1992 CHRYSLER ELECTRONIC SERVICE MANUAL – PDF DOWNLOAD
VIDEO PREVIEW:
IMAGE PREVIEW:
DESCRIPTION:
1992 CHRYSLER ELECTRONIC SERVICE MANUAL – PDF DOWNLOAD
- Proper service and repair is important to the safe, reliable, operation of all motor vehicles. The service procedures recommended and described in this publication were developed for professional service personnel and are effective methods for performing vehicle repair.
- Following these procedures will help assure efficient economical vehicle performance and service reliability. Some of these service procedures require the use of special tools designed for specific procedures.
- These special tools should be used when recommended throughout this publication. Special attention should be exercised when working with spring or tension loaded fasteners and devices such as E-Clips, Circlips, Snap rings, etc., as careless removal may cause personal injury. Always wear safety goggles whenever working on vehicles or vehicle components.
- It is important to note that this publication contains various Cautions and Warnings. These should be carefully read in order to minimize the risk of personal injury, or the possibility that improper service methods may damage the vehicle or render it unsafe. It is important to note that these Cautions and Warnings cover only the situations and procedures DaimlerChrysler Corporation has encountered and recommended.
- DaimlerChrysler Corporation could not possibly know, evaluate, and advise the service trade of all conceivable ways that service may be performed, or of the possible hazards of each. Consequently, DaimlerChrysler Corporation has not undertaken any such broad service review.
- Accordingly, anyone who uses a service procedure, or tool, that is not recommended in this publication must assure oneself thoroughly that neither personal safety, nor vehicle safety, be jeopardized by the service methods they select.
TABLE OF CONTENTS:
1992 CHRYSLER ELECTRONIC SERVICE MANUAL – PDF DOWNLOAD
WELCOME............................................................................................................................................ 1 INSTR.............................................................................................................................................. 2 IBC................................................................................................................................................ 13 IFC................................................................................................................................................ 14 92AS_0............................................................................................................................................. 15 LUBRICATION AND MAINTENANCE.................................................................................................................... 15 GENERAL INFORMATION........................................................................................................................ 15 INTRODUCTION........................................................................................................................... 15 PARTS AND LUBRICANT RECOMMENDATIONS.................................................................................................... 15 SEVERE SERVICE......................................................................................................................... 15 FUEL USAGE............................................................................................................................. 15 CLASSIFICATION OF LUBRICANTS........................................................................................................... 15 ENGINE OIL......................................................................................................................... 15 GEAR LUBRICANTS.................................................................................................................... 15 LUBRICANTS AND GREASES............................................................................................................. 16 PARTS REQUIRING NO LUBRICATION......................................................................................................... 16 JUMP STARTING PROCEDURE................................................................................................................ 16 TO JUMP START A DISABLED VEHICLE:.................................................................................................. 16 NLGI SYMBOL........................................................................................................................ 16 LUBRICATION AND MAINTENANCE SCHEDULES.............................................................................................. 17 GENERAL MAINTENANCE SCHEDULES SEVERE SERVICE SCHEDULES............................................................................. 18 HOISTING RECOMMENDATIONS............................................................................................................... 19 FLUID CAPACITIES................................................................................................................... 19 TO HOIST OR JACK VEHICLE SEE FIG. 2................................................................................................ 20 TOWING RECOMMENDATIONS................................................................................................................. 20 RECOMMENDED TOWING EQUIPMENT....................................................................................................... 20 GROUND CLEARANCE................................................................................................................... 20 LOCKED VEHICLE TOWING.............................................................................................................. 20 FLAT TOWING WITH TOW BAR........................................................................................................... 20 TOWING— FRONT WHEEL LIFT........................................................................................................... 21 TOWING— REAR WHEEL LIFT............................................................................................................ 21 ENGINE..................................................................................................................................... 22 FREQUENCY OF ENGINE OIL AND FILTER CHANGES............................................................................................. 22 ENGINE OIL......................................................................................................................... 22 OIL FILTER......................................................................................................................... 22 ENGINE OIL............................................................................................................................. 22 BREAK- IN PERIOD................................................................................................................... 22 SELECTING ENGINE OIL............................................................................................................... 22 ENGINE OIL ADDITIVES............................................................................................................... 23 CRANKCASE OIL LEVEL INSPECTION..................................................................................................... 23 ENGINE OIL CHANGE.................................................................................................................. 23 RECOMMENDED VISCOSITY GRADES....................................................................................................... 23 ENGINE OIL FILTER...................................................................................................................... 