1998 Chrysler Voyager Factory Service Manual
Original Chrysler manual with thousands of detailed images and diagrams.
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Full list of manual chapters:
INTRODUCTION NS
GENERAL INFORMATION
VEHICLE SAFETY CERTIFICATION LABEL
VEHICLE IDENTIFICATION NUMBER
VIN CHECK DIGIT
BODY CODE PLATE
LOCATION AND DECODING
VIN CODE BREAKDOWN CHART
BODY CODE PLATE – LINE 3
BODY CODE PLATE LINE 2
BODY CODE PLATE LINE 1
IF TWO BODY CODE PLATES ARE REQUIRED
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS
FASTENER IDENTIFICATION
FASTENER IDENTIFICATION
FASTENER IDENTIFICATION
FASTENER STRENGTH
METRIC SYSTEM
CONVERSION FORMULAS AND EQUIVALENT VALUES
TORQUE REFERENCES
METRIC CONVERSION
TORQUE SPECIFICATIONS
INTRODUCTION NS/GS
GENERAL INFORMATION
E- MARK LABEL
VEHICLE IDENTIFICATION NUMBER
VIN CHECK DIGIT
BODY CODE PLATE
LOCATION AND DECODING
BODY CODE PLATE— LINE 3
VIN DECODING INFORMATION
BODY CODE PLATE— LINE 2
BODY CODE PLATE LINE 1
IF TWO BODY CODE PLATES ARE REQUIRED
MANUFACTURER PLATE
LUBRICATION AND MAINTENANCE
GENERAL INFORMATION
INTRODUCTION
PARTS AND LUBRICANT RECOMMENDATIONS
INTERNATIONAL SYMBOLS
CLASSIFICATION OF LUBRICANTS
ENGINE OIL
FLUID CAPACITIES
GENERAL INFORMATION
INTRODUCTION
UNSCHEDULED INSPECTION
SCHEDULE – A
SCHEDULE – B
SERVICE PROCEDURES
JUMP STARTING PROCEDURE
TO JUMP START A DISABLED VEHICLE:
TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS
RECOMMENDED TOWING EQUIPMENT
GROUND CLEARANCE
LOCKED VEHICLE TOWING
FLAT TOWING WITH TOW BAR
FLAT BED TOWING TIE DOWNS
TOWING—FRONT WHEEL LIFT
TOWING—REAR WHEEL LIFT
HOISTING RECOMMENDATIONS
LUBRICATION AND MAINTENANCE 1
GENERAL INFORMATION
GENERAL INFORMATION
ENGINE OIL — GASOLINE ENGINES
SAE VISCOSITY GRADE
ENGINE OIL— DIESEL ENGINES
SAE VISCOSITY GRADE
MANUAL TRANSMISSION FLUID (A- 558 and A-598 Models)
FLUID CAPACITIES
MAINTENANCE SCHEDULES
GENERAL INFORMATION
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE— DIESEL ENGINE
UNSCHEDULED INSPECTION
SCHEDULE— A (DIESEL)
SCHEDULE— B (DIESEL)
JUMP STARTING, HOISTING AND TOWING
SERVICE PROCEDURES
TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS
RECOMMENDED TOWING EQUIPMENT
GROUND CLEARANCE
LOCKED VEHICLE TOWING
FLAT TOWING WITH TOW BAR
FLAT BED TOWING TIE DOWNS
TOWING— FRONT WHEEL LIFT
TOWING— REAR WHEEL LIFT
TOWING— TOW HOOKS
SUSPENSION
WHEEL ALIGNMENT
DESCRIPTION AND OPERATION
GENERAL INFORMATION
DIAGNOSIS AND TESTING
SUSPENSION AND STEERING DIAGNOSIS
PRE-WHEEL ALIGNMENT INSPECTION
SERVICE PROCEDURES
WHEEL ALIGNMENT CHECK AND ADJUSTMENT PROCEDURE
CASTER AND CAMBER
FRONT TOE SETTING PROCEDURE
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS
FRONT SUSPENSION
DESCRIPTION AND OPERATION
FRONT SUSPENSION DESCRIPTION
SUSPENSION CRADLE (CROSSMEMBER)
Mc PHERSON STRUT ASSEMBLY
STEERING KNUCKLE
LOWER CONTROL ARM
STABILIZER BAR
STABILIZER BAR ATTACHING LINK
HUB AND BEARING ASSEMBLY
COIL SPRING
BALL JOINT
WHEEL MOUNTING STUDS
DIAGNOSIS AND TESTING
Mc PHERSON STRUT
STEERING KNUCKLE
LOWER CONTROL ARM
BALL JOINT (LOWER)
STABILIZER BAR
HUB AND BEARING ASSEMBLY
SERVICE PROCEDURES
SUSPENSION CRADLE THREAD REPAIR PROCEDURE
TOOL REQUIREMENT FOR M8x1.25 Thread
TOOL REQUIREMENT FOR M10x1.5 Thread
REMOVAL AND INSTALLATION
Mc PHERSON STRUT
REMOVAL
INSTALLATION
STEERING KNUCKLE
REMOVE
INSTALL
LOWER CONTROL ARM
REMOVE
INSTALL
BALL JOINT
REMOVE
INSTALL
STABILIZER BAR
REMOVE
INSTALL
HUB AND BEARING ASSEMBLY
REMOVE
INSTALL
FRONT WHEEL MOUNTING STUDS
REMOVE
INSTALL
REAR WHEEL MOUNTING STUDS
REMOVE
INSTALL
DISASSEMBLY AND ASSEMBLY
Mc PHERSON STRUT
DISASSEMBLY
ASSEMBLY
BALL JOINT SEAL BOOT
REMOVE
INSTALL
LOWER CONTROL ARM FRONT BUSHING
REMOVE
INSTALL
LOWER CONTROL ARM REAR BUSHING
REMOVE
INSTALL
STABILIZER BAR BUSHING
Disassembly/Assembly
SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUES
REAR SUSPENSION
SPECIAL TOOLS
FRONT SUSPENSION
GENERAL INFORMATION
REAR SUSPENSION
DESCRIPTION AND OPERATION
REAR WHEEL ALIGNMENT
REAR TRACK BAR
STABILIZER BAR
SHOCK ABSORBERS (REAR LOAD LEVELING)
REMOVAL AND INSTALLATION
REAR SPRINGS (FWD)
REMOVAL
FRONT BUSHING REPLACEMENT
INSTALLATION
REAR SPRINGS (AWD)
REMOVE
FRONT BUSHING REPLACEMENT
INSTALL
SHOCK ABSORBER
REMOVE/INSTALL
REAR TRACK BAR
REMOVE
INSTALL
TRACK BAR MOUNT
REMOVE
INSTALLATION
STABILIZER BAR
REMOVAL
INSPECTION
INSTALLATION
JOUNCE BUMPER
REMOVAL-STANDARD
INSTALLATION-STANDARD
REMOVAL-HEAVY DUTY
INSTALLATION-HEAVY DUTY
LEAF SPRING REAR MOUNT
REMOVE
INSTALLATION
LEAF SPRING FRONT MOUNT
REMOVE
INSTALL
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUES
SUSPENSION 1
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS
BRAKES
GENERAL INFORMATION
GENERAL INFORMATION
GENERAL VEHICLE SERVICE CAUTIONS
BASE BRAKE SYSTEM COMPONENT DESCRIPTION
BASE BRAKE SYSTEM
DESCRIPTION AND OPERATION
FRONT DISC BRAKE SYSTEM
REAR DRUM BRAKES
REAR DISC BRAKES
PARKING BRAKE SYSTEM OPERATION
PROPORTIONING VALVES
FIXED PROPORTIONING VALVE
HEIGHT SENSING PROPORTIONING VALVE
CHASSIS TUBES AND HOSES
MASTER CYLINDER
POWER BRAKE VACUUM BOOSTER OPERATION
RED BRAKE WARNING LAMP OPERATION
STOP LAMP SWITCH
HUB/BEARING REAR WHEEL
DIAGNOSIS AND TESTING
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE
BRAKE SYSTEM DIAGNOSIS CHARTS
MISCELLANEOUS BRAKE SYSTEM CONDITIONS
RED BRAKE WARNING LAMP FUNCTION
POWER BRAKE SYSTEM DIAGNOSTICS
BRAKE NOISE
VEHICLE ROAD TEST
ADJUSTER REAR DRUM BRAKE (AUTOMATIC)
BRAKE ROTOR
CHECKING ROTOR FOR RUNOUT AND THICKNESS
PROPORTIONING VALVES
FIXED PROPORTIONING VALVE TEST PROCEDURE
HEIGHT SENSING PROPORTIONING VALVE
BRAKE FLUID CONTAMINATION
RED BRAKE WARNING LAMP TEST
TRACTION CONTROL LAMP TEST
STOP LAMP SWITCH TEST PROCEDURE
SERVICE PROCEDURES
MASTER CYLINDER FLUID LEVEL CHECK
BLEEDING BASE BRAKE HYDRAULIC SYSTEM
PRESSURE BLEEDING PROCEDURE
BLEEDING WITHOUT A PRESSURE BLEEDER
MASTER CYLINDER BLEEDING PROCEDURE
ROTOR MACHINING (FRONT/REAR)
BRAKE ROTOR MACHINING PROCEDURES
REFACING BRAKE ROTOR
RESURFACNG BRAKE ROTOR
ROTOR REFINISHING LIMITS
BRAKE DRUM MACHINING
BRAKE TUBE REPAIR PROCEDURE
DOUBLE INVERTED TUBING FLARES
ISO TUBING FLARES
PARK BRAKE AUTO ADJUSTER MECHANISM RELEASE
REMOVAL AND INSTALLATION
WHEEL AND TIRE INSTALLATION
FRONT DISC BRAKE CALIPER
SERVICE PRECAUTIONS
REMOVE
INSTALL
REAR DISC BRAKE CALIPER
REMOVE
INSTALL
FRONT DISC BRAKE PADS
REMOVE
INSTALL
REAR DISC BRAKE SHOES
REMOVE
CALIPER INSPECTION
INSTALL
REAR BRAKE DRUM
REMOVE
INSTALL
REAR DRUM BRAKE SHOES
REMOVE
INSTALL
BRAKE SUPPORT PLATE (REAR DRUM BRAKES)
REMOVE
INSTALL
REAR BRAKE WHEEL CYLINDER
REMOVE
INSTALL
HUB/BEARING
FRONT WHEEL DRIVE
ALL WHEEL DRIVE
MASTER CYLINDER
REMOVE
BLEEDING MASTER CYLINDER
INSTALL
VACUUM BOOSTER 2.4 LITER ENGINE
REMOVE
INSTALL
VACUUM BOOSTER 3.0 LITER ENGINE
REMOVE
INSTALL
VACUUM BOOSTER 3.3/3.8 LITER ENGINE
REMOVE
INSTALL
JUNCTION BLOCK
REMOVE
INSTALL
PROPORTIONING VALVE (W/ABS BRAKES)
REMOVE
INSTALL
PROPORTIONING VALVE (W/O ABS BRAKES)
REMOVE
INSTALL
HYDRAULIC BRAKE TUBES AND HOSES
PARK BRAKE PEDAL MECHANISM
REMOVE
INSTALL
PARK BRAKE SHOES (WITH REAR DISC BRAKES)
REMOVE
INSTALL
FRONT PARK BRAKE CABLE
REMOVE
INSTALL
INTERMEDIATE PARK BRAKE CABLE
REMOVE
INSTALL
RIGHT REAR PARK BRAKE CABLE
REMOVE
INSTALL
LEFT REAR PARK BRAKE CABLE
REMOVE
INSTALL
STOP LAMP SWITCH
REMOVE
INSTALL
DISASSEMBLY AND ASSEMBLY
MASTER CYLINDER TO POWER BRAKE BOOSTER VACUUM SEAL
MASTER CYLINDER FLUID RESERVOIR
MASTER CYLINDER FLUID RESERVOIR FILL TUBE
REMOVE
INSTALL
MASTER CYLINDER BRAKE FLUID LEVEL SWITCH
FRONT DISC BRAKE CALIPER
CLEANING AND INSPECTION
CALIPER GUIDE PIN BUSHING SERVICE
CALIPER DISASSEMBLY
CALIPER ASSEMBLY
WHEEL CYLINDER REAR DRUM BRAKE
DISASSEMBLE
ASSEMBLE
CLEANING AND INSPECTION
FRONT DISC BRAKE PAD LINING INSPECTION
REAR DISC BRAKES
BRAKE PAD LINING WEAR
CALIPER INSPECTION
REAR DRUM BRAKE SHOE LINING INSPECTION
REAR DRUM BRAKE WHEEL CYLINDER
BRAKE HOSE AND BRAKE LINES INSPECTION
REAR WHEEL HUB AND BEARING ASSEMBLY
ADJUSTMENTS
STOP LAMP SWITCH
REAR DRUM BRAKE SHOE ADJUSTMENT
PARK BRAKE SHOES (WITH REAR DISC BRAKES)
PARK BRAKE CABLE ADJUSTMENT
PROPORTIONING VALVE (HEIGHT SENSING)
SPECIFICATIONS
BRAKE FLUID
VEHICLE BRAKE SYSTEM COMPONENT SPECIFICATIONS
BRAKE ACTUATION SYSTEM S
BRAKE FASTENER TORQUE SPECIFICATION
SPECIAL TOOLS
SPECIAL TOOLS—BASE BRAKES
ANTILOCK BRAKE SYSTEM ± TEVES MARK-20
DESCRIPTION AND OPERATION
ANTILOCK BRAKES OPERATION DESCRIPTION
ABS BRAKES COMPONENT ABBREVIATION LIST
ABS BRAKES OPERATION AND VEHICLE PERFORMANCE
NORMAL BRAKING SYSTEM FUNCTION
ABS SYSTEM OPERATION
VEHICLE HANDLING PERFORMANCE DURING ABS BRAKING
NOISE AND BRAKE PEDAL FEEL
TIRE NOISE AND MARKS
START UP CYCLE
PREMATURE ABS CYCLING
ABS BRAKE SYSTEM COMPONENTS
ABS MASTER CYLINDER AND POWER BRAKE BOOSTER
INTEGRATED CONTROL UNIT (ICU)
INLET VALVES AND SOLENOIDS
OUTLET VALVES AND SOLENOIDS
ASR VALVE (ABS WITH TRACTION CONTROL ONLY)
HCU BRAKE FLUID ACCUMULATORS AND NOISE DAMPING CHAMBER
HCU PUMP/MOTOR
ABS FUSES
ABS RELAYS
PROPORTIONING VALVES
WHEEL SPEED SENSORS
CONTROLLER ANTILOCK BRAKES (CAB)
CONTROLLER ANTILOCK BRAKE INPUTS
CONTROLLER ANTILOCK BRAKE OUTPUTS
ABS WARNING LAMP (YELLOW)
HYDRAULIC CIRCUITS AND VALVE OPERATION
NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION
TEVES MARK 20 ABS CIRCUIT AND SOLENOID VALVE FUNCTION
TEVES MARK 20 SECONDARY ABS CIRCUIT AND SOLENOID VALVE FUNCTION
TEVES MARK 20 ABS WITH TRACTION CONTROL NORMAL BRAKING HYDRAULIC CIRCUIT – SOLENOID AND SHUTTLE VALVE FUNCTION
TEVES MARK 20 ABS WITH TRACTION CONTROL ABS BRAKING HYDRAULIC CIRCUIT – SOLENOID AND SHUTTLE VALVE FUNCTION
TEVES MARK 20 ABS WITH TRACTION CONTROL– TRACTION CONTROL HYDRAULIC CIRCUIT – SOLENOID AND SHUTTLE VALVE FUNCTION
DIAGNOSIS AND TESTING
ABS GENERAL DIAGNOSTICS INFORMATION
ABS WIRING DIAGRAM INFORMATION
ABS DIAGNOSTICS MANUAL
DRB DIAGNOSTIC SCAN TOOL USAGE
ABS BRAKE DIAGNOSTIC TOOL CONNECTOR
ABS SYSTEM SELF DIAGNOSTICS
START-UP CYCLE
DRIVE-OFF CYCLE
ONGOING TESTS
ABS DIAGNOSTIC TROUBLE CODES
LATCHING VERSUS NON-LATCHING DIAGNOSTIC TROUBLE CODES
INTERMITTENT DIAGNOSTIC TROUBLE CODES
TONEWHEEL INSPECTION
PROPORTIONING VALVE
BRAKE FLUID CONTAMINATION
TEST DRIVING ABS COMPLAINT VEHICLE
ABS SERVICE PRECAUTIONS
SERVICE PROCEDURES
BRAKE FLUID LEVEL INSPECTION
BLEEDING TEVES MARK 20 HYDRAULIC SYSTEM
ABS BLEEDING PROCEDURE
REMOVAL AND INSTALLATION
ABS GENERAL SERVICE PRECAUTIONS
HYDRAULIC CONTROL UNIT
REMOVE
INSTALL
CONTROLLER ANTILOCK BRAKES (CAB)
REMOVE
INSTALL
WHEEL SPEED SENSOR (FRONT)
REMOVE
INSTALL
WHEEL SPEED SENSOR (REAR FWD)
REMOVE
INSTALL
WHEEL SPEED SENSOR (REAR AWD)
REMOVE
INSTALL
TONE WHEEL (REAR FWD)
REMOVE
INSTALL
TONE WHEEL (REAR AWD)
SPECIFICATIONS
SPEED SENSOR TONE WHEEL RUNOUT
WHEEL SPEED SENSOR TO TONE WHEEL CLEARANCE
FRONT WHEEL
REAR WHEEL
BRAKE FASTENER TORQUE SPECIFICATIONS
BRAKES 1
GENERAL INFORMATION
BASE BRAKE SYSTEM COMPONENT DESCRIPTION
DESCRIPTION AND OPERATION
MASTER CYLINDER
DIAGNOSIS AND TESTING
REAR DRUM BRAKE ADJUSTMENT
MASTER CYLINDER FLUID LEVEL CHECK
REMOVAL AND INSTALLATION
FRONT PARK BRAKE CABLE AND LEVER ASSEMBLY- RHD and LHD VEHICLES
REMOVE
INSTALL
BRAKE PEDAL TORQUE SHAFT ASSEMBLY
REMOVE
INSTALL
CLUTCH
GENERAL INFORMATION
CLUTCH COMPONENTS
CLUTCH CABLE AND PEDAL — LHD
HYDRAULIC LINKAGE AND COMPONENTS — RHD
CLUTCH DISC AND COVER APPLICATION
CLUTCH REPLACEMENT
DESCRIPTION AND OPERATION
CLUTCH RELEASE SYSTEM
CLUTCH CABLE — LHD
HYDRAULIC CLUTCH — RHD
CLUTCH PEDAL POSITION SWITCH
DIAGNOSIS AND TESTING
CLUTCH PEDAL POSITION SWITCH
CLUTCH PEDAL POSITION SWITCH– ELECTRICAL TEST
CLUTCH PEDAL POSITION SWITCH– MECHANICAL TEST
SERVICE DIAGNOSIS– CLUTCH PEDAL POSITION SWITCH
CLUTCH DIAGNOSIS
SERVICE DIAGNOSIS– CLUTCH GRAB/ CHATTER
SERVICE DIAGNOSIS– CLUTCH SLIPS
SERVICE DIAGNOSIS– IMPROPER CLUTCH RELEASE
SERVICE DIAGNOSIS– CLUTCH PEDAL NOISE
DRIVE PLATE MISALIGNMENT
CLUTCH COVER AND DISC RUNOUT
CLUTCH CHATTER COMPLAINTS
CLASH– INTO– REVERSE COMPLAINTS
REMOVAL AND INSTALLATION
CLUTCH CABLE SYSTEM — LHD
REMOVAL
INSTALLATION
CLUTCH PEDAL POSITION SWITCH
REMOVAL
INSTALLATION
HYDRAULIC CLUTCH LINKAGE SYSTEM — RHD
REMOVAL
INSTALLATION
QUICK CONNECT COUPLING — RHD
REMOVAL
INSTALLATION
MASTER CYLINDER SYSTEM — RHD
REMOVAL
INSTALLATION
SLAVE CYLINDER ASSEMBLY — RHD
REMOVAL
INSTALLATION
MODULAR CLUTCH ASSEMBLY (2.0L AND 2.4L GASOLINE)
CLUTCH ASSEMBLY (2.5L DIESEL)
REMOVAL
INSPECTION
INSTALLATION
CLUTCH RELEASE BEARING AND FORK
REMOVAL
INSTALLATION
CLEANING AND INSPECTION
CLUTCH CONTAMINATION
OIL CONTAMINATION
GREASE CONTAMINATION
ROAD SPLASH/ WATER CONTAMINATION
CLEANING PRECAUTIONS
ADJUSTMENTS
CLUTCH CABLE — LHD
ADJUSTER MECHANISM FUNCTION CHECK — LHD
CLUTCH PEDAL POSITION SWITCH
SPECIFICATIONS
CLUTCH TIGHTENING REFERENCE
COOLING SYSTEM
GENERAL INFORMATION
ACCESSORY DRIVE BELTS
COOLING SYSTEM
COOLANT RECOVERY SYSTEM (CRS)
AUTOMATIC TRANSMISSION OIL COOLER 2.4L
ENGINE THERMOSTAT
WATER PUMPS
COOLANT
RADIATOR
RADIATOR PRESSURE CAP
ENGINE BLOCK HEATER
DESCRIPTION AND OPERATION
WATER PIPES—3.0L ENGINE
COOLANT PERFORMANCE
RADIATOR HOSES AND CLAMPS
WATER PUMP 2.4L ENGINE
WATER PUMP—3.0L ENGINE
WATER PUMP—3.3/3.8L ENGINES
