1996, Jeep Grand Cherokee Shop Manual
1996 ZJ Jeep Grand Cherokee
Service Manual and Supplement in high quality PDF format.
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Full list of manual chapters:
LUBRICATION AND MAINTENANCE
GENERAL INFORMATION
GENERAL INFORMATION
INTRODUCTION
PARTS AND LUBRICANT RECOMMENDATIONS
INTERNATIONAL SYMBOLS
CLASSIFICATION OF LUBRICANTS
ENGINE OIL
FLUID CAPACITIES
FUEL TANK
ENGINE OIL W/FILTER CHANGE
COOLING SYSTEM
AUTOMATIC TRANSMISSION
FRONT AXLE
REAR AXLE
MAINTENANCE SCHEDULES
GENERAL INFORMATION
INTRODUCTION
EMISSION CONTROL SYSTEM MAINTENANCE
UNSCHEDULED INSPECTION
AT EACH STOP FOR FUEL
ONCE A MONTH
AT EACH OIL CHANGE
SCHEDULE—A
SCHEDULE—B
JUMP STARTING, HOISTING AND TOWING
SERVICE PROCEDURES
JUMP STARTING PROCEDURE
TO JUMP START A DISABLED VEHICLE:
DISCONNECT CABLE CLAMPS AS FOLLOWS:
TOWING RECOMMENDATIONS
SAFETY PRECAUTIONS
GROUND CLEARANCE
FLAT-BED TOWING RAMP ANGLE
TWO-WHEEL-DRIVE VEHICLE TOWING
TOWING-REAR END LIFTED
TOWING-FRONT END LIFTED
2WD—AUTOMATIC TRANSMISSION
FOUR-WHEEL-DRIVE VEHICLE TOWING
4WD TOWING-REAR END LIFTED
4WD TOWING-FRONT END LIFTED
EMERGENCY TOW HOOKS
HOISTING RECOMMENDATIONS
FLOOR JACK
HOIST
SUSPENSION
ALIGNMENT
GENERAL INFORMATION
WHEEL ALIGNMENT
SERVICE PROCEDURES
PRE-ALIGNMENT INSPECTION
TOE POSITION
SPECIFICATIONS
FRONT WHEELS
REAR AXLE
FRONT SUSPENSION
DESCRIPTION AND OPERATION
FRONT SUSPENSION
DIAGNOSIS AND TESTING
SHOCK DIAGNOSIS
REMOVAL AND INSTALLATION
SHOCK ABSORBER
REMOVAL
INSTALLATION
COIL SPRING
REMOVAL
INSTALLATION
STEERING KNUCKLE
LOWER SUSPENSION ARM
REMOVAL
INSTALLATION
UPPER SUSPENSION ARM
REMOVAL
INSTALLATION
AXLE BUSHING
REMOVAL
INSTALLATION
STABILIZER BAR
REMOVAL
INSTALLATION
TRACK BAR
REMOVAL
INSTALLATION
HUB BEARING
REMOVAL
INSTALLATION
WHEEL MOUNTING STUDS
REMOVAL
INSTALLATION
SPECIFICATIONS
TORQUE CHART
SPECIAL TOOLS
FRONT SUSPENSION
REAR SUSPENSION
DESCRIPTION AND OPERATION
REAR SUSPENSION
DIAGNOSIS AND TESTING
SHOCK DIAGNOSIS
REMOVAL AND INSTALLATION
SHOCK ABSORBER
REMOVAL
INSTALLATION
COIL SPRING
REMOVAL
INSTALLATION
LOWER SUSPENSION ARM
REMOVAL
INSTALLATION
UPPER SUSPENSION ARM
REMOVAL
INSTALLATION
STABILIZER BAR
REMOVAL
INSTALLATION
TRACK BAR
REMOVAL
INSTALLATION
SPECIFICATIONS
TORQUE CHART
DIFFERENTIAL AND DRIVELINE
PROPELLER SHAFTS
GENERAL INFORMATION
PROPELLER SHAFTS
FRONT PROPELLER SHAFT
UNIVERSAL JOINTS
LUBRICATION
PRECAUTIONS
DIAGNOSIS AND TESTING
VIBRATION
UNBALANCE
RUNOUT
SERVICE PROCEDURES
UNIVERSAL JOINT ANGLE
INFORMATION
INSPECTION
PROPELLER SHAFT ANGLE MEASUREMENT
REMOVAL AND INSTALLATION
FRONT PROPELLER SHAFT
REMOVAL
INSTALLATION
MEASUREMENT
REAR PROPELLER SHAFT
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
SINGLE CARDAN
REMOVAL
ASSEMBLY
DOUBLE CARDAN (CV)
REMOVAL
INSTALLATION
CLEANING AND INSPECTION
SINGLE AND DOUBLE CARDAN JOINT
ADJUSTMENTS
ADJUSTMENT AT AXLE WITH LEAF SPRINGS
SPECIFICATIONS
TORQUE
SPECIAL TOOLS
PROPELLER SHAFT
FRONT AXLE—TUBE AND MODEL 30
GENERAL INFORMATION
INFORMATION
SELEC–TRAC
LUBRICATION SPECIFICATIONS
PINION GEAR DEPTH INFORMATION
DIAGNOSIS AND TESTING
GENERAL INFORMATION
GEAR AND BEARING NOISE
GEAR NOISE
BEARING NOISE
LOW SPEED KNOCK
VIBRATION
DRIVELINE SNAP
FRONT DRIVE AXLE
SERVICE PROCEDURES
LUBRICANT CHANGE
REMOVAL AND INSTALLATION
DRIVE AXLE ASSEMBLY REPLACEMENT
REMOVAL
INSTALLATION
PINION SEAL REPLACEMENT
REMOVAL
INSTALLATION
HUB BEARING AND AXLE SHAFT
REMOVAL
INSTALLATION
STEERING KNUCKLE AND BALL STUDS
KNUCKLE REMOVAL
UPPER BALL STUD REPLACEMENT
LOWER BALL STUD REPLACEMENT
KNUCKLE INSTALLATION
AXLE BUSHING REPLACEMENT
DIFFERENTIAL
REMOVAL
INSTALLATION
INNER AXLE SHAFT OIL SEAL REPLACEMENT
SELECT–TRAC
PINION GEAR
REMOVAL/DISASSEMBLY
PINION GEAR ASSEMBLY/INSTALLATION
DISASSEMBLY AND ASSEMBLY
AXLE SHAFT—CARDAN U-JOINT
DISASSEMBLY
ASSEMBLY
DIFFERENTIAL
DISASSEMBLY
DIFFERENTIAL ASSEMBLY
DIFFERENTIAL AND PINION MEASUREMENT
DIFFERENTIAL ZERO END PLAY MEASUREMENT
PINION GEAR DEPTH MEASUREMENT
DIFFERENTIAL SHIM PACK MEASUREMENT AND ADJUSTMENT
BACKLASH AND CONTACT PATTERN ANALYSIS
FINAL ASSEMBLY
CLEANING AND INSPECTION
CARDAN U-JOINT
DIFFERENTIAL
SPECIFICATIONS
FRONT AXLE—MODEL 30
TORQUE—MODEL 30 AXLE
SPECIAL TOOLS
FRONT AXLE—MODEL 30
MODEL 35 AXLE
GENERAL INFORMATION
GENERAL INFORMATION
LUBRICANT SPECIFICATIONS
DESCRIPTION AND OPERATION
AXLES
IDENTIFICATION
STANDARD DIFFERENTIAL OPERATION
TRAC-LOK OPERATION
DIAGNOSIS AND TESTING
GENERAL INFORMATION
GEAR AND BEARING NOISE
GEAR NOISE
BEARING NOISE
LOW SPEED KNOCK
VIBRATION
DRIVELINE SNAP
REAR AXLE ALIGNMENT
MEASUREMENT
LIMITED SLIP DIFFERENTIAL
SERVICE DIAGNOSIS
TRAC-LOK NOISE DIAGNOSIS
DIFFERENTIAL TEST
SERVICE PROCEDURES
LUBRICANT CHANGE
REMOVAL AND INSTALLATION
DRIVE AXLE ASSEMBLY REPLACEMENT VEHICLES
REMOVAL
INSTALLATION
PINION SHAFT SEAL REPLACEMENT
REMOVAL
INSTALLATION
AXLE SHAFT
REMOVAL
INSTALLATION
AXLE SHAFT SEAL AND BEARING
REMOVAL
INSTALLATION
DIFFERENTIAL
REMOVAL
DIFFERENTIAL INSTALLATION
DIFFERENTIAL SIDE BEARINGS
REMOVAL
DIFFERENTIAL SIDE BEARING INSTALLATION
RING GEAR
REMOVAL
RING GEAR INSTALLATION
PINION GEAR
REMOVAL
PINION GEAR INSTALLATION
FINAL ASSEMBLY
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL
DISASSEMBLE
DIFFERENTIAL ASSEMBLE
TRAC-LOK DIFFERENTIAL
DISASSEMBLY
ASSEMBLY
CLEANING AND INSPECTION
AXLE COMPONENTS
TRAC-LOK
PRESOAK PLATES AND DISC
ADJUSTMENTS
PINION GEAR DEPTH
GENERAL INFORMATION
PINION DEPTH MEASUREMENT AND ADJUSTMENT
DIFFERENTIAL BEARING PRELOAD AND GEAR LASH
DIFFERENTIAL SHIM PACK MEASUREMENT
GEAR BACKLASH AND CONTACT PATTERN ANALYSIS
SPECIFICATIONS
MODEL 35 AXLE
MODEL 35 AXLE
SPECIAL TOOLS
FRONT AXLE—MODEL 35
MODEL 44 AXLE
GENERAL INFORMATION
GENERAL INFORMATION
LUBRICANT SPECIFICATIONS
DESCRIPTION AND OPERATION
AXLES
IDENTIFICATION
STANDARD DIFFERENTIAL OPERATION
TRAC-LOK OPERATION
DIAGNOSIS AND TESTING
GENERAL INFORMATION
GEAR AND BEARING NOISE
GEAR NOISE
BEARING NOISE
LOW SPEED KNOCK
VIBRATION
DRIVELINE SNAP
REAR AXLE ALIGNMENT
MEASUREMENT
LIMITED SLIP DIFFERENTIAL
SERVICE DIAGNOSIS
TRAC-LOK NOISE DIAGNOSIS
DIFFERENTIAL TEST
SERVICE PROCEDURES
LUBRICANT CHANGE
REMOVAL AND INSTALLATION
REAR AXLE
REMOVAL
INSTALLATION
PINION SHAFT SEAL REPLACEMENT
REMOVAL
INSTALLATION
AXLE SHAFT
REMOVAL
INSTALLATION
AXLE SHAFT SEAL AND BEARING
REMOVAL
INSTALLATION
DIFFERENTIAL
REMOVAL
DIFFERENTIAL INSTALLATION
DIFFERENTIAL SIDE BEARINGS
REMOVAL
DIFFERENTIAL SIDE BEARING INSTALLATION
RING GEAR
REMOVAL
RING GEAR INSTALLATION
PINION GEAR
REMOVAL
PINION GEAR INSTALLATION
FINAL ASSEMBLY
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL
DISASSEMBLE
DIFFERENTIAL ASSEMBLE
TRAC-LOK DIFFERENTIAL
DISASSEMBLY
ASSEMBLY
CLEANING AND INSPECTION
AXLE COMPONENTS
TRAC-LOK
PRESOAK PLATES AND DISC
ADJUSTMENTS
PINION GEAR DEPTH
GENERAL INFORMATION
PINION DEPTH MEASUREMENT AND ADJUSTMENT
DIFFERENTIAL BEARING PRELOAD AND GEAR LASH
DIFFERENTIAL SHIM PACK MEASUREMENT
GEAR BACKLASH AND CONTACT PATTERN ANALYSIS
SPECIFICATIONS
MODEL 44 AXLE
TORQUE
SPECIAL TOOLS
MODEL 44 AXLE
BRAKES
BASE BRAKE SYSTEM
GENERAL INFORMATION
BRAKE SYSTEM
SERVICE WARNINGS and CAUTIONS
DESCRIPTION AND OPERATION
BRAKE PEDAL
STOP LAMP SWITCH
RED BRAKE WARNING LAMP
POWER BRAKE BOOSTER
MASTER CYLINDER
COMBINATION VALVE
FRONT DISC BRAKES
REAR DISC BRAKES
PARKING BRAKES
BRAKE HOSES AND LINES
DIAGNOSIS AND TESTING
BASE BRAKE SYSTEM
PRELIMINARY BRAKE CHECK
ROAD TESTING
STOP LAMP SWITCH
SWITCH CIRCUIT IDENTIFICATION
SWITCH CONTINUITY TEST
RED BRAKE WARNING LAMP
MASTER CYLINDER/POWER BOOSTER
POWER BOOSTER VACUUM TEST
POWER BOOSTER CHECK VALVE TEST
COMBINATION VALVE
Metering Valve
Pressure Differential Switch
FRONT DISC BRAKE ROTOR
ROTOR MINIMUM THICKNESS
FRONT ROTOR THICKNESS VARIATION
FRONT ROTOR LATERAL RUNOUT
REAR DISC BRAKE ROTOR
ROTOR MINIMUM THICKNESS
REAR ROTOR THICKNESS VARIATION
REAR ROTOR LATERAL RUNOUT
PARKING BRAKE
BRAKE LINE AND HOSES
BRAKE FLUID CONTAMINATION
SERVICE PROCEDURES
BRAKE FLUID LEVEL
MASTER CYLINDER
BLEEDING PROCEDURE
BRAKE BLEEDING
MANUAL BLEEDING
DISC ROTOR MACHINING
BRAKE LINE
FLARING PROCEDURE
REMOVAL AND INSTALLATION
STOP LAMP SWITCH
REMOVAL
INSTALLATION
BRAKE PEDAL
REMOVAL
INSTALLATION
COMBINATION VALVE
REMOVAL
INSTALLATION
MASTER CYLINDER
REMOVAL
INSTALLATION
POWER BRAKE BOOSTER
REMOVAL
INSTALLATION
DISC BRAKE CALIPER
REMOVAL
INSTALLATION
DISC BRAKESHOE
REMOVAL
INSTALLATION
DISC BRAKE ROTOR
REMOVAL
INSTALLATION
REAR DISC BRAKE CALIPER
REMOVAL
INSTALLATION
REAR DISC BRAKESHOES
REMOVAL
INSTALLATION
REAR DISC BRAKE ROTOR
REMOVAL
INSTALLATION
PARKING BRAKE HAND LEVER
REMOVAL
INSTALLATION
FRONT PARKING BRAKE CABLE
REMOVAL
INSTALLATION
REAR PARKING BRAKE CABLE
REMOVAL
INSTALLATION
PARKING BRAKESHOES
REMOVAL
INSTALLATION
PARKING BRAKE CAM AND LEVER
REMOVAL
INSTALLATION
SPLASH SHIELD/CALIPER BRACKET/LEVER BOOT
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
MASTER CYLINDER RESERVOIR
REMOVAL
INSTALLATION
DISC BRAKE CALIPER
DISASSEMBLY
ASSEMBLY
REAR DISC BRAKE CALIPER
DISASSEMBLY
ASSEMBLY