24 SELECTING OIL FILTER............................................................................................................... 24 OIL FILTER REMOVAL:................................................................................................................ 24 OIL FILTER INSTALLATION:........................................................................................................... 24 ENGINE COOLING SYSTEM.................................................................................................................. 24 WARNINGS AND PRECAUTIONS........................................................................................................... 24 COOLING SYSTEM INSPECTION.......................................................................................................... 24 SELECTING ANTIFREEZE............................................................................................................... 25 RADIATOR CAP....................................................................................................................... 25 COOLING SYSTEM SERVICE............................................................................................................. 25 ENGINE AIR CLEANER..................................................................................................................... 25 AIR CLEANER SERVICE................................................................................................................ 25 CRANKCASE VENTILATION SYSTEM........................................................................................................... 26 PCV SYSTEM TEST.................................................................................................................... 26 FUEL RECOMMENDATIONS................................................................................................................... 27 SELECTING GASOLINE................................................................................................................. 27 FUEL FILTER............................................................................................................................ 28 IGNITION CABLES, DISTRIBUTOR CAP, AND ROTOR............................................................................................ 28 SPARK PLUGS............................................................................................................................ 28 DRIVE BELTS............................................................................................................................ 28 EMISSION CONTROL SYSTEM................................................................................................................ 28 BATTERY................................................................................................................................ 28 RUBBER AND PLASTIC COMPONENT INSPECTION................................................................................................ 28 EXHAUST SYSTEM ISOLATOR AND HANGER................................................................................................. 28 DRIVETRAIN................................................................................................................................. 29 CLUTCH AND GEARSHIFT LINKAGE........................................................................................................... 29 MANUAL TRANSAXLE....................................................................................................................... 29 SELECTING MANUAL TRANSAXLE OIL..................................................................................................... 29 AUTOMATIC TRANSAXLE SHIFT MECHANISM.................................................................................................... 29 AUTOMATIC TRANSAXLE.................................................................................................................... 29 SELECTING AUTOMATIC TRANSAXLE FLUID................................................................................................ 30 POWER TRANSFER UNIT.................................................................................................................... 30 SELECTING LUBRICANT................................................................................................................ 30 OVERRUNNING CLUTCH..................................................................................................................... 30 SELECTING LUBRICANT................................................................................................................ 31 DRIVE LINE MODULE...................................................................................................................... 31 SELECTING LUBRICANT................................................................................................................ 31 DRIVE SHAFT CV AND TRIPOD JOINT BOOTS.................................................................................................. 31 FRONT WHEEL BEARINGS (REAR WHEEL BEAR-INGS ON ALL WHEEL DRIVE MODELS).................................................................. 31 TIRES.................................................................................................................................. 32 TIRE ROTATION...................................................................................................................... 32 CHASSIS AND BODY........................................................................................................................... 33 STEERING LINKAGE....................................................................................................................... 33 INSPECTION......................................................................................................................... 33 TIE ROD END LUBRICATION............................................................................................................ 33 LOWER BALL JOINTS...................................................................................................................... 33 INSPECTION......................................................................................................................... 33 BALL JOINT LUBRICATION............................................................................................................. 33 POWER STEERING......................................................................................................................... 33 POWER STEERING FLUID INSPECTION.................................................................................................... 34 REAR WHEEL BEARINGS (FRONT WHEEL DRIVE ONLY)........................................................................................... 35 INSPECTION......................................................................................................................... 35 REAR WHEEL BEARING LUBRICATION..................................................................................................... 35 BRAKES................................................................................................................................. 35 BRAKE PAD AND LINING INSPECTION.................................................................................................... 35 BRAKE HOSE INSPECTION.............................................................................................................. 35 BRAKE LINE INSPECTION.............................................................................................................. 36 BRAKE RESERVOIR LEVEL INSPECTION................................................................................................... 36 HEADLAMPS.............................................................................................................................. 36 DRIVER SUPPLEMENTAL AIRBAG SYSTEM...................................................................................................... 