TOE
SPECIFICATIONS
WHEEL ALIGNMENT
THEFT SECURITY and TRANSPONDER KEY
VEHICLE THEFT SECURITY
DESCRIPTION
VEHICLE THEFT SECURITY SYSTEM
VEHICLE THEFT SECURITY SYSTEM - EXPORT
SENTRY KEY IMMOBILIZER SYSTEM
OPERATION
VEHICLE THEFT SECURITY SYSTEM
TRIGGERING THE VTSS
VEHICLE THEFT SECURITY SYSTEM - EXPORT
SENTRY KEY IMMOBILIZER SYSTEM
DIAGNOSIS AND TESTING - SENTRY KEY IMMOBILIZER SYSTEM
GENERAL TROUBLESHOOTING TIPS
STANDARD PROCEDURE
STANDARD PROCEDURE - RKE/VTSS CONFIGURING A NEW MODULE
STANDARD PROCEDURE - SENTRY KEY IMMOBILIZER SYSTEM INITIALIZATION
DOOR CYLINDER LOCK SWITCH
REMOVAL
INSTALLATION
HOOD AJAR SWITCH - EXPORT
REMOVAL
INSTALLATION
INTRUSION SENSOR - EXPORT
DESCRIPTION
OPERATION
DISARMING THE INTRUSION SENSOR
REMOVAL
INSTALLATION
LIFTGATE CYLINDER LOCK SWITCH
REMOVAL
INSTALLATION
SKIS INDICATOR LAMP
DESCRIPTION
OPERATION
SIREN - EXPORT
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
TRANSPONDER KEY
DESCRIPTION
OPERATION
STANDARD PROCEDURE - TRANSPONDER PROGRAMMING
USING A DRB III SCAN TOOL
"CUSTOMER LEARN" MODE
TIRES, WHEELS and STUDS
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND WHEEL RUNOUT
METHOD 1 (RELOCATE WHEEL ON HUB)
METHOD 2 (RELOCATE TIRE ON WHEEL)
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE AND WHEEL BALANCE
STANDARD PROCEDURE - TIRE AND WHEEL MATCH MOUNTING
STANDARD PROCEDURE - TIRE AND WHEEL ROTATION
NON-DIRECTIONAL TREAD PATTERN TIRES
DIRECTIONAL TREAD PATTERN TIRES
REMOVAL
REMOVAL - TIRE AND WHEEL ASSEMBLY (ALUMINUM WHEEL)
REMOVAL - TIRE AND WHEEL ASSEMBLY (STEEL WHEEL)
INSTALLATION
INSTALLATION - TIRE AND WHEEL ASSEMBLY (ALUMINUM WHEEL)
INSTALLATION - TIRE AND WHEEL ASSEMBLY (STEEL WHEEL)
TIRES
DESCRIPTION
DESCRIPTION - TIRE
TIRE IDENTIFICATION
TIRE CHAINS
DESCRIPTION - RADIAL-PLY TIRES
DESCRIPTION - REPLACEMENT TIRES
DESCRIPTION - SPARE TIRE (TEMPORARY)
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - TIRE NOISE OR VIBRATION
DIAGNOSIS AND TESTING - TIRE WEAR PATTERNS
DIAGNOSIS AND TESTING - TREAD WEAR INDICATORS
DIAGNOSIS AND TESTING - VEHICLE LEAD DIAGNOSIS AND CORRECTION
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE INFLATION PRESSURES
STANDARD PROCEDURE - TIRE PRESSURE FOR HIGH SPEED OPERATION
STANDARD PROCEDURE - TIRE LEAK REPAIRING