CLEANING AND INSPECTION
CALIPER
CLEANING
INSPECTION
ADJUSTMENTS
STOP LAMP SWITCH
PARKING BRAKE CABLE TENSIONER
ADJUSTMENT
PARKING BRAKESHOE
SPECIFICATIONS
BRAKE FLUID
BRAKE COMPONENTS
TORQUE CHART
SPECIAL TOOLS
BASE BRAKES
ANTILOCK BRAKES
GENERAL INFORMATION
ABS
DESCRIPTION AND OPERATION
ABS
NORMAL BRAKING
ANTILOCK BRAKING
CONTROLLER ANTILOCK BRAKES (CAB)
HYDRAULIC CONTROL UNIT (HCU)
WHEEL SPEED SENSORS AND TONE WHEEL
SPEED SENSOR AIR GAP
COMBINATION VALVE
ACCELERATION SWITCH
ABS SYSTEM RELAYS
ABS WARNING LAMP
DIAGNOSIS AND TESTING
ABS BRAKE SYSTEM
ABS WARNING LAMP DISPLAY
DRB SCAN TOOL
ABS DIAGNOSTIC CONNECTOR
SERVICE PROCEDURES
BLEEDING ABS BRAKE SYSTEM
REMOVAL AND INSTALLATION
CONTROLLER ANTILOCK BRAKES
REMOVAL
INSTALLATION
HYDRAULIC CONTROLLER UNIT
REMOVAL
INSTALLATION
FRONT WHEEL SPEED SENSOR
REMOVAL
INSTALLATION
REAR WHEEL SPEED SENSOR
REMOVAL
INSTALLATION
ACCELERATION SWITCH
REMOVAL
INSTALLATION
SPECIFICATIONS
TORQUE CHART
COOLING SYSTEM
GENERAL INFORMATION
ENGINE ACCESSORY DRIVE BELTS
COOLING SYSTEM
COOLING SYSTEM COMPONENTS
SYSTEM COOLANT ROUTING
WATER PUMP BYPASS HOSE—5.2L V-8 ENGINE
COOLANT
RADIATOR
DESCRIPTION AND OPERATION
AUTOMATIC TRANSMISSION OIL COOLERS
COOLANT RESERVE/OVERFLOW SYSTEM
ACCESSORY DRIVE BELT TENSION
4.0L ENGINE
5.2L ENGINE
ENGINE BLOCK HEATER
THERMOSTAT
COOLANT PERFORMANCE
ETHYLENE-GLYCOL MIXTURES
COOLANT SELECTION-ADDITIVES
RADIATOR PRESSURE CAP
WATER PUMP
COOLING SYSTEM HOSES
VISCOUS FAN DRIVE
NOISE
LEAKS
DIAGNOSIS AND TESTING
ON-BOARD DIAGNOSTICS (OBD)
FOR CERTAIN COOLING SYSTEM COMPONENTS
ACCESSING DIAGNOSTIC TROUBLE CODES
ERASING TROUBLE CODES
DRB SCAN TOOL
WATER PUMP TESTS
LOOSE IMPELLER
INSPECTING FOR INLET RESTRICTIONS
THERMOSTAT
ON-BOARD DIAGNOSTICS
BELT DIAGNOSIS
SERPENTINE ACCESSORY DRIVE BELT DIAGNOSIS—4.0L 6-CYLINDER ENGINE0 - 2 ZJ (Continued)
SERPENTINE ACCESSORY DRIVE BELT DIAGNOSIS—5.2L 8-CYLINDER ENGINE0 - 4 ZJ (Continued)
PRELIMINARY CHECKS
ENGINE COOLING SYSTEM OVERHEATING
COOLING SYSTEM
RADIATOR COOLANT FLOW CHECK
TESTING COOLING SYSTEM FOR LEAKS
ULTRAVIOLET LIGHT METHOD
PRESSURE TESTER METHOD
INTERNAL LEAKAGE INSPECTION
COMBUSTION LEAKAGE TEST (WITHOUT PRESSURE TESTER)
VISCOUS FAN DRIVE
TESTING
RADIATOR CAP-TO-FILLER NECK SEAL—PRESSURE RELIEF CHECK
PRESSURE TESTING RADIATOR CAP
LOW COOLANT LEVEL-AERATION
DEAERATION
SERVICE PROCEDURES
ROUTINE COOLANT LEVEL CHECK
ADDING ADDITIONAL COOLANT
COOLANT LEVEL CHECK—SERVICE
DRAINING AND FILLING COOLING SYSTEM
DRAINING COOLING SYSTEM
DRAINING ENTIRE SYSTEM
PARTIAL DRAINING
REFILLING COOLING SYSTEM
COOLING SYSTEM CLEANING/REVERSE FLUSHING
CLEANING
REVERSE FLUSHING
REVERSE FLUSHING RADIATOR
REVERSE FLUSHING ENGINE
CHEMICAL CLEANING
REMOVAL AND INSTALLATION
TRANSMISSION OIL COOLER—AUXILIARY
REMOVAL
INSTALLATION
WATER PUMP 4.0L ENGINE
REMOVAL
INSTALLATION
WATER PUMP 5.2L ENGINE
REMOVAL
INSTALLATION
THERMOSTAT 4.0L ENGINE
REMOVAL
INSTALLATION
THERMOSTAT 5.2L ENGINE
REMOVAL
INSTALLATION
RADIATOR
REMOVAL
INSTALLATION
WATER PUMP BYPASS HOSE
WITHOUT AIR CONDITIONING
WITH AIR CONDITIONING
ENGINE BLOCK HEATER
REMOVAL
INSTALLATION
BELT REPLACEMENT/ADJUSTMENT
4.0L ENGINE
5.2L Engine
AUTOMATIC BELT TENSIONER
REMOVAL
INSTALLATION
COOLING SYSTEM FAN 4.0L ENGINE
REMOVAL
INSTALLATION
COOLING SYSTEM FAN 5.2L ENGINE
REMOVAL
INSTALLATION
VISCOUS FAN DRIVE
REMOVAL/INSTALLATION
CLEANING AND INSPECTION
RADIATOR CAP
INSPECTION
RADIATOR
CLEANING
FAN BLADE INSPECTION
WATER PUMP INSPECTION
SPECIFICATIONS
INFORMATION
COOLING SYSTEM CAPACITIES
DRIVE BELT TENSION
TORQUE
SPECIAL TOOLS
COOLING
BATTERY
GENERAL INFORMATION
OVERVIEW
INTRODUCTION
DESCRIPTION AND OPERATION
BATTERY
BATTERY SIZE AND RATINGS
COLD CRANKING AMPERAGE
RESERVE CAPACITY
BATTERY MOUNTING
DIAGNOSIS AND TESTING
BATTERY
ABNORMAL BATTERY DISCHARGING
BUILT-IN TEST INDICATOR
HYDROMETER TEST
OPEN-CIRCUIT VOLTAGE TEST
LOAD TEST
IGNITION-OFF DRAW TEST
DIAGNOSIS
SERVICE PROCEDURES
BATTERY CHARGING
CHARGING A COMPLETELY DISCHARGED BATTERY
CHARGING TIME REQUIRED
REMOVAL AND INSTALLATION
BATTERY
SPECIFICATIONS
BATTERY
STARTING SYSTEMS
GENERAL INFORMATION
OVERVIEW
INTRODUCTION
DESCRIPTION AND OPERATION
STARTING SYSTEM
STARTER
STARTER RELAY
DIAGNOSIS AND TESTING
STARTING SYSTEM
INSPECTION
COLD CRANKING TEST
FEED CIRCUIT TESTS
CONTROL CIRCUIT TESTS
SOLENOID TEST
RELAY TEST
RELAY CIRCUIT TEST
PARK/NEUTRAL POSITION SWITCH TEST
IGNITION SWITCH TEST
REMOVAL AND INSTALLATION
STARTER
4.0L ENGINE
5.2L ENGINE
STARTER RELAY
SPECIFICATIONS
STARTING SYSTEM
CHARGING SYSTEM
GENERAL INFORMATION
OVERVIEW
DESCRIPTION AND OPERATION
CHARGING SYSTEM OPERATION
GENERATOR
BATTERY TEMPERATURE SENSOR
VOLTAGE REGULATOR
DIAGNOSIS AND TESTING
CHARGING SYSTEM
INSPECTION
CHARGING SYSTEM RESISTANCE TESTS
PREPARATION
TEST
CURRENT OUTPUT TEST
PREPARATION
TEST 1
TEST 2
RESULTS
BATTERY TEMPERATURE SENSOR
ON-BOARD DIAGNOSTIC SYSTEM TEST
GENERAL INFORMATION
DIAGNOSTIC TROUBLE CODES
RETRIEVING DIAGNOSTIC TROUBLE CODES
ERASING DIAGNOSTIC TROUBLE CODES
REMOVAL AND INSTALLATION
GENERATOR
BATTERY TEMPERATURE SENSOR
REMOVAL
INSTALLATION
SPECIFICATIONS
GENERATOR RATINGS
TORQUE SPECIFICATIONS
IGNITION SYSTEM
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
IGNITION SYSTEM
POWERTRAIN CONTROL MODULE (PCM)
DISTRIBUTOR
SPARK PLUGS
SPARK PLUG CABLES
IGNITION COIL
AUTOMATIC SHUTDOWN (ASD) RELAY
CRANKSHAFT POSITION SENSOR—5.2L V-8 ENGINE
CRANKSHAFT POSITION SENSOR—4.0L ENGINE
SENSOR OPERATION
CAMSHAFT POSITION SENSOR
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
ENGINE COOLANT TEMPERATURE SENSOR
THROTTLE POSITION SENSOR
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
IGNITION SWITCH AND KEY LOCK CYLINDER
DIAGNOSIS AND TESTING
AUTOMATIC SHUTDOWN (ASD) RELAY TEST
TESTING FOR SPARK AT COIL
IGNITION COIL TEST
FAILURE TO START TEST
DISTRIBUTOR CAP
DISTRIBUTOR ROTOR
IGNITION TIMING
MAP SENSOR
CRANKSHAFT POSITION SENSOR—4.0L ENGINE
CRANKSHAFT POSITION SENSOR—5.2L ENGINES
CAMSHAFT POSITION SENSOR
ENGINE COOLANT TEMPERATURE SENSOR
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
SPARK PLUG CABLES
TESTING
SPARK PLUG CONDITIONS
NORMAL OPERATING
COLD FOULING/CARBON FOULING
WET FOULING OR GAS FOULING
OIL OR ASH ENCRUSTED
ELECTRODE GAP BRIDGING
SCAVENGER DEPOSITS
CHIPPED ELECTRODE INSULATOR
PREIGNITION DAMAGE
SPARK PLUG OVERHEATING
REMOVAL AND INSTALLATION
SPARK PLUG CABLES
SPARK PLUGS
PLUG REMOVAL
PLUG CLEANING
PLUG GAP ADJUSTMENT
SPARK PLUG GAP
PLUG INSTALLATION
IGNITION COIL—5.2L ENGINES
REMOVAL
INSTALLATION
IGNITION COIL—4.0L ENGINE
REMOVAL
INSTALLATION
AUTOMATIC SHUTDOWN (ASD) RELAY
CRANKSHAFT POSITION SENSOR—5.2L ENGINES
REMOVAL
INSTALLATION
CRANKSHAFT POSITION SENSOR—4.0L ENGINE
REMOVAL
INSTALLATION
CAMSHAFT POSITION SENSOR
REMOVAL
INSTALLATION
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
ENGINE COOLANT TEMPERATURE SENSOR
THROTTLE POSITION SENSOR
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
DISTRIBUTOR—5.2L ENGINE
REMOVAL
INSTALLATION
CHECKING DISTRIBUTOR POSITION
DISTRIBUTOR—4.0L ENGINE
REMOVAL—4.0L ENGINE
INSTALLATION
POWERTRAIN CONTROL MODULE (PCM)
IGNITION SWITCH AND KEY CYLINDER
REMOVAL
INSTALLATION
SHIFTER/IGNITION INTERLOCK
SPECIFICATIONS
VECI LABEL SPECIFICATIONS
IGNITION TIMING
ENGINE FIRING ORDER—4.0L 6-CYLINDERENGINE
ENGINE FIRING ORDER—5.2L V-8 ENGINE
TORQUE SPECIFICATIONS
SPARK PLUGS
SPARK PLUG CABLE RESISTANCE
IGNITION COIL
INSTRUMENT PANEL SYSTEMS
GENERAL INFORMATION
INTRODUCTION
INSTRUMENT PANEL
INSTRUMENT CLUSTERS
GRAPHIC DISPLAY MODULE
VEHICLE INFORMATION CENTER
GAUGES
INDICATOR LAMPS
BODY CONTROL MODULE
JUNCTION BLOCK
DESCRIPTION AND OPERATION
COOLANT TEMPERATURE GAUGE
FUEL GAUGE
ODOMETER/TRIP ODOMETER
OIL PRESSURE GAUGE
SPEEDOMETER
TACHOMETER
VOLTMETER
AIRBAG INDICATOR LAMP
ANTI-LOCK BRAKE SYSTEM LAMP
BRAKE WARNING LAMP
CHECK GAUGES LAMP
CLUSTER ILLUMINATION LAMPS
CRUISE-ON INDICATOR LAMP
HEADLAMP HIGH BEAM INDICATOR LAMP
LOW FUEL WARNING LAMP
MALFUNCTION INDICATOR LAMP
MASTER LIGHTING INDICATOR LAMP
SEAT BELT REMINDER LAMP
TURN SIGNAL INDICATOR LAMPS
UPSHIFT INDICATOR LAMP
WAIT-TO-START LAMP
WATER-IN-FUEL LAMP
DIAGNOSIS AND TESTING
GAUGE CLUSTER
COOLANT TEMPERATURE GAUGE
FUEL GAUGE
ODOMETER - TRIP ODOMETER
OIL PRESSURE GAUGE
SPEEDOMETER
TACHOMETER
VOLTMETER
AIRBAG INDICATOR LAMP
ANTI-LOCK BRAKE SYSTEM LAMP
BRAKE WARNING LAMP
CHECK GAUGES LAMP
CLUSTER ILLUMINATION LAMPS
CRUISE-ON INDICATOR LAMP
GRAPHIC DISPLAY MODULE
GDM ILLUMINATION
FOUR-WHEEL DRIVE INDICATOR LAMPS
HEADLAMP HIGH BEAM INDICATOR LAMP
LOW FUEL WARNING LAMP
MALFUNCTION INDICATOR LAMP
SEAT BELT REMINDER LAMP
TURN SIGNAL INDICATOR LAMPS
VEHICLE INFORMATION CENTER
COOLANT LEVEL LOW/COOLANT SENSOR BAD
FOUR-WHEEL DRIVE DISPLAY AND INDICATORS/SERVICE 4WD SWITCH
REAR LAMP FAILURE
TURN SIGNAL ON
WASHER LEVEL LOW/WASHER SENSOR BAD
SERVICE PROCEDURES
VEHICLE INFORMATION CENTER
REMOVAL AND INSTALLATION
SWITCH POD BEZELS
KNEE BLOCKER
CLUSTER BEZEL
INSTRUMENT CLUSTER
CLUSTER LENS, HOOD, AND MASK
GAUGES
CLUSTER BULBS