36 BODY LUBRICATION....................................................................................................................... 36 92AS_2............................................................................................................................................. 39 FRONT SUSPENSION AND DRIVE SHAFTS.............................................................................................................. 39 GENERAL INFORMATION........................................................................................................................ 39 FRONT SUSPENSION........................................................................................................................... 40 FRONT SUSPENSION MAJOR COMPONENTS (Fig. 1, 2 and 3).................................................................................... 40 STRUT SUPPORT...................................................................................................................... 40 STEERING KNUCKLE................................................................................................................... 40 LOWER CONTROL ARM.................................................................................................................. 40 DRIVESHAFTS........................................................................................................................ 40 SUSPENSION/ STEERING/ DRIVE DIAGNOSIS/ FRONT WHEEL DRIVE........................................................................... 43 FRONT SUSPENSION SERVICE PROCEDURES........................................................................................................ 44 WHEEL ALIGNMENT........................................................................................................................ 44 PRE- ALIGNMENT..................................................................................................................... 44 CAMBER ADJUSTMENT.................................................................................................................. 44 TOE ADJUSTMENT..................................................................................................................... 46 STRUT DAMPER ASSEMBLY.................................................................................................................. 46 REMOVAL............................................................................................................................ 46 SHOCK ABSORBER INSPECT............................................................................................................. 46 INSTALLATION....................................................................................................................... 46 DISASSEMBLY (STRUT DAMPER)......................................................................................................... 47 ASSEMBLE (STRUT DAMPER)............................................................................................................ 47 SUSPENSION COIL SPRINGS................................................................................................................ 48 SPRING RETAINER UPPER.............................................................................................................. 48 SPRING SEAT LOWER.................................................................................................................. 48 SHOCK ABSORBERS (Strut Damper)......................................................................................................... 48 INSPECTION......................................................................................................................... 48 LOWER CONTROL ARM...................................................................................................................... 48 REMOVAL (ASSEMBLY)................................................................................................................. 48 INSTALLATION (ASSEMBLY)............................................................................................................ 49 LOWER CONTROL ARM PIVOT BUSHINGS....................................................................................................... 49 LARGE BUSHING...................................................................................................................... 49 SMALL BUSHING...................................................................................................................... 50 SMALL BUSHING...................................................................................................................... 50 LARGE BUSHING...................................................................................................................... 51 BALL JOINTS............................................................................................................................ 51 INSPECTION BALL JOINT WEAR......................................................................................................... 51 BALL JOINT REMOVAL................................................................................................................. 52 BALL JOINT INSTALLATION............................................................................................................ 52 BALL JOINT SEAL INSTALLATION....................................................................................................... 52 SWAY BAR............................................................................................................................... 53 REMOVAL............................................................................................................................ 53 INSPECTION......................................................................................................................... 53 INSTALLATION....................................................................................................................... 53 KNUCKLE (FRONT SUSPENSION)............................................................................................................. 54 REMOVAL............................................................................................................................ 54 INSTALL............................................................................................................................ 56 HUB AND BEARING ASSEMBLY............................................................................................................... 58 REMOVAL............................................................................................................................ 59 INSTALLATION....................................................................................................................... 61 DRIVESHAFTS................................................................................................................................ 64 GENERAL INFORMATION.................................................................................................................... 64 DRIVESHAFT IDENTIFICATION.............................................................................................................. 64 DRIVESHAFT SERVICE PROCEDURES.......................................................................................................... 64 HUB NUT AND HUB ASSEMBLY REMOVAL................................................................................................... 65 DRIVESHAFT ASSEMBLIES.............................................................................................................. 66 HUB NUT ASSEMBLIES INSTALL......................................................................................................... 68 DRIVESHAFT RECONDITIONING.............................................................................................................. 