CLEANING - TIRES
WHEELS
DESCRIPTION - WHEEL
DIAGNOSIS AND TESTING - WHEEL INSPECTION
CLEANING
WHEEL AND WHEEL TRIM CARE
SPECIFICATIONS
WHEEL
WHEEL COVER
REMOVAL
INSTALLATION
WHEEL MOUNTING STUDS - FRONT
REMOVAL
INSTALLATION
WHEEL MOUNTING STUDS - REAR
REMOVAL
INSTALLATION
TRANSAXLE - MANUAL and AUTOMATIC
G288 MANUAL TRANSAXLE
G288 MANUAL TRANSAXLE
DESCRIPTION
TRANSAXLE IDENTIFICATION
OPERATION
NEUTRAL
FIRST GEAR
SECOND GEAR
THIRD GEAR
FOURTH GEAR
FIFTH GEAR
REVERSE GEAR
SHIFT SYSTEM
REMOVAL
REMOVAL—2.2L TURBO DIESEL
REMOVAL—2.4L TURBO
DISASSEMBLY
ASSEMBLY
INSTALLATION
INSTALLATION—2.2L TURBO DIESEL
INSTALLATION—2.4L TURBO
SPECIFICATIONS
SPECIAL TOOLS
AXLE SEAL
REMOVAL
INSTALLATION
BACKUP LAMP SWITCH
REMOVAL
INSTALLATION
CLUTCH BELLHOUSING
DISASSEMBLY
ASSEMBLY
DETENT PLUG
DESCRIPTION
REMOVAL
INSTALLATION
DIFFERENTIAL
DESCRIPTION
OPERATION
REMOVAL
DISASSEMBLY
ASSEMBLY
INSTALLATION
FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL CHECKING
STANDARD PROCEDURE - FLUID DRAIN AND FILL
GEAR SHIFT BOOT
REMOVAL
INSTALLATION
GEAR SHIFT CABLE
REMOVAL
INSTALLATION
ADJUSTMENTS
ADJUSTMENT - GEARSHIFT CROSSOVER CABLE
GEAR SHIFT KNOB
REMOVAL
INSTALLATION
GEAR SHIFT MECHANISM
REMOVAL
INSTALLATION
INPUT SHAFT
DESCRIPTION
DISASSEMBLY
ASSEMBLY
OUTPUT SHAFT
DESCRIPTION
DISASSEMBLY
ASSEMBLY
REVERSE SHAFT
DESCRIPTION
DISASSEMBLY
ASSEMBLY
SYNCHRONIZER
DESCRIPTION
REMOVAL
DISASSEMBLY
INSPECTION
ASSEMBLY
INSTALLATION
TRANSAXLE HOUSING
DISASSEMBLY
ASSEMBLY
T350 MANUAL TRANSAXLE
T350 MANUAL TRANSAXLE
DESCRIPTION
TRANSAXLE IDENTIFICATION
GEAR RATIOS
GEARSHIFT PATTERN
LUBRICANT/ADDITIVES
SEALANTS
DIAGNOSIS AND TESTING - COMMON PROBLEM CAUSES
HARD SHIFTING
NOISY OPERATION
SLIPS OUT OF GEAR
LOW LUBRICANT LEVEL
CLUTCH PROBLEMS
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION
ASSEMBLY
BEARING ADJUSTMENT PROCEDURE
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT
INSTALLATION
SPECIFICATIONS
SPECIAL TOOLS
AXLE SEAL
REMOVAL
INSTALLATION
BACK-UP LAMP SWITCH
REMOVAL
INSTALLATION
DIFFERENTIAL
DISASSEMBLY
ASSEMBLY
Measure and Adjust Side Gear End-Play
ADJUSTMENTS
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT / SHIM SELECTION
DIFFERENTIAL BEARING CUPS
REMOVAL
INSTALLATION
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND FILL