LEFT SWITCH POD
RIGHT SWITCH POD
BODY CONTROL MODULE
LOWER RIGHT INSTRUMENT PANEL MODULE
GRAPHIC DISPLAY MODULE/VEHICLE INFORMATION CENTER
GLOVE BOX LAMP AND SWITCH
GLOVE BOX LATCH STRIKER
CIGAR LIGHTER
POWER OUTLET
POWER OUTLET DOOR
INSTRUMENT PANEL CENTER BEZEL
GLOVE BOX
GLOVE BOX COMPONENTS
GLOVE BOX BEZEL
GLOVE BOX HINGE
GLOVE BOX BIN
GLOVE BOX LATCH AND HANDLE
GLOVE BOX LOCK CYLINDER
COWL TOP TRIM PANEL
INSTRUMENT PANEL TOP PAD
JUNCTION BLOCK
INSTRUMENT PANEL ASSEMBLY
AUDIO SYSTEMS
GENERAL INFORMATION
INTRODUCTION
MEMORY SYSTEM
DESCRIPTION AND OPERATION
RADIOS
REMOTE RADIO SWITCHES
BODY CONTROL MODULE
IGNITION-OFF DRAW FUSE
SPEAKERS
ANTENNA
RADIO NOISE SUPPRESSION
DIAGNOSIS AND TESTING
AUDIO SYSTEM
RADIO
REMOTE RADIO SWITCHES
SPEAKERS
ANTENNA
TEST 1
TEST 2
TEST 3
TEST 4
RADIO FREQUENCY INTERFERENCE
REMOVAL AND INSTALLATION
RADIO
REMOTE RADIO SWITCHES
AMPLIFIER
SPEAKERS
INSTRUMENT PANEL
FRONT DOOR
REAR DOOR
ANTENNA
HORN SYSTEMS
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
HORN RELAY
HORN SWITCH
HORN
BODY CONTROL MODULE
DIAGNOSIS AND TESTING
HORN RELAY
RELAY TESTS
RELAY CIRCUIT TESTS
HORN SWITCH
HORN
REMOVAL AND INSTALLATION
HORN RELAY
HORN SWITCH
HORN
VEHICLE SPEED CONTROL SYSTEM
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
SPEED CONTROL SERVO
SPEED CONTROL SWITCHES
STOP LAMP SWITCH
SERVO CABLE
POWERTRAIN CONTROL MODULE (PCM)
VACUUM RESERVOIR
VEHICLE SPEED SENSOR
DIAGNOSIS AND TESTING
ROAD TEST
ON-BOARD DIAGNOSTICS TEST
DIAGNOSTIC TROUBLE CODES
RETRIEVING DIAGNOSTIC TROUBLE CODES
SPEED CONTROL DIAGNOSTIC TROUBLE CODES0 - 2 ZJ (Continued)
SPEED CONTROL ELECTRICAL TEST
VEHICLE SPEED SENSOR
SPEED CONTROL SWITCHES
STOP LAMP SWITCH
VACUUM SUPPLY TEST
SPEED CONTROL SERVO
POWERTRAIN CONTROL MODULE (PCM)
REMOVAL AND INSTALLATION
SPEED CONTROL SERVO
4.0L ENGINES—REMOVAL/INSTALLATION
5.2L ENGINES—REMOVAL/INSTALLATION
SPEED CONTROL SWITCHES
REMOVAL/INSTALLATION
STOP LAMP SWITCH
SERVO CABLE
REMOVAL/INSTALLATION
POWERTRAIN CONTROL MODULE
VACUUM RESERVOIR
REMOVAL/INSTALLATION
VEHICLE SPEED SENSOR
SPECIFICATIONS
TORQUE
TURN SIGNAL AND HAZARD WARNING SYSTEMS
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
TURN SIGNAL SYSTEM
HAZARD WARNING SYSTEM
COMBINATION FLASHER
MULTI-FUNCTION SWITCH
TURN SIGNAL INDICATOR LAMPS
VEHICLE INFORMATION CENTER
TURN SIGNAL LAMPS
DIAGNOSIS AND TESTING
INTRODUCTION
TURN SIGNAL/HAZARD WARNING SYSTEM
MULTI-FUNCTION SWITCH
REMOVAL AND INSTALLATION
COMBINATION FLASHER
MULTI-FUNCTION SWITCH
WIPER AND WASHER SYSTEMS
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
WINDSHIELD WIPER SYSTEM
WINDSHIELD WASHER SYSTEM
REAR WIPER AND WASHER SYSTEM
WIPER ARMS AND BLADES
WIPER LINKAGE AND PIVOTS
WIPER MOTORS
FRONT
REAR
WIPER AND WASHER SWITCHES
FRONT
REAR
BODY CONTROL MODULE
INTERMITTENT WIPE RELAY
WASHER RESERVOIR
WASHER PUMPS
WASHER NOZZLES AND PLUMBING
FRONT
REAR
DIAGNOSIS AND TESTING
WIPER SYSTEMS
FRONT
REAR
WASHER SYSTEMS
FRONT
REAR
WIPER AND WASHER SWITCHES
FRONT
REAR
INTERMITTENT WIPE RELAY
RELAY TESTS
RELAY CIRCUIT TESTS
REMOVAL AND INSTALLATION
WIPER BLADES AND ELEMENTS
FRONT
REAR
WIPER ARMS
FRONT
REAR
WIPER MOTOR
FRONT
REAR
WIPER LINKAGE AND PIVOTS
INTERMITTENT WIPE RELAY
WIPER AND WASHER SWITCHES
FRONT
REAR
WASHER PUMPS AND RESERVOIR
LAMPS
LAMP DIAGNOSIS
GENERAL INFORMATION
GENERAL INFORMATION
SAFETY PRECAUTIONS
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
HEADLAMP DIAGNOSIS
HEADLAMP DIAGNOSIS
FOG LAMP DIAGNOSIS
DAYTIME RUNNING LAMP DIAGNOSIS
DAYTIME RUNNING LAMP DIAGNOSIS
LAMP OUTAGE MODULE DIAGNOSIS
HEADLAMP ALIGNMENT
GENERAL INFORMATION
HEADLAMP ALIGNMENT
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
ALIGNMENT SCREEN PREPARATION
HEADLAMP ADJUSTMENT USING ALIGNMENT SCREEN
FOG LAMP ADJUSTMENT
SPECIAL TOOLS
SPECIAL TOOLS—HEADLAMP ALIGNMENT
LAMP BULB SERVICE
REMOVAL AND INSTALLATION
HEADLAMP BULB
REMOVAL
INSTALLATION
FOG LAMP BULB
REMOVE
INSTALLATION
PARKING LAMP BULB
REMOVAL
INSTALLATION
TURN SIGNAL AND SIDE MARKER LAMP BULB
REMOVAL
INSTALLATION
TAIL, STOP, TURN SIGNAL, BACK-UP AND SIDE MARKER LAMP BULBS
REMOVAL
INSTALLATION
LICENSE PLATE LAMP BULB
REMOVAL
INSTALLATION
CENTER HIGH MOUNTED STOP LAMP (CHMSL) BULB
REMOVAL
INSTALLATION
UNDERHOOD LAMP BULB
REMOVAL
INSTALLATION
VISOR VANITY LAMP BULB
REMOVAL
INSTALLATION
OVERHEAD CONSOLE READING LAMP BULB
REMOVAL
INSTALLATION
DOME LAMP BULB
REMOVAL
INSTALLATION
READING LAMP BULB
REMOVAL
INSTALLATION
DOOR COURTESY LAMP BULB
REMOVAL
INSTALLATION
CARGO LAMP BULB
REMOVAL
INSTALLATION
LAMP SERVICE
REMOVAL AND INSTALLATION
HEADLAMP
REMOVAL
INSTALLATION
FOG LAMP
REMOVAL
INSTALLATION
PARKING LAMP
REMOVAL
INSTALLATION
TURN SIGNAL AND SIDE MARKER LAMP
REMOVAL
INSTALLATION
TAIL, STOP, TURN SIGNAL, BACK-UP AND SIDE MARKER LAMP
REMOVAL
INSTALLATION
LICENSE PLATE LAMP
REMOVAL
INSTALLATION
CENTER HIGH MOUNTED STOP LAMP (CHMSL)
REMOVAL
INSTALLATION
UNDERHOOD LAMP
REMOVAL
INSTALLATION
VISOR VANITY LAMP
REMOVAL
INSTALLATION
DOME/READING LAMP
REMOVAL
INSTALLATION
DOOR COURTESY LAMP
REMOVAL
INSTALLATION
CARGO LAMP
REMOVAL
INSTALLATION
LAMP SYSTEMS
GENERAL INFORMATION
DAYTIME RUNNING LAMP SYSTEM
LAMP OUTAGE MODULE
AUTO HEADLAMP SENSOR
REMOVAL AND INSTALLATION
DAYTIME RUNNING LIGHT MODULE
REMOVAL
INSTALLATION
AUTO HEADLAMP SENSOR
REMOVAL
INSTALLATION
LAMP OUTAGE MODULE
REMOVAL
INSTALLATION
BULB APPLICATION
GENERAL INFORMATION
GENERAL INFORMATION
SPECIFICATIONS
EXTERIOR LAMPS
INTERIOR LAMPS
PASSIVE RESTRAINT SYSTEMS
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
AIRBAG MODULE
DRIVER'S SIDE
PASSENGER'S SIDE
STORAGE
IMPACT SENSORS
CLOCKSPRING
AIRBAG CONTROL MODULE
DIAGNOSIS AND TESTING
AIRBAG SYSTEM
SERVICE PROCEDURES
AIRBAG SYSTEM
UNDEPLOYED
DEPLOYED
CLEAN-UP PROCEDURE
REMOVAL AND INSTALLATION
AIRBAG MODULE
DRIVER'S SIDE
PASSENGER'S SIDE
DRIVER'S AIRBAG TRIM COVER AND HORN SWITCH
PASSENGER'S AIRBAG REAR MOUNTING BRACKET
IMPACT SENSORS
AIRBAG CONTROL MODULE
CLOCKSPRING
ADJUSTMENTS
CLOCKSPRING CENTERING
ELECTRICALLY HEATED SYSTEMS
DEFOGGER SYSTEM
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
REAR GLASS HEATING GRID
HEATED MIRRORS
DEFOGGER SWITCH
DEFOGGER RELAY
BODY CONTROL MODULE
DIAGNOSIS AND TESTING
DEFOGGER SYSTEM
REAR GLASS HEATING GRID
DEFOGGER SWITCH
DEFOGGER RELAY
RELAY TEST
RELAY CIRCUIT TEST
SERVICE PROCEDURES
REAR GLASS HEATING GRID REPAIRS
REMOVAL AND INSTALLATION
DEFOGGER SWITCH
DEFOGGER RELAY
HEATED SEATS
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
HEATED SEAT SWITCH
HEATED SEAT CONTROL MODULE
HEATED SEAT ELEMENTS AND SENSOR
DIAGNOSIS AND TESTING
HEATED SEAT SYSTEM
HEATED SEAT SWITCH
HEATED SEAT CONTROL MODULE
HEATED SEAT ELEMENT
SEAT CUSHION
SEAT BACK
HEATED SEAT SENSOR
REMOVAL AND INSTALLATION
HEATED SEAT SWITCH
HEATED SEAT CONTROL MODULE
POWER LOCK SYSTEMS
GENERAL INFORMATION
INTRODUCTION
POWER LOCK SYSTEM
POWER LIFTGLASS RELEASE SYSTEM
REMOTE KEYLESS ENTRY SYSTEM
MEMORY SYSTEM
DESCRIPTION AND OPERATION
POWER LOCK SWITCH
DOOR MODULE
BODY CONTROL MODULE
POWER LOCK MOTOR
CIRCUIT BREAKER
REMOTE KEYLESS ENTRY TRANSMITTER
REMOTE KEYLESS ENTRY RECEIVER
DIAGNOSIS AND TESTING
POWER LOCK/REMOTE KEYLESS ENTRY SYSTEM
CIRCUIT BREAKER
DOOR MODULE
POWER LOCK MOTOR
REMOTE KEYLESS ENTRY TRANSMITTER
POWER LIFTGLASS RELEASE SYSTEM
SERVICE PROCEDURES
REMOTE KEYLESS ENTRY TRANSMITTER BATTERY REPLACEMENT
REMOTE KEYLESS ENTRY TRANSMITTER PROGRAMMING
REMOVAL AND INSTALLATION
DOOR MODULE
POWER LOCK MOTOR
FRONT DOOR
REAR DOOR
LIFTGATE
VEHICLE THEFT/SECURITY SYSTEMS
GENERAL INFORMATION
INTRODUCTION
ARMING
DISARMING
POWER-UP MODE
TAMPER ALERT
DESCRIPTION AND OPERATION
BODY CONTROL MODULE
HOOD SWITCH
DOOR AJAR SWITCH
DOOR LOCK CYLINDER SWITCH
LIFTGATE AJAR SWITCH
LIFTGATE LOCK CYLINDER SWITCH
LIFTGLASS AJAR SWITCH
AUTO HEADLAMP RELAY
HORN RELAY
PARK LAMP RELAY
SET LAMP
DIAGNOSIS AND TESTING
VEHICLE THEFT SECURITY SYSTEM
Self-Diagnostics
RELAYS
REMOVAL AND INSTALLATION
HOOD SWITCH
DOOR AJAR SWITCH
DOOR LOCK CYLINDER SWITCH
LIFTGATE AJAR SWITCH
LIFTGATE LOCK CYLINDER SWITCH
LIFTGLASS AJAR SWITCH
AUTO HEADLAMP AND PARK LAMP RELAYS
HORN RELAY
SET LAMP
POWER SEAT SYSTEMS
GENERAL INFORMATION
INTRODUCTION
MEMORY SYSTEM
DESCRIPTION AND OPERATION
MEMORY SEAT MODULE
POWER SEAT SWITCH
POWER LUMBAR SWITCH
POWER SEAT ADJUSTER/MOTORS
POWER RECLINER ADJUSTER/MOTORS
POWER LUMBAR ADJUSTER/MOTORS
CIRCUIT BREAKER
DIAGNOSIS AND TESTING
POWER SEAT SYSTEM
CIRCUIT BREAKER
POWER SEAT SWITCH
POWER LUMBAR SWITCH
POWER SEAT ADJUSTER/MOTORS
POWER RECLINER ADJUSTER/MOTOR
POWER LUMBAR ADJUSTER/MOTOR
REMOVAL AND INSTALLATION
POWER SEAT SWITCH
POWER LUMBAR SWITCH
POWER SEAT ADJUSTER/MOTORS
POWER RECLINER ADJUSTER/MOTOR
POWER LUMBAR ADJUSTER/MOTOR
MEMORY SEAT MODULE
POWER WINDOW SYSTEMS
GENERAL INFORMATION
INTRODUCTION
POWER WINDOW SYSTEM
DESCRIPTION AND OPERATION
POWER WINDOW SWITCH
DOOR MODULE
BODY CONTROL MODULE
POWER WINDOW MOTOR
CIRCUIT BREAKER
DIAGNOSIS AND TESTING
POWER WINDOW SYSTEM
ALL WINDOWS INOPERATIVE