69 INNER C/ V JOINT....................................................................................................................... 69 DISASSEMBLE........................................................................................................................ 69 TRIPOD ASSEMBLY REMOVAL FROM INTERCONNECTING SHAFT................................................................................. 70 INSPECT TRIPOD AND HOUSING......................................................................................................... 72 ASSEMBLE C/ V JOINT................................................................................................................ 72 INNER C/ V JOINT HOUSING INSTALLATION.............................................................................................. 73 OUTER C/ V JOINT....................................................................................................................... 73 DISASSEMBLE........................................................................................................................ 73 WEAR SLEEVE........................................................................................................................ 74 INSPECT............................................................................................................................ 75 ASSEMBLE........................................................................................................................... 76 C/ V JOINT BOOTS....................................................................................................................... 78 HANDLING AND CLEANING.............................................................................................................. 78 B00TS INSPECT...................................................................................................................... 78 BOOTS INSTALL...................................................................................................................... 78 LEFT INNER, LEFT AND RIGHT OUTER C/ V JOINT WITH PLASTIC BOOTS..................................................................... 81 RIGHT INNER C/ V JOINT WITH RUBBER BOOT............................................................................................ 81 S. S. G INNER C/ V JOINT LARGE CLAMP (MANUAL TRANS ONLY)........................................................................... 82 DAMPER WEIGHTS......................................................................................................................... 83 DRIVESHAFT POSITIONING SPECIFICATIONS.................................................................................................. 83 SPECIFICATIONS............................................................................................................................. 84 DRIVESHAFT DIMENSIONS INSTALLED TORQUE SPECIFICATIONS.................................................................................. 84 ALIGNMENT SPECIFICATIONS AT CURB HEIGHT............................................................................................ 85 92AS_3............................................................................................................................................. 87 REAR SUSPENSION AND DRIVELINE.................................................................................................................. 87 TWO WHEEL DRIVE REAR SUSPENSION............................................................................................................ 87 GENERAL INFORMATION.................................................................................................................... 87 REAR SPRINGS........................................................................................................................... 87 REMOVAL............................................................................................................................ 87 INSTALLATION....................................................................................................................... 87 REAR SHOCK ABSORBERS................................................................................................................... 88 REMOVAL AND INSTALLATION........................................................................................................... 88 REAR WHEEL ALIGNMENT— FRONT WHEEL DRIVE VAN/ WAGONS ONLY............................................................................... 88 INSTALLATION OF REAR ALIGNMENT SHIMS............................................................................................... 88 REAR SWAY BAR.......................................................................................................................... 90 REMOVAL............................................................................................................................ 90 INSPECTION......................................................................................................................... 91 ALL WHEEL DRIVE REAR SUSPENSION............................................................................................................ 91 GENERAL INFORMATION.................................................................................................................... 91 REAR WHEEL BEARINGS.................................................................................................................... 91 REMOVAL............................................................................................................................ 91 INSTALLATION....................................................................................................................... 92 REAR SPRINGS........................................................................................................................... 93 REMOVAL............................................................................................................................ 93 INSTALLATION....................................................................................................................... 93 JOUNCE BUMPER.......................................................................................................................... 94 REAR SHOCK ABSORBERS................................................................................................................... 94 REMOVAL AND INSTALLATION........................................................................................................... 94 REAR DRIVE LINE MODULE ASSEMBLY (ALL WHEEL DRIVE).......................................................................................... 95 GENERAL INFORMATION.................................................................................................................... 95 REAR DRIVE LINE NOISE DIAGNOSIS........................................................................................................ 95 REAR CARRIER ASSEMBLY NOISE........................................................................................................ 95 TIRE NOISE......................................................................................................................... 96 GEAR NOISE (DRIVE PINION AND RING GEAR)............................................................................................ 96 BEARING NOISE (DRIVE PINION AND DIFFER-ENTIAL)..................................................................................... 96 ENGINE AND TRANSMISSION NOISE...................................................................................................... 96 FLUID LEAK DIAGNOSIS................................................................................................................... 96 REAR DRIVE LINE MODULE ASSEMBLY SERVICE PROCEDURES......................................................................................... 97 REAR DRIVE LINE MODULE ASSEMBLY........................................................................................................ 