GEAR SHIFT BOOT
REMOVAL
INSTALLATION
GEAR SHIFT CABLE
REMOVAL
INSTALLATION
ADJUSTMENTS
ADJUSTMENT - GEARSHIFT CROSSOVER CABLE
GEAR SHIFT KNOB
REMOVAL
INSTALLATION
GEAR SHIFT MECHANISM
REMOVAL
INSTALLATION
INPUT BEARING AND SLEEVE
REMOVAL
INSTALLATION
INPUT SHAFT
DISASSEMBLY
ASSEMBLY
OUTPUT SHAFT
DISASSEMBLY
OUTPUT BEARING AND RACE
REMOVAL
INSTALLATION
REAR BEARING OIL FEED TROUGH
REMOVAL
INSTALLATION
SHIFT CROSSOVER LEVER
REMOVAL
INSTALLATION
SHIFT CROSSOVER SHAFT
REMOVAL
INSTALLATION
SHIFT CROSSOVER SHAFT BUSHING
REMOVAL
INSTALLATION
SHIFT RAIL AND FORK
DISASSEMBLY
SHIFT RAIL BUSHINGS
REMOVAL
INSTALLATION
SHIFT SELECTOR SHAFT
REMOVAL
INSTALLATION
SHIFT SELECTOR SHAFT BUSHING
REMOVAL
INSTALLATION
SHIFT SHAFT SEALS
REMOVAL
INSTALLATION
SYNCHRONIZER
DISASSEMBLY
CLEANING
CLEAN
INSPECTION
INSPECT
ASSEMBLY
VEHICLE SPEED SENSOR
DESCRIPTION
VEHICLE SPEED SENSOR
REMOVAL
INSTALLATION
41TE AUTOMATIC TRANSAXLE
41TE AUTOMATIC TRANSAXLE
DESCRIPTION
TRANSAXLE IDENTIFICATION
OPERATION
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - 41TE TRANSAXLE GENERAL DIAGNOSIS
DIAGNOSIS AND TESTING - ROAD TEST
DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TESTS
TEST ONE-SELECTOR IN LOW (1st GEAR)
TEST TWO-SELECTOR IN DRIVE (2nd GEAR)
TEST TWO A–SELECTOR IN OD (4th Gear)
TEST THREE-OVERDRIVE CLUTCH CHECK (3rd and 2nd Gear)
TEST FOUR-SELECTOR IN OVERDRIVE (4th Gear)
TEST FIVE-SELECTOR IN OVERDRIVE (4th Gear-CC on)
TEST SIX-SELECTOR IN REVERSE
TEST RESULT INDICATIONS
DIAGNOSIS AND TESTING - CLUTCH AIR PRESSURE TESTS
OVERDRIVE CLUTCH
REVERSE CLUTCH
2/4 CLUTCH
LOW/REVERSE CLUTCH
UNDERDRIVE CLUTCH
DIAGNOSIS AND TESTING - TORQUE CONVERTER HOUSING FLUID LEAKAGE
TORQUE CONVERTER LEAKAGE
REMOVAL
DISASSEMBLY
ASSEMBLY
INSTALLATION
SCHEMATICS AND DIAGRAMS
41TE TRANSAXLE HYDRAULIC SCHEMATICS
SPECIFICATIONS
SPECIAL TOOLS
ACCUMULATOR
DESCRIPTION
OPERATION
DRIVING CLUTCHES
DESCRIPTION
OPERATION
UNDERDRIVE CLUTCH
OVERDRIVE CLUTCH
REVERSE CLUTCH
FINAL DRIVE
DESCRIPTION
OPERATION
DISASSEMBLY
ASSEMBLY
ADJUSTMENTS
DIFFERENTIAL BEARING PRELOAD MEASUREMENT AND ADJUSTMENT
FLUID
STANDARD PROCEDURE
FLUID LEVEL AND CONDITION CHECK
FLUID LEVEL CHECK
FLUID LEVEL CHECK USING DRB
FLUID CONDITION
STANDARD PROCEDURE - FLUID AND FILTER SERVICE
FLUID/FILTER SERVICE (RECOMMENDED)
DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE)
GEAR SHIFT CABLE
REMOVAL
INSTALLATION
ADJUSTMENTS
GEARSHIFT CABLE
ADJUSTMENT
HOLDING CLUTCHES
DESCRIPTION
OPERATION
2/4 CLUTCH
LOW/REVERSE CLUTCH
INPUT CLUTCH ASSEMBLY
DISASSEMBLY
ASSEMBLY
OIL PUMP
DESCRIPTION
OPERATION
DISASSEMBLY
ASSEMBLY
PLANETARY GEARTRAIN
DESCRIPTION
OPERATION
SEAL - OIL PUMP
REMOVAL
INSTALLATION
SHIFT INTERLOCK CABLE
REMOVAL
INSTALLATION
SHIFT INTERLOCK MECHANISM
REMOVAL
INSTALLATION
SHIFT INTERLOCK SYSTEM
ADJUSTMENTS
BRAKE/TRANSMISSION SHIFT INTERLOCK SYSTEM
VERIFICATION
ADJUSTMENT
SOLENOID/PRESSURE SWITCH ASSY
DESCRIPTION
OPERATION
SOLENOIDS
PRESSURE SWITCHES
REMOVAL
INSTALLATION
SPEED SENSOR - INPUT
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
SPEED SENSOR - OUTPUT
DESCRIPTION
OPERATION
VEHICLE SPEED SIGNAL
REMOVAL
INSTALLATION
TORQUE CONVERTER
DESCRIPTION
IMPELLER
TURBINE
STATOR
TORQUE CONVERTER CLUTCH (TCC)
OPERATION
TURBINE
STATOR
TORQUE CONVERTER CLUTCH (TCC)
REMOVAL
INSTALLATION
TRANSMISSION CONTROL RELAY
DESCRIPTION
OPERATION
TRANSMISSION RANGE SENSOR
DESCRIPTION
OPERATION
TRANSMISSION TEMPERATURE SENSOR
CALCULATED TEMPERATURE
VALVE BODY
DESCRIPTION
OPERATION
REGULATOR VALVE
SOLENOID SWITCH VALVE
MANUAL VALVE
CONVERTER CLUTCH SWITCH VALVE
CONVERTER CLUTCH CONTROL VALVE
T/C REGULATOR VALVE
LOW/REVERSE SWITCH VALVE
REMOVAL
DISASSEMBLY
ASSEMBLY
INSTALLATION
WIPERS and WASHERS
WIPERS/WASHERS
DESCRIPTION
FRONT WINDSHIELD WIPER SYSTEM
FRONT WINDSHIELD WASHER SYSTEM
REAR WINDSHIELD WIPER SYSTEM
REAR WINDSHIELD WASHER SYSTEM
OPERATION
FRONT WINDSHIELD WIPER SYSTEM
FRONT WINDSHIELD WASHER SYSTEM
REAR WINDSHIELD WIPER SYSTEM
REAR WINDSHIELD WASHER SYSTEM
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FRONT WIPER CONDITIONS
MOTOR WILL NOT OPERATE ALL SWITCH POSITIONS
MOTOR OPERATES SLOWLY AT ALL SPEEDS
WIPERS RUN AT HIGH SPEED WITH SWITCH IN LOW SPEED POSITION OR WIPERS RUN AT LOW SPEED WITH SWITCH IN HIGH SPEED POSITION.
WIPERS WILL OPERATE CONTINUOUSLY WITH THE SWITCH IN THE INTERMITTENT POSITION - WHEN WIPER SWITCH IS TURNED OFF, WIPERS STOP WHEREVER THEY ARE WITHOUT RETURNING TO PARK POSITION.
WIPERS DO NOT OPERATE WHEN WASHER MOTOR IS ENGAGED (PULSE WIPE) OR WIPERS DO OPERATE IN INTERMITTENT POSITION.