ONE WINDOW INOPERATIVE
CIRCUIT BREAKER
DOOR MODULE
POWER WINDOW SWITCH
POWER WINDOW MOTOR
REMOVAL AND INSTALLATION
DOOR MODULE
POWER WINDOW SWITCH
POWER WINDOW MOTOR
FRONT DOOR
REAR DOOR
POWER MIRROR SYSTEMS
OUTSIDE POWER MIRRORS
GENERAL INFORMATION
INTRODUCTION
MEMORY SYSTEM
DESCRIPTION AND OPERATION
POWER MIRROR
POWER MIRROR SWITCH
DOOR MODULE
DIAGNOSIS AND TESTING
POWER MIRROR SYSTEM
POWER MIRROR
LIMITED OR NO MIRROR MOVEMENT
NO MIRROR HEAT
NO MIRROR DIMMING (Driver's Side Only)
NO MIRROR MEMORY
REMOVAL AND INSTALLATION
DOOR MODULE
POWER MIRROR
AUTOMATIC DAY/NIGHT MIRROR
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
AUTOMATIC DAY/NIGHT MIRROR
DIAGNOSIS AND TESTING
AUTOMATIC DAY/NIGHT MIRROR
REMOVAL AND INSTALLATION
AUTOMATIC DAY/NIGHT MIRROR
CHIME/BUZZER WARNING SYSTEMS
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
BODY CONTROL MODULE
BODY CONTROL MODULE INPUTS
OVERHEAD CONSOLE SYSTEMS
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
TRIP COMPUTER
COMPASS
THERMOMETER
READING/COURTESY LAMPS
GARAGE DOOR OPENER STORAGE BIN
SUNGLASSES STORAGE BIN
DIAGNOSIS AND TESTING
TRIP COMPUTER/COMPASS/DISPLAY MODULE
SELF-DIAGNOSTICS
THERMOMETER
SENSOR TEST
SENSOR CIRCUIT TEST
SERVICE PROCEDURES
COMPASS VARIATION ADJUSTMENT
COMPASS CALIBRATION
COMPASS DEMAGNETIZING
REMOVAL AND INSTALLATION
OVERHEAD CONSOLE
LONG-TYPE
SHORT-TYPE
TRIP COMPUTER, COMPASS, THERMOMETER, DISPLAY MODULE
PUSH-BUTTON MODULE
AMBIENT TEMPERATURE SENSOR
READING/COURTESY LAMP BULBS
WIRING DIAGRAMS
8W-01 GENERAL INFORMATION
DESCRIPTION AND OPERATION
HOW TO USE THIS GROUP
SECTION IDENTIFICATION
CONNECTOR/GROUND LOCATIONS
SPLICE LOCATIONS
NOTES, CAUTIONS, and WARNINGS
WIRE CODE IDENTIFICATION
CIRCUIT IDENTIFICATION
CONNECTORS
TAKE OUTS
SYMBOLS
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES
DIAGNOSIS AND TESTING
TROUBLESHOOTING TOOLS
INTERMITTENT AND POOR CONNECTIONS
TROUBLESHOOTING TESTS
TESTING FOR VOLTAGE
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
TERMINAL/CONNECTOR REPAIR—THOMAS AND BETTS CONNECTORS
CONNECTOR REPLACEMENT
CONNECTOR AND TERMINAL REPLACEMENT
TERMINAL REPLACEMENT
DIODE REPLACEMENT
SPECIAL TOOLS
WIRING/TERMINAL
8W-02 COMPONENT INDEX
GENERAL INFORMATION
INTRODUCTION
8W-11 POWER DISTRIBUTION
DESCRIPTION AND OPERATION
INTRODUCTION
8W-12 JUNCTION BLOCK
DESCRIPTION AND OPERATION
INTRODUCTION
8W-15 GROUND DISTRIBUTION
DESCRIPTION AND OPERATION
INTRODUCTION
8W-20 CHARGING SYSTEM
DESCRIPTION AND OPERATION
CHARGING SYSTEM
HELPFUL INFORMATION
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-21 STARTING SYSTEM
DESCRIPTION AND OPERATION
STARTING SYSTEM
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-30 FUEL/IGNITION SYSTEMS
DESCRIPTION AND OPERATION
IGNITION SWITCH
BATTERY FEED
HELPFUL INFORMATION
GROUND
HELPFUL INFORMATION
DATA LINK CONNECTOR
AUTOMATIC SHUT DOWN (ASD) RELAY
HELPFUL INFORMATION
FUEL PUMP RELAY
HELPFUL INFORMATION
FUEL PUMP MODULE
FUEL PUMP MOTOR
FUEL LEVEL SENSOR
VEHICLE SPEED SENSOR
HELPFUL INFORMATION
HEATED OXYGEN SENSORS
HELPFUL INFORMATION
BATTERY TEMPERATURE SENSOR
CRANKSHAFT POSITION SENSOR
HELPFUL INFORMATION
CAMSHAFT POSITION SENSOR
HELPFUL INFORMATION
ENGINE COOLANT TEMPERATURE SENSOR
HELPFUL INFORMATION
EVAPORATIVE SYSTEM LEAK DETECTION PUMP
THROTTLE POSITION SENSOR
HELPFUL INFORMATION
MANIFOLD ABSOLUTE PRESSURE SENSOR
HELPFUL INFORMATION
INTAKE AIR TEMPERATURE SENSOR
HELPFUL INFORMATION
OIL PRESSURE SENSOR
FUEL INJECTORS
HELPFUL INFORMATION
IGNITION COIL
HELPFUL INFORMATION
IDLE AIR CONTROL (IAC) MOTOR
DUTY CYCLE EVAP\PURGE SOLENOID
CCD BUS
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-31 TRANSMISSION CONTROL SYSTEM
DESCRIPTION AND OPERATION
OVERDRIVE SWITCH
TRANSMISSION CONTROL RELAY
TRANSMISSION SOLENOID ASSEMBLY
SHIFT INTERLOCK
OUTPUT SHAFT SPEED SENSOR
GOVERNOR PRESSURE SENSOR
TRANSMISSION TEMPERATURE SENSOR
HELPFUL INFORMATION
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-33 VEHICLE SPEED CONTROL
DESCRIPTION AND OPERATION
VEHICLE SPEED CONTROL
HELPFUL INFORMATION
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-35 ALL-WHEEL ANTI-LOCK BRAKES
DESCRIPTION AND OPERATION
INTRODUCTION
WHEEL SPEED SENSORS
G-SWITCH
ABS MAIN RELAY
ABS PUMP MOTOR RELAY
HYDRAULIC CONTROL UNIT
ABS WARNING LAMP
HELPFUL INFORMATION
STOP LAMP SWITCH INPUT
DATA LINK CONNECTOR
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-39 VEHICLE THEFT SECURITY SYSTEM
DESCRIPTION AND OPERATION
INTRODUCTION
VEHICLE THEFT SECURITY SYSTEM OPERATION
SYSTEM ARMING
SYSTEM DISARMING
HORNS
PARKING LAMPS
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-40 INSTRUMENT CLUSTER
DESCRIPTION AND OPERATION
INTRODUCTION
WARNING LAMPS—EXCEPT ABS
SPEEDOMETER
TACHOMETER
VOLTMETER
FUEL GAUGE
ENGINE COOLANT TEMPERATURE GAUGE
ABS WARNING LAMP
HELPFUL INFORMATION
OIL PRESSURE GAUGE
HIGH BEAM INDICATOR LAMP
TURN SIGNAL INDICATOR LAMPS
ILLUMINATION LAMPS
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-41 HORN/CIGAR LIGHTER
DESCRIPTION AND OPERATION
HORN
CIGAR LIGHTER
HELPFUL INFORMATION
POWER OUTLET
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-42 AIR CONDITIONING/HEATER
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
MANUAL A/C-HEATER
BLOWER MOTOR—MANUAL A/C-HEATER
A/C OPERATION—MANUAL A/C
HELPFUL INFORMATION
BLEND AIR DOOR MOTOR ACTUATOR—MANUAL A/C-HEATER
AUTOMATIC TEMPERATURE CONTROL (ATC)
AUTOMATIC TEMPERATURE CONTROL (ATC) MODULE
AMBIENT TEMPERATURE SENSOR
IN-CAR TEMPERATURE SENSOR
SOLAR SENSOR
A/C OPERATION—AUTOMATIC TEMPERATURE CONTROL
HELPFUL INFORMATION
RECIRCULATION DOOR MOTOR—AUTOMATIC TEMPERATURE CONTROL
MODE DOOR MOTOR—AUTOMATIC TEMPERATURE CONTROL
BLEND DOOR MOTOR—AUTOMATIC TEMPERATURE CONTROL
BLOWER MOTOR—AUTOMATIC TEMPERATURE CONTROL
BLOWER MOTOR POWER MODULE
HIGH SPEED BLOWER MOTOR RELAY
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-43 AIRBAG SYSTEM
DESCRIPTION AND OPERATION
INTRODUCTION
AIRBAG IMPACT SENSORS
AIRBAG SQUIB (AIRBAG IGNITER)
AIRBAG WARNING LAMP
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-44 INTERIOR LIGHTING
DESCRIPTION AND OPERATION
INTRODUCTION
ILLUMINATION LAMPS
COURTESY LAMPS, CARGO LAMP, IGNITION SWITCH KEY-IN HALO LAMP
DOOR COURTESY LAMPS
LIFTGATE COURTESY LAMP DISABLE SWITCH
GLOVE BOX LAMP
UNDERHOOD LAMP
VISOR VANITY MIRRORS
OVERHEAD CONSOLE LAMPS
DAY/NIGHT MIRROR
UNIVERSAL GARAGE DOOR OPENER
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-45 BODY CONTROL MODULE
DESCRIPTION AND OPERATION
INTRODUCTION
A/C SELECT SWITCH
AMBIENT TEMPERATURE SENSOR
COURTESY LAMP SWITCH
LIFTGATE COURTESY LAMP DISABLE SWITCH
AUTO HEADLAMPS
PARK LAMP SWITCH SENSE
INSTRUMENT PANEL DIMMING
IGNITION SWITCH SENSE
AJAR CHIME
KEY-IN IGNITION CHIME
SEAT BELT SWITCH
LOW OIL PRESSURE WARNING CHIME
ENGINE TEMPERATURE CRITICAL CHIME
LOW FUEL WARNING LAMP ANNOUNCEMENT CHIME
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-46 MESSAGE CENTER
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
GRAPHIC DISPLAY MODULE
TRANSFER CASE RANGE DISPLAY
VEHICLE INFORMATION CENTER
TRANSFER CASE RANGE DISPLAY
LAMP OUTAGE
LOW WASHER FLUID WARNING
LOW ENGINE COOLANT WARNING
DOOR AJAR AND LIFTGATE AJAR DISPLAYS
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-47 AUDIO SYSTEM
GENERAL INFORMATION
INTRODUCTION
DESCRIPTION AND OPERATION
RADIO MEMORY
RADIO ILLUMINATION
SPEAKERS—STANDARD RADIO
POWER AMPLIFIER AND SPEAKERS
RADIO REMOTE SWITCHES
POWER ANTENNA—EXPORT ONLY
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-48 REAR WINDOW DEFOGGER
DESCRIPTION AND OPERATION
REAR WINDOW DEFOGGER
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-49 OVERHEAD CONSOLE
DESCRIPTION AND OPERATION
OVERHEAD CONSOLE
OVERHEAD CONSOLE LAMPS
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-50 FRONT LIGHTING
DESCRIPTION AND OPERATION
INTRODUCTION
PARKING LAMPS
HEADLAMPS
AUTO HEADLAMPS
FOG LAMPS
DAYTIME RUNNING LAMPS MODULE
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-51 REAR LIGHTING
DESCRIPTION AND OPERATION
TAIL LAMPS, REAR LICENSE PLATE LAMPS AND SIDE MARKER LAMPS
HELPFUL INFORMATION
STOP LAMPS AND CHMSL LAMPS
BACK-UP LAMPS
HELPFUL INFORMATION
LAMP OUTAGE MODULE (LOM)
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-52 TURN SIGNALS
DESCRIPTION AND OPERATION
ELECTRONIC FLASHER RELAY
TURN SIGNALS
HAZARD FLASHERS
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-53 WIPERS
DESCRIPTION AND OPERATION
INTERMITTENT WIPER OPERATION
REAR WIPER/WASHER
HELPFUL INFORMATION
LOW WASHER FLUID LEVEL SENSOR
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-54 TRAILER TOW
GENERAL INFORMATION1996 Grand Cherokee81-370-614726-02-96February, 1996
INTRODUCTION
DESCRIPTION AND OPERATION
TRAILER TOW—FACTORY INSTALLED
STOP LAMP RELAY
RIGHT TURN RELAY
LEFT TURN RELAY
HELPFUL INFORMATION
TRAILER TOW—AFTER-MARKET
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-60 POWER WINDOWS
DESCRIPTION AND OPERATION
INTRODUCTION
POWER WINDOWS
LEFT FRONT WINDOW OPERATION
RIGHT FRONT WINDOW OPERATION
LEFT REAR WINDOW
RIGHT REAR WINDOW
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-61 POWER DOOR LOCKS
DESCRIPTION AND OPERATION
INTRODUCTION
POWER DOOR LOCKS
REMOTE KEYLESS ENTRY
LIFTGLASS
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-62 POWER MIRRORS
DESCRIPTION AND OPERATION
INTRODUCTION
POWER MIRROR
LEFT MIRROR ADJUSTMENT
RIGHT MIRROR ADJUSTMENT
HEATER ELEMENTS
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-63 POWER SEAT
DESCRIPTION AND OPERATION
INTRODUCTION
POWER SEATS
LUMBAR ADJUSTMENT
DRIVER'S SEAT
PASSENGER'S SEAT
MEMORY SEATS
SEAT POSITION SENSORS
MEMORY SWITCH
HEATED SEATS
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-64 POWER SUNROOF
DESCRIPTION AND OPERATION
POWER SUNROOF
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-65 SPEED PROPORTIONAL STEERING
DESCRIPTION AND OPERATION
INTRODUCTION
SPEED PROPORTIONAL STEERING CONTROL MODULE
SPEED PROPORTIONAL STEERING SOLENOID
DATA LINK CONNECTOR
SCHEMATICS AND DIAGRAMS
WIRING DIAGRAM INDEX
8W-70 SPLICE INFORMATION
DESCRIPTION AND OPERATION
INTRODUCTION
8W-80 CONNECTOR PIN-OUTS
DESCRIPTION AND OPERATION
INTRODUCTION
8W-90 CONNECTOR LOCATIONS
DESCRIPTION AND OPERATION
INTRODUCTION
SCHEMATICS AND DIAGRAMS
CONNECTOR/GROUND LOCATIONS
8W-95 SPLICE LOCATIONS
DIAGNOSIS AND TESTING
INTRODUCTION
SCHEMATICS AND DIAGRAMS
SPLICE LOCATIONS
ENGINE
STANDARD SERVICE INFORMATION
GENERAL INFORMATION
FORM-IN-PLACE GASKETS—GASOLINE ENGINES
MOPAR SILICONE RUBBER ADHESIVE SEALANT
MOPAR GASKET MAKER
SURFACE PREPARATION
GASKET APPLICATION
ENGINE PERFORMANCE
HONING CYLINDER BORES
MEASURING WITH PLASTIGAGE
CRANKSHAFT MAIN BEARING CLEARANCE
CONNECTING ROD BEARING CLEARANCE
REPAIR DAMAGED OR WORN THREADS
SERVICE ENGINE ASSEMBLY (SHORT BLOCK)
HYDROSTATIC LOCK
ENGINE OIL
ENGINE OIL SPECIFICATION
API SERVICE GRADE CERTIFIED
SAE VISCOSITY
ENERGY CONSERVING OIL
CONTAINER IDENTIFICATION
ENGINE OIL ADDITIVES
OIL LEVEL INDICATOR (DIPSTICK)
CRANKCASE OIL LEVEL INSPECTION
ENGINE OIL CHANGE
ENGINE OIL FILTER CHANGE
ENGINE DIAGNOSIS
DIAGNOSIS AND TESTING
GENERAL INFORMATION
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
CYLINDER COMPRESSION PRESSURE TEST
ENGINE CYLINDER HEAD GASKET FAILURE DIAGNOSIS
CYLINDER-TO-CYLINDER LEAKAGE TEST
CYLINDER-TO-WATER JACKET LEAKAGE TEST
CYLINDER COMBUSTION PRESSURE LEAKAGE TEST
INSPECTION (ENGINE OIL LEAKS IN GENERAL)
Air Leak Detection Test Method
INSPECTION FOR REAR SEAL AREA LEAKS
HYDRAULIC TAPPETS
OIL LEVEL
TAPPET NOISE DIAGNOSIS
ENGINE OIL PRESSURE
ENGINE—PERFORMANCE
ENGINE—MECHANICAL
ENGINE—LUBRICATION
4.0L ENGINE
DESCRIPTION AND OPERATION
ENGINE DESCRIPTION
BUILD DATE CODE
LUBRICATION SYSTEM
OIL PUMP PRESSURE
OVERSIZE AND UNDERSIZE COMPONENT CODES
SERVICE PROCEDURES
VALVE TIMING
PISTON FITTING
BORE GAGE METHOD
PISTON RING FITTING
FITTING CONNECTING ROD BEARINGS
INSPECTION
SIDE CLEARANCE MEASUREMENT
FITTING CRANKSHAFT MAIN BEARINGS
INSPECTION
FITTING BEARINGS (CRANKSHAFT INSTALLED)
MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED)
MAIN BEARING FITTING CHART
REMOVAL AND INSTALLATION
ENGINE MOUNTS—FRONT
REMOVAL
INSTALLATION
ENGINE MOUNT—REAR
REMOVAL
INSTALLATION
ENGINE ASSEMBLY
REMOVAL
INSTALLATION
ENGINE CYLINDER HEAD COVER
REMOVAL
INSTALLATION
ROCKER ARMS AND PUSH RODS
REMOVAL
INSTALLATION
VALVE STEM SEAL AND SPRING
REMOVAL
INSTALLATION
ENGINE CYLINDER HEAD
REMOVAL
INSTALLATION
VALVES AND VALVE SPRINGS
REMOVAL
INSTALLATION
HYDRAULIC TAPPETS
REMOVAL
INSTALLATION
VIBRATION DAMPER
REMOVAL
INSTALLATION
TIMING CASE COVER
REMOVAL
INSTALLATION
TIMING CHAIN AND SPROCKETS
REMOVAL
INSTALLATION
CAMSHAFT
REMOVAL
INSTALLATION
CAMSHAFT PIN REPLACEMENT
REMOVAL
CAMSHAFT BEARINGS
INSTALLATION
CRANKSHAFT MAIN BEARINGS
REMOVAL
INSTALLATION
OIL PAN
REMOVAL
INSTALLATION
PISTONS AND CONNECTING RODS
REMOVAL
INSTALLATION
REAR MAIN OIL SEALS
REMOVAL
INSTALLATION
OIL PUMP
REMOVAL
INSTALLATION
TIMING CASE COVER OIL SEAL
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
VALVE SERVICE
VALVE REFACING
VALVE SEAT REFACING
VALVE STEM OIL SEAL REPLACEMENT
VALVE GUIDES
VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT
VALVE SPRING TENSION TEST
CYLINDER BLOCK
DISASSEMBLY
ASSEMBLY
CLEANING AND INSPECTION
ENGINE CYLINDER HEAD
CLEANING
INSPECTION
ENGINE CYLINDER HEAD COVER
CLEANING
INSPECTION
ROCKER ARMS AND PUSH RODS
CLEANING
INSPECTION
HYDRAULIC TAPPETS
CLEANING
INSPECTION
LEAK-DOWN TEST
CYLINDER BLOCK
CLEANING
INSPECTION—CYLINDER BORE
HONING—CYLINDER BORE
SPECIFICATIONS
4.0L ENGINE SPECIFICATIONS
SPECIAL TOOLS
4.0L ENGINE
5.2L ENGINE
GENERAL INFORMATION
VALVES AND VALVE SPRINGS
OIL PUMP PRESSURE
PISTON AND CONNECTING ROD ASSEMBLY
DESCRIPTION AND OPERATION
ENGINE DESCRIPTION
LUBRICATION SYSTEM
ENGINE COMPONENTS
CYLINDER HEAD
PISTONS
SERVICE PROCEDURES
VALVE TIMING
MEASURING TIMING CHAIN STRETCH
FITTING PISTONS
FITTING PISTON RINGS
FITTING CONNECTING ROD BEARINGS
CRANKSHAFT MAIN BEARINGS
CRANKSHAFT
REMOVAL AND INSTALLATION
ENGINE MOUNTS—FRONT
REMOVAL
INSTALLATION
ENGINE MOUNTS—REAR
REMOVAL
INSTALLATION
ENGINE ASSEMBLY
REMOVAL
INSTALLATION
CYLINDER HEAD COVER
REMOVAL
INSTALLATION
ROCKER ARMS AND PUSH RODS
REMOVAL
INSTALLATION
VALVE SPRING AND STEM SEAL REPLACEMENT-IN VEHICLE
CYLINDER HEAD
REMOVAL
INSTALLATION
VALVES AND VALVE SPRINGS
REMOVAL
INSTALLATION
HYDRAULIC TAPPETS
REMOVAL
INSTALLATION
VIBRATION DAMPER
REMOVAL
INSTALLATION
TIMING CHAIN COVER
REMOVAL
INSTALLATION
TIMING CHAIN
REMOVAL
INSTALLATION
CAMSHAFT
REMOVAL
INSTALLATION
CAMSHAFT BEARINGS
REMOVAL
INSTALLATION
CRANKSHAFT MAIN BEARINGS
REMOVAL
INSTALLATION
DISTRIBUTOR DRIVE SHAFT BUSHING
REMOVAL
INSTALLATION
DISTRIBUTOR INSTALLATION
OIL PAN
REMOVAL
INSTALLATION
PISTON AND CONNECTING ROD ASSEMBLY
REMOVAL
INSTALLATION
CRANKSHAFT
REMOVAL
INSTALLATION
OIL PUMP
REMOVAL
INSTALLATION
FRONT CRANKSHAFT OIL SEAL
CRANKSHAFT REAR OIL SEALS
UPPER SEAL —CRANKSHAFT REMOVED
UPPER SEAL —CRANKSHAFT INSTALLED
LOWER SEAL
ENGINE CORE OIL AND CAMSHAFT PLUGS
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TAPPETS
DISASSEMBLE
ASSEMBLE
VALVE SERVICE
VALVE GUIDES
REFACING VALVES AND VALVE SEATS
VALVE SPRING INSPECTION
OIL PUMP
DISASSEMBLE
ASSEMBLE
CYLINDER BLOCK
DISASSEMBLE
ASSEMBLE
CLEANING AND INSPECTION
CYLINDER HEADS
CLEANING
INSPECTION
PISTON AND CONNECTING ROD ASSEMBLY
INSPECTION
CRANKSHAFT INSPECTION OF JOURNALS
OIL PAN
CLEANING
INSPECTION
OIL PUMP
CYLINDER BLOCK
CLEANING
INSPECTION
SPECIFICATIONS
5.2L ENGINE
SPECIAL TOOLS
5.2L ENGINE
EXHAUST SYSTEM AND INTAKE MANIFOLD
GENERAL INFORMATION
EXHAUST SYSTEM
CATALYTIC CONVERTER
HEAT SHIELDS
BAND CLAMP (TORCA)
DIAGNOSIS AND TESTING
EXHAUST SYSTEM DIAGNOSIS
REMOVAL AND INSTALLATION
EXHAUST PIPE—4.0/5.2L ENGINES
REMOVAL
INSTALLATION
CATALYTIC CONVERTER—4.0/5.2L ENGINES
REMOVAL
INSTALLATION
MUFFLER AND TAILPIPE—4.0/5.2L ENGINES
REMOVAL
INSTALLATION
INTAKE AND EXHAUST MANIFOLD—4.0L ENGINE
REMOVAL
INSTALLATION
INTAKE MANIFOLD—5.2L ENGINE
REMOVAL
INSTALLATION
EXHAUST MANIFOLD—5.2L ENGINE
REMOVAL
INSTALLATION
CLEANING AND INSPECTION
INTAKE AND EXHAUST MANIFOLD—4.0L ENGINE
INTAKE MANIFOLD— 5.2L ENGINE
CLEANING
INSPECTION
EXHAUST MANIFOLD—5.2L ENGINE
CLEANING
INSPECTION
SPECIFICATIONS
TORQUE
FRAME AND BUMPERS
REMOVAL AND INSTALLATION
FRONT BUMPER/FASCIA
REMOVAL
INSTALLATION
REAR BUMPER FASCIA
REMOVAL
INSTALLATION
REAR BUMPER
REMOVAL
INSTALLATION
FRAME
GENERAL INFORMATION
GENERAL INFORMATION
REMOVAL AND INSTALLATION
FRONT TOW HOOK
REMOVAL
INSTALLATION
FRONT SKID PLATE
REMOVAL
INSTALLATION
TRANSFER CASE SKID PLATE
REMOVAL
INSTALLATION
FUEL TANK SKID PLATE
REMOVAL
INSTALLATION
REAR TOW HOOK
REMOVAL
INSTALLATION
TRAILER HITCH
REMOVAL
INSTALLATION
SPECIFICATIONS
VEHICLE DIMENSIONS
TORQUE SPECIFICATIONS
FUEL SYSTEM
GENERAL INFORMATION
GENERAL INFORMATION
INTRODUCTION
FUEL REQUIREMENTS
GASOLINE/OXYGENATE BLENDS
FUEL DELIVERY SYSTEM
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM
FUEL PUMP MODULE
FUEL PUMP
FUEL GAUGE SENDING UNIT
FUEL FILTER
FUEL PRESSURE REGULATOR
FUEL TANK
FUEL INJECTORS—5.2L ENGINES
FUEL INJECTORS—4.0L ENGINE
FUEL RAIL
FUEL TANK FILLER TUBE CAP
QUICK-CONNECT FITTINGS
DIAGNOSIS AND TESTING
FUEL PUMP PRESSURE TEST–4.0L ENGINE
FUEL PUMP PRESSURE TEST—5.2L ENGINES WITH PRESSURE TEST PORT
FUEL PUMP PRESSURE TEST-5.2L ENGINES WITHOUT PRESSURE TEST PORT
FUEL PUMP CAPACITY TEST
FUEL PRESSURE LEAK DOWN TEST
FUEL GAUGE SENDING UNIT
FUEL INJECTORS
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE PROCEDURE–WITH PRESSURE TEST PORT
FUEL SYSTEM PRESSURE RELEASE PROCEDURE—WITHOUT PRESSURE TEST PORT
FUEL TUBES/LINES/HOSES AND CLAMPS
QUICK-CONNECT FITTINGS
SINGLE-TAB TYPE
TWO-TAB TYPE FITTING
PLASTIC RETAINER RING TYPE FITTING
FUEL LINE AT FUEL RAIL
FUEL LINE AT FUEL RAIL—5.2L ENGINES
REMOVAL AND INSTALLATION
FUEL FILTER
REMOVAL
INSTALLATION
FUEL PRESSURE REGULATOR
FUEL PUMP RELAY
FUEL PUMP MODULE
REMOVAL
INSTALLATION
FUEL PUMP INLET STRAINER
FUEL LEVEL SENSOR
FUEL INJECTOR RAIL—5.2L ENGINES