97 REMOVAL AND INSTALLATION........................................................................................................... 97 REAR CARRIER UNIT...................................................................................................................... 98 REMOVAL AND INSTALLATION........................................................................................................... 98 REAR CARRIER OUTPUT SHAFT SEALS........................................................................................................ 99 REMOVAL............................................................................................................................ 99 INSTALLATION....................................................................................................................... 100 FRONT OVERRUNNING CLUTCH SEAL.......................................................................................................... 101 REMOVAL............................................................................................................................ 101 INSTALLATION....................................................................................................................... 103 DRIVE PINION SEAL AND/ OR REAR OVERRUN-NING CLUTCH SEAL................................................................................ 103 REAR CARRIER COMPONENT IDENTIFICATION.............................................................................................. 104 REMOVAL............................................................................................................................ 105 INSTALLATION....................................................................................................................... 107 DRIVE PINION BEARING SHIM SELECTION.................................................................................................... 108 REAR DRIVELINE MODULE DIFFERENTIAL SIDE GEARS.......................................................................................... 108 CASE COVER SERVICE..................................................................................................................... 109 DIFFERENTIAL CARRIER END COVER (RE- SEAL).......................................................................................... 109 OVERRUNNING CLUTCH COVER (RESEAL).................................................................................................. 110 OVERRUNNING CLUTCH CASE TO REAR CARRIER CASE (RESEAL).............................................................................. 110 TORQUE TUBE AND OVERRUNNING CLUTCH COMPONENTS...................................................................................... 111 TORQUE TUBE............................................................................................................................ 112 REMOVAL AND INSTALLATION........................................................................................................... 112 FRONT BEARING...................................................................................................................... 112 REAR BEARING....................................................................................................................... 113 OVERRUNNING CLUTCH..................................................................................................................... 114 VACUUM MOTOR....................................................................................................................... 114 REMOVAL............................................................................................................................ 115 INSTALLATION....................................................................................................................... 117 OVERRUNNING CLUTCH CASE............................................................................................................ 118 PROPELLER SHAFT SERVICE................................................................................................................ 119 REMOVAL AND INSTALLATION........................................................................................................... 119 HALF SHAFT SERVICE..................................................................................................................... 120 REMOVAL AND INSTALLATION........................................................................................................... 120 REAR HALF SHAFT JOINT/ BOOT REPLACEMENT............................................................................................ 121 REAR DRIVE LINE MODULE VACUUM ACTUATION DIAGNOSIS.......................................................................................... 123 REAR WHEELS NOT OVERRUNNING............................................................................................................ 123 NO ALL WHEEL DRIVE, IN FORWARD; PROPELLER SHAFT TURNING NO ALL WHEEL DRIVE FORWARD OR REVERSE.......................................... 124 XNO ALL WHEEL DRIVE, REVERSE ONLY; PROPELLER SHAFT TURNING......................................................................... 125 NO ALL WHEEL DRIVE, REVERSE ONLY; PROPELLER SHAFT TURNING (CONT.).................................................................. 126 VACUUM ACTUATION SCHEMATIC (SOLENOIDS ENERGIZED) VACUUM ACTUATION SCHEMATIC (SOLENOIDS DE- ENERGIZED).............................. 127 SPECIFICATIONS............................................................................................................................. 128 FASTENER TORQUE SPECIFICATIONS ........................................................................................................ 128 REAR WHEEL BEARING TORQUE SPECIFICATIONS .............................................................................................. 128 REAR CARRIER ASSEMBLY TORQUE SPECIFICATIONS............................................................................................ 128 OVERRUNNING CLUTCH AND TORQUE TUBE ASSEMBLY TORQUE SPECIFICATIONS BOLT APPLICATIONS AND TORQUE SPECIFICATIONS.......................... 129 BOLT APPLICATIONS AND TORQUE SPECIFICATIONS............................................................................................ 129 92AS_5............................................................................................................................................. 131 BRAKES......................................................................................................................................... 131 GENERAL INFORMATION........................................................................................................................ 131 SERVICE ADJUSTMENTS........................................................................................................................ 133 ADJUSTING REAR SERVICE BRAKES.......................................................................................................... 133 FRONT WHEEL DRIVE.................................................................................................................. 133 ALL WHEEL DRIVE.................................................................................................................... 133 MASTER CYLINDER FLUID LEVEL............................................................................................................ 134 NON- ABS BRAKES.................................................................................................................... 134 ABS BRAKES......................................................................................................................... 135 BLEEDING BRAKE SYSTEM.................................................................................................................. 135 PRESSURE BLEEDING.................................................................................................................. 