DIAGNOSIS AND TESTING
ACCESSORY DRIVE BELT
COOLING SYSTEM DIAGNOSIS
RADIATOR COOLANT FLOW TEST
RADIATOR FAN CONTROL
ELECTRIC FAN MOTOR TEST
TESTING COOLING SYSTEM FOR LEAKS
RADIATOR FAN OPERATION
RADIATOR CAP TO FILLER NECK SEAL PRESSURE RELIEF CHECK
PRESSURE TESTING RADIATOR CAP
LOW COOLANT LEVEL AERATION
DEAERATION
TEMPERATURE GAUGE INDICATION
SERVICE PROCEDURES
COOLANT LEVEL CHECK—ROUTINE
COOLANT—ADDING ADDITIONAL
COOLANT LEVEL SERVICE
COOLING SYSTEM DRAINING
COOLING SYSTEM—REFILLING
REMOVAL AND INSTALLATION
WATER PUMP—2.4L ENGINE
REMOVAL
INSTALLATION
WATER PUMP INLET TUBE—2.4L ENGINE
REMOVAL
INSTALLATION
WATER PUMP—3.0L ENGINE
REMOVAL
INSPECTION
INSTALLATION
WATER PUMP—3.3/3.8L ENGINES
REMOVAL
INSTALLATION
THERMOSTAT—2.4L ENGINE
REMOVAL
INSTALLATION—2.4L ENGINE
THERMOSTAT—3.0L ENGINE
REMOVAL
INSTALLATION—3.0L ENGINE
THERMOSTAT—3.3/3.8L ENGINES
REMOVAL
INSTALLATION
RADIATOR
REMOVAL
INSTALLATION
RADIATOR DRAINCOCK
REMOVAL
INSTALLATION
FAN MODULE
REMOVAL
INSTALLATION
ENGINE BLOCK HEATER
REMOVAL
INSTALLATION
ACCESSORY DRIVE BELTS—2.4L
REMOVAL/INSTALLATION-ADJUST
ACCESSORY DRIVE BELTS—3.0L
GENERATOR/POWER STEERING PUMP BELT
AIR CONDITIONING BELT
ACCESSORY DRIVE BELT—3.3/3.8L
REMOVE/INSTALL
CLEANING AND INSPECTION
WATER PUMP
ACCESSORY DRIVE BELT
RADIATOR PRESSURE CAP
INSPECTION
COOLING SYSTEM CLEANING
REVERSE FLUSHING THE RADIATOR
REVERSE FLUSHING THE ENGINE
CHEMICAL CLEANING
ADJUSTMENTS
PROPER BELT TENSION
BELT TENSION GAUGE METHOD
BELT TENSION CHART
SPECIFICATIONS
COOLING SYSTEM CAPACITY
TORQUE CHART
SPECIAL TOOLS
COOLING
COOLING SYSTEM 1
GENERAL INFORMATION
COOLING SYSTEM — 2.0L GASOLINE
COOLING SYSTEM — 2.5L VM DIESEL
COOLANT PRESSURE BOTTLE
2.5L VM DIESEL
LOW COOLANT LEVEL SENSOR
RADIATOR
DESCRIPTION AND OPERATION
WATER PUMP
2.0L GASOLINE
2.5L VM DIESEL
THERMOSTAT OPERATION
2.5 VM DIESEL
PRESSURE/ VENT CAP
COOLANT PERFORMANCE
ETHYLENE- GLYCOL MIXTURES
BELT TENSION
AUTOMATIC BELT TENSIONER
THERMOSTAT
DIAGNOSIS
TESTING
SERVICE PROCEDURES
ADDING ADDITIONAL COOLANT
2.5L VM DIESEL
DRAINING COOLING SYSTEM
2.0L GASOLINE
2.5L VM DIESEL
REFILLING COOLING SYSTEM
2.0L GASOLINE
2.5L VM DIESEL
REMOVAL AND INSTALLATION
WATER PUMP — 2.0L GASOLINE
REMOVAL
INSTALLATION
WATER PUMP — 2.5L VM DIESEL
REMOVAL
INSTALLATION
ENGINE THERMOSTAT— 2.0L GASOLINE
REMOVAL
INSTALLATION
THERMOSTAT — 2.5L VM DIESEL
REMOVAL
INSTALLATION
RADIATOR — 2.5L VM DIESEL
REMOVAL
INSTALLATION
WATER PUMP BELT — 2.5L VM DIESEL
REMOVAL
INSTALLATION
GENERATOR/ POWER STEERING BELT — 2.5L VM DIESEL
REMOVAL
INSTALLATION
CLEANING AND INSPECTION
WATER PUMP
ADJUSTMENTS
BELT TENSION GAUGE METHOD
BELT TENSION CHART
SPECIFICATIONS
COOLING SYSTEM CAPACITY TORQUE CHART
SPECIAL TOOLS
COOLING
BATTERY
GENERAL INFORMATION
INTRODUCTION
SAFETY PRECAUTIONS AND WARNINGS
DESCRIPTION AND OPERATION
BATTERY IGNITION OFF DRAW (IOD)
CHARGING TIME REQUIRED
SIZE OF BATTERY
BATTERY CHARGING TIMETABLE
TEMPERATURE
CHARGER CAPACITY
STATE OF CHARGE
DIAGNOSIS AND TESTING
BATTERY BUILT-IN TEST INDICATOR
USING TEST INDICATOR
CAUSES OF BATTERY DISCHARGING
ABNORMAL BATTERY DISCHARGING
BATTERY IGNITION OFF DRAW (IOD)
BATTERY DIAGNOSIS AND TESTING
BATTERY LOAD TEST
BATTERY LOAD TEST TEMPERATURE
BATTERY OPEN CIRCUIT VOLTAGE TEST
BATTERY OPEN CIRCUIT VOLTAGE
SERVICE PROCEDURES
BATTERY CHARGING
CHARGING COMPLETELY DISCHARGED BATTERY
BATTERY CHARGING RATE
VISUAL INSPECTION
REMOVAL AND INSTALLATION
BATTERY
REMOVAL
INSTALLATION
BATTERY TRAY
REMOVAL
INSTALLATION
SPECIFICATIONS
BATTERY SPECIFICATIONS
CRANKING RATING
RESERVE CAPACITY RATING
TORQUE
BATTERY 1
GENERAL INFORMATION
INTRODUCTION
SAFETY PRECAUTIONS AND WARNINGS
DESCRIPTION AND OPERATION
BATTERY IGNITION OFF DRAW (IOD)
CHARGING TIME REQUIRED
SIZE OF BATTERY
TEMPERATURE
CHARGER CAPACITY
STATE OF CHARGE
USING HYDROMETER
DIAGNOSIS AND TESTING
BATTERY DISCHARGING
CAUSE OF BATTERY DISCHARGING
ABNORMAL BATTERY DISCHARGING
BATTERY IGNITION OFF DRAW
BATTERY LOAD TEST
BATTERY OPEN CIRCUIT VOLTAGE TEST
SERVICE PROCEDURES
BATTERY CHARGING
CHARGING COMPLETELY DISCHARGED BATTERY
VISUAL INSPECTION
REMOVAL AND INSTALLATION
BATTERY
REMOVAL
INSTALLATION
BATTERY TRAY
REMOVAL
INSTALLATION
SPECIFICATIONS
BATTERY SPECIFICATIONS
CRANKING RATING
TORQUE
STARTER
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
SUPPLY CIRCUIT AND CONTROL CIRCUIT
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
FEED CIRCUIT RESISTANCE TEST
FEED CIRCUIT TEST
REMOVAL AND INSTALLATION
STARTER—2.4L ENGINE
REMOVAL
INSTALLATION
STARTER—3.0L ENGINE
REMOVAL
INSTALLATION
STARTER—3.3/3.8L ENGINE
REMOVAL
INSTALLATION
SPECIFICATIONS
STARTER
TORQUE
STARTING SYSTEM
REMOVAL AND INSTALLATION
STARTER
2.0L ENGINE
2.4L ENGINE - With Manual Transaxle
2.4L ENGINE - With Automatic Transaxle
3.0L ENGINE
3.3/3.8L ENGINE
2.5L DIESEL ENGINE
CHARGING SYSTEM
GENERAL INFORMATION
OVERVIEW
DESCRIPTION AND OPERATION
CHARGING SYSTEM OPERATION
GENERATOR
BATTERY TEMPERATURE SENSOR
ELECTRONIC VOLTAGE REGULATOR
DIAGNOSIS AND TESTING
CHARGING SYSTEM
INSPECTION
CHARGING SYSTEM RESISTANCE TESTS
PREPARATION
TEST
CURRENT OUTPUT TEST
PREPARATION
CHAR GING SYSTEM TEST
OVERCHAR GE TEST
TEST
ON-BOARD DIAGNOSTIC SYSTEM TEST
GENERAL INFORMATION
DIAGNOSTIC TROUBLE CODES
ERASING DIAGNOSTIC TROUBLE CODES
VOLTAGE DROP TEST
REMOVAL AND INSTALLATION
GENERATOR—2.4L ENGINE
REMOVAL
INSTALLATION
GENERATOR—3.0L ENGINE
REMOVAL
INSTALLATION
GENERATOR—3.3/3.8 L ENGINE
REMOVAL
INSTALLATION
SPECIFICATIONS
GENERATOR
TORQUE
IGNITION SYSTEM
GENERAL INFORMATION
GENERAL INFORMATION
INTRODUCTION
POWERTRAIN CONTROL MODULE
IGNITION SYSTEM
SPARK PLUGS 2.4/3.0L
SPARK PLUGS 3.3/3.8L
3.3/3.8L SPARK PLUG GAP MEASUREMENT
SPARK PLUG CABLE
SPARK PLUG CABLES—3.3/3.8L
IGNITION COIL
AUTOMATIC SHUTDOWN (ASD) RELAY
CRANKSHAFT POSITION SENSOR
CAMSHAFT POSITION SENSOR
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
THROTTLE POSITION SENSOR (TPS)
LOCK KEY CYLINDER
KNOCK SENSOR
DIAGNOSIS AND TESTING
TESTING FOR SPARK AT COIL—2.4/3.3/3.8L ENGINES
TESTING FOR SPARK AT COIL—3.0L
CHECK COIL TEST—2.4L
CHECK COIL TEST—3.3/3.8L
FAILURE TO START TEST
IGNITION TIMING PROCEDURE
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST
CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR
ENGINE COOLANT TEMPERATURE SENSOR
INTAKE AIR TEMPERATURE SENSOR
SPARK PLUG CONDITION
NORMAL OPERATING CONDITIONS
COLD FOULING (CARBON FOULING)
FUEL FOULING
OIL FOULING
OIL OR ASH ENCRUSTED
HIGH SPEED MISS
ELECTRODE GAP BRIDGING
SCAVENGER DEPOSITS
CHIPPED ELECTRODE INSULATOR
PREIGNITION DAMAGE
SPARK PLUG OVERHEATING
THROTTLE POSITION SENSOR
SERVICE PROCEDURES
SPARK PLUG GAP ADJUSTMENT
POWERTRAIN CONTROL MODULE
REMOVAL
INSTALLATION
IGNITION TIMING PROCEDURE
2.4L ENGINE
DESCRIPTION AND OPERATION
FIRING ORDER—2.4L
CRANKSHAFT POSITION SENSOR
CAMSHAFT POSITION SENSOR
INTAKE AIR TEMPERATURE SENSOR 2.4L
REMOVAL AND INSTALLATION
SPARK PLUG CABLE SERVICE—2.4L
REMOVAL
INSTALLATION
IGNITION COIL—2.4L
REMOVAL
INSTALLATION
SPARK PLUG SERVICE
CRANKSHAFT POSITION SENSOR
REMOVAL
INSTALLATION
CAMSHAFT POSITION SENSOR
REMOVAL
INSTALLATION
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR—2.4/3.3/3.8L
REMOVAL
INSTALLATION
THROTTLE POSITION SENSOR
ENGINE COOLANT TEMPERATURE SENSOR—2.4L
REMOVAL
INSTALLATION
KNOCK SENSOR—2.4L
REMOVAL
INSTALLATION
INTAKE AIR TEMPERATURE SENSOR—2.4L
REMOVAL
INSTALLATION
SPECIFICATIONS
IGNITION COIL
SPARK PLUG
TORQUE
SPARK PLUG CABLE RESISTANCE 2.4L
3.0L ENGINE
DESCRIPTION AND OPERATION
FIRING ORDER—3.0L
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
CAMSHAFT POSITION SENSOR
REMOVAL AND INSTALLATION
SPARK PLUG SERVICE
REMOVAL
INSTALLATION
IGNITION COIL—3.OL
REMOVAL
INSTALLATION
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR—3.0L
REMOVAL
INSTALLATION
ENGINE COOLANT TEMPERATURE SENSOR—3.0L
REMOVAL
INSTALLATION
CRANKSHAFT POSITION SENSOR
REMOVAL
INSTALLATION
THROTTLE POSITION SENSOR
DISASSEMBLY AND ASSEMBLY
DISTRIBUTOR—3.0L
REMOVAL
INSTALLATION
CLEANING AND INSPECTION
DISTRIBUTOR CAP
DISTRIBUTOR ROTOR—3.0L
SPECIFICATIONS
SPARK PLUG
TORQUE
SPARK PLUG CABLE RESISTANCE 3.0L
3.3/3.8L ENGINE
DESCRIPTION AND OPERATION
FIRING ORDER 3.3/3.8L
REMOVAL AND INSTALLATION
SPARK PLUG CABLE SERVICE 3.3/3.8L ENGINES
SPARK PLUG CABLES #3 AND #5
SPARK PLUG CABLE #1
SPARK PLUG SERVICE—3.3/3.8L ENGINES
SPARK PLUG #3 AND #5
SPARK PLUG #1
IGNITION COIL
REMOVAL
INSTALLATION
CRANKSHAFT POSITION SENSOR
REMOVAL
INSTALLATION
CAMSHAFT POSITION SENSOR
REMOVAL
INSTALLATION
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
REMOVAL
INSTALLATION
ENGINE COOLANT TEMPERATURE SENSOR
REMOVAL
INSTALLATION
THROTTLE POSITION SENSOR
KNOCK SENSOR—3.3/3.8L
REMOVAL
INSTALLATION
SPECIFICATIONS
IGNITION COIL
SPARK PLUG
TORQUE
SPARK PLUG CABLE RESISTANCE 3.3/3.8L
IGNITION SWITCH AND LOCK CYLINDER
DESCRIPTION AND OPERATION
IGNITION INTERLOCK
LOCK KEY CYLINDER
REMOVAL AND INSTALLATION
IGNITION SWITCH
REMOVAL
INSTALLATION
LOCK KEY CYLINDER
REMOVAL
INSTALLATION
IGNITION INTERLOCK
LOCK CYLINDER HOUSING
INSTRUMENT PANEL AND SYSTEMS
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
INSTRUMENT CLUSTER
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
HEADLAMP SWITCH
SELF DIAGNOSTIC TEST
DIM TEST
INSTRUMENT CLUSTER DTC TABLE
CLUSTER CALIBRATION TABLE
CALIBRATION TEST
ODOMETER SEGMENT TEST
ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST
CONDITIONS
INSTRUMENT CLUSTER DIAGNOSIS
SPEEDOMETER DIAGNOSIS
TACHOMETER DIAGNOSIS
FUEL GAUGE DIAGNOSIS
TEMPERATURE GAUGE DIAGNOSIS
ODOMETER DIAGNOSIS
ELECTRONIC GEAR INDICATOR DISPLAY DIAGNOSIS
TRACTION CONTROL SWITCH
MECHANICAL TRANSMISSION RANGE INDICATOR (PRND21) DIAGNOSIS
SWITCH CONTINUITY TABLE
REMOVAL AND INSTALLATION
CONVENIENCE BIN - CUP HOLDER
REMOVAL
INSTALLATION
CONVENIENCE BIN LAMP
REMOVAL
INSTALLATION
CONVENIENCE BIN TRACK
REMOVAL
INSTALLATION
BODY CONTROL MODULE (BCM)
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER LENS - MECHANICAL TRANSMISSION RANGE INDICATOR (PRND21)
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER ELECTRONIC ODOMETER AND TRANSMISSION RANGE INDICATOR
REMOVAL
INSTALLATION
GLOVE BOX
REMOVAL (FIG. 4)
INSTALLATION
GLOVE BOX LAMP AND SWITCH
REMOVAL
INSTALLATION
GLOVE BOX LOCK STRIKER
REMOVAL
INSTALLATION
HEADLAMP SWITCH
REMOVAL
INSTALLATION
HEADLAMP SWITCH LAMP(S)
REMOVAL
INSTALLATION
HVAC CONTROL LAMP
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER BACK PANEL
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER BEZEL
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER LAMPS
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER LENS
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER SUBDIAL
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER SUBDIAL—MECHANICAL TRANSMISSION RANGE INDICATOR
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER WITH ELECTRONIC TRANSMISSION RANGE INDICATOR
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER WITH MECHANICAL TRANSMISSION RANGE INDICATOR
REMOVAL
INSTALLATION
INSTRUMENT PANEL
REMOVAL
INSTALLATION
INSTRUMENT PANEL LEFT END COVER
REMOVAL
INSTALLATION
INSTRUMENT PANEL LOUVERS
CENTER LOUVER HOUSING
LEFT LOUVER HOUSING
PASSENGER SIDE LOUVERS
PASSENGER SIDE LOUVER OUTER HOUSINGS
INSTRUMENT PANEL TOP COVER
REMOVAL
INSTALLATION
INSTRUMENT PANEL RIGHT END COVER
REMOVAL
INSTALLATION
JUNCTION BLOCK
REMOVAL
INSTALLATION
KNEE BLOCKER REINFORCEMENT
REMOVAL
INSTALLATION
LOWER CONSOLE
REMOVAL
INSTALLATION
LOWER INSTRUMENT PANEL
REMOVAL
INSTALLATION
LOWER STEERING COLUMN COVER
REMOVAL
INSTALLATION
MECHANICAL TRANSMISSION RANGE INDICATOR
REMOVAL
INSTALLATION
MESSAGE CENTER
REMOVAL
INSTALLATION
MESSAGE CENTER LAMP
REMOVAL
INSTALLATION
OUTLET (12 VOLT) BASE
REMOVAL
INSTALLATION
OVER STEERING COLUMN BEZEL
REMOVAL
INSTALLATION
POWER MIRROR SWITCH
REMOVAL
INSTALLATION
POWER MIRROR SWITCH LAMP
REMOVAL
INSTALLATION
RADIO BEZEL AND HVAC CONTROL
REMOVAL
INSTALLATION
REAR HEATER-A/C SWITCH
REMOVAL
INSTALLATION
REAR HEATER-A/C SWITCH LAMP
REMOVAL
INSTALLATION
TRACTION CONTROL SWITCH
REMOVAL
INSTALLATION
INSTRUMENT PANEL AND SYSTEMS 1
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
HEADLAMP AND POWER MIRROR SWITCH LAMP( S)
INSTRUMENT CLUSTER
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
HEADLAMP SWITCH
SELF DIAGNOSTIC TEST
INSTRUMENT CLUSTER DTC CHART
DIM TEST
CLUSTER CALIBRATION TABLE
CALIBRATION TEST
ODOMETER SEGMENT TEST
CONDITIONS
REMOVAL AND INSTALLATION
CONVENIENCE BIN - CUP HOLDER
REMOVAL
INSTALLATION
ASH RECEIVER – CONVENIENCE BIN LAMP MODULE
REMOVAL
INSTALLATION
CONVENIENCE BIN
REMOVAL
INSTALLATION
BODY CONTROL MODULE (BCM)
REMOVAL
INSTALLATION
CIGAR LIGHTER BASE
REMOVAL
INSTALLATION
GLOVE BOX
REMOVAL (FIG. 4)
INSTALLATION
GLOVE BOX LAMP AND SWITCH
REMOVAL
INSTALLATION
GLOVE BOX LOCK STRIKER
REMOVAL
INSTALLATION
HEADLAMP SWITCH
REMOVAL
INSTALLATION
HEADLAMP SWITCH LAMP( S)
REMOVAL
INSTALLATION
HVAC CONTROL LAMP
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER BACK PANEL
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER BEZEL
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER LENS
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER SUBDIAL