REMOVAL
INSTALLATION
FUEL INJECTOR RAIL—4.0L ENGINE
REMOVAL
INSTALLATION
FUEL INJECTOR(S)
REMOVAL
INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
ACCELERATOR PEDAL
REMOVAL
INSTALLATION
THROTTLE CABLE
REMOVAL
INSTALLATION
SPECIFICATIONS
VECI LABEL SPECIFICATIONS
FUEL TANK CAPACITY
FUEL SYSTEM PRESSURE
TORQUE CHART
FUEL INJECTION SYSTEM
INTRODUCTION
MODES OF OPERATION
IGNITION SWITCH (KEY-ON) MODE
ENGINE START-UP MODE
ENGINE WARM-UP MODE
IDLE MODE
CRUISE MODE
ACCELERATION MODE
DECELERATION MODE
WIDE OPEN THROTTLE MODE
IGNITION SWITCH OFF MODE
DESCRIPTION AND OPERATION
SYSTEM DIAGNOSIS
POWERTRAIN CONTROL MODULE (PCM)
AIR CONDITIONING (A/C) CONTROLS—PCM INPUT
AUTOMATIC SHUTDOWN (ASD) RELAY SENSE—PCM INPUT
BATTERY TEMPERATURE SENSOR—PCM INPUT
BATTERY VOLTAGE—PCM INPUT
FIVE VOLT SENSOR SUPPLY—PRIMARY
FIVE VOLT SENSOR SUPPLY—SECONDARY
FUEL LEVEL SENSOR—PCM INPUT
BRAKE SWITCH—PCM INPUT
CAMSHAFT POSITION SENSOR—PCM INPUT
CRANKSHAFT POSITION SENSOR—5.2L ENGINES—PCM INPUT
CRANKSHAFT POSITION SENSOR—4.0L ENGINE—PCM INPUT
ENGINE COOLANT TEMPERATURE SENSOR—5.2L ENGINES—PCM INPUT
ENGINE COOLANT TEMPERATURE SENSOR—4.0L ENGINE—PCM INPUT
OXYGEN SENSOR (O2S)—PCM INPUT
UPSTREAM HEATED OXYGEN SENSOR
DOWNSTREAM HEATED OXYGEN SENSOR
IGNITION CIRCUIT SENSE—PCM INPUT
INTAKE MANIFOLD AIR TEMPERATURE SENSOR—5.2L ENGINES—PCM INPUT
INTAKE MANIFOLD AIR TEMPERATURE SENSOR—4.0L ENGINE—PCM INPUT
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR—5.2L ENGINES—PCM INPUT
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR—4.0L ENGINE—PCM INPUT
OUTPUT SHAFT SPEED SENSOR—PCM INPUT
OVERDRIVE/OVERRIDE SWITCH-PCM INPUT
SPEED CONTROL SWITCHES—PCM INPUT
TRANSMISSION PARK/NEUTRAL SWITCH—PCM INPUT
TRANSMISSION GOVERNOR PRESSURE SENSOR—PCM INPUT
TRANSMISSION TEMPERATURE SENSOR—PCM INPUT
THROTTLE POSITION SENSOR (TPS)—5.2L ENGINE—PCM INPUT
THROTTLE POSITION SENSOR (TPS)—4.0L ENGINE—PCM INPUT
VEHICLE SPEED AND DISTANCE SENSOR—PCM INPUT
POWER GROUND
AIR CONDITIONING (A/C) CLUTCH RELAY—PCM OUTPUT
AUTO SHUTDOWN (ASD) RELAY—PCM OUTPUT
DATA LINK CONNECTOR—PCM INPUT AND OUTPUT
DUTY CYCLE EVAP PURGE SOLENOID VALVE-PCM OUTPUT
FUEL INJECTORS—5.2L ENGINES—PCM OUTPUT
FUEL INJECTORS—4.0L ENGINE—PCM OUTPUT
FUEL PUMP RELAY-PCM OUTPUT
GENERATOR FIELD—PCM OUTPUT
GENERATOR LAMP—PCM OUTPUT
IDLE AIR CONTROL (IAC) MOTOR—5.2L ENGINES—PCM OUTPUT
IDLE AIR CONTROL (IAC) MOTOR—4.0L ENGINE—PCM OUTPUT
IGNITION COIL—5.2L ENGINES—PCM OUTPUT
IGNITION COIL—4.0L ENGINES—PCM OUTPUT
MALFUNCTION INDICATOR (CHECK ENGINE) LAMP—PCM OUTPUT
OVERDRIVE LAMP—PCM OUTPUT
SPEED CONTROL SOLENOIDS—PCM OUTPUT
TACHOMETER—PCM OUTPUT
THREE-FOUR SHIFT SOLENOID—PCM OUTPUT
TORQUE CONVERTOR CLUTCH (TCC) SOLENOID—PCM OUTPUT
MANUAL TRANSMISSION
TRANSMISSION RELAY—PCM OUTPUT
VARIABLE FORCE SOLENOID—PCM OUTPUT
THROTTLE BODY—5.2L ENGINES
THROTTLE BODY—4.0L ENGINE
DIAGNOSIS AND TESTING
VISUAL INSPECTION—5.2L ENGINE
VISUAL INSPECTION—4.0L ENGINE
ASD AND FUEL PUMP RELAYS
OPERATION
TESTING
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST—5.2L ENGINES
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST—4.0L ENGINE
OXYGEN (O2S) SENSORS—5.2L ENGINE
OXYGEN (O2S) SENSORS—4.0L ENGINE
CAMSHAFT AND CRANKSHAFT POSITION SENSORS
ENGINE COOLANT TEMPERATURE SENSOR—5.2L ENGINE
ENGINE COOLANT TEMPERATURE SENSOR—4.0L ENGINE
IDLE AIR CONTROL (IAC) MOTOR—5.2L ENGINE
IDLE AIR CONTROL (IAC) MOTOR—4.0L ENGINE
INTAKE MANIFOLD AIR TEMPERATURE SENSOR—5.2L ENGINE
INTAKE MANIFOLD AIR TEMPERATURE SENSOR—4.0L ENGINE
VEHICLE SPEED SENSOR
THROTTLE POSITION SENSOR (TPS)—5.2L ENGINE
THROTTLE POSITION SENSOR (TPS)—4.0L ENGINE
THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE
5.2L ENGINE
REMOVAL AND INSTALLATION
AUTOMATIC SHUTDOWN (ASD) RELAY
FUEL PUMP RELAY
THROTTLE BODY—5.2L ENGINE
REMOVAL
INSTALLATION
THROTTLE BODY—4.0L ENGINE
REMOVAL
INSTALLATION
THROTTLE POSITION SENSOR (TPS)—5.2L ENGINE
REMOVAL
INSTALLATION
THROTTLE POSITION SENSOR (TPS)—4.0L ENGINE
REMOVAL
INSTALLATION
IDLE AIR CONTROL (IAC) MOTOR—5.2L ENGINE
REMOVAL
INSTALLATION
IDLE AIR CONTROL (IAC) MOTOR—4.0L ENGINE
REMOVAL
INSTALLATION
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR—5.2L ENGINES
REMOVAL
INSTALLATION
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR—4.0L ENGINE
REMOVAL
INSTALLATION
DUTY CYCLE EVAP CANISTER PURGE SOLENOID
POWERTRAIN CONTROL MODULE (PCM)
REMOVAL
INSTALLATION
CRANKSHAFT POSITION SENSOR
CAMSHAFT POSITION SENSOR
OXYGEN SENSOR—5.2L ENGINE
REMOVAL
INSTALLATION
OXYGEN SENSOR—4.0L ENGINE
REMOVAL
INSTALLATION
AIR CLEANER HOUSING
REMOVAL
INSTALLATION
AIR CLEANER ELEMENT (FILTER)
REMOVAL/INSTALLATION
ENGINE COOLANT TEMPERATURE SENSOR—5.2L ENGINE
REMOVAL
INSTALLATION
ENGINE COOLANT TEMPERATURE SENSOR—4.0L ENGINE
REMOVAL
INSTALLATION
INTAKE MANIFOLD AIR TEMPERATURE SENSOR—5.2L ENGINE
REMOVAL
INSTALLATION
INTAKE MANIFOLD AIR TEMPERATURE SENSOR—4.0L ENGINE
REMOVAL
INSTALLATION
VEHICLE SPEED SENSOR
REMOVAL
INSTALLATION
SPECIFICATIONS
VECI LABEL SPECIFICATIONS
TORQUE CHART
SPECIAL TOOLS
FUEL SYSTEM
STEERING
POWER STEERING
GENERAL INFORMATION
STEERING SYSTEM
DIAGNOSIS AND TESTING
POWER STEERING SYSTEM DIAGNOSIS CHARTS
STEERING NOISE
BINDING AND STICKING
LOOSE STEERING AND VEHICLE LEAD
POWER STEERING PUMP
DESCRIPTION AND OPERATION
POWER STEERING PUMP
DIAGNOSIS AND TESTING
POWER STEERING PUMP
POWER STEERING PUMP PRESSURE TEST
PUMP LEAKAGE DIAGNOSIS
SERVICE PROCEDURES
POWER STEERING PUMP—INITIAL OPERATION
REMOVAL AND INSTALLATION
POWER STEERING PUMP — 4.0L
REMOVAL
INSTALLATION
POWER STEERING PUMP — 5.2L
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
PUMP PULLEY
REMOVAL
INSTALLATION
TC-SERIES PUMP RESERVOIR
REMOVAL
INSTALLATION
SPECIFICATIONS
TORQUE CHART
SPECIAL TOOLS
POWER STEERING PUMP
POWER STEERING GEAR
DESCRIPTION AND OPERATION
POWER STEERING GEAR
POWER STEERING GEAR LEAKAGE DIAGNOSIS
REMOVAL AND INSTALLATION
PITMAN SHAFT SEALS (IN VEHICLE)
REMOVAL
INSTALLATION
STEERING GEAR
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
PITMAN SHAFT
REMOVAL
INSTALLATION
HOUSING END PLUG
REMOVAL
INSTALLATION
ADJUSTER PLUG ASSEMBLY
REMOVAL
INSTALLATION
SPOOL VALVE
REMOVAL
INSTALLATION
RACK PISTON AND WORM SHAFT
REMOVAL
INSTALLATION
PITMAN SHAFT SEALS AND BEARING
REMOVAL
INSTALLATION
ADJUSTMENTS
STEERING GEAR
WORM THRUST BEARING PRELOAD
OVER-CENTER
SPECIFICATIONS
POWER STEERING GEAR
TORQUE CHART
SPECIAL TOOLS
POWER STEERING GEAR
STEERING COLUMN
GENERAL INFORMATION
STEERING COLUMN
SERVICE PRECAUTIONS
DIAGNOSIS AND TESTING
IGNITION SWITCH
TEST AND REPAIR
REMOVAL AND INSTALLATION
STEERING COLUMN
INSTALLATION
SPECIFICATIONS
TORQUE CHART
SPEED PROPORTIONAL STEERING
DESCRIPTION AND OPERATION
SPEED PROPORTIONAL STEERING
SPEED PROPORTIONAL STEERING CONTROL MODULE
STEERING WHEEL SPEED SENSOR
SPEED PROPORTIONAL STEERING SOLENOID
POWER STEERING GEAR
DIAGNOSIS AND TESTING
SPEED PROPORTIONAL STEERING
REMOVAL AND INSTALLATION
STEERING WHEEL SPEED SENSOR
REMOVAL
INSTALLATION
SPEED PROPORTIONAL STEERING CONTROL MODULE
REMOVAL
INSTALLATION
STEERING LINKAGE
GENERAL INFORMATION
STEERING LINKAGE
SERVICE PROCEDURES
STEERING LINKAGE
REMOVAL AND INSTALLATION
TIE ROD
REMOVAL
INSTALLATION
PITMAN ARM
REMOVAL
INSTALLATION
DRAG LINK
REMOVAL
INSTALLATION
STEERING DAMPENER
REMOVAL
INSTALLATION
SPECIFICATIONS
TORQUE CHART
SPECIAL TOOLS
STEERING LINKAGE
TRANSMISSION AND TRANSFER CASE
42/44RE AUTOMATIC TRANSMISSION
GENERAL INFORMATION
42/44 RE TRANSMISSION
TRANSMISSION IDENTIFICATION
RECOMMENDED FLUID
TORQUE CONVERTER—ELECTRONIC CLUTCH
TRANSMISSION GEAR RATIOS
GEARSHIFT MECHANISM
DESCRIPTION AND OPERATION
ELECTRONIC GOVERNOR
GOVERNOR PRESSURE SOLENOID VALVE
GOVERNOR PRESSURE SENSOR
GOVERNOR BODY AND TRANSFER PLATE
TRANSMISSION FLUID TEMPERATURE THERMISTOR
TRANSMISSION SPEED SENSOR
THROTTLE POSITION SENSOR (TPS)
POWERTRAIN CONTROL MODULE (PCM)
GOVERNOR PRESSURE CURVES
SHIFT VALVE OPERATION
HYDRAULIC CONTROL SYSTEM
PRESSURE REGULATION
Shift Valve Flow Control
OVERDRIVE OFF SWITCH
3-4 SHIFT SEQUENCE
CONVERTER CLUTCH ENGAGEMENT
QUICK FILL VALVE
CONVERTER DRAINBACK VALVE
BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM
DIAGNOSIS AND TESTING
AUTOMATIC TRANSMISSION DIAGNOSIS
PRELIMINARY DIAGNOSIS
VEHICLE IS DRIVEABLE
VEHICLE IS DISABLED
PARK/NEUTRAL POSITION SWITCH
SWITCH TEST
CHECKING FLUID LEVEL AND CONDITION
EFFECTS OF INCORRECT FLUID LEVEL
CAUSES OF BURNED FLUID
FLUID CONTAMINATION
OIL COOLER FLOW CHECK
OVERDRIVE ELECTRICAL CONTROLS
BRAKE TRANSMISSION SHIFT INTERLOCK
GEARSHIFT CABLE
TRANSMISSION CONTROL CABLE ADJUSTMENT
ROAD TESTING
ANALYZING ROAD TEST
HYDRAULIC PRESSURE TEST
Pressure Test Port Locations
PRESSURE TEST PROCEDURE
CONVERTER STALL TEST
STALL TEST PROCEDURE
STALL TEST ANALYSIS
Stall Speed Too High
Stall Speed Low
Stall Speed Normal But Acceleration Poor
Converter Noise During Test
AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION
Front Clutch Air Test
Rear Clutch Air Test
Front Servo Air Test
Rear Servo Air Test