135 BLEEDING WITHOUT A PRESSURE BLEEDER................................................................................................ 136 TEST FOR FLUID CONTAMINATION........................................................................................................... 137 WHEEL STUD NUT TIGHTENING.............................................................................................................. 137 BRAKE HOSE AND TUBING.................................................................................................................. 137 INSPECTION OF BRAKE HOSE AND TUBING................................................................................................ 137 INSTALLATION OF BRAKE HOSE......................................................................................................... 137 TYPES OF TUBING FLARES............................................................................................................. 137 REPAIR AND INSTALLATION OF BRAKE TUB- ING.......................................................................................... 138 TO REPAIR OR FLARE TUBING.......................................................................................................... 138 DOUBLE INVERTED TUBING FLARES...................................................................................................... 138 ISO TUBING FLARES.................................................................................................................. 139 STOP LAMP SWITCH ADJUSTMENT............................................................................................................ 139 TESTING APPLICATION ADJUSTER OPERATION................................................................................................. 140 BRAKE DIAGNOSIS............................................................................................................................ 145 BASIC DIAGNOSIS GUIDE.................................................................................................................. 145 BRAKE SYSTEM DIAGNOSTICS............................................................................................................... 146 BRAKE SYSTEM DIAGNOSTICS........................................................................................................... 147 BRAKE SYSTEM DIAGNOSTICS........................................................................................................... 148 BRAKE SYSTEM DIAGNOSTICS........................................................................................................... 149 DRUM BRAKES................................................................................................................................ 150 GENERAL INFORMATION.................................................................................................................... 150 SERVICE PROCEDURES..................................................................................................................... 150 BRAKE DRUM REMOVAL................................................................................................................. 150 BRAKE SHOE REMOVAL................................................................................................................. 150 CLEANING AND INSPECTION............................................................................................................ 152 BRAKE SHOE INSTALLATION............................................................................................................ 152 DRUM REFACING RECOMMENDATIONS.......................................................................................................... 153 BRAKE DRUM INSTALLATION................................................................................................................ 154 FRONT WHEEL DRIVE.................................................................................................................. 154 ALL WHEEL DRIVE.................................................................................................................... 154 BRAKE SUPPORT PLATE.................................................................................................................... 154 FRONT WHEEL DRIVE.................................................................................................................. 154 ALL WHEEL DRIVE.................................................................................................................... 154 FRONT WHEEL DRIVE.................................................................................................................. 155 ALL WHEEL DRIVE.................................................................................................................... 155 WHEEL CYLINDERS............................................................................................................................ 156 GENERAL INFORMATION.................................................................................................................... 156 SERVICE PROCEDURES..................................................................................................................... 156 REMOVING WHEEL CYLINDERS FROM BRAKE SUPPORT PLATES................................................................................. 156 DISASSEMBLING WHEEL CYLINDERS...................................................................................................... 156 ASSEMBLING WHEEL CYLINDERS......................................................................................................... 157 INSTALLING WHEEL CYLINDERS............................................................................................................. 157 HYDRAULIC SYSTEM CONTROL VALVES............................................................................................................ 158 GENERAL INFORMATION.................................................................................................................... 158 PRESSURE DIFFERENTIAL WARNING LIGHT SWITCH......................................................................................... 158 HEIGHT SENSING DUAL PROPORTIONING UNIT OPERATION................................................................................... 158 ABS BRAKE PROPORTIONING VALVE OPERATION................................................................................................ 159 PROPORTIONING VALVE APPLICATIONS................................................................................................... 160 SERVICE PROCEDURES......................................................................................................................... 161 BRAKE WARNING SYSTEM................................................................................................................... 161 CHECKING THE BRAKE WARNING SWITCH UNIT............................................................................................. 161 HEIGHT SENSING PROPORTIONING VALVE..................................................................................................... 161 TESTING THE HEIGHT SENSING VALVE UNIT.............................................................................................. 161 INSTALLATION AND ADJUSTMENT (FIG. 4)............................................................................................... 161 TESTING ABS PROPORTIONING VALVES....................................................................................................... 162 PROPORTIONING VALVE PRESSURES ABS- BRAKES.......................................................................................... 162 DISC BRAKES................................................................................................................................ 163 GENERAL INFORMATION.................................................................................................................... 163 SHOE AND LINING WEAR............................................................................................................... 163 SERVICE PRECAUTIONS.................................................................................................................... 165 KELSEY HAYES DOUBLE PIN FAMILY CALIPER..................................................................................................... 165 SERVICE PROCEDURES..................................................................................................................... 165 BRAKE SHOE REMOVAL................................................................................................................. 165 BRAKE SHOE INSTALLATION................................................................................................................ 167 CLEANING AND INSPECTION............................................................................................................ 168 DISASSEMBLING CALIPER.................................................................................................................. 168 CLEANING AND INSPECTION................................................................................................................ 169 ASSEMBLING CALIPER..................................................................................................................... 170 BRAKE DISC (ROTOR)......................................................................................................................... 172 GENERAL INFORMATION.................................................................................................................... 172 INSPECTION DIAGNOSIS................................................................................................................... 172 SERVICE PROCEDURES..................................................................................................................... 173 CHECKING BRAKING DISC FOR RUNOUT AND THICKNESS..................................................................................... 173 BRAKING DISC REMOVAL................................................................................................................... 174 INSTALLING BRAKING DISC................................................................................................................ 174 REFINISHING BRAKING DISC............................................................................................................... 174 REFACING BRAKING DISC.............................................................................................................. 174 RESURFACING BRAKING DISC........................................................................................................... 175 BRAKING DISC (ROTOR) REFINISHING LIMITS............................................................................................ 175 PARKING BRAKES............................................................................................................................. 176 GENERAL INFORMATION.................................................................................................................... 176 SERVICE PROCEDURES..................................................................................................................... 178 ADJUSTING PARKING BRAKE............................................................................................................ 178 PARKING BRAKE PEDAL ASSEMBLY........................................................................................................... 178 REMOVE............................................................................................................................. 178 INSTALL............................................................................................................................ 178 FRONT PARKING BRAKE CABLE.............................................................................................................. 178 REMOVE............................................................................................................................. 178 INSTALL............................................................................................................................ 179 REAR PARKING BRAKE CABLE............................................................................................................... 179 REMOVE............................................................................................................................. 179 INSTALL............................................................................................................................ 179 MASTER CYLINDER............................................................................................................................ 179 GENERAL INFORMATION.................................................................................................................... 179 RESERVOIR REPLACEMENT.................................................................................................................. 180 SERVICE PROCEDURES..................................................................................................................... 180 MASTER CYLINDER.................................................................................................................... 180 POWER BRAKES............................................................................................................................... 181 GENERAL INFORMATION.................................................................................................................... 181 SERVICE PROCEDURES..................................................................................................................... 182 POWER BRAKE BOOSTER ASSEMBLY....................................................................................................... 182 WHEEL BEARINGS............................................................................................................................. 184 FRONT WHEEL BEARINGS................................................................................................................... 184 REAR WHEEL BEARINGS (FRONT WHEEL DRIVE)................................................................................................ 184 NORMAL SERVICE..................................................................................................................... 184 INSPECTION......................................................................................................................... 184 REMOVAL AND INSTALLATION........................................................................................................... 184 ANTI- LOCK BRAKE SYSTEM (BENDIX ANTI- LOCK 10 AS BODY FWD/ AWD)............................................................................ 186 GENERAL INFORMATION.................................................................................................................... 186 ANTI- LOCK BRAKE SYSTEM DEFINITIONS.................................................................................................... 186 MAJOR ABS COMPONENTS................................................................................................................... 187 HYDRAULIC ASSEMBLY................................................................................................................. 187 WHEEL SPEED SENSORS................................................................................................................ 187 CONTROLLER- ANTI- LOCK BRAKE (CAB)................................................................................................. 187 PUMP/ MOTOR ASSEMBLY............................................................................................................... 188 ANTI- LOCK OPERATION AND PERFORMANCE................................................