DIAGNOSIS AND TESTING - REAR WIPER SYSTEM
DIAGNOSIS AND TESTING - WASHER SYSTEM
FRONT WASHER NOZZLE
REMOVAL
INSTALLATION
FRONT WIPER ARMS
REMOVAL
INSTALLATION
ADJUSTMENTS
ADJUSTMENT - FRONT WIPER ARMS
ADJUSTMENT - FRONT WIPER ARMS - RHD
FRONT WIPER BLADES
REMOVAL
CLEANING - FRONT WIPER BLADES
INSTALLATION
FRONT WIPER BLADE ELEMENTS
REMOVAL
INSTALLATION
FRONT WIPER MODULE
REMOVAL
INSTALLATION
FRONT WIPER MODULE - RHD
REMOVAL
INSTALLATION
FRONT WIPER MOTOR
DIAGNOSIS AND TESTING - WIPER MOTOR
REMOVAL
INSTALLATION
FRONT WIPER MOTOR - RHD
REMOVAL
INSTALLATION
FRONT WIPER SWITCH
DIAGNOSIS AND TESTING - FRONT WIPER/WASHER SWITCH
REMOVAL
INSTALLATION
REAR WASHER NOZZLE
REMOVAL
INSTALLATION
REAR WIPER ARMS
REMOVAL
INSTALLATION
REAR WIPER BLADE
REMOVAL
INSTALLATION
REAR WIPER MOTOR
REMOVAL
INSTALLATION
REAR WIPER SWITCH
DIAGNOSIS AND TESTING - REAR WIPER SWITCH
IN-VEHICLE TESTING
BENCH TESTING
REMOVAL
WASHER HOSES
REMOVAL
INSTALLATION
WASHER PUMP MOTOR
REMOVAL
INSTALLATION
WASHER PUMP MOTOR - RHD
REMOVAL
INSTALLATION
WASHER RESERVOIR
REMOVAL
INSTALLATION
WIRING DIAGRAMS
8W-01 WIRING DIAGRAM INFORMATION
WIRING DIAGRAM INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING DIAGRAMS
SYMBOLS
TERMINOLOGY
DESCRIPTION - CIRCUIT INFORMATION
DESCRIPTION - CIRCUIT FUNCTIONS
DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION
DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION
IDENTIFICATION
LOCATIONS
WARNING
WARNINGS - GENERAL
DIAGNOSIS AND TESTING - WIRING HARNESS
TROUBLESHOOTING TOOLS
INTERMITTENT AND POOR CONNECTIONS
TROUBLESHOOTING WIRING PROBLEMS
STANDARD PROCEDURE
STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES
STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL
STANDARD PROCEDURE - TESTING FOR CONTINUITY
STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND
STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS
STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP
SPECIAL TOOLS
WIRING/TERMINAL
CONNECTOR
REMOVAL
INSTALLATION
DIODE
REMOVAL
INSTALLATION
TERMINAL
REMOVAL
INSTALLATION
WIRE
STANDARD PROCEDURE - WIRE SPLICING
8W-02 COMPONENT INDEX
8W-10 POWER DISTRIBUTION
8W-11 FUSE BLOCK
8W-15 GROUND DISTRIBUTION
8W-18 BUS COMMUNICATIONS
8W-20 CHARGING SYSTEM
8W-21 STARTING SYSTEM
8W-30 FUEL/IGNITION SYSTEM
8W-31 TRANSMISSION CONTROL SYSTEM
8W-33 VEHICLE SPEED CONTROL
8W-35 ANTILOCK BRAKES
8W-39 VEHICLE THEFT SECURITY SYSTEM
8W-40 INSTRUMENT CLUSTER
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
8W-42 AIR CONDITIONING-HEATER
8W-43 OCCUPANT RESTRAINT SYSTEM
8W-44 INTERIOR LIGHTING
8W-47 AUDIO SYSTEM
8W-48 REAR WINDOW DEFOGGER
8W-49 OVERHEAD CONSOLE
8W-50 FRONT LIGHTING
8W-51 REAR LIGHTING
8W-52 TURN SIGNALS
8W-53 WIPERS
8W-60 POWER WINDOWS
8W-61 POWER DOOR LOCKS
8W-62 POWER MIRRORS
8W-63 POWER SEAT
8W-64 POWER SUNROOF
8W-70 SPLICE INFORMATION
8W-80 CONNECTOR PIN-OUTS
8W-91 CONNECTOR/GROUND/SPLICE LOCATION
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION
8W-97 POWER DISTRIBUTION
POWER DISTRIBUTION
DESCRIPTION
OPERATION
CIGAR LIGHTER/POWER OUTLET
DESCRIPTION
INSTRUMENT PANEL MOUNTED
FRONT CONSOLE AND REAR CARGO MOUNTED
OPERATION
CIGAR LIGHTER/POWER OUTLET (INSTRUMENT PANEL AND CONSOLE MOUNTED)
POWER OUTLET (REAR CARGO AREA MOUNTED)
REMOVAL
INSTALLATION
FUSE BLOCK
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
IOD FUSE
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
POWER DISTRIBUTION CENTER
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
RELAY
REMOVAL
INSTALLATION
WARNING, DISCLAIMER and COPYRITHGT NOTICE
INDEX
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