CONVERTER HOUSING FLUID LEAK DIAGNOSIS
LEAK DIAGNOSIS PROCEDURE
TORQUE CONVERTER LEAK POINTS
LEAK TESTING WITH AIR PRESSURE
AIR PRESSURE LEAK TEST PROCEDURE
CONVERTER HOUSING AREA LEAK CORRECTION
DIAGNOSIS TABLES AND CHARTS—RE TRANSMISSION
SERVICE PROCEDURES
FLUID LEVEL CHECK
FLUID LEVEL CHECK PROCEDURE
FLUID AND FILTER REPLACEMENT
PAN AND FILTER REMOVAL
INSPECTION AND CLEANING
FILTER AND PAN INSTALLATION
TRANSMISSION FILL PROCEDURE
CONVERTER DRAINBACK CHECK VALVE SERVICE
ALUMINUM THREAD REPAIR
FLUSHING COOLERS AND TUBES
COOLER FLUSH USING TOOL 6906
COOLER FLUSH USING SUCTION GUN AND MINERAL SPIRITS
REMOVAL AND INSTALLATION
SPEEDOMETER SERVICE
SPEEDOMETER ASSEMBLY REMOVAL
SPEEDOMETER INSTALLATION AND INDEXING
PARK/NEUTRAL POSITION SWITCH
Switch Replacement
YOKE SEAL REPLACEMENT
REMOVAL
INSTALLATION
OVERDRIVE HOUSING BUSHING
REMOVAL
INSTALLATION
OUTPUT SHAFT REAR BEARING
REMOVAL
INSTALLATION
OUTPUT SHAFT FRONT BEARING
REMOVAL
INSTALLATION
GEARSHIFT CABLE
REMOVAL
INSTALLATION
BRAKE TRANSMISSION SHIFT INTERLOCK
REMOVAL
INSTALLATION
PARK LOCK
REMOVAL
INSTALLATION
GOVERNOR SOLENOID AND PRESSURE SENSOR
REMOVAL
INSTALLATION
VALVE BODY
REMOVAL
INSTALLATION
TRANSMISSION COOLER LINE AND FITTINGS
COOLER LINE AND FITTING SERVICE
TRANSMISSION COOLER
MAIN COOLER REPLACEMENT
AUXILIARY COOLER REPLACEMENT
OVERDRIVE UNIT
REMOVAL
INSTALLATION
TRANSMISSION/OVERDRIVE
REMOVAL
TRANSMISSION/OVERDRIVE INSTALLATION
TORQUE CONVERTER
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
VALVE BODY
VALVE BODY MAIN COMPONENT DISASSEMBLE
VALVE BODY ASSEMBLE
TRANSMISSION
DISASSEMBLE
TRANSMISSION ASSEMBLY PREPARATION
TRANSMISSION ASSEMBLE
OVERRUNNING CLUTCH/LOW-REVERSE DRUM
DISASSEMBLE
OVERRUNNING CLUTCH/LOW-REVERSE DRUM, ASSEMBLE
FRONT SERVO PISTON
DISASSEMBLE
ASSEMBLE
REAR SERVO PISTON
DISASSEMBLE
ASSEMBLE
OIL PUMP AND REACTION SHAFT SUPPORT
DISASSEMBLE
OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLE
FRONT CLUTCH
DISASSEMBLE
ASSEMBLE
REAR CLUTCH
DISASSEMBLE
ASSEMBLE
PLANETARY GEARTRAIN/OUTPUT SHAFT
DISASSEMBLE
ASSEMBLE
OVERDRIVE UNIT
DISASSEMBLE
OVERDRIVE UNIT ASSEMBLE
OVERDRIVE GEARTRAIN
DISASSEMBLE
ASSEMBLE
CLEANING AND INSPECTION
VALVE BODY
TRANSMISSION
GENERAL INFORMATION
TRANSMISSION CASE CLEANING AND INSPECTION
OVERRUNNING CLUTCH/LOW-REVERSE DRUM/REAR SUPPORT
ACCUMULATOR
FRONT SERVO
REAR SERVO
OIL PUMP AND REACTION SHAFT SUPPORT
FRONT CLUTCH
REAR CLUTCH
PLANETARY GEARTRAIN
OVERDRIVE
ADJUSTMENTS
BRAKE TRANSMISSION SHIFT INTERLOCK
Park Interlock Cable Adjustment Procedure
TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT
Checking Throttle Valve Cable Adjustment
Throttle Valve Cable Adjustment Procedure
GEARSHIFT CABLE
Gearshift Adjustment Procedure
FRONT BAND ADJUSTMENT
REAR BAND ADJUSTMENT
VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS
SPECIFICATIONS
TRANSMISSION
GENERAL
TORQUE
SPECIAL TOOLS
42/44 RE
NV231 TRANSFER CASE
GENERAL INFORMATION
GENERAL INFORMATION
OPERATING RANGES
SHIFT MECHANISM
TRANSFER CASE IDENTIFICATION
RECOMMENDED LUBRICANT AND FILL LEVEL
NV231 DIAGNOSIS
REMOVAL AND INSTALLATION
SHIFT LEVER
REMOVAL
INSTALLATION
NV231 TRANSFER CASE
REMOVAL
TRANSFER CASE INSTALLATION
DISASSEMBLY AND ASSEMBLY
NV231 TRANSFER CASE
DISASSEMBLE
NV231 TRANSFER CASE ASSEMBLE
CLEANING AND INSPECTION
NV231 TRANSFER CASE
MAINSHAFT/SPROCKET/HUB INSPECTION
INPUT GEAR AND PLANETARY CARRIER
SHIFT FORKS/HUBS/SLEEVES
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
LOW RANGE ANNULUS GEAR
FRONT-REAR CASES AND FRONT RETAINER
OIL PUMP/OIL PICKUP
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT
SPECIFICATIONS
TORQUE
SPECIAL TOOLS
SPECIAL TOOLS—NV231
NV249 TRANSFER CASE
GENERAL INFORMATION
GENERAL INFORMATION
SHIFT MECHANISM
TRANSFER CASE IDENTIFICATION
RECOMMENDED LUBRICANT AND FILL LEVEL
DIAGNOSIS AND TESTING
NV249 DIAGNOSIS
SERVICE PROCEDURES
RECOMMENDED LUBRICANT AND FILL LEVEL
REMOVAL AND INSTALLATION
SPEEDOMETER
REMOVAL
SPEEDOMETER INSTALLATION AND INDEXING
TRANSFER CASE
REMOVAL
TRANSFER CASE INSTALLATION
TRANSFER CASE BEARINGS AND SEALS
OUTPUT SHAFT FRONT SEAL
OUTPUT SHAFT FRONT BEARING
REPLACING FRONT OUTPUT SHAFT REAR BEARING
REPLACING FRONT BEARING
REPLACING FRONT BEARING RETAINER SEAL
REPLACING INPUT GEAR PILOT BEARING
REPLACING EXTENSION HOUSING SEAL
REPLACING REAR RETAINER SEAL AND BUSHING
DISASSEMBLY AND ASSEMBLY
TRANSFER CASE
TRANSFER CASE DISASSEMBLY
TRANSFER CASE ASSEMBLE
INPUT AND LOW RANGE GEAR
DISASSEMBLE
INPUT AND LOW RANGE GEAR ASSEMBLE
CLEANING AND INSPECTION
NV249 COMPONENTS
MAINSHAFT
INPUT AND LOW RANGE GEARS
Gear Cases And Extension
Geartrain
OIL PUMP AND VISCOUS COUPLING
BEARINGS AND SEALS
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT
SPECIFICATIONS
TORQUE
SPECIAL TOOLS
NV249 TRANSFER CASE
TIRES AND WHEELS
TIRES
DESCRIPTION AND OPERATION
TIRE INFORMATION
TIRE IDENTIFICATION
TIRE CHAINS
RADIAL-PLY TIRES
SPARE TIRE (TEMPORARY)
TIRE INFLATION PRESSURES
TIRE PRESSURE FOR HIGH—SPEED OPERATION
REPLACEMENT TIRES
DIAGNOSIS AND TESTING
PRESSURE GAUGES
TREAD WEAR INDICATORS
TIRE WEAR PATTERNS
TIRE NOISE OR VIBRATION
LEAD CORRECTION CHART
SERVICE PROCEDURES
ROTATION
MATCH MOUNTING
REPAIRING LEAKS
CLEANING AND INSPECTION
CLEANING OF TIRES
WHEELS
DESCRIPTION AND OPERATION
WHEEL
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
WHEEL REPLACEMENT
TIRE AND WHEEL BALANCE
SPECIFICATIONS
TORQUE CHART
BODY
GENERAL SERVICE INFORMATION
GENERAL INFORMATION
SAFETY PRECAUTIONS AND WARNINGS
PAINT
GENERAL INFORMATION
PAINT CODE
BASE COAT/CLEAR COAT FINISH
WET SANDING, BUFFING, AND POLISHING
PAINTED SURFACE TOUCHUP
TOUCHUP PROCEDURE
AFTER MARKET PAINT REPAIR PRODUCTS
STATIONARY GLASS
DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS
REMOVAL AND INSTALLATION
WINDSHIELD
REMOVAL
INSTALLATION
QUARTER WINDOW GLASS
REMOVAL
INSTALLATION
LIFTGATE GLASS
REMOVAL
INSTALLATION
POWER SUNROOF
GENERAL INFORMATION
GENERAL INFORMATION
REMOVAL AND INSTALLATION
WIND DEFLECTOR
REMOVAL
INSTALLATION
GLASS PANEL
REMOVAL
INSTALLATION
SUNROOF ADJUSTMENT BRACKET
REMOVAL
INSTALLATION
DRAIN CHANNEL
REMOVAL
INSTALLATION
DRIVE CABLE LOCATORS
REMOVAL
INSTALLATION
MOTOR AND DRIVE GEARS
REMOVAL
INSTALLATION
DRIVE CABLES
REMOVAL
INSTALLATION
SUNSHADE
REMOVAL
INSTALLATION
GUIDE ASSEMBLY
REMOVAL
INSTALLATION
CLEANING AND INSPECTION
GENERAL INFORMATION
ADJUSTMENTS
GLASS PANEL VERTICAL HEIGHT ADJUSTMENT
SEATS
REMOVAL AND INSTALLATION
BUCKET SEAT BACK
REMOVAL
INSTALLATION
BUCKET SEAT BACK COVER
REMOVAL
INSTALLATION
LUMBAR SUPPORT
REMOVAL
INSTALLATION
BUCKET SEAT CUSHION COVER
REMOVAL
INSTALLATION
BUCKET SEAT TRACK
REMOVAL
INSTALLATION
REAR SEAT BACK COVER
REMOVAL
INSTALLATION
REAR SEAT CUSHION COVER
REMOVAL
INSTALLATION
BODY COMPONENTS
DIAGNOSIS AND TESTING
WATER LEAKS
VISUAL INSPECTION BEFORE WATER LEAK TESTS
WATER LEAK TESTS
WATER LEAK DETECTION
WIND NOISE
VISUAL INSPECTION BEFORE TESTS
TRAINING THE UNIVERSAL TRANSMITTER
TESTING TRANSMITTER
SERVICE PROCEDURES
BODY LUBRICATION
REMOVAL AND INSTALLATION
GRILLE
REMOVAL
INSTALLATION
GRILLE OPENING REINFORCEMENT (GOR)
REMOVAL
INSTALLATION
HOOD
REMOVAL
INSTALLATION
HOOD HINGE
INSTALLATION
HOOD LATCH
REMOVAL
INSTALLATION
HOOD LATCH STRIKER
REMOVAL
INSTALLATION
HOOD RELEASE CABLE
REMOVAL
INSTALLATION
SAFETY LATCH STRIKER
REMOVAL
INSTALLATION
COWL GRILLE AND SCREEN
REMOVAL
INSTALLATION
EXTERIOR NAMEPLATES
REMOVAL
INSTALLATION
BODY STRIPES/DECALS
REMOVAL
INSTALLATION
SIDE VIEW MIRRORS
REMOVAL
INSTALLATION
FRONT FENDER
REMOVAL
INSTALLATION
FRONT DOOR TRIM PANEL
REMOVAL
INSTALLATION
FRONT DOOR
REMOVAL
INSTALLATION
FRONT DOOR HINGE
REMOVAL
INSTALLATION
FRONT DOOR OUTSIDE HANDLE
REMOVAL
INSTALLATION
FRONT DOOR LOCK CYLINDER
REMOVAL
INSTALLATION
FRONT DOOR LATCH
REMOVAL
INSTALLATION
FRONT DOOR LATCH STRIKER
REMOVAL
INSTALLATION
FRONT DOOR INSIDE HANDLE ACTUATOR
REMOVAL
INSTALLATION
FRONT DOOR INNER BELT SEAL
REMOVAL
INSTALLATION
FRONT DOOR OUTER BELT SEAL
REMOVAL
INSTALLATION
FRONT DOOR RUN CHANNEL WEATHERSTRIP
REMOVAL
INSTALLATION
FRONT DOOR OPENING WEATHERSTRIP
REMOVAL
INSTALLATION
FRONT DOOR WINDOW REGULATOR
REMOVAL
INSTALLATION
FRONT DOOR WINDOW GLASS
REMOVAL
INSTALLATION
REAR DOOR TRIM PANEL
REMOVAL
INSTALLATION
REAR DOOR
REMOVAL
INSTALLATION
REAR DOOR HINGE
REMOVAL
INSTALLATION
REAR DOOR OUTSIDE HANDLE
REMOVAL
INSTALLATION
REAR DOOR LATCH
REMOVAL
INSTALLATION
REAR DOOR LATCH STRIKER
REMOVAL
INSTALLATION
REAR DOOR INSIDE HANDLE ACTUATOR
REMOVAL
INSTALLATION
REAR DOOR INNER BELT SEAL
REMOVAL
INSTALLATION
REAR DOOR OUTER BELT SEAL
REMOVAL
INSTALLATION
REAR DOOR OPENING WEATHERSTRIP
REMOVAL
INSTALLATION
REAR DOOR WINDOW REGULATOR
REMOVAL
INSTALLATION
REAR DOOR WINDOW GLASS
REMOVAL
INSTALLATION
FUEL DOOR
REMOVAL
INSTALLATION
BODY SIDE CLADDING
REMOVAL—FRONT DOOR
INSTALLATION—FRONT DOOR
REMOVAL—REAR DOOR
INSTALLATION—REAR DOOR
REMOVAL—FENDER/QUARTER PANEL
INSTALLATION—FENDER/QUARTER PANEL
A-PILLAR TRIM
REMOVAL
INSTALLATION
ASSIST HANDLE
REMOVAL
INSTALLATION
FRONT DOOR SCUFF PLATE
REMOVAL
INSTALLATION
UPPER B-PILLAR TRIM PANEL
REMOVAL
INSTALLATION
LOWER B-PILLAR TRIM PANEL
REMOVAL
INSTALLATION
REAR DOOR SCUFF PLATE
REMOVAL
INSTALLATION
C-PILLAR TRIM
REMOVAL
INSTALLATION
QUARTER TRIM PANELS
INSTALLATION
D-PILLAR TRIM
REMOVAL
INSTALLATION
FRONT SHOULDER BELT/BUCKLE
REMOVAL—BUCKLE
INSTALLATION—BUCKLE
REMOVAL—SHOULDER BELT
INSTALLATION—SHOULDER BELT
REAR SHOULDER/LAP BELT/BUCKLE
REMOVAL—LAP BELT/BUCKLE
INSTALLATION—LAP BELT/BUCKLE
REMOVAL—SHOULDER BELT
INSTALLATION—SHOULDER BELT
FRONT BUCKET SEAT
REMOVAL
INSTALLATION
FLOOR CONSOLE
REMOVAL
INSTALLATION
REAR SEAT CUSHION
REMOVAL
INSTALLATION
REAR SEATBACK
REMOVAL
INSTALLATION
REAR SEAT BACK WITH CHILD SEAT
REMOVAL
INSTALLATION
CHILD SEAT MODULE
REMOVAL
INSTALLATION
FRONT CARPET/MAT
REMOVAL
INSTALLATION
CARGO CARPET/MAT
REMOVAL
INSTALLATION
REARVIEW MIRROR
REMOVAL
INSTALLATION
REARVIEW MIRROR SUPPORT BRACKET
INSTALLATION
SUNVISOR
REMOVAL
INSTALLATION
HEADLINER
REMOVAL
INSTALLATION
LIFTGATE TRIM PANEL
UPPER TRIM PANEL REMOVAL
UPPER TRIM PANEL INSTALLATION
LOWER TRIM PANEL REMOVAL
LOWER TRIM PANEL INSTALLATION
LIFTGATE
REMOVAL
INSTALLATION
LIFTGATE HINGE
REMOVAL
INSTALLATION
LIFTGATE OUTSIDE HANDLE
REMOVAL
INSTALLATION
LIFTGATE LOCK CYLINDER
LIFTGATE LATCH
REMOVAL
INSTALLATION
LIFTGATE LATCH STRIKER
REMOVAL
INSTALLATION
LIFTGATE OPENING WEATHERSTRIP
REMOVAL
INSTALLATION
LIFTGATE FLIP-UP GLASS
REMOVAL
INSTALLATION
FLIP-UP GLASS SWITCH
REMOVAL
INSTALLATION
LIFTGATE FLIP-UP GLASS WEATHERSTRIP
REMOVAL
INSTALLATION
LIFTGATE FLIP-UP GLASS LATCH
REMOVAL
INSTALLATION
LIFTGATE FLIP-UP GLASS LATCH HANDLE/STRIKER
REMOVAL
INSTALLATION
LICENSE PLATE LAMP HOUSING
REMOVAL
INSTALLATION
QUARTER WINDOW APPLIQUE/AIR EXHAUSTER
REMOVAL
INSTALLATION
LUGGAGE RACK
REMOVAL
INSTALLATION
ADJUSTMENTS
HOOD ADJUSTMENT
DOOR
IN AND OUT
UP AND DOWN
DOOR LATCH ADJUSTMENT
LIFTGATE
SPECIAL TOOLS
BODY
HEATING AND AIR CONDITIONING
GENERAL INFORMATION
HEATER AND AIR CONDITIONER
HEATER AND AIR CONDITIONER CONTROLS
SERVICE WARNINGS AND PRECAUTIONS
COOLING SYSTEM REQUIREMENTS
COOLANT PRECAUTIONS
REFRIGERANT HOSES/TUBES PRECAUTIONS
DESCRIPTION AND OPERATION
ACCUMULATOR
AMBIENT TEMPERATURE SENSOR
BLOWER MOTOR
BLOWER MOTOR POWER MODULE
BLOWER MOTOR RESISTOR
BLOWER MOTOR SWITCH
COMPRESSOR
COMPRESSOR CLUTCH
COMPRESSOR CLUTCH RELAY
CONDENSER
EVAPORATOR COIL
FIXED ORIFICE TUBE
HIGH PRESSURE CUT-OFF SWITCH
HIGH PRESSURE RELIEF VALVE
HIGH SPEED BLOWER MOTOR RELAY
IN-VEHICLE TEMPERATURE SENSOR
LOW PRESSURE CYCLING CLUTCH SWITCH
REFRIGERANT
REFRIGERANT LINE COUPLERS
REFRIGERANT LINES
REFRIGERANT OIL
REFRIGERANT SYSTEM SERVICE EQUIPMENT
MANIFOLD GAUGE SET CONNECTIONS
REFRIGERANT SYSTEM SERVICE PORTS
SOLAR SENSOR
DIAGNOSIS AND TESTING
A/C PERFORMANCE
HEATER PERFORMANCE
PREPARATIONS
MAXIMUM HEATER OUTPUT
TEMPERATURE CONTROL
VACUUM SYSTEM
ONE-WAY CHECK VALVE
HEATER-A/C CONTROLS
LOCATING VACUUM LEAKS
ATC SYSTEM
SELF-DIAGNOSTIC DISPLAY
ENTERING THE ATC SELF-DIAGNOSTIC MODE
FAULT CODE TESTS
INPUT CIRCUIT TESTS
OUTPUT CIRCUIT/ACTUATOR TESTS
BLOWER MOTOR
VIBRATION
NOISE
BLOWER MOTOR RESISTOR
BLOWER MOTOR SWITCH
COMPRESSOR
COMPRESSOR CLUTCH COIL
COMPRESSOR CLUTCH RELAY
CIRCUIT TEST
HIGH PRESSURE CUT-OFF SWITCH
HIGH SPEED BLOWER MOTOR RELAY
RELAY TEST
RELAY CIRCUIT TEST
LOW PRESSURE CYCLING CLUTCH SWITCH
REFRIGERANT SYSTEM LEAKS
SYSTEM EMPTY
SYSTEM LOW
SERVICE PROCEDURES
REFRIGERANT RECOVERY
REFRIGERANT SYSTEM EVACUATE
REFRIGERANT SYSTEM CHARGE
REFRIGERANT CHARGE CAPACITY
PARTIAL CHARGE METHOD
REFRIGERANT OIL LEVEL
REMOVAL AND INSTALLATION
REFRIGERANT LINE COUPLERS
REMOVAL
INSTALLATION
COMPRESSOR
REMOVAL
INSTALLATION
COMPRESSOR CLUTCH
REMOVAL
INSPECTION
INSTALLATION
CLUTCH BREAK-IN
HIGH PRESSURE CUT-OFF SWITCH
REMOVAL
INSTALLATION
HIGH PRESSURE RELIEF VALVE
REMOVAL
INSTALLATION
CONDENSER
REMOVAL
INSTALLATION
FIXED ORIFICE TUBE
REMOVAL
INSTALLATION
ACCUMULATOR
REMOVAL
INSTALLATION
LOW PRESSURE CYCLING CLUTCH SWITCH
AMBIENT TEMPERATURE SENSOR
HEATER-A/C CONTROL
REMOVAL
INSTALLATION
SOLAR SENSOR
REMOVAL
INSTALLATION
IN-VEHICLE TEMPERATURE SENSOR
REMOVAL
INSTALLATION
BLOWER MOTOR
REMOVAL
INSTALLATION
BLOWER MOTOR RESISTOR/POWER MODULE
REMOVAL
INSTALLATION
HIGH SPEED BLOWER MOTOR RELAY
REMOVAL
INSTALLATION
TEMPERATURE/BLEND-AIR DOOR MOTOR
REMOVAL
INSTALLATION
DUCTS AND OUTLETS
DEFROSTER DUCT
DEMISTER DUCTS
PANEL DUCTS
FLOOR DUCTS
DEMISTER OUTLETS
PANEL OUTLETS
PANEL/DEFROST DOOR
REMOVAL
INSTALLATION
RECIRCULATING AIR DOOR ACTUATOR
REMOVAL
INSTALLATION
HEATER-A/C HOUSING
REMOVAL
INSTALLATION
HEATER CORE
REMOVAL
INSTALLATION
EVAPORATOR COIL
REMOVAL
INSTALLATION
HEAT/DEFROST DOOR ACTUATOR
REMOVAL
INSTALLATION
PANEL/DEFROST DOOR ACTUATOR
REMOVAL
INSTALLATION
HEAT/DEFROST - PANEL/DEFROST DOOR MOTOR
REMOVAL
INSTALLATION
HEAT/DEFROST DOOR
REMOVAL
INSTALLATION
RECIRCULATING AIR DOOR
REMOVAL
INSTALLATION
TEMPERATURE/BLEND-AIR DOOR
REMOVAL
INSTALLATION
EMISSION CONTROL SYSTEMS
ON-BOARD DIAGNOSTICS
GENERAL INFORMATION
SYSTEM DESCRIPTION
DESCRIPTION AND OPERATION
MALFUNCTION INDICATOR LAMP (MIL)
STATE DISPLAY TEST MODE
CIRCUIT ACTUATION TEST MODE
DIAGNOSTIC TROUBLE CODES
OBTAINING DIAGNOSTIC TROUBLE CODES
MONITORED SYSTEMS
DTC 21—OXYGEN SENSOR (O2S) MONITOR
DTC 21—OXYGEN SENSOR HEATER MONITOR
DTC 31—LEAK DETECTION PUMP MONITOR
DTC 43—MISFIRE MONITOR
DTC 51/52—FUEL SYSTEM MONITOR
DTC 64—CATALYST 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
EVAPORATIVE EMISSION CONTROLS
DESCRIPTION AND OPERATION
EVAPORATION CONTROL SYSTEM
PRESSURE RELIEF/ROLLOVER VALVE
EVAPORATION (EVAP) CANISTER
DUTY CYCLE EVAP CANISTER PURGE SOLENOID
FUEL TANK FILLER TUBE CAP
LEAK DETECTION PUMP (LDP)—4.0L CALIFORNIA EMISSIONS PACKAGE
POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM—5.2L ENGINE
CRANKCASE VENTILATION (CCV) SYSTEM—4.0L ENGINE
CRANKCASE BREATHER/FILTER—5.2L ENGINE
VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL
DIAGNOSIS AND TESTING
PCV VALVE TEST—5.2L ENGINE
VACUUM SCHEMATICS
LEAK DETECTION PUMP (LDP)
EVAP CANISTER
REMOVAL
INSTALLATION
EVAPORATIVE CANISTER PURGE SOLENOID
REMOVAL
INSTALLATION
PRESSURE RELIEF/ROLLOVER VALVE
REMOVAL
INSTALLATION
FUEL TANK FILLER TUBE CAP
LEAK DETECTION PUMP (LDP)
REMOVAL/INSTALLATION
SPECIFICATIONS
TORQUE CHART
INTRODUCTION
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN)
VEHICLE IDENTIFICATION NUMBER DECODING CHART0 - 2 ZJ (Continued)
VEHICLE SAFETY CERTIFICATION LABEL
BODY CODE PLATE
VEHICLE DIMENSIONS
INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS
FASTENER IDENTIFICATION
THREAD IDENTIFICATION
GRADE/CLASS IDENTIFICATION
METRIC SYSTEM
TORQUE REFERENCES
LUBRICATIONANDMAINTENANCE
GENERALINFORMATION
FLUIDCAPACITIES
FUELTANK
ENGINEOILW/FILTERCHANGE
COOLINGSYSTEM
AUTOMATICTRANSMISSION
TRANSFERCASE242NVG.1.4L(3.0pts.)249NVG.1.1L(2.5pts.)
FRONTAXLE
REARAXLE
DIFFERENTIAL AND DRIVELINE
MODEL 44 AXLE
GENERAL INFORMATION
MODEL 44 ALUMINUM AXLE
LUBRICANT SPECIFICATIONS
DESCRIPTION AND OPERATION
STANDARD DIFFERENTIAL
TRAC-LOK OPERATION
DIAGNOSIS AND TESTING
GEAR NOISE
BEARING NOISE
LOW SPEED KNOCK
VIBRATION
DRIVELINE SNAP
TRAC–LOK DIFFERENTIAL NOISE
TRAC–LOK TEST
SERVICE PROCEDURES
LUBRICANT CHANGE
REMOVAL AND INSTALLATION
REAR AXLE
REMOVAL
INSTALLATION
PINION SHAFT SEAL REPLACEMENT
REMOVAL
INSTALLATION
COLLAPSIBLE SPACER
REMOVAL W/PINION INSTALLED
REMOVAL W/PINION REMOVAL
INSTALLATION
AXLE SHAFT
REMOVAL
INSTALLATION
AXLE SHAFT SEAL AND BEARING
REMOVAL
INSTALLATION
DIFFERENTIAL
REMOVAL
DIFFERENTIAL INSTALLATION
DIFFERENTIAL SIDE BEARINGS
REMOVAL
DIFFERENTIAL SIDE BEARING INSTALLATION
RING GEAR
REMOVAL
RING GEAR INSTALLATION
PINION GEAR
REMOVAL
PINION GEAR INSTALLATION
FINAL ASSEMBLY
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL
DISASSEMBLE
DIFFERENTIAL ASSEMBLE
TRAC-LOK DIFFERENTIAL
DISASSEMBLY
ASSEMBLY
CLEANING AND INSPECTION
AXLE COMPONENTS
TRAC-LOK
PRESOAK PLATES AND DISC
ADJUSTMENTS
PINION GEAR DEPTH
GENERAL INFORMATION
PINION DEPTH MEASUREMENT AND ADJUSTMENT
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH
DIFFERENTIAL PRELOAD AND GEAR BACKLASH SHIM SELECTION
GEAR CONTACT PATTERN ANALYSIS
SPECIFICATIONS
MODEL 44 AXLE
TORQUE
SPECIAL TOOLS
MODEL 44 AXLE
TRANSMISSION AND TRANSFER CASE
NV242 TRANSFER CASE
GENERAL INFORMATION
NV 242 TRANSFER CASE
OPERATING RANGES
SHIFT MECHANISM
TRANSFER CASE IDENTIFICATION
RECOMMENDED LUBRICANT AND FILL LEVEL
NV242 DIAGNOSIS
REMOVAL AND INSTALLATION
SHIFT LEVER
REMOVAL
INSTALLATION
TRANSFER CASE
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
NV242 TRANSFER CASE
DISASSEMBLE
ASSEMBLE
CLEANING AND INSPECTION
NV242 TRANSFER CASE
MAINSHAFT/SPROCKET/HUB INSPECTION
INPUT GEAR AND PLANETARY CARRIER
SHIFT FORKS/HUBS/SLEEVES
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
LOW RANGE ANNULUS GEAR
FRONT-REAR CASES AND FRONT RETAINER
OIL PUMP/OIL PICKUP
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT
SPECIFICATIONS
TORQUE
NV242
WELCOME
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