REMOVAL
INSTALLATION
INSTRUMENT CLUSTER
REMOVAL
INSTALLATION
INSTRUMENT PANEL
REMOVAL
INSTALLATION
INSTRUMENT PANEL LEFT END COVER
REMOVAL
INSTALLATION
INSTRUMENT PANEL LOUVERS
CENTER LOUVER HOUSING
LEFT LOUVER HOUSING
PASSENGER SIDE LOUVERS
PASSENGER SIDE LOUVER OUTER HOUSINGS
INSTRUMENT PANEL TOP COVER
REMOVAL
INSTALLATION
INSTRUMENT PANEL RIGHT END COVER
REMOVAL
INSTALLATION
JUNCTION BLOCK
REMOVAL
INSTALLATION
KNEE BLOCKER REINFORCEMENT
REMOVAL
INSTALLATION
LOWER CONSOLE
REMOVAL
INSTALLATION
LOWER INSTRUMENT PANEL
REMOVAL
INSTALLATION
LOWER STEERING COLUMN COVER
REMOVAL
INSTALLATION
MESSAGE CENTER
REMOVAL
INSTALLATION
OVER STEERING COLUMN BEZEL
REMOVAL
INSTALLATION
POWER MIRROR SWITCH
REMOVAL
INSTALLATION
POWER MIRROR SWITCH LAMP
REMOVAL
INSTALLATION
RADIO BEZEL AND HVAC CONTROL
REMOVAL
INSTALLATION
REAR HEATER- A/ C SWITCH
REMOVAL
INSTALLATION
REAR HEATER- A/ C SWITCH LAMP
REMOVAL
INSTALLATION
AUDIO SYSTEMS
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
ANTENNA
INTERFERENCE ELIMINATION
RADIOS
RADIO IGNITION INTERFERENCE
CHOKE—INFINITY SPEAKERS
REMOTE RADIO SWITCHES
NAME BRAND SPEAKER RELAY
DIAGNOSIS AND TESTING
ANTENNA
TEST 1
TEST 2
TEST 3
TEST 4
AUDIO SYSTEM
RADIO
AUDIO SYSTEM DIAGNOSIS
REMOTE RADIO SWITCHES
REMOTE RADIO SWITCH TEST
REMOVAL AND INSTALLATION
ANTENNA MAST AND CABLE LEAD
REMOVAL
INSTALLATION
ANTENNA EXTENSION CABLE
REMOVAL
INSTALLATION
RADIO/TAPE/CD PLAYER
REMOVAL
INSTALLATION
INSTRUMENT PANEL SPEAKER
INSTALLATION
INSTALLATION
FRONT DOOR SPEAKER
REMOVAL
INSTALLATION
REMOTE RADIO SWITCHES
REMOVAL
INSTALLATION
QUARTER PANEL SPEAKER
REMOVAL
INSTALLATION
D PILLAR SPEAKER
REMOVAL
INSTALLATION
HORNS
DESCRIPTION AND OPERATION
INTRODUCTION
DIAGNOSIS AND TESTING
HORN
HORN RELAY
HORNS WILL NOT SOUND
FUSE BLOWN
FUSE OK
HORNS SOUND CONTINUOUSLY
HORN SYSTEM
HORN SYSTEM TEST
REMOVAL AND INSTALLATION
HORN SWITCH
HORNS
REMOVAL
INSTALLATION
VEHICLE SPEED CONTROL SYSTEM
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
SPEED CONTROL SERVO
SPEED CONTROL SWITCHES
AUTOMATIC SPEED CONTROL OVERSPEED REDUCTION
STOP LAMP SWITCH
SERVO CABLE
POWERTRAIN CONTROL MODULE
VACUUM RESERVOIR
VEHICLE SPEED AND DISTANCE
DIAGNOSIS AND TESTING
ROAD TEST
OVERSHOOT/UNDERSHOOT FOLLOWING SPEED CONTROL SET
CHECKING FOR DIAGNOSTIC CODES
SPEED CONTROL DIAGNOSTIC TROUBLE CODES
SPEED CONTROL SLOWS DOWN BY ITSELF
SPEED CONTROL ELECTRICAL TEST
SERVO VACUUM TEST
SPEED CONTROL SWITCH TEST
STOP LAMP SWITCH TEST
ELECTRICAL TESTS AT POWERTRAIN CONTROL MODULE
VACUUM SUPPLY TEST
VEHICLE SPEED SENSOR
REMOVAL AND INSTALLATION
SPEED CONTROL SERVO
REMOVAL
INSTALLATION
SPEED CONTROL SWITCHES
REMOVAL
INSTALLATION
STOP LAMP SWITCH
REMOVAL
INSTALLATION
SPEED CONTROL CABLE
REMOVAL
INSTALLATION
POWERTRAIN CONTROL MODULE
VACUUM RESEROIR
REMOVAL
INSTALLATION
VEHICLE SPEED SENSOR
VEHICLE SPEED CONTROL SYSTEM 1
GENERAL INFORMATION
INTRODUCTION
TURN SIGNAL AND FLASHERS
GENERAL INFORMATION
INTRODUCTION
COMBINATION FLASHER
DESCRIPTION AND OPERATION
COMBINATION FLASHER FUNCTION
COMBINATION FLASHER / DAYTIME RUNNING LAMPS (DRL) MODULE
DIAGNOSIS AND TESTING
TURN SIGNAL MULTI-FUNCTION SWITCH
TURN SIGNAL MULTI-FUNCTION SWITCH TEST
COMBINATION FLASHER WITH / WITHOUT DAYTIME RUNNING LAMPS MODULE—CIRCUIT DIAGNOSTICS
JUNCTION BLOCK TERMINAL CALL-OUT
JUNCTION BLOCK TERMINAL CALL-OUT WITH DRL
COMBINATION FLASHER DIAGNOSIS
COMBINATION FLASHER DIAGNOSIS WITH DRL
REMOVAL AND INSTALLATION
MULTI-FUNCTION SWITCH
REMOVAL
INSTALLATION
COMBINATION FLASHER WITH / WITHOUT DRL MODULE
REMOVAL
INSTALLATION
WINDSHIELD WIPERS AND WASHERS
WINDSHIELD WIPERS AND WASHER
GENERAL INFORMATION
INTRODUCTION
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
FAILED PARK SWITCH
WIPER SYSTEM DIAGNOSIS
MULTI-FUNCTION SWITCH
REMOVAL AND INSTALLATION
MULTI-FUNCTION SWITCH
REMOVAL
INSTALLATION
WINDSHIELD WASHER BOTTLE
REMOVAL
INSTALLATION
WINDSHIELD WIPER BLADE
REMOVAL
INSTALLATION
WINDSHIELD WIPER BLADE ELEMENT
REMOVAL
INSTALLATION
WINDSHIELD WIPER MOTOR
REMOVAL
INSTALLATION
WIPER ARM
REMOVAL
INSTALLATION
WIPER UNIT
REMOVAL
INSTALLATION
WIPER LINKAGE
REMOVAL
INSTALLATION
CLEANING AND INSPECTION
WIPER BLADES
ADJUSTMENTS
WIPER ARM ALIGNMENT
REAR WIPER AND WASHER
DESCRIPTION AND OPERATION
INTRODUCTION
REAR WINDOW WIPER/WASHER SWITCHES
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
REMOVAL AND INSTALLATION
REAR GLASS RUBBER GROMMET
REMOVAL
INSTALLATION
REAR WINDOW WIPER MOTOR
REMOVAL
INSTALLATION
REAR WIPER ARM
REMOVAL
INSTALLATION
REAR WIPER BLADE
REMOVAL
INSTALLATION
REAR WIPER BLADE ELEMENT
WIPER AND WASHER SYSTEMS 1
HEADLAMP WASHERS
GENERAL INFORMATION
INTRODUCTION
REMOVAL AND INSTALLATION
WINDSHIELD/ HEADLAMP WASHER RESERVOIR
HEADLAMP WASHER NOZZLE
HEADLAMP WASHER PUMP
LAMPS
LAMP DIAGNOSIS
GENERAL INFORMATION
GENERAL INFORMATION
SAFETY PRECAUTIONS
ELECTRONIC DAYTIME RUNNING LIGHT (DRL)
SYSTEM FUNCTION
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
HEADLAMP DIAGNOSIS
FOG LAMP DIAGNOSIS
HEADLAMP ALIGNMENT
GENERAL INFORMATION
HEADLAMP ALIGNMENT
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
ADJUSTMENTS
HEADLAMP/FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN
ALIGNMENT SCREEN PREPARATION
HEADLAMP ADJUSTMENT
HEADLAMP ADJUSTMENT – TOWN AND COUNTRY
BUBBLE LEVEL CALIBRATION (VERTICAL AIM)
MAGNIFYING WINDOW CALIBRATION (HORIZONTAL AIM)
FOG LAMP ALIGNMENT
REMOVAL AND INSTALLATION
HEADLAMP BULB
REMOVAL
INSTALLATION
HEADLAMP BULB – TOWN and COUNTRY
HEADLAMP HIGH BEAM
HEADLAMP LOW BEAM
FOG LAMP BULB
REMOVAL
INSTALLATION
FOG LAMP BULB – TOWN and COUNTRY
REMOVAL
INSTALLATION
FRONT SIDE MARKER LAMP BULB TOWN and COUNTRY
REMOVAL
INSTALLATION
PARKING AND TURN SIGNAL BULB
REMOVAL
INSTALLATION
FRONT PARKING AND TURN SIGNAL LAMP BULB TOWN and COUNTRY
REMOVAL
INSTALLATION
TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP BULB
REMOVAL
INSTALLATION
LICENSE PLATE LAMP BULB
REMOVAL
INSTALLATION
CENTER HIGH MOUNTED STOP LAMP (CHMSL) BULB
REMOVAL
INSTALLATION
EXTERIOR LAMP SERVICE
GENERAL INFORMATION
HEADLAMP MODULE
HEADLAMP SWITCH
HEADLAMP DIMMER SWITCH
REMOVAL AND INSTALLATION
HEADLAMP MODULE
REMOVAL
INSTALLATION
FOG LAMP
REMOVAL
INSTALLATION
FOG LAMP – TOWN and COUNTRY
REMOVAL
INSTALLATION
FRONT SIDE MARKER LAMP TOWN and COUNTRY
REMOVAL
INSTALLATION
FRONT PARKING AND TURN SIGNAL LAMP – TOWN and COUNTRY
REMOVAL
INSTALLATION
TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP
REMOVAL
INSTALLATION
LICENSE PLATE LAMP
REMOVAL
INSTALLATION
CENTER HIGH MOUNTED STOP LAMP (CHMSL)
REMOVAL
INSTALLATION
INTERIOR LAMPS
REMOVAL AND INSTALLATION
HEADER READING/COURTESY LAMP BULB
REMOVAL
INSTALLATION
OVERHEAD CONSOLE READING/COURTESY LAMP
REMOVAL
INSTALLATION
HEADER READING/COURTESY LAMP BULB
REMOVAL
INSTALLATION
GLOVE BOX LAMP AND SWITCH
REMOVAL
INSTALLATION
GLOVE BOX LAMP BULB
REMOVAL
INSTALLATION
IGNITION HALO LAMP BULB
REMOVAL
INSTALLATION
CONVENIENCE BIN LAMP
REMOVAL
INSTALLATION
INSTRUMENT PANEL LAMPS AND SWITCHES
DOME LAMP
REMOVAL
INSTALLATION
DOME LAMP BULB
REMOVAL
INSTALLATION
FRONT DOOR COURTESY LAMP
REMOVAL
INSTALLATION
FRONT DOOR COURTESY LAMP BULB
REMOVAL
INSTALLATION
RAIL LAMP MODULE BULB
REMOVAL
INSTALLATION
LIFTGATE COURTESY LAMP
REMOVAL
INSTALLATION
LIFTGATE COURTESY LAMP BULB
REMOVAL
INSTALLATION
BULB APPLICATION
GENERAL INFORMATION
INTRODUCTION
SPECIFICATIONS
EXTERIOR LAMP BULBS
INTERIOR LAMP BULBS
LAMPS 1
LAMP DIAGNOSIS
GENERAL INFORMATION
INTRODUCTION
HEADLAMP LEVELING MOTOR
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
HEADLAMP DIAGNOSIS
FOG LAMP DIAGNOSIS
HEADLAMP LEVELING MOTOR DIAGNOSIS
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
ADJUSTMENTS
HEADLAMP/ FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN
ALIGNMENT SCREEN PREPARATION
HEADLAMP ADJUSTMENT
FOG LAMP ALIGNMENT
REMOVAL AND INSTALLATION
HEADLAMP BULB
REMOVAL
INSTALLATION
FRONT TURN SIGNAL LAMP BULB
REMOVAL
INSTALLATION
CITYLIGHT LAMP BULB
REMOVAL
INSTALLATION
FOG LAMP BULB
REMOVAL
INSTALLATION
SIDE REPEATER LAMP BULB
REMOVAL
INSTALLATION
TAIL LAMP BULB
REMOVAL
INSTALLATION
LICENSE PLATE LAMP BULB
REMOVAL
INSTALLATION
CENTER HIGH MOUNTED STOP LAMP (CHMSL) BULB
REMOVAL
INSTALLATION
LAMP SERVICE
GENERAL INFORMATION
HEADLAMP SWITCH
HEADLAMP DIMMER SWITCH
REMOVAL AND INSTALLATION
HEADLAMP MODULE
REMOVAL
INSTALLATION
HEADLAMP LEVELING MOTOR
REMOVAL
INSTALLATION
FOG LAMP
REMOVAL
INSTALLATION
SIDE REPEATER LAMP
REMOVAL
INSTALLATION
TAIL LAMP
REMOVAL
INSTALLATION
LICENSE PLATE LAMP
REMOVAL
INSTALLATION
CENTER HIGH MOUNTED STOP LAMP (CHMSL)
REMOVAL
INSTALLATION
BULB APPLICATION
GENERAL INFORMATION
INTRODUCTION
CLEANING AND INSPECTION
HEADLAMP CLEANING
SPECIFICATIONS
EXTERIOR LAMP BULBS
INTERIOR LAMP BULBS
RESTRAINT SYSTEM
GENERAL INFORMATION
WARNINGS AND PRECAUTIONS
DESCRIPTION AND OPERATION
AIRBAG CONTROL MODULE (ACM)
CLOCKSPRING
DRIVER AND PASSENGER AIRBAG MODULES
DIAGNOSIS AND TESTING
AIRBAG SYSTEM TEST
SERVICE PROCEDURES
CLEANUP PROCEDURE
SERVICE OF DEPLOYED AIRBAG MODULE
HANDLING AIRBAG MODULE
DEPLOYED MODULE
UNDEPLOYED
REMOVAL AND INSTALLATION
AIRBAG CONTROL MODULE
REMOVAL
INSTALLATION
CLOCKSPRING
REMOVAL
INSTALLATION
DRIVER AIRBAG MODULE
DEPLOYED MODULE
UNDEPLOYED
PASSENGER AIRBAG
DEPLOYED MODULE
UNDEPLOYED
ADJUSTMENTS
CLOCKSPRING CENTERING PROCEDURE
ELECTRICALLY HEATED SYSTEMS
DESCRIPTION AND OPERATION
INTRODUCTION
HVAC MOUNTED SWITCH
DIAGNOSIS AND TESTING
SYSTEM TEST
GRID LINE TEST
SERVICE PROCEDURES
GRID LINE AND TERMINAL REPAIR
POWER DOOR LOCKS
POWER DOOR LOCKS
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
AUTOMATIC DOOR LOCK FEATURE
DOOR LOCK CIRCUIT PROTECTION
DOOR LOCK INHIBIT FEATURE
SLIDING DOOR LOCK MEMORY FEATURE
DIAGNOSIS AND TESTING
AUTOMATIC DOOR LOCK SYSTEM TEST
DOOR LOCK MOTOR
DOOR LOCK SWITCH TEST
DOOR LOCK SWITCH TEST
SERVICE PROCEDURES
AUTOMATIC DOOR LOCKS DISABLE OR ENABLE
REMOVAL AND INSTALLATION
FRONT DOOR LOCK MOTOR/LATCH
LIFTGATE LOCK MOTOR
REMOVAL
INSTALLATION
SLIDING DOOR LOCK CONTACTS
REMOVAL
INSTALLATION
SLIDING DOOR LOCK MOTOR
REMOVAL
INSTALLATION
SLIDING DOOR LOCK PLUNGER
REMOVAL
INSTALLATION
REMOTE KEYLESS ENTRY
DESCRIPTION AND OPERATION
INTRODUCTION
VEHICLE ACCESS CODE (VAC) PROGRAMMING
DIAGNOSIS AND TESTING
RKE DIAGNOSTICS
SERVICE PROCEDURES
HORN CHIRP DISABLE OR ENABLE
ADJUSTMENTS
PROGRAMMING RKE MODULE
REMOVAL AND INSTALLATION
RKE MODULE
REMOVAL
INSTALLATION
SPECIFICATIONS
RKE TRANSMITTER BATTERY
RKE TRANSMITTER RANGE
VEHICLE THEFT SECURITY SYSTEM
GENERAL INFORMATION
INTRODUCTION
ENABLING
DESCRIPTION AND OPERATION
ARMING PROCEDURE
METHOD-A
METHOD-B
TIME-OUT PERIOD
TRIGGERING THE VTSS
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
REMOVAL AND INSTALLATION
BODY CONTROL MODULE
REMOVAL
INSTALLATION
DOOR LOCK CYLINDER SWITCH
REMOVAL
INSTALLATION
FRONT DOOR AJAR (VTSS TRIGGER) SWITCH
REMOVAL
INSTALLATION
HOOD AJAR (VTSS TRIGGER) SWITCH
REMOVAL
INSTALLATION
LIFTGATE AJAR (VTSS TRIGGER) SWITCH
REMOVAL
INSTALLATION
LIFTGATE LOCK CYLINDER SWITCH
REMOVAL
INSTALLATION
SLIDING DOOR AJAR (VTSS TRIGGER) SWITCH
REMOVAL
INSTALLATION
VEHICLE THEFT/ SECURITY SYSTEMS
GENERAL INFORMATION
INTRODUCTION
SMART KEY IMMOBILIZER SYSTEM
DESCRIPTION AND OPERATION
SMART KEY IMMOBILIZER MODULE
SMART KEY IMMOBILIZER TRANSPONDER
SMART KEY IMMOBILIZER SYSTEM INDICATOR LAMP
DIAGNOSIS AND TESTING
SMART KEY IMMOBILIZER SYSTEM
SERVICE PROCEDURES
SMART KEY IMMOBILIZER SYSTEM TRANSPONDER PROGRAMMING
PROGRAMMING THE SKIM MODULE WITH THE DRBIII
PROGRAMMING IGNITION KEYS WITH THE DRBIII
REMOVAL AND INSTALLATION
SMART KEY IMMOBILIZER MODULE
POWER WINDOWS
GENERAL INFORMATION
INTRODUCTION
DIAGNOSIS AND TESTING
POWER VENT WINDOW MOTOR TEST
POWER WINDOW AND VENT SWITCH TEST
DRIVER DOOR POWER WINDOW SWITCH TEST
POWER WINDOW MOTOR TEST
WIRING VOLTAGE TEST
REMOVAL AND INSTALLATION
POWER VENT WINDOW MOTOR
REMOVAL
INSTALLATION
POWER WINDOW SWITCH
POWER WINDOW MOTOR
REMOVAL
INSTALLATION
POWER SEATS
POWER SEATS
GENERAL INFORMATION
INTRODUCTION
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
SEAT MOTORS
POWER SEAT SWITCH
MEMORY SEAT AND MIRROR SYSTEM
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
POWER SIDE VIEW MIRROR POSITION SENSING
MEMORY SELECTOR SWITCHES
DEFINITION OF: MOMENTARILY AND RELEASE
SEAT AND RECLINER SWITCHES
POSITION SENSING SEAT AND RECLINER POTENTIOMETERS
DIAGNOSIS AND TESTING
MEMORY SELECTOR SWITCHES
SIDE VIEW MIRROR SWITCH STUCK
DIAGNOSTIC MODE
MODE 1
MIRROR MECHANIZATION TABLE
MODE 2
CIRCUIT DESCRIPTION
SEAT AND RECLINER POSITION SENSING
SERVICE PROCEDURES
REMOTE KEYLESS ENTRY (RKE) DATA LINK
SEAT ACTUATIONS TABLE
REMOVAL AND INSTALLATION
MEMORY SWITCHES
REMOVAL
INSTALLATION
SEAT TRACK ASSEMBLY
POWER MIRRORS
GENERAL INFORMATION
INTRODUCTION
HEATED MIRROR
MEMORY MIRRORS
DIAGNOSIS AND TESTING
MIRROR MOTOR TEST
MIRROR SWITCH TEST
HEATED MIRROR TEST
TEST PROCEDURE
REMOVAL AND INSTALLATION
POWER MIRROR
REMOVAL
INSTALLATION
POWER MIRROR SWITCH
CHIME WARNING/REMINDER SYSTEM
GENERAL INFORMATION
INTRODUCTION
DIAGNOSIS AND TESTING
CHIME SYSTEM DIAGNOSIS
NO TONE WHEN IGNITION SWITCH IS TURNED ON AND DRIVER'S SEAT BELT IS NOT BUCKLED.
NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS TURNED ON.
FASTEN SEAT BELT LAMP OR TONE CONTINUES FOR MORE THAN 10 SECONDS AFTER SEAT BELTS ARE FASTENED AND DRIVER'S DOOR IS CLOSED.
NO TONE WHEN PARK OR HEADLAMPS ARE ON AND DRIVER'S DOOR IS OPEN.
DOME LAMP ON CHIME
ENGINE TEMPERATURE CRITICAL CHIME
EXTERIOR LAMPS ON CHIME
KEY-IN IGNITION CHIME
LOW OIL PRESSURE CHIME OPERATION
SEAT BELT CHIME
SEAT BELT LAMP
TURN SIGNAL ON CHIME
WARNING LAMP ANNOUNCEMENT CHIME
CHIME WARNING/ REMINDER SYSTEM 1
GENERAL INFORMATION
INTRODUCTION
DIAGNOSIS AND TESTING
CATALYST OVERHEAT WARNING CHIME
CHIME SYSTEM DIAGNOSIS
NO TONE WHEN IGNITION SWITCH IS TURNED ON AND DRIVER'S SEAT BELT IS NOT BUCKLED
NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS TURNED ON
FASTEN SEAT BELT LAMP OR TONE CONTINUES FOR MORE THAN 10 SECONDS AFTER SEAT BELTS ARE FASTENED AND DRIVER'S DOOR IS CLOSED
NO TONE WHEN PARK OR HEADLAMPS ARE ON AND DRIVER'S DOOR IS OPEN
DOME LAMP ON CHIME
ENGINE TEMPERATURE CRITICAL CHIME
EXTERIOR LAMPS ON CHIME
KEY- IN IGNITION CHIME
LOW OIL PRESSURE CHIME OPERATION
SEAT BELT CHIME
SEAT BELT LAMP
TURN SIGNAL ON CHIME
WARNING LAMP ANNOUNCEMENT CHIME
OVERHEAD CONSOLE
DESCRIPTION AND OPERATION
COMPASS/TEMPERATURE MINI TRIP COMPUTER SELF-DIAGNOSTIC TEST
COMPASS MINI-TRIP COMPUTER (CMTC)
THERMOMETER AND COMPASS
THERMOMETER
COMPASS
UNIVERSAL TRANSMITTER
DIAGNOSIS AND TESTING
READING/DOME LAMP DIAGNOSIS
TRAVELER MESSAGES
UNIVERSAL TRANSMITTER
SERVICE PROCEDURES
COMPASS CALIBRATION PROCEDURE
COMPASS CALIBRATION PROCEDURE (FAST METHOD)
DEMAGNETIZING PROCEDURE
UNIVERSAL TRANSMITTER
TRAINING
ERASING
REMOVAL AND INSTALLATION
AMBIENT TEMPERATURE SENSOR
REMOVAL
INSTALLATION
COMPASS MINI-TRIP COMPUTER (CMTC) MODULE
REMOVAL
INSTALLATION
COMPASS MINI-TRIP COMPUTER (CMTC) LAMP BULBS
REMOVAL
INSTALLATION
FRONT HEADER READING/COURTESY LAMP
REMOVAL
INSTALLATION
OVERHEAD CONSOLE
REMOVAL
INSTALLATION
READING/COURTESY LAMP
Removal
Installation
READING/COURTESY LAMP ASSEMBLY
Removal
Installation
UNIVERSAL TRANSMITTER
REMOVAL
INSTALLATION
SPECIAL TOOLS
SPECIAL TOOL
WIRING DIAGRAMS
8W- 01 GENERAL INFORMATION
DESCRIPTION AND OPERATION
INTRODUCTION
CIRCUIT INFORMATION
CIRCUIT FUNCTIONS
SECTION IDENTIFICATION
SYMBOLS
TERMINOLOGY
CONNECTOR INFORMATION
IDENTIFICATION
LOCATIONS
SPLICE LOCATIONS
NOTES, CAUTIONS, and WARNINGS
TAKE OUTS
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES
POSITIVE TEMPERATURE COEFFICIENT
DIAGNOSIS AND TESTING
TROUBLESHOOTING TOOLS
INTERMITTENT AND POOR CONNECTIONS
TROUBLESHOOTING TESTS
TESTING FOR VOLTAGE POTENTIAL
TESTING FOR CONTINUITY
TESTING FOR A SHORT TO GROUND
TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS
TESTING FOR A VOLTAGE DROP
TROUBLESHOOTING WIRING PROBLEMS
SERVICE PROCEDURES
WIRING REPAIR
TERMINAL/ CONNECTOR REPAIR- MOLEX CONNECTORS
CONNECTOR REPLACEMENT
CONNECTOR AND TERMINAL REPLACEMENT
TERMINAL/ CONNECTOR REPAIR- AUGAT CONNECTORS
TERMINAL REPLACEMENT
DIODE REPLACEMENT
SPECIAL TOOLS
WIRING/ TERMINAL
8W- 02 COMPONENT INDEX
8W- 10 POWER DISTRIBUTION
8W- 12 JUNCTION BLOCK
8W- 15 GROUND DISTRIBUTION
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 ANTI- LOCK 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 AIRBAG SYSTEM
8W- 44 INTERIOR LIGHTING
8W- 45 BODY CONTROL MODULE
8W- 46 MESSAGE CENTER
8W- 47 AUDIO SYSTEM
8W- 48 WINDOW DEFOGGERS
8W- 49 OVERHEAD CONSOLE
8W- 50 FRONT LIGHTING
8W- 51 REAR LIGHTING
8W- 52 TURN SIGNALS
8W- 53 WIPERS
8W- 54 TRAILER TOW
8W- 60 POWER WINDOWS
8W- 61 POWER DOOR LOCKS
8W- 62 POWER MIRRORS
8W- 63 POWER SEAT
8W- 70 SPLICE INFORMATION
8W- 80 CONNECTOR PIN- OUTS
8W- 90 CONNECTOR/ GROUND LOCATIONS
DESCRIPTION AND OPERATION
INTRODUCTION
CONNECTOR/ GROUND LOCATIONS
CONNECTOR/ GROUND LOCATIONS
8W- 95 SPLICE LOCATIONS
DESCRIPTION AND OPERATION
INTRODUCTION
SPLICE LOCATION INDEX
SPLICE LOCATIONS (RHD)
ENGINE
STANDARD SERVICE PROCEDURES
GENERAL INFORMATION
FORM- IN- PLACE GASKETS
MOPART SILICONE RUBBER ADHESIVE SEALANT
MOPART GASKET MAKER
MOPART TORQUE CURE GASKET MAKER
GASKET DISASSEMBLY
SURFACE PREPARATION
FORM- IN- PLACE GASKET APPLICATION
CRANKSHAFT SPROCKET BOLT ACCESS PLUG
ENGINE CORE PLUGS
REMOVAL
INSTALLATION
ENGINE PERFORMANCE
HONING CYLINDER BORES
MEASURING MAIN BEARING AND CONNECTING ROD BEARING CLEARANCES
PREFERRED METHOD
ALTERNATIVE METHOD
PLASTIGAGE PROCEDURE
CONNECTING ROD BEARING CLEARANCE
REPAIR OF DAMAGED OR WORN THREADS
HYDROSTATIC LOCKED ENGINE
ENGINE OIL
ENGINE OIL SERVICE
ENGINE OIL SPECIFICATION
API SERVICE GRADE CERTIFIED
SAE VISCOSITY
ENERGY CONSERVING OIL
CONTAINER IDENTIFICATION
ENGINE OIL CHANGE
ENGINE DIAGNOSIS
DIAGNOSIS AND TESTING
GENERAL INFORMATION
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
CYLINDER COMPRESSION PRESSURE TEST
CYLINDER COMBUSTION PRESSURE LEAKAGE TEST
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
INSPECTION (ENGINE OIL LEAKS IN GENERAL)
INSPECTION FOR REAR SEAL AREA LEAKS
ENGINE DIAGNOSIS— PERFORMANCE
ENGINE DIAGNOSIS— MECHANICAL
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION
ENGINE LUBRICATION SYSTEM
OIL PAN
PRESSURE LUBRICATION
MAIN/ ROD BEARINGS
CAMSHAFT/ HYDRAULIC LASH ADJUSTERS
BALANCE SHAFTS
SPLASH LUBRICATION
ENGINE COMPONENTS
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE
SERVICE PROCEDURES
FITTING PISTONS
FITTING PISTON RINGS
PISTON RINGS— INSTALLATION
CYLINDER BORE AND PISTON SPECIFICATION CHART
PISTON RING SPECIFICATION CHART
FITTING CONNECTING ROD BEARINGS
FITTING MAIN BEARINGS
CRANKSHAFT MAIN BEARINGS
MAIN BEARING INSTALLATION
CRANKSHAFT SPECIFICATION CHART
CRANKSHAFT END PLAY
CRANKSHAFT SPECIFICATION CHART
OPTIONAL CRANKSHAFT END PLAY CHECK
VALVE SERVICE RECONDITION
VALVE REMOVAL
VALVE INSPECTION
VALVE GUIDES
TESTING VALVE SPRINGS
REFACING VALVES AND VALVE SEATS
VALVE GUIDE SPECIFICATION CHART
VALVE SPECIFICATION CHART
VALVE INSTALLATION
2.4L ENGINE
REMOVAL AND INSTALLATION
ENGINE MOUNT— FRONT
REMOVAL
INSTALLATION
ENGINE MOUNT— LEFT
REMOVAL
INSTALLATION
ENGINE MOUNT— RIGHT
REMOVAL
INSTALLATION
ENGINE MOUNT— REAR
REMOVAL
INSTALLATION
STRUCTURAL COLLAR
REMOVAL
INSTALLATION
ENGINE ASSEMBLY
REMOVAL
INSTALLATION
CYLINDER HEAD COVER
REMOVAL
INSTALLATION
CAMSHAFT
REMOVAL
CAMSHAFT END PLAY
INSTALLATION
CAMSHAFT FOLLOWER
REMOVAL
INSTALLATION
BALANCE SHAFTS CARRIER ASSEMBLY
BALANCE SHAFTS
BALANCE SHAFT CARRIER
BALANCE SHAFT INSTALLATION
HYDRAULIC LASH ADJUSTER
REMOVAL
INSTALLATION
VALVE SPRINGS AND VALVE SEALS IN VEHICLE
REMOVAL
INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
VALVES AND VALVE SPRINGS
REMOVAL
INSTALLATION
VIBRATION DAMPER
REMOVAL
INSTALLATION
TIMING BELT COVER
FRONT COVER
REAR COVER
TIMING BELT
REMOVAL
INSTALLATION
TIMING BELT TENSIONER ASSEMBLY
REMOVAL
INSTALLATION
CAMSHAFT OIL SEAL— FRONT
REMOVAL
INSTALLATION
CRANKSHAFT OIL SEAL— FRONT
REMOVAL
INSTALLATION
CRANKSHAFT OIL SEAL— REAR
REMOVAL
INSTALLATION
OIL PAN
REMOVAL
INSTALLATION
CRANKSHAFT
REMOVAL
INSTALLATION
OIL FILTER
OIL PUMP
REMOVAL
INSTALLATION
PISTON AND CONNECTING ROD
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
OIL PUMP
DISASSEMBLY
ASSEMBLY
CLEANING AND INSPECTION
CYLINDER HEAD
CLEANING
INSPECTION
VALVE GUIDES
VALVE AND VALVE SPRING
VALVES
VALVE GUIDE SPECIFICATION CHART
VALVE SPRINGS
CRANKSHAFT
OIL PUMP
CYLINDER BLOCK
CYLINDER BORE INSPECTION
ADJUSTMENTS
ENGINE MOUNTS
ENGINE MOUNT INSULATOR ADJUSTMENT
CYLINDER BORE AND PISTON SPECIFICATION CHART
SPECIFICATIONS
2.4L ENGINE
TORQUE CHART 2.4L
SPECIAL TOOLS
2.4L ENGINE
3.0L ENGINE
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION NUMBER
ENGINE LUBRICATION
ENGINE COMPONENTS
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE
SERVICE PROCEDURES
AUTO LASH ADJUSTER
FUNCTION CHECK
FITTING CONNECTING ROD BEARINGS
CONNECTING ROD CLEARANCE
CONNECTING ROD SIDE CLEARANCE
FITTING MAIN BEARING
INSPECTION
CRANKSHAFT OIL CLEARANCE— MECHANICAL MEASUREMENT
PLASTIGAGE MEASUREMENT
CONNECTING ROD SPECIFICATION CHART
CRANKSHAFT BEARING INSTALLATION
CRANKSHAFT SPECIFICATION CHART
CHECKING CRANKSHAFT END PLAY
CRANKSHAFT SIZE CLASSIFICATION CHART
CRANKSHAFT SPECIFICATION CHART
VALVE SERVICE RECONDITION
VALVES
VALVE SEAT
INSTALLATION
VALVE SPECIFICATION CHART
REMOVAL AND INSTALLATION
ENGINE MOUNTS
RIGHT SIDE MOUNT
FRONT MOUNT
LEFT SIDE MOUNT
REAR MOUNT
ENGINE MOUNT RUBBER INSULATORS
ENGINE ASSEMBLY
REMOVAL
INSTALLATION
CYLINDER HEAD COVER
REMOVAL
INSTALLATION
CAMSHAFT
REMOVAL
CAMSHAFT INSPECTION
CAMSHAFT INSTALL
ROCKER ARMS
INSTALL ROCKER ARM SHAFT ASSEMBLY
CAMSHAFT SEAL
CAMSHAFT END SEAL (PLUG)— IN VEHICLE SERVICE
CAMSHAFT OIL SEAL PLUG— OUT OF VEHICLE SERVICE
CAMSHAFT END SEAL (PLUG) SERVICE — OUT OF VEHICLE SERVICE
CYLINDER HEAD
REMOVAL
INSTALLATION
TIMING BELT
REMOVAL
CAMSHAFT SPROCKETS
TIMING BELT TENSIONER
INSTALLATION— TIMING BELT
OIL PAN
PISTON AND CONNECTING ROD
FITTING PISTONS
FITTING PISTON RINGS
PISTON RINGS— INSTALLATION
PISTON RING SPECIFICATION CHART
CRANKSHAFT
REMOVAL
CRANKSHAFT BEARINGS— INSTALLATION
REAR CRANKSHAFT SEAL
REAR CRANKSHAFT SEAL RETAINER
FRONT CRANKSHAFT OIL SEAL
OIL PUMP
REMOVAL
INSTALLATION
OIL FILTER AND ADAPTOR
DISASSEMBLY AND ASSEMBLY
ROCKER ARMS AND SHAFTS
ROCKER ARM SHAFTS
REASSEMBLE
ASSEMBLE ROCKER ASSEMBLY
CLEANING AND INSPECTION
TIMING BELT
INSPECTION
CYLINDER HEAD
CLEANING AND INSPECTION
CYLINDER BORE
INSPECTION
OIL PUMP
OIL RELIEF PLUNGER
ADJUSTMENTS
ENGINE MOUNTS
ENGINE MOUNT INSULATOR ADJUSTMENT
SPECIFICATIONS
3.0L ENGINE
TORQUE CHART 3.0L
SPECIAL TOOLS
3.0L ENGINE
3.3/3.8L ENGINE
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION
ENGINE LUBRICATION SYSTEM
ENGINE COMPONENTS
DIAGNOSIS AND TESTING
HYDRAULIC TAPPETS
PRELIMINARY STEP TO CHECKING THE HYDRAULIC TAPPETS
OIL LEVEL TOO HIGH
OIL LEVEL TOO LOW
VALVE TRAIN NOISE DIAGNOSIS
CHECKING ENGINE OIL PRESSURE
SERVICE PROCEDURES
VALVE TIMING
MEASURING TIMING CHAIN FOR STRETCH
FITTING PISTONS AND RINGS
FITTING PISTONS
FITTING RINGS
FITTING CONNECTING ROD BEARINGS
CYLINDER BORE AND PISTON SPECIFICATION CHART
FITTING MAIN BEARINGS
CRANKSHAFT OIL CLEARANCE
PISTON RING SPECIFICATION CHART
PLASTIGAGE (OIL CLEARANCE) MEASUREMENT
CRANKSHAFT END PLAY
DIAL INDICATOR METHOD
CONNECTING ROD SPECIFICATION CHART
CRANKSHAFT SPECIFICATION CHART
FEELER GAUGE METHOD
VALVE SERVICE RECONDITION
VALVE INSPECTION
REFACING VALVES AND VALVE SEATS
VALVE GUIDE SPECIFICATION CHART
VALVE SPECIFICATION CHART
TESTING VALVE SPRINGS
REMOVAL AND INSTALLATION
WIPER UNIT
ENGINE MOUNTS
RIGHT SIDE MOUNT
FRONT MOUNT
LEFT SIDE MOUNT
REAR MOUNT
ENGINE MOUNT RUBBER INSULATORS
ENGINE ASSEMBLY
REMOVAL
INSTALLATION
CRANKSHAFT DAMPER
REMOVAL
INSTALLATION
ROCKER ARMS AND SHAFT ASSEMBLY
REMOVAL
INSTALLATION
VALVE STEM SEALS OR SPRINGS, CYLINDER HEAD NOT REMOVED
CYLINDER HEAD COVER
REMOVAL
INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
INTAKE MANIFOLD SEALING
VALVES AND VALVE SPRINGS
REMOVAL
VALVE INSTALLATION
TAPPET REMOVAL
INSTALLATION
TIMING CHAIN COVER
REMOVAL
INSTALLATION
TIMING CHAIN
REMOVAL
INSTALLATION
CAMSHAFT
REMOVAL— ENGINE REMOVED FROM VEHICLE
INSTALLATION
CAMSHAFT BEARINGS
REMOVAL
INSTALLATION
OIL PAN
REMOVAL
INSTALLATION
PISTON AND CONNECTING ROD
REMOVAL
INSTALLING PISTON AND CONNECTING ROD ASSEMBLY
CRANKSHAFT
MAIN BEARINGS
CRANKSHAFT MAIN JOURNALS
REMOVAL
INSTALLATION
CRANKSHAFT OIL SEAL— FRONT
REMOVAL
INSTALLATION
CRANKSHAFT OIL SEAL— REAR
REMOVAL
INSTALLATION
REAR CRANKSHAFT SEAL RETAINER
OIL FILTER
ENGINE OIL GALLERY PLUGS
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
OIL PUMP
DISASSEMBLY
OIL PUMP ASSEMBLY
HYDRAULIC TAPPETS
DISASSEMBLY
ASSEMBLY
CLEANING AND INSPECTION
CYLINDER HEAD
OIL PAN
OIL PUMP
INSPECTION AND REPAIR
ENGINE BLOCK AND BORE
CLEANING AND INSPECTION
CYLINDER BORE INSPECTION
ADJUSTMENTS
ENGINE MOUNTS
ENGINE MOUNT INSULATOR ADJUSTMENT
SPECIFICATIONS
3.3/ 3.8L ENGINE
CYLINDER BORE AND PISTON SPECIFICATION CHART
TORQUE CHART
SPECIAL TOOLS
3.3/ 3.8L ENGINE
ENGINE 1
2.0L SOHC ENGINE
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION
GENERAL SPECIFICATION
ENGINE LUBRICATION SYSTEM
ENGINE LUBRICATION
PRESSURE LUBRICATION
MAIN/ ROD BEARINGS
CAMSHAFT/ HYDRAULIC LASH ADJUSTERS
SPLASH LUBRICATION
ENGINE COMPONENTS
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE
SERVICE PROCEDURES
CYLINDER BORE AND PISTON SIZING
SIZING PISTONS
CYLINDER BORE AND PISTON SPECIFICATION CHART
FITTING PISTON RINGS
FITTING CONNECTING RODS
PISTON RING SPECIFICATION CHART
CONNECTING ROD SPECIFICATION CHART
FITTING CRANKSHAFT BEARINGS
CRANKSHAFT END PLAY
DIAL INDICATOR METHOD
REMOVAL AND INSTALLATION
CYLINDER HEAD COVER
REMOVAL
INSTALLATION
CRANKSHAFT SPECIFICATION CHART
SPARK PLUG TUBE
SPARK PLUG TUBE SEALS
CAMSHAFT
REMOVAL
INSTALLATION
ROCKER ARM/ HYDRAULIC LASH ADJUSTER
REMOVAL
INSTALLATION
HYDRAULIC LASH ADJUSTER NOISE
VALVE SEALS AND SPRINGS IN VEHICLE
REMOVAL
INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
TIMING BELT COVER
REMOVAL
INSTALLATION
CAMSHAFT OIL SEAL
REMOVAL
INSTALLATION
TIMING BELT SYSTEM
CHECKING BELT TIMING— COVER INSTALLED
REMOVAL— TIMING BELT
CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE AND BELT INSTALLATION —SOHC ENGINE
TIMING BELT w/AUTO TENIONER IF EQUIPPED
OIL PAN
REMOVAL
INSTALLATION
FRONT CRANKSHAFT OIL SEAL
REMOVAL
INSTALLATION
CRANKSHAFT OIL SEAL— REAR
REMOVAL
INSTALLATION
CRANKSHAFT
REMOVAL
CRANKSHAFT MAIN BEARINGS LOCATION
CRANKSHAFT MAIN JOURNALS INSPECTION
INSTALLATION
OIL FILTER ADAPTER
REMOVE AND INSTALL
OIL FILTER
REMOVE AND INSTALL
OIL PUMP
REMOVAL
INSTALLATION
PISTON AND CONNECTING ROD
REMOVAL
PISTON RING— REMOVAL
PISTON RINGS— INSTALLATION
PISTON AND ROD —INSTALLATION
VIBRATION DAMPER
REMOVAL
INSTALLATION
FEELER GAGE METHOD
DISASSEMBLY AND ASSEMBLY
OIL PUMP
VALVE SERVICE WITH THE CYLINDER HEAD REMOVED
REMOVAL
VALVE INSPECTION
VALVE GUIDES
TESTING VALVE SPRINGS
VALVE GUIDE SPECIFICATION CHART
REFACING VALVES AND VALVE SEATS
VALVE SPECIFICATION CHART
CLEANING
VALVE INSTALLATION
CLEANING AND INSPECTION
CYLINDER HEAD AND CAMSHAFT JOURNALS
INSPECTING CYLINDER HEAD
CLEANING
OIL PUMP
CYLINDER BLOCK AND BORE
CYLINDER BORE INSPECTION
CYLINDER BORE AND PISTON SPECIFICATION CHART
SPECIFICATIONS
ENGINE 2.0L SOHC
TORQUE CHART 2.0L SOHC
SPECIAL TOOLS
ENGINE 2.0L SOHC
2.5L VM DIESEL
GENERAL INFORMATION
GENERAL SPECIFICATION
ENGINE IDENTIFICATION
DESCRIPTION AND OPERATION
LUBRICATION SYSTEM
DIAGNOSIS AND TESTING
ENGINE DIAGNOSIS— PERFORMANCE
ENGINE DIAGNOSIS— MECHANICAL
ENGINE DIAGNOSIS— MECHANICAL CONT
ENGINE DIAGNOSIS— MECHANICAL CONT
HYDRAULIC TAPPETS
OIL LEVEL HIGH
OIL LEVEL LOW
TAPPET NOISE DIAGNOSIS
SERVICE PROCEDURES
CHECKING OIL LEVEL
CHANGING ENGINE OIL AND FILTER
ENGINE OIL CHANGE
ENGINE OIL
ENGINE OIL FILTER CHANGE
TIMING PROCEDURE
VALVE AND SEAT REFACING
VALVE REFACING
VALVE SEAT REFACING
VALVE STAND DOWN
VALVE GUIDE HEIGHT
VALVE STEM- TO- GUIDE CLEARANCE MEASUREMENT
FITTING PISTON RING
CRANKSHAFT END PLAY
REMOVAL AND INSTALLATION
ENGINE MOUNT— FRONT
ENGINE MOUNT— RIGHT
MOUNT— LEFT SIDE
ENGINE MOUNT— REAR
ENGINE ASSEMBLY
REMOVAL
CYLINDER HEAD COVER
REMOVAL
INSTALLATION
ROCKER ARMS AND PUSH RODS
REMOVAL
INSTALLATION
VALVE SPRINGS— CYLINDER HEAD NOT REMOVED
REMOVAL
INSTALLATION
CYLINDER HEAD
REMOVAL
CYLINDER HEAD GASKET
INSTALLATION CYLINDER HEAD
VALVES AND VALVE SPRINGS— HEAD OFF
REMOVAL
INSTALLATION
HYDRAULIC TAPPETS
REMOVAL
INSTALLATION
VIBRATION DAMPER
REMOVAL
INSTALLATION
TIMING GEAR COVER OIL SEAL
REMOVAL
INSTALLATION
INJECTION PUMP
TIMING GEAR COVER
REMOVAL
INSTALLATION
CAMSHAFT
REMOVAL
THRUST PLATE INSPECTION
INSTALLATION
CAMSHAFT BEARINGS
REMOVAL
INSTALLATION
CRANKSHAFT MAIN BEARINGS
REMOVAL
INSTALLATION
OIL PAN
REMOVAL
INSTALLATION
OIL PUMP
REMOVAL
INSTALLATION
OIL PUMP PRESSURE RELIEF VALVE
REMOVAL
INSTALLATION
OIL FILTER ADAPTER AND OIL COOLER
REMOVAL
INSTALLATION
VACUUM PUMP
REMOVAL
INSTALLATION
PISTONS AND CONNECTING ROD
REMOVAL
PISTON PIN— REMOVAL
PISTON RING— REMOVAL
FITTING PISTON RINGS
PISTON RINGS— INSTALLATION
PISTON PIN— INSTALLATION
PISTON— INSTALLATION
CYLINDER LINER
REMOVAL
INSTALLATION
CRANKSHAFT— REMOVAL
REAR CRANKSHAFT OIL SEAL
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TAPPETS
DISASSEMBLE AND ASSEMBLE
CLEANING AND INSPECTION
CYLINDER HEAD COVERS
ROCKER ARMS AND PUSH RODS
CLEANING
INSPECTION
CYLINDER HEAD
CLEANING
INSPECTION
VALVE GUIDE HEIGHT
VALVE STEM- TO- GUIDE CLEARANCE MEASUREMENT
TIMING GEAR COVER
VALVES AND VALVE SPRINGS
VALVE CLEANING
INSPECTION
HYDRAULIC TAPPETS
OIL PUMP
CLEANING
INSPECTION
PISTON AND CONNECTING ROD
PISTONS
CONNECTING ROD
PISTON PIN
CRANKSHAFT
CRANKSHAFT JOURNALS
BEARING- TO- JOURNAL CLEARANCE
CRANKSHAFT MAIN BEARING
INSPECTION
OIL PAN
CYLINDER LINER
INSPECTION
SPECIFICATIONS
2.5L VM DIESEL
SPECIAL TOOLS
2.5L VM DIESEL
TORQUE
EXHAUST SYSTEM AND INTAKE MANIFOLD
GENERAL INFORMATION
EXHAUST SYSTEM
CATALYTIC CONVERTERS
EXHAUST GAS RECIRCULATION (EGR)
HEAT SHIELDS
EXHAUST FLEX- JOINT COUPLING
DESCRIPTION AND OPERATION
INTAKE/ EXHAUST MANIFOLD— 2.4L ENGINE
INTAKE/ EXHAUST MANIFOLD— 3.0L ENGINE
INTAKE/ EXHAUST MANIFOLD— 3.3/ 3.8L ENGINES
DIAGNOSIS AND TESTING
EXHAUST SYSTEM
REMOVAL AND INSTALLATION
EXHAUST PIPES, MUFFLERS AND TAILPIPES
REMOVAL
INSTALLATION
UPPER INTAKE MANIFOLD— 2.4L ENGINE
REMOVAL
INSTALLATION
INTAKE MANIFOLD LOWER— 2.4L ENGINE
REMOVAL
INSTALLATION
EXHAUST MANIFOLD— 2.4L ENGINE
REMOVAL
INSTALLATION
INTAKE MANIFOLD— 3.0L ENGINE
REMOVAL
INSTALLATION
EXHAUST MANIFOLD— 3.0L ENGINE
REMOVAL
INSTALLATION
INTAKE MANIFOLD— 3.3/ 3.8L ENGINE
REMOVAL
INSTALLATION
EXHAUST MANIFOLDS— 3.3/ 3.8L ENGINE
REMOVAL
INSTALLATION
CLEANING AND INSPECTION
INTAKE MANIFOLD
INSPECTION
CLEANING
EXHAUST MANIFOLD
INSPECTION
CLEANING
SPECIFICATIONS
TORQUE CHART
FRAME AND BUMPERS
BUMPERS AND FASCIA
REMOVAL AND INSTALLATION
FRONT BUMPER FASCIA
REMOVAL
INSTALLATION
FRONT BUMPER REINFORCEMENT
REMOVAL
INSTALLATION
REAR BUMPER FASCIA
REMOVAL
INSTALLATION
REAR BUMPER REINFORCEMENT
REMOVAL
INSTALLATION
FRAME
REMOVAL AND INSTALLATION
FRONT CROSSMEMBER
REMOVAL
INSTALLATION
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL
INSTALLATION
SPECIFICATIONS
FRAME AND BODY OPENING DIMENSIONS
VEHICLE PREPARATION
FRAME AND BUMPERS 1
FRAME
REMOVAL AND INSTALLATION
FRONT TOW HOOK BRACKET
REMOVAL
INSTALLATION
REAR TOW HOOK BRACKET
REMOVAL
INSTALLATION
FUEL SYSTEM
GENERAL INFORMATION
GENERAL INFORMATION
INTRODUCTION
PCM REPLACEMENT
FUEL REQUIREMENTS
GASOLINE/ OXYGENATE BLENDS
E- 85 GENERAL INFORMATION
ETHANOL FUEL (E- 85)
FUEL REQUIREMENTS
STARTING
CRUISING RANGE
REPLACEMENT PARTS
FUEL DELIVERY SYSTEM
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM
FUEL PUMP MODULE
ELECTRIC FUEL PUMP
FUEL PUMP ELECTRICAL CONTROL
ELECTRICAL PUMP REPLACEMENT
FUEL LEVEL SENSOR
FUEL PRESSURE REGULATOR
FUEL INJECTORS
FUEL TANK
PRESSURE- VACUUM FILLER CAP
QUICK- CONNECT FITTINGS
DIAGNOSIS AND TESTING
FUEL PUMP PRESSURE TEST 2.4/ 3.3/ 3.8L
FUEL PRESSURE BELOW SPECIFICATIONS
FUEL LEVEL SENSOR
FUEL INJECTORS
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE PROCEDURE— 2.4/ 3.3/ 3.8L
FUEL SYSTEM PRESSURE RELEASE PROCEDURE— 3.0L ENGINE
HOSES AND CLAMPS
QUICK- CONNECT FITTINGS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION
FUEL FILTER
REMOVAL
INSTALLATION
FUEL PUMP MODULE
REMOVAL
INSTALLATION
FUEL PRESSURE REGULATOR
REMOVAL
INSTALLATION
FUEL PUMP INLET STRAINER
REMOVAL
INSTALLATION
FUEL LEVEL SENSOR
REMOVAL
INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
FUEL INJECTOR RAIL— 2.4L
REMOVAL
INSTALLATION
FUEL INJECTOR RAIL— 3.0L
REMOVAL
INSTALLATION
FUEL INJECTOR RAIL— 3.3/ 3.8L
REMOVAL
INSTALLATION
FUEL INJECTOR— 2.4L
REMOVAL
INSTALLATION
FUEL INJECTORS— 3.0L
REMOVAL
INSTALLATION
FUEL INJECTOR— 3.3/ 3.8L
REMOVAL
INSTALLATION
ACCELERATOR PEDAL
REMOVAL
INSTALLATION
THROTTLE CABLE
REMOVAL
INSTALLATION
SPECIFICATIONS
TORQUE
FUEL TANK CAPACITY
FUEL INJECTION SYSTEM
GENERAL INFORMATION
INTRODUCTION
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 (WOT) MODE
IGNITION SWITCH OFF MODE
DESCRIPTION AND OPERATION
SYSTEM DIAGNOSIS
CCD BUS
POWERTRAIN CONTROL MODULE (PCM)
AIR CONDITIONING PRESSURE TRANSDUCER— PCM INPUT
AIR CONDITIONING SWITCH SENSE— PCM INPUT
AUTOMATIC SHUTDOWN (ASD) SENSE— PCM INPUT
BATTERY VOLTAGE— PCM INPUT
BRAKE SWITCH— PCM INPUT
CAMSHAFT POSITION SENSOR— PCM INPUT
3.3/ 3.8L
2.4L
CRANKSHAFT POSITION SENSOR— PCM INPUT
3.0/ 3.3/ 3.8L
2.4L
ENGINE COOLANT TEMPERATURE SENSOR— PCM INPUT
3.0/ 3.3/ 3.8L
2.4L
HEATED OXYGEN SENSOR (O2S SENSOR)— PCM INPUT
UPSTREAM HEATED OXYGEN SENSOR
DOWNSTREAM HEATED OXYGEN SENSOR
KNOCK SENSOR— PCM INPUT
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— PCM INPUT
SPEED CONTROL— PCM INPUT
TRANSAXLE PARK/ NEUTRAL SWITCH— PCM INPUT
THROTTLE POSITION SENSOR (TPS)— PCM INPUT
VEHICLE SPEED AND DISTANCE— PCM INPUT
INTAKE AIR TEMPERATURE SENSOR— PCM INPUT (2.4L ONLY)
AIR CONDITIONING (A/ C) CLUTCH RELAY— PCM OUTPUT
GENERATOR FIELD— PCM OUTPUT
AUTOMATIC SHUTDOWN RELAY— PCM OUTPUT
FUEL PUMP RELAY— PCM OUTPUT
STARTER RELAY— PCM OUTPUT
IDLE AIR CONTROL MOTOR— PCM OUTPUT
DUTY CYCLE EVAP CANISTER PURGE SOLENOID— PCM OUTPUT
PROPORTIONAL PURGE SOLENOID
ELECTRONIC EGR TRANSDUCER SOLENOID— PCM OUTPUT
DATA LINK CONNECTOR— PCM OUTPUT
AUTOMATIC TRANSAXLE CONTROL MODULE— PCM OUTPUT
FUEL INJECTORS— PCM OUTPUT
IGNITION COIL— PCM OUTPUT
TORQUE CONVERTER CLUTCH SOLENOID— PCM OUTPUT
MALFUNCTION INDICATOR (CHECK ENGINE) LAMP— PCM OUTPUT
SOLID STATE FAN RELAY— PCM OUTPUT
SPEED CONTROL SOLENOIDS— PCM OUTPUT
TACHOMETER— PCM OUTPUT
THROTTLE BODY
DIAGNOSIS AND TESTING
VISUAL INSPECTION— 2.4L ENGINE
VISUAL INSPECTION— 3.0L ENGINE
VISUAL INSPECTION— 3.3/ 3.8L ENGINES
ASD AND FUEL PUMP RELAYS
OPERATION
TESTING
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
HEATED OXYGEN SENSOR
KNOCK SENSOR
CAMSHAFT AND CRANKSHAFT POSITION SENSOR
ENGINE COOLANT TEMPERATURE SENSOR
THROTTLE POSITION SENSOR
THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE
REMOVAL AND INSTALLATION
THROTTLE BODY
REMOVAL
INSTALLATION
FUEL PUMP RELAY
AUTOMATIC SHUTDOWN (ASD) RELAY
THROTTLE POSITION SENSOR
REMOVAL
INSTALLATION
IDLE AIR CONTROL MOTOR
REMOVAL
INSTALLATION
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— 2.4/ 3.3/ 3.8L
REMOVAL
INSTALLATION
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— 3.0L
REMOVAL
INSTALLATION
PROPORTIONAL PURGE SOLENOID VALVE
REMOVAL
INSTALLATION
POWERTRAIN CONTROL MODULE
REMOVAL
INSTALLATION
CRANKSHAFT POSITION SENSOR
CAMSHAFT POSITION SENSOR
UPSTREAM OXYGEN SENSOR
REMOVAL
INSTALLATION
DOWNSTREAM OXYGEN SENSOR
REMOVAL
INSTALLATION
KNOCK SENSOR
AIR CLEANER ELEMENT
REMOVAL
INSTALLATION
ENGINE COOLANT TEMPERATURE SENSOR— 2.4L
REMOVAL
INSTALLATION
ENGINE COOLANT TEMPERATURE SENSOR— 3.0L
REMOVAL
INSTALLATION
ENGINE COOLANT TEMPERATURE SENSOR— 3.3/ 3.8L
REMOVAL
INSTALLATION
INTAKE AIR TEMPERATURE SENSOR— 2.4L
REMOVAL
INSTALLATION
SPECIFICATIONS
TORQUE
SPECIAL TOOLS
FUEL
FUEL SYSTEM— 2.5L DIESEL ENGINE/ 2.0L GAS ENGINE
GENERAL INFORMATION
GENERAL INFORMATION
INTRODUCTION— 2.5L DIESEL
INTRODUCTION— 2.0L ENGINE
FUEL REQUIREMENTS— 2.5L DIESEL
FUEL REQUIREMENTS— 2.0L ENGINE
GASOLINE/ OXYGENATE BLENDS
FUEL DELIVERY SYSTEM - 2.5L DIESEL ENGINE
DESCRIPTION AND OPERATION
INTRODUCTION
FUEL SYSTEM PRESSURE WARNING
FUEL TANK
FUEL TANK MODULE
FUEL GAUGE SENDING UNIT
FUEL FILTER/ WATER SEPARATOR
FUEL SHUTDOWN SOLENOID
FUEL INJECTION PUMP
FUEL INJECTORS
FUEL TUBES/ LINES/ HOSES AND CLAMPS— LOW-PRESSURE TYPE
QUICK- CONNECT FITTINGS— LOW PRESSURE TYPE
HIGH- PRESSURE FUEL LINES
FUEL DRAIN TUBES
FUEL HEATER
FUEL HEATER RELAY
WASTEGATE (TURBOCHARGER)
DIAGNOSIS AND TESTING
GENERAL INFORMATION
VISUAL INSPECTION
AIR IN FUEL SYSTEM
FUEL HEATER RELAY TEST
FUEL INJECTOR TEST
FUEL INJECTOR SENSOR TEST
FUEL INJECTION PUMP TEST
FUEL SUPPLY RESTRICTIONS
LOW– PRESSURE LINES
HIGH– PRESSURE LINES
FUEL SHUTDOWN SOLENOID TEST
HIGH- PRESSURE FUEL LINE LEAK TEST
WASTEGATE (TURBOCHARGER)
SERVICE PROCEDURES
AIR BLEED PROCEDURES
AIR BLEEDING AT FUEL FILTER
FUEL INJECTION PUMP BLEEDING
HIGH– PRESSURE FUEL LINE BLEEDING
FUEL INJECTION PUMP TIMING
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL
REMOVAL
INSTALLATION
AIR CLEANER ELEMENT
REMOVAL
INSTALLATION
FUEL DRAIN TUBES
FUEL FILTER/ WATER SEPARATOR
DRAINING WATER FROM FILTER BOWL
FUEL FILTER REMOVAL
FUEL FILTER INSTALLATION
FUEL HEATER
FUEL HEATER RELAY
FUEL LEVEL SENSOR
REMOVAL
INSTALLATION
FUEL INJECTION PUMP
REMOVAL
INSTALLATION/ ADJUSTING PUMP TIMING
FUEL INJECTORS
REMOVAL
INSTALLATION
FUEL SHUTDOWN SOLENOID
REMOVAL
INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
FUEL RESERVOIR MODULE
REMOVAL
INSTALLATION
HIGH- PRESSURE LINES
REMOVAL
INSTALLATION
SPECIFICATIONS
FUEL TANK CAPACITY
IDLE SPEED
FUEL INJECTOR FIRING SEQUENCE
FUEL SYSTEM PRESSURE
FUEL DELIVERY SYSTEM-2.0L ENGINE
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM
FUEL PUMP MODULE
ELECTRIC FUEL PUMP
FUEL LEVEL SENSOR
FUEL PRESSURE REGULATOR
FUEL INJECTORS
FUEL TANK
PRESSURE- VACUUM FILLER CAP— 2.0L ENGINE
QUICK- CONNNECT FITTINGS— 2.0L ENGINE
DIAGNOSIS AND TESTING
FUEL PUMP PRESSURE TEST— 2.0L ENGINE
FUEL LEVEL SENSOR— 2.0L ENGINE
FUEL INJECTORS— 2.0L ENGINE
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE PROCEDURE— 2.0L ENGINE
HOSES AND CLAMPS— 2.0L ENGINE
QUICK- CONNNECT FITTINGS— 2.0L ENGINE
REMOVAL AND INSTALLATION
FUEL FILTER— 2.0L ENGINE
FUEL PUMP MODULE— 2.0L ENGINE
FUEL PRESSURE REGULATOR— 2.0L ENGINE
FUEL PRESSURE REGULATOR— 2.0L ENGINE
FUEL LEVEL SENSOR— 2.0L ENGINE
FUEL TANK— 2.0L ENGINE
FUEL INJECTORS
REMOVAL
INSTALLATION
ACCELERATOR PEDAL
TORQUE SPECIFICATION
FUEL INJECTION SYSTEM-2.0L ENGINE
GENERAL INFORMATION
INTRODUCTION— 2.0L ENGINE
MODES OF OPERATION— 2.0L ENGINE
DESCRIPTION AND OPERATION
SYSTEM DIAGNOSIS— 2.0L ENGINE
POWERTRAIN CONTROL MODULE— 2.0L ENGINE
AIR CONDITIONING PRESSURE TRANSDUCER— PCM INPUT— 2.0L ENGINE
AIR CONDITIONING SWITCH SENSE— PCM INPUT— 2.0L ENGINE
AUTOMATIC SHUTDOWN (ASD) SENSE— PCM INPUT— 2.0L ENGINE
BATTERY VOLTAGE— PCM INPUT— 2.0L ENGINE
CAMSHAFT POSITION SENSOR— PCM INPUT— 2.0L ENGINE
CRANKSHAFT POSITION SENSOR— PCM INPUT— 2.0L ENGINE
ENGINE COOLANT TEMPERATURE SENSOR— PCM INPUT— 2.0L ENGINE
HEATED OXYGEN SENSOR— PCM INPUT— 2.0L ENGINE
KNOCK SENSOR— PCM INPUT— 2.0L ENGINE
MANIFOLD ABSOLUTE PRESSURE (MAP SENSOR)— PCM INPUT— 2.0L ENGINE
SPEED CONTROL— PCM INPUT— 2.0L ENGINE
THROTTLE POSITION SENSOR/ IDLE AIR CONTROL MOTOR— PCM INPUT— 2.0L ENGINE
AIR CONDITIONING (A/ C) RELAY— PCM OUTPUT— 2.0L ENGINE
GENERATOR FIELD— PCM OUTPUT— 2.0L ENGINE
AUTOMATIC SHUTDOWN RELAY— PCM OUTPUT— 2.0L ENGINE
FUEL PUMP RELAY— PCM OUTPUT— 2.0L ENGINE
STARTER RELAY— PCM OUTPUT— 2.0L ENGINE
IDLE AIR CONTROL MOTOR— PCM OUTPUT— 2.0L ENGINE
ELECTRONIC EGR TRANSDUCER— PCM OUTPUT— 2.0L ENGINE
DATA LINK CONNECTOR— PCM OUTPUT— 2.0L ENGINE
FUEL INJECTORS— PCM OUTPUT— 2.0L ENGINE
IGNITION COIL— PCM OUTPUT— 2.0L ENGINE
MALFUNCTION INDICATOR (CHECK ENGINE) LAMP— PCM OUTPUT— 2.0L ENGINE
RADIATOR FAN CONTROL MODULE— PCM OUTPUT— 2.0L ENGINE
SPEED CONTROL SOLENOIDS— PCM OUTPUT— 2.0L ENGINE
TACHOMETER— PCM OUTPUT— 2.0L ENGINE
THROTTLE BODY— 2.0L ENGINE
DIAGNOSIS AND TESTING
VISUAL INSPECTION— SOHC
ASD AND FUEL PUMP RELAYS— 2.0L ENGINE
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— 2.0L ENGINE
KNOCK SENSOR— 2.0L ENGINE
CAMSHAFT AND CRANKSHAFT POSITION SENSOR
ENGINE COOLANT TEMPERATURE SENSOR
THROTTLE POSITION SENSOR
THROTTLE BODY MINIMUM AIR FLOW
SPECIFICATIONS
TORQUE
FUEL INJECTION SYSTEM - 2.5L DIESEL ENGINE
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
POWERTRAIN CONTROL MODULE (PCM)
BOOST PRESSURE SENSOR
VEHICLE THEFT ALARM
BATTERY VOLTAGE— PCM INPUT
SENSOR RETURN— PCM INPUT (ANALOG GROUND)
SIGNAL GROUND— PCM INPUT
IGNITION CIRCUIT SENSE— PCM INPUT
START SIGNAL— PCM INPUT
POWER GROUND
NEEDLE MOVEMENT OR INSTRUMENTED FIRST INJECTOR— PCM INPUT
FUEL INJECTOR SENSOR— GROUND
ENGINE COOLANT TEMPERATURE SENSOR— PCM INPUT
ENGINE SPEED SENSOR— PCM INPUT
AIR CONDITIONING (A/ C) CONTROLS— PCM INPUTS
BRAKE SWITCH— PCM INPUT
DATA LINK CONNECTOR— PCM INPUT AND OUTPUT
VEHICLE SPEED SENSOR— PCM INPUT
SPEED CONTROL— PCM INPUTS
DIESEL PCM RELAY— PCM INPUT
FIVE VOLT POWER— PCM OUTPUT
ENGINE COOLANT GAUGE— PCM OUTPUT
ENGINE OIL PRESSURE GAUGE— PCM OUTPUT
GLOW PLUG LAMP— PCM OUTPUT
SPEED CONTROL— PCM OUTPUTS
AIR CONDITIONING RELAY— PCM OUTPUT
FUEL TIMING SOLENOID— PCM OUTPUT
TACHOMETER— PCM OUTPUT
GLOW PLUG RELAY— PCM OUTPUT
GLOW PLUGS
GLOW PLUG CONTROL
EXHAUST GAS RECIRCULATION (EGR) SOLENOID— PCM OUTPUT
DIAGNOSIS AND TESTING
DIESEL DIAGONSTICS
DIESEL PCM RELAY TEST
ENGINE SPEED SENSOR TEST
ENGINE COOLANT TEMPERATURE SENSOR TEST
SENSOR RESISTANCE (OHMS)
GLOW PLUG TEST
GLOW PLUG RELAY TEST
RELAYS— OPERATION/ TESTING
OPERATION
GLOW PLUG CONTROL
TESTING
BOOST PRESSURE SENSOR
VEHICLE SPEED SENSOR TEST
DIAGNOSTIC TROUBLE CODES
REMOVAL AND INSTALLATION
DIESEL PCM RELAY
A/ C CLUTCH RELAY
ENGINE SPEED SENSOR
REMOVAL
INSTALLATION
ENGINE COOLANT TEMPERATURE SENSOR
REMOVAL
INSTALLATION
GLOW PLUGS
REMOVAL
INSTALLATION
GLOW PLUG RELAY
REMOVAL
INSTALLATION
POWERTRAIN CONTROL MODULE (PCM)
REMOVAL
INSTALLATION
VEHICLE SPEED SENSOR
REMOVAL
INSTALLATION
SPECIFICATIONS
GLOW PLUG CURRENT DRAW
TORQUE CHART— 2.5L DIESEL
STEERING
GENERAL INFORMATION
GENERAL INFORMATION
STEERING SYSTEM AND COMPONENT DESCRIPTION
DIAGNOSIS AND TESTING
STEERING SYSTEM DIAGNOSIS CHARTS
STEERING NOISE
BINDING STICKING SEIZED SHAKE SHUDDER VIBRATION
LOW ASSIST, NO ASSIST, HARD STEERING POOR RETURN TO CENTER
LOOSE STEERING
VEHICLE LEADS TO THE SIDE POWER STEERING FLUID LEAK
FOAMY OR MILKY POWER STEERING FLUID
POWER STEERING PUMP
DESCRIPTION AND OPERATION
POWER STEERING PUMP OPERATION
DIAGNOSIS AND TESTING
POWER STEERING PUMP FLOW RATE AND PRESSURE TEST
POWER STEERING PUMP FLOW AND PRESSURE TEST PROCEDURE
SERVICE PROCEDURES
POWER STEERING SYSTEM FLUID LEVEL CHECK
POWER STEERING PUMP INITIAL OPERATION
REMOVAL AND INSTALLATION
2.4 LITER POWER STEERING PUMP
REMOVE
INSTALL
3.0 LITER POWER STEERING PUMP
REMOVE
INSTALL
3.3/ 3.8 LITER POWER STEERING PUMP
REMOVE
INSTALL
POWER STEERING FLUID RESERVOIR TO PUMP SUPPLY HOSE
REMOVE
INSTALL
POWER STEERING FLUID PRESSURE HOSE
REMOVE
INSTALL
POWER STEERING FLUID RETURN HOSE
REMOVE
INSTALL
REMOTE POWER STEERING FLUID RESERVOIR
REMOVE
INSTALL
DISASSEMBLY AND ASSEMBLY
POWER STEERING PUMP PULLEY
DISASSEMBLY
ASSEMBLY
POWER STEERING PUMP FLOW CONTROL VALVE SEAL
DISASSEMBLE
ASSEMBLE
SPECIFICATIONS
POWER STEERING SYSTEM SPECIFICATIONS
POWER STEERING PUMP FASTENER TORQUE SPECIFICATIONS
SPECIAL TOOLS
POWER STEERING PUMP
POWER STEERING GEAR
DESCRIPTION AND OPERATION
STEERING GEAR OPERATION DESCRIPTION
DIAGNOSIS AND TESTING
POWER STEERING GEAR
POWER STEERING PUMP FLOW AND PRESSURE TEST PROCEDURE
REMOVAL AND INSTALLATION
STEERING GEAR
REMOVE
INSTALL
DISASSEMBLY AND ASSEMBLY
STEERING GEAR INNER TIE ROD BOOT
DISASSEMBLE
ASSEMBLE
OUTER TIE ROD END
DISASSEMBLE
ASSEMBLE
SPECIFICATIONS
STEERING GEAR FASTENER TORQUE SPECIFICATIONS
SPECIAL TOOLS
POWER STEERING GEAR
STEERING COLUMN
DESCRIPTION AND OPERATION
STEERING COLUMN DESCRIPTION
DIAGNOSIS AND TESTING
STEERING COLUMN
SERVICE PROCEDURES
STEERING COLUMN SERVICE PROCEDURE WARNINGS
REMOVAL AND INSTALLATION
STEERING COLUMN ASSEMBLY
REMOVE
INSTALL
SPECIFICATIONS
STEERING COLUMN FASTENER TORQUE SPECIFICATIONS
POWER STEERING - 2.5L VM DIESEL
POWER STEERINGÐ 2.5L VM DIESEL
GENERAL INFORMATION
POWER STEERING PUMP
STEERING GEAR OPERATION— RHD and LHD VEHICLES
POWER STEERING GEAR
SERVICE PROCEDURES
POWER STEERING PUMP – INITIAL OPERATION
REMOVAL AND INSTALLATION
POWER STEERING PUMP— 2.5L DIESEL
REMOVAL
INSTALLATION
TRANSAXLE AND POWER TRANSFER UNIT
GENERAL INFORMATION
31TH TRANSAXLE
FLUID LEVEL AND CONDITION
SELECTION OF LUBRICANT
SPECIAL ADDITIVES
DESCRIPTION AND OPERATION
TORQUE CONVERTER CLUTCH
HYDRAULIC CONTROL SYSTEM
PRESSURE SUPPLY SYSTEM
PRESSURE REGULATING VALVES
FLOW CONTROL VALVES
CLUTCHES, BAND SERVOS, AND ACCUMULATOR
GEARSHIFT AND PARKING LOCK CONTROLS
TORQUE CONVERTER CLUTCH SOLENOID WIRING CONNECTOR
GOVERNOR
DIAGNOSIS AND TESTING
THREE SPEED TRANSAXLE DIAGNOSIS AND TESTS
31TH HYDRAULIC TROUBLE CODE CHARTS
ROAD TEST
HYDRAULIC PRESSURE TESTS
TEST ONE (SELECTOR IN 1)
TEST TWO (SELECTOR IN 2)
TEST THREE (SELECTOR IN D)
TEST FOUR (SELECTOR IN REVERSE)
TEST RESULT INDICATIONS
GOVERNOR PRESSURE
THROTTLE PRESSURE
CLUTCH AND SERVO AIR PRESSURE TESTS
FRONT CLUTCH
REAR CLUTCH
KICKDOWN SERVO (FRONT)
LOW AND REVERSE SERVO (REAR)
FLUID LEAKAGE- TRANSAXLE TORQUE CONVERTER HOUSING AREA
TORQUE CONVERTER LEAKAGE
SERVICE PROCEDURES
FLUID AND FILTER CHANGE
30,000 MILE TRANSAXLE OIL CHANGE
SEVERE USAGE SERVICE
FLUID DRAIN AND REFILL
ALUMINUM THREAD REPAIR
FLUSHING COOLERS AND TUBES
COOLER FLUSH USING TOOL 6906A
OIL PUMP VOLUME CHECK
REMOVAL AND INSTALLATION
VEHICLE SPEED SENSOR PINION GEAR
REMOVAL
INSTALLATION
PARK/ NEUTRAL STARTING AND BACK- UP LAMP SWITCH
TEST
REMOVAL
INSTALLATION
TRANSAXLE AND TORQUE CONVERTER REMOVAL
REMOVAL
INSTALLATION
FRONT PUMP OIL SEAL
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
TRANSAXLE
DISASSEMBLY
ASSEMBLY
VALVE BODY RECONDITION
OIL PUMP- RECONDITION
FRONT CLUTCH- RECONDITION
INSPECTION
DISASSEMBLY
ASSEMBLY
REAR CLUTCH- RECONDITION
INSPECTION
DISASSEMBLY
ASSEMBLY
FRONT PLANETARY and ANNULUS GEAR-RECONDITION
LOW/ REVERSE (REAR) SERVO- RECONDITION
DISASSEMBLY ASSEMBLY
ACCUMULATOR- RECONDITION
DISASSEMBLY
ASSEMBLY
KICKDOWN SERVO (CONTROLLED LOAD) -RECONDITION
DISASSEMBLY ASSEMBLY
TRANSFER SHAFT REPAIR
DISASSEMBLY
DETERMINING SHIM THICKNESS
ASSEMBLY
PARKING PAWL
DISASSEMBLY ASSEMBLY
OUTPUT SHAFT REPAIR
DETERMINING SHIM THICKNESS
DIFFERENTIAL REPAIR
DETERMINING SHIM THICKNESS
CLEANING AND INSPECTION
VALVE BODY
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT
THROTTLE PRESSURE LINKAGE ADJUSTMENT
ROD ADJUSTMENT PROCEDURE
BAND ADJUSTMENT
KICKDOWN BAND (FRONT)
LOW/ REVERSE BAND (REAR)
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS
LINE PRESSURE
THROTTLE PRESSURE
BEARING ADJUSTMENT PROCEDURES
OUTPUT SHAFT BEARING
DIFFERENTIAL BEARING
TRANSFER SHAFT BEARING
DIFFERENTIAL BEARING SHIM CHART
SCHEMATICS AND DIAGRAMS
31TH TRANSAXLE HYDRAULIC SCHEMATIC
SPECIFICATIONS
31TH AUTOMATIC TRANSAXLE
31TH TORQUE SPECIFICATIONS
SPECIAL TOOLS
31TH AUTOMATIC TRANSAXLE
GENERAL INFORMATION
41TE FOUR SPEED AUTOMATIC TRANSAXLE
TRANSAXLE IDENTIFICATION
OPERATION
FLUID LEVEL AND CONDITION
SELECTION OF LUBRICANT
SPECIAL ADDITIVES
DESCRIPTION AND OPERATION
CLUTCH AND GEAR
HYDRAULICS
SOLENOIDS
SENSORS
ELECTRONICS
ADAPTIVE CONTROLS
TORQUE MANAGEMENT
ON- BOARD DIAGNOSTICS
TRANSMISSION CONTROL MODULE
GEARSHIFT AND PARKING LOCK CONTROLS
TRANSMISSION RANGE SENSOR
SHIFT POSITION INDICATOR
DIAGNOSIS AND TESTING
41TE TRANSAXLE GENERAL DIAGNOSIS
ROAD TEST
HYDRAULIC PRESSURE TESTS
TEST ONE- SELECTOR IN LOW
TEST TWO- SELECTOR IN DRIVE
TEST THREE- OVERDRIVE CLUTCH CHECK
TEST FOUR- SELECTOR IN CIRCLE DRIVE, OVERDRIVE GEAR
TEST FIVE- SELECTOR IN CIRCLE DRIVE, OVERDRIVE
TEST SIX- SELECTOR IN REVERSE
TEST RESULT INDICATIONS
CLUTCH AIR PRESSURE TESTS
OVERDRIVE CLUTCH
REVERSE CLUTCH
2/ 4 CLUTCH
LOW/ REVERSE CLUTCH
UNDERDRIVE CLUTCH
FLUID LEAKAGE- TORQUE CONVERTER HOUSING AREA
TORQUE CONVERTER LEAKAGE
SHIFT POSITION INDICATOR
SERVICE PROCEDURES
FLUID AND FILTER CHANGE
30,000 MILE TRANSAXLE OIL CHANGE
SEVERE USAGE SERVICE
FLUID DRAIN AND REFILL
ALUMINUM THREAD REPAIR
FLUSHING COOLERS AND TUBES
COOLER FLUSH USING TOOL 6906A
OIL PUMP VOLUME CHECK
TRANSAXLE QUICK LEARN PROCEDURE
PINION FACTOR PROCEDURE
REMOVAL AND INSTALLATION
GEARSHIFT CABLE
REMOVAL
INSTALLATION
ADJUSTMENT
MANUAL VALVE LEVER (SHIFT LEVER)
REMOVAL
INSTALLATION
SOLENOID ASSEMBLY- REPLACE
TRANSMISSION RANGE SENSOR
REMOVAL
INSTALLATION
SPEED SENSOR- INPUT
SPEED SENSOR- OUTPUT
TRANSMISSION CONTROL MODULE
REMOVAL
INSTALLATION
VALVE BODY
REMOVAL
INSTALLATION
TRANSAXLE
REMOVAL
INSTALLATION
OIL PUMP SEAL
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
VALVE BODY RECONDITION
TRANSAXLE DISASSEMBLE
OIL PUMP INSPECTION
INPUT CLUTCHES- RECONDITION
DISASSEMBLY
ASSEMBLY
TRANSAXLE ASSEMBLE
OUTPUT GEAR BEARING ADJUSTMENT
OUTPUT GEAR BEARING SHIM CHART
TRANSFER SHAFT BEARING
TRANSFER SHAFT BEARING SHIM CHART
LOW/ REVERSE REACTION PLATE CHART
DETERMINING No. 4 THRUST PLATE THICKNESS INPUT SHAFT END PLAY
NO. 4 THRUST PLATE CHART
DIFFERENTIAL REPAIR
DISASSEMBLE
CHECKING SIDE GEAR END PLAY
ASSEMBLE
DIFFERENTIAL SERVICE TOOLS
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT
DIFFERENTIAL BEARING SHIM CHART
CLEANING AND INSPECTION
CLEANING VALVE BODY
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT
SCHEMATICS AND DIAGRAMS
41TE TRANSAXLE HYDRAULIC SCHEMATICS
SPECIFICATIONS
41TE AUTOMATIC TRANSAXLE
41TE TORQUE SPECIFICATIONS
SPECIAL TOOLS
41TE AUTOMATIC TRANSAXLE
GENERAL INFORMATION
POWER TRANSFER UNIT
DIAGNOSIS AND TESTING
SEAL IDENTIFICATION
FLUID LEAK DIAGNOSIS
REMOVAL AND INSTALLATION
POWER TRANSFER UNIT (P. T. U.)
REMOVAL
INSTALLATION
END COVER SEAL
INPUT SHAFT SEAL
REMOVAL
INSTALLATION
DIFFERENTIAL CARRIER SEAL
REMOVAL
INSTALLATION
REAR COVER O- RING
REMOVAL
INSTALLATION
POWER TRANSFER UNIT OUTPUT SEAL
REMOVAL
INSTALLATION
INPUT SHAFT COVER SEAL
REMOVAL
INSTALLATION
HALF SHAFT INNER SEAL
REMOVAL
INSTALLATION
INPUT SHAFT END SEAL
REMOVAL
INSTALLATION
OUTER HALF SHAFT SEAL
REMOVAL
INSTALLATION
END COVER BALL BEARING
REMOVAL
INSTALLATION
ADJUSTMENTS
OUTPUT FLANGE SHIM SELECTION
SPECIFICATIONS
TORQUE
SPECIAL TOOLS
SDP POWER TRANSFER UNIT
A– 598 MANUAL TRANSAXLE
GENERAL INFORMATION
A- 598 MANUAL TRANSAXLE
A- 558 MANUAL TRANSAXLE— RHD VEHICLES
TRANSAXLE IDENTIFICATION INFORMATION
TRANSAXLE IDENTIFICATION INFORMATION— RHD VEHICLES
SELECTION OF LUBRICANT
SELECTION OF LUBRICANT— RHD VEHICLES
SPECIAL ADDITIVES
SPECIAL ADDITIVES— RHD VEHICLES
GEAR RATIOS
GEAR RATIOS— RHD VEHICLES
GEARSHIFT PATTERN
GEARSHIFT PATTERN— RHD VEHICLES
DESCRIPTION AND OPERATION
GEARSHIFT LEVERS
AXLE SEALS
DIAGNOSIS AND TESTING
COMMON PROBLEM CAUSES
HARD SHIFTING
NOISY OPERATION
SLIPS OUT OF GEAR
LOW LUBRICANT LEVEL
CLUTCH PROBLEMS
SERVICE PROCEDURES
FLUID DRAIN AND FILL
TRANSAXLE FLUID DRAIN
TRANSAXLE FLUID FILL
FLUID DRAIN AND FILL— RHD VEHICLES
TRANSAXLE FLUID DRAIN
TRANSAXLE FLUID FILL
REMOVAL AND INSTALLATION
GEARSHIFT KNOB
REMOVAL
INSTALLATION
GEARSHIFT BOOT
REMOVAL
INSTALLATION
GEARSHIFT BOOT
REMOVAL
INSTALLATION
GEARSHIFT CABLES
REMOVAL
INSTALLATION
GEARSHIFT CABLES— RHD VEHICLES
REMOVAL
INSTALLATION
GEARSHIFT MECHANISM REPLACEMENT
REMOVAL
INSTALLATION
GEARSHIFT MECHANISM REPLACEMENT— RHD VEHICLES
REMOVAL
INSTALLATION
VEHICLE SPEED SENSOR DRIVE GEAR
REMOVAL
INSTALLATION
BACK- UP LAMP SWITCH
REMOVAL
INSTALLATION
CRANKSHAFT POSITION SENSOR — 2.5L VM DIESEL
REMOVAL
INSTALLATION
CROSSOVER LEVER
REMOVAL
INSTALLATION
SELECTOR LEVER
REMOVAL
INSTALLATION
AXLE SEALS
EXTENSION HOUSING AXLE SEAL
DIFFERENTIAL BEARING RETAINER AXLE SEAL
SHIFT SHAFT SEALS
REMOVAL
INSTALLATION
TRANSAXLE
REMOVAL
INSTALLATION
INPUT SHAFT FRONT BEARING RETAINER
REMOVAL
INSTALLATION
INPUT SHAFT SEAL
REMOVAL
INSTALLATION
A- 558 TRANSAXLE ASSEMBLY— RHD VEHICLES
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
TRANSAXLE
DISASSEMBLY
ASSEMBLY
INPUT SHAFT
DISASSEMBLY
ASSEMBLY
INTERMEDIATE SHAFT
DISASSEMBLY
ASSEMBLY
DIFFERENTIAL
DIFFERENTIAL BEARINGS
RING GEAR
DIFFERENTIAL GEARS
SYNCHRONIZER
DISASSEMBLY
ASSEMBLY
SHIFT COVER
DISASSEMBLY
ASSEMBLY
TRANSAXLE CASE
INTERMEDIATE SHAFT FRONT BEARING CUP
INPUT SHAFT FRONT BEARING
SHIFT RAIL BUSHINGS
REVERSE SHIFT LEVER
CLEANING AND INSPECTION
TRANSAXLE
SYNCHRONIZER
CLEAN
INSPECT
ADJUSTMENTS
GEARSHIFT CROSSOVER CABLE
GEARSHIFT CROSSOVER CABLE
BEARING ADJUSTMENT PROCEDURE
GENERAL RULES ON SERVICING BEARINGS
INTERMEDIATE SHAFT BEARING PRELOAD
SPECIFICATIONS
A- 598 (T- 750) MANUAL TRANSAXLE
NV T750 (A- 598) MANUAL TRANSAXLE FLUID FILL
A- 558 MANUAL TRANSAXLE— RHD VEHICLES
SPECIAL TOOLS
A- 558 MANUAL TRANSAXLE FLUID FILL
A- 598 (T- 750) MANUAL TRANSAXLE
A- 558 MANUAL TRANSAXLE RHD VEHICLES
TIRES AND WHEELS
DESCRIPTION AND OPERATION
TIRE INFORMATION
TIRE IDENTIFICATION
TIRE CHAINS
RADIAL-PLY TIRES
SPARE TIRE (TEMPORARY)
TIRE INFLATION PRESSURES
TIRE PRESSURE FOR HIGH-SPEED DRIVING
REPLACEMENT TIRES
DIAGNOSIS AND TESTING
PRESSURE GAUGES
TREAD WEAR INDICATORS
TIRE WEAR PATTERNS
TIRE NOISE OR VIBRATION
LEAD CORRECTION CHART
LEAD CORRECTION CHART
SERVICE PROCEDURES
TIRE AND WHEEL ROTATION (NON-DIRECTIONAL THREAD PATTERN)
REPAIRING TIRE LEAKS
TIRE AND WHEEL MATCH MOUNTING
CLEANING AND INSPECTION
CLEANING TIRES
SPECIFICATIONS
TIRE SPECIFICATIONS
DESCRIPTION AND OPERATION
WHEEL INFORMATION
DIAGNOSIS AND TESTING
WHEEL INSPECTION
TIRE AND WHEEL RUNOUT
METHOD 1 (RELOCATE WHEEL ON HUB)
METHOD 2 (RELOCATE TIRE ON WHEEL)
SERVICE PROCEDURES
WHEEL INSTALLATION
TIRE AND WHEEL BALANCE
SPECIFICATIONS
WHEEL SPECIFICATIONS
BODY
GENERAL INFORMATION
SAFETY PRECAUTIONS AND WARNINGS
GENERAL INFORMATION
PAINT CODE
BASE COAT/ CLEAR COAT FINISH
WET SANDING, BUFFING, AND POLISHING
PAINTED SURFACE TOUCH- UP
TOUCH- UP PROCEDURE
AFTERMARKET PAINT REPAIR PRODUCTS
EXTERIOR COLORS
INTERIOR COLORS
DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS
REMOVAL AND INSTALLATION
WINDSHIELD
WINDSHIELD REMOVAL – EXTERIOR METHOD
WINDSHIELD REMOVAL – INTERIOR METHOD
WINDSHIELD INSTALLATION
BODY SIDE/ SLIDING DOOR STATIONARY GLASS
REMOVAL
INSTALLATION
REAR WINDOW
REAR WINDOW REMOVAL – EXTERIOR METHOD
REAR WINDOW REMOVAL – INTERIOR METHOD
REAR WINDOW INSTALLATION
REMOVAL AND INSTALLATION
ARM REST
REMOVAL
INSTALLATION
BENCH SEAT BACK COVER
REMOVAL
INSTALLATION
BENCH SEAT BACK HINGE
REMOVAL
INSTALLATION
SYNCHRONIZING CABLE ADJUSTMENT
BENCH SEAT BACK HINGE COVERS
REMOVAL
INSTALLATION
BENCH SEAT RISER – FIRST REAR
REMOVAL
INSTALLATION
BENCH SEAT RISER – SECOND REAR
REMOVAL
INSTALLATION
BENCH SEAT TRACK – SECOND REAR
REMOVAL
INSTALLATION
BUCKET SEAT BACK
REMOVAL
INSTALLATION
BUCKET SEAT BACK ASSIST STRAP
REMOVAL
INSTALLATION
BUCKET SEAT CUSHION PAN
REMOVAL
INSTALLATION
BUCKET SEAT CUSHION SIDE COVER
REMOVAL
INSTALLATION
BUCKET SEAT RECLINER – MANUAL
REMOVAL
INSTALLATION
BUCKET SEAT RECLINER – POWER
REMOVAL
INSTALLATION
BUCKET SEAT RISER – MANUAL TRACK
REMOVAL
INSTALLATION
BUCKET SEAT TRACK – MANUAL
REMOVAL
INSTALLATION
BUCKET SEAT TRACK – POWER
REMOVAL
INSTALLATION
BUCKET SEAT TRACK FRONT COVER – POWER
REMOVAL
INSTALLATION
BUCKET SEAT TRACK REAR COVER – POWER
REMOVAL
INSTALLATION
CHILD RESTRAINT SEAT MODULE
REMOVAL
INSTALLATION
HEAD RESTRAINT – BENCH SEAT
REMOVAL
INSTALLATION
HEAD RESTRAINT – BUCKET SEAT
REMOVAL
INSTALLATION
HEAD RESTRAINT SLEEVE
REMOVAL
INSTALLATION
HEATED SEAT HEATING ELEMENT
HEATED SEAT MODULE
REMOVAL
INSTALLATION
HEATED SEAT SWITCH
REMOVAL
INSTALLATION
MECHANICAL LUMBAR HANDLE ASSEMBLY
REMOVAL
INSTALLATION
PLASTIC GROCERY BAG RETAINER
REMOVAL
INSTALLATION
POWER SEAT SWITCH
REMOVAL
INSTALLATION
RECLINER HANDLE – MANUAL
REMOVAL
INSTALLATION
UNDER SEAT STORAGE BIN
REMOVAL
INSTALLATION
UNDER SEAT STORAGE BIN GUIDE
REMOVAL
INSTALLATION
UNDER SEAT STORAGE BIN LOCK/ LATCH
REMOVAL
INSTALLATION
DIAGNOSIS AND TESTING
WATER LEAKS
VISUAL INSPECTION BEFORE WATER LEAK TESTS
WATER LEAK TESTS
WATER LEAK DETECTION
WIND NOISE
VISUAL INSPECTION BEFORE TESTS
SERVICE PROCEDURES
HEAT STAKING
REMOVAL AND INSTALLATION
A- PILLAR LOWER EXTENSION TRIM
REMOVAL
INSTALLATION
A- PILLAR TRIM PANEL
REMOVAL
INSTALLATION
COWL COVER
REMOVAL
INSTALLATION
COWL TRIM
REMOVAL
INSTALLATION
FLOOR CARPET
REMOVAL
INSTALLATION
FRONT DOOR
REMOVAL
INSTALLATION
FRONT DOOR APPLIQUE
REMOVAL
INSTALLATION
FRONT DOOR CHECK STRAP
REMOVAL
INSTALLATION
FRONT DOOR FRAME CLOSEOUT MOLDINGS
REMOVAL – A- PILLAR, HEADER, OR B- PILLAR
INSTALLATION – A- PILLAR, HEADER, OR B- PILLAR
FRONT DOOR GLASS
REMOVAL
INSTALLATION
FRONT DOOR GLASS RUN WEATHER- STRIP
REMOVAL
INSTALLATION
FRONT DOOR HINGE
REMOVAL
INSTALLATION
FRONT DOOR INNER BELT MOLDING
REMOVAL
INSTALLATION
FRONT DOOR LATCH
REMOVAL
INSTALLATION
FRONT DOOR LATCH STRIKER
REMOVAL
INSTALLATION
FRONT DOOR LOCK CYLINDER
REMOVAL
INSTALLATION
FRONT DOOR OUTER BELT MOLDING
REMOVAL
INSTALLATION
FRONT DOOR OUTSIDE HANDLE
REMOVAL
INSTALLATION
FRONT DOOR REFLECTOR
REMOVAL
INSTALLATION
FRONT DOOR SILL PLATE
REMOVAL
INSTALLATION
FRONT DOOR TRIM PANEL
REMOVAL
INSTALLATION
FRONT DOOR WEATHER- STRIP
REMOVAL
INSTALLATION
FRONT DOOR WINDOW CRANK
REMOVAL
INSTALLATION
FRONT DOOR WINDOW REGULATOR
REMOVAL
INSTALLATION
FRONT SEAT
REMOVAL
INSTALLATION
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL
INSTALLATION
FUEL FILL DOOR BLOCKER LATCH
REMOVAL
INSTALLATION
FUEL FILL DOOR BLOCKER LATCH STRIKER
REMOVAL
INSTALLATION
FUEL FILL DOOR BLOCKER LOCKOUT LINK
REMOVAL
INSTALLATION
FUEL FILLER HOUSING – WITH BLOCKER LATCH
REMOVAL
INSTALLATION
GRILLE
REMOVAL
INSTALLATION
HEADLINING
REMOVAL
INSTALLATION
HOOD
REMOVAL
INSTALLATION
HOOD HINGE
REMOVAL
INSTALLATION
ADJUSTMENTS
SLIDING DOOR ADJUSTMENTS
PRELIMINARY CHECKS
UP/ DOWN ADJUSTMENT
FORE/ AFT ADJUSTMENT
SEAL COMPRESSION
STABILIZER ADJUSTMENT
BODY 1
REMOVAL AND INSTALLATION
HEAD RESTRAINT
REMOVAL
INSTALLATION
HEAD RESTRAINT ESCUTCHEON
REMOVAL
INSTALLATION
HEAD RESTRAINT SLEEVE
REMOVAL
INSTALLATION
BENCH SEAT BACK COVER
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION
GEARSHIFT CONSOLE
REMOVAL
INSTALLATION
LIFTGATE CHMSL ACCESS PANEL
REMOVAL
INSTALLATION
HEATING AND AIR CONDITIONING
GENERAL INFORMATION
INTRODUCTION
SAFETY PRECAUTIONS AND WARNINGS
DESCRIPTION AND OPERATION
AIR DISTRIBUTION DUCTS
A/ C PRESSURE TRANSDUCER
A/ C SERVICE PORTS
REAR BLOWER SPEED SWITCH
COMPRESSOR HIGH-PRESSURE RELIEF VALVE
CONDENSATE DRAIN
ENGINE COOLING SYSTEM REQUIREMENTS
EVAPORATOR PROBE
HANDLING TUBING AND FITTINGS
HVAC CONTROL MODULE
SIDE DOOR HEATER A/ C OUTLETS
SIDE WINDOW DEMISTER
SYSTEM AIRFLOW
SYSTEM OIL LEVEL
REFRIGERANT OIL LEVEL CHECK
SERVICING REFRIGERANT OIL LEVEL
DIAGNOSIS AND TESTING
ACTUATOR CALIBRATION/ DIAGNOSTICS AND COOLDOWN TEST
GENERAL INFORMATION
ACTUATOR CALIBRATION
REFRIGERANT OIL CAPACITIES
DIAGNOSTICS
COOLDOWN TEST
CALIBRATION/ COOLDOWN LED DISPLAY CODES
CALIBRATION/ DIAGNOSTICS TEST ENTRY
CALIBRATION/ COOLDOWN LED DISPLAY CODES
COOLDOWN TEST ENTRY
CALIBRATION DIAGNOSTICS AND COOLDOWN ABORT
EEPROM DATA
ACTUATOR CALIBRATION AND DIAGNOSTICS
FAIL CODES/ LEVEL DISPLAY
WIPE BUTTON LED
LEVEL 1– FAILURE CODE VALUES (INTERMITTENT WIPE BUTTON LED)
TEMPERATURE AND MODE POTENTIOMETER DIAGNOSTICS
POTENTIOMETER VS. POSITION AND FLASH RATE
EVAPORATOR PROBE TEMPERATURE DIAGNOSTICS
HVAC CONTROL DIAGNOSTIC CONDITIONS
A/ C PERFORMANCE TEST
PERFORMANCE TEST PROCEDURE
A/ C PRESSURE TRANSDUCER
A/ C PERFORMANCE TEMPERATURES
A/ C PRESSURE TRANSDUCER VOLTAGE
BLOWER MOTOR AND WHEEL ASSEMBLY
VIBRATION AND/ OR NOISE DIAGNOSIS
COMPRESSOR NOISE DIAGNOSIS
COMPRESSOR CLUTCH/ COIL
TESTS
EXPANSION VALVE
TESTS
HEATER PERFORMANCE TEST
PRE-DIAGNOSTIC PREPARATIONS
MAXIMUM HEATER OUTPUT: TEST AND ACTION
TEMPERATURE REFERENCE TABLE
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT
TEMPERATURE CONTROL
SYSTEM CHARGE LEVEL TEST
SERVICE PROCEDURES
R-134a REFRIGERANT
CHARGING REFRIGERANT SYSTEM
EVACUATING REFRIGERANT SYSTEM
THERMOCOUPLE PROBE
STICKING HVAC CONTROL MODULE PUSH BUTTONS
SYSTEM LEAK CHECKING
EMPTY REFRIGERANT SYSTEM LEAK TEST
LOW REFRIGERANT LEVEL LEAK TEST
REMOVAL AND INSTALLATION
A/ C PRESSURE TRANSDUCER
REMOVAL
INSTALLATION
A/ C SERVICE PORTS
REMOVAL
INSTALLATION
BLEND-AIR DOOR ACTUATOR
REMOVAL
INSTALLATION
BLOWER MOTOR AND WHEEL ASSEMBLY
REMOVAL
INSTALLATION
BLOWER MOTOR RESISTOR BLOCK
REMOVAL
INSTALLATION
BLOWER MOTOR WHEEL
COMPRESSOR
REMOVAL
INSTALLATION
COMPRESSOR CLUTCH/ COIL
REMOVAL
INSTALLATION
CLUTCH BREAK-IN
CONDENSER ASSEMBLY
REMOVAL
INSTALLATION
DISCHARGE LINE
REMOVAL
INSTALLATION
EVAPORATOR PROBE
REMOVAL
INSTALLATION
EXPANSION VALVE
REMOVAL
INSTALLATION
FILTER-DRIER ASSEMBLY
REMOVAL
INSTALLATION
HEATER A/ C UNIT HOUSING
REMOVAL
INSTALLATION
HEATER CORE
REMOVAL
INSTALLATION
HEATER HOSES
REMOVAL
INSTALLATION
LIQUID LINE
REMOVAL
INSTALLATION
MODE DOOR ACTUATOR
REMOVAL
INSTALLATION
SIDE WINDOW DEMISTER DUCTS
LEFT SIDE
RIGHT SIDE
SUCTION LINE
REMOVAL
INSTALLATION
RECIRC DOOR ACTUATOR
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
HEATER A/ C UNIT RECONDITION
DISASSEMBLY - EVAPORATOR HOUSING
ASSEMBLY - EVAPORATOR HOUSING
DISASSEMBLY - DISTRIBUTION HOUSING
ASSEMBLY - DISTRIBUTION HOUSING
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
REAR BLOWER RESISTOR BLOCK
REAR HEATER AND A/ C LINES
SYSTEM OPERATION
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
REMOVAL AND INSTALLATION
AIR DISTRIBUTION DUCT- A/ C
REMOVAL
INSTALLATION
AIR DISTRIBUTION DUCT- HEATER
REMOVAL
INSTALLATION
EVAPORATOR AND EXPANSION VALVE
REMOVAL
INSTALLATION
REAR AIR CONDITIONING LINES
REMOVAL
INSTALLATION
REAR HEATER A/ C AIR OUTLETS
REMOVAL
INSTALLATION
REAR HEATER- A/ C AUXILIARY CONDENSER
REMOVAL
INSTALLATION
REAR HEATER A/ C BLOWER MOTOR
REMOVAL
INSTALLATION
REAR HEATER- A/ C CONTROL ILLUMINATION BULB
REMOVAL
INSTALLATION
REAR HEATER A/ C UNIT
REMOVAL
INSTALLATION
REAR HEATER CORE
REMOVAL
INSTALLATION
REAR HEATER LINES
REMOVAL
INSTALLATION
MODE DOOR
REMOVAL
INSTALLATION
MODE DOOR ACTUATOR
REMOVAL
INSTALLATION
HEATING AND AIR CONDITIONING 1
GENERAL INFORMATION
INTRODUCTION
SAFETY PRECAUTIONS AND WARNINGS
DESCRIPTION AND OPERATION
AIR DISTRIBUTION DUCTS
A/ C PRESSURE TRANSDUCER
A/ C SERVICE PORTS
COMPRESSOR
COMPRESSOR HIGH- PRESSURE RELIEF VALVE
CONDENSATE DRAIN
ENGINE COOLING SYSTEM REQUIREMENTS
EVAPORATOR PROBE
HANDLING TUBING AND FITTINGS
HVAC CONTROL MODULE
SIDE DOOR HEATER A/ C OUTLETS
SIDE WINDOW DEMISTER
SYSTEM AIRFLOW
SYSTEM OIL LEVEL
REFRIGERANT OIL LEVEL CHECK
REFRIGERANT OIL CAPACITIES
SERVICING REFRIGERANT OIL LEVEL
DIAGNOSIS AND TESTING
ACTUATOR CALIBRATION/ DIAGNOSTICS AND COOLDOWN TEST
GENERAL INFORMATION
ACTUATOR CALIBRATION
REFRIGERANT OIL CAPACITIES
DIAGNOSTICS
COOLDOWN TEST
CALIBRATION/ COOLDOWN LED DISPLAY CODES
CALIBRATION/ DIAGNOSTICS TEST ENTRY
COOLDOWN TEST ENTRY
CALIBRATION DIAGNOSTICS AND COOLDOWN ABORT
EEPROM DATA
ACTUATOR CALIBRATION AND DIAGNOSTICS
FAIL CODES/ LEVEL DISPLAY
TEMPERATURE AND MODE POTENTIOMETER DIAGNOSTICS
EVAPORATOR PROBE TEMPERATURE DIAGNOSTICS
WIPE BUTTON LED
LEVEL 1– FAILURE CODE VALUES (INTERMITTENT WIPE BUTTON LED)
POTENTIOMETER VS. POSITION AND FLASH RATE
HVAC CONTROL DIAGNOSTIC CONDITIONS
A/ C PERFORMANCE TEST
PERFORMANCE TEST PROCEDURE
A/ C PRESSURE TRANSDUCER
BLOWER MOTOR AND WHEEL ASSEMBLY
VIBRATION AND/ OR NOISE DIAGNOSIS
COMPRESSOR NOISE DIAGNOSIS
COMPRESSOR CLUTCH/ COIL
TESTS
EXPANSION VALVE
TESTS
HEATER PERFORMANCE TEST
PRE- DIAGNOSTIC PREPARATIONS
MAXIMUM HEATER OUTPUT: TEST AND ACTION
TEMPERATURE REFERENCE CHART
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT
TEMPERATURE CONTROL
SYSTEM CHARGE LEVEL TEST
SERVICE PROCEDURES
R-134a REFRIGERANT
CHARGING REFRIGERANT SYSTEM
EVACUATING REFRIGERANT SYSTEM
THERMOCOUPLE PROBE
STICKING HVAC CONTROL MODULE PUSH BUTTONS
SYSTEM LEAK CHECKING
EMPTY REFRIGERANT SYSTEM LEAK TEST
LOW REFRIGERANT LEVEL LEAK TEST
REMOVAL AND INSTALLATION
A/ C PRESSURE TRANSDUCER
REMOVAL
INSTALLATION
A/ C SERVICE PORTS
REMOVAL
INSTALLATION
BLEND- AIR DOOR ACTUATOR
REMOVAL
INSTALLATION
BLOWER MOTOR AND WHEEL ASSEMBLY
REMOVAL
INSTALLATION
BLOWER MOTOR RESISTOR BLOCK
REMOVAL
INSTALLATION
BLOWER MOTOR WHEEL
COMPRESSOR (2.5L TURBO DIESEL)
REMOVAL
INSTALLATION
CONDENSER ASSEMBLY
REMOVAL
INSTALLATION
DISCHARGE LINE
REMOVAL
INSTALLATION
EVAPORATOR PROBE
REMOVAL
INSTALLATION
EXPANSION VALVE
REMOVAL
INSTALLATION
FILTER- DRIER ASSEMBLY
REMOVAL
INSTALLATION
HEATER A/ C UNIT HOUSING
REMOVAL
INSTALLATION
HEATER CORE
REMOVAL
INSTALLATION
HEATER HOSES
REMOVAL
INSTALLATION
LIQUID LINE
REMOVAL
INSTALLATION
MODE DOOR ACTUATOR
REMOVAL
INSTALLATION
SIDE WINDOW DEMISTER DUCTS
LEFT SIDE
RIGHT SIDE
SUCTION LINE
REMOVAL
INSTALLATION
RECIRC DOOR ACTUATOR
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
HEATER A/ C UNIT RECONDITION
DISASSEMBLY— EVAPORATOR HOUSING
ASSEMBLY— EVAPORATOR HOUSING
DISASSEMBLY— DISTRIBUTION HOUSING
ASSEMBLY— DISTRIBUTION HOUSING
EMISSION CONTROL SYSTEMS
GENERAL INFORMATION
SYSTEM DESCRIPTION
DESCRIPTION AND OPERATION
MALFUNCTION INDICATOR LAMP (MIL)
STATE DISPLAY TEST MODE
STATE DISPLAY INPUTS AND OUTPUTS
STATE DISPLAY SENSORS
CIRCUIT ACTUATION TEST MODE
DIAGNOSTIC TROUBLE CODES
BULB CHECK
OBTAINING DTC'S USING DRB SCAN TOOL
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS
MONITORED SYSTEMS
HEX 66, and 7A—OXYGEN SENSOR (O2S) MONITOR
HEX 67, 69, 7C, and 7D—OXYGEN SENSOR HEATER MONITOR
HEX 2E—EGR MONITOR
HEX 6A,6B, 6C, 6D, 6E, AE, and AF—MISFIRE MONITOR
HEX 76, 77, 78, and 79—FUEL SYSTEM MONITOR
HEX 70, and B4 CATALYST MONITOR
HEX A0, A1, B7, and B8 LEAK DETECTION PUMP MONITOR
TRIP DEFINITION
COMPONENT MONITORS
NON-MONITORED CIRCUITS
FUEL PRESSURE
SECONDARY IGNITION CIRCUIT
CYLINDER COMPRESSION
EXHAUST SYSTEM
FUEL INJECTOR MECHANICAL MALFUNCTIONS
EXCESSIVE OIL CONSUMPTION
THROTTLE BODY AIR FLOW
VACUUM ASSIST
PCM SYSTEM GROUND
PCM CONNECTOR ENGAGEMENT
HIGH AND LOW LIMITS
LOAD VALUE
DESCRIPTION AND OPERATION
EVAPORATION CONTROL SYSTEM
ROLLOVER VALVE
EVAPORATIVE (EVAP) CANISTER
PROPORTIONAL PURGE SOLENOID
PRESSURE-VACUUM FILLER CAP
LEAK DETECTION PUMP
POSITIVE CRANKCASE VENTILATION (PCV) SYSTEMS
PCV VALVE
CRANKCASE VENT FILTER
VEHICLE EMISSION CONTROL INFORMATION LABEL
DIAGNOSIS AND TESTING
LEAK DETECTION PUMP
PCV VALVE TEST
ROLLOVER VALVES
REMOVAL AND INSTALLATION
LEAK DETECTION PUMP REPLACEMENT
REMOVAL
INSTALLATION
DESCRIPTION AND OPERATION
GENERAL INFORMATION
DIAGNOSIS AND TESTING
EGR SYSTEM ON-BOARD DIAGNOSTICS
EGR SYSTEM TEST
EGR GAS FLOW TEST
EGR VALVE LEAKAGE TEST
EGR VALVE CONTROL (TRANSDUCER) TEST
TESTING ELECTRICAL SOLENOID PORTION OF VALVE
TESTING VACUUM TRANSDUCER PORTION OF VALVE
REMOVAL AND INSTALLATION
EGR VALVE SERVICE—3.0L ENGINES
REMOVAL
INSTALLATION
EGR VALVE SERVICE—3.3/3.8L ENGINES
REMOVAL
INSTALLATION
EGR TUBE SERVICE—3.0L ENGINES
REMOVAL
INSTALLATION
EGR TUBE SERVICE—3.3/3.8L ENGINES
REMOVAL
INSTALLATION
SPECIAL TOOLS
EMISSION CONTROL SYSTEM
EMISSION CONTROL SYSTEM 1
GENERAL INFORMATION
SYSTEM DESCRIPTION 2.5L DIESEL ENGINE
MONITORED CIRCUITS
NON– MONITORED CIRCUITS
HIGH AND LOW LIMITS
DESCRIPTION AND OPERATION
DIAGNOSTIC TROUBLE CODES
ACCESSING DIAGNOSTIC TROUBLE CODES
ERASING TROUBLE CODES
DESCRIPTION AND OPERATION
VACUUM HOSE ROUTING SCHEMATIC
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
GENERAL INFORMATION
EGR SYSTEM OPERATION
DIAGNOSIS AND TESTING
EGR GAS FLOW TEST
ELECTRIC VACUUM MODULATOR (EVM) TEST
VACUUM TEST
REMOVAL AND INSTALLATION
EGR VALVE
REMOVAL
INSTALLATION
EGR TUBE
REMOVAL
INSTALLATION
ELECTRIC VACUUM MODULATOR (EVM)
REMOVAL
INSTALLATION
SPECIFICATIONS
TORQUE CHART— 2.5L DIESEL
GENERAL INFORMATION
GENERAL INFORMATION
POSITIVE CRANKCASE VENTILATION SYSTEM (PCV) SYSTEM— 2.0L ENGINE
REMOVAL AND INSTALLATION
EGR VALVE
REMOVAL
INSTALLATION
EGR TUBE
REMOVAL
INSTALLATION
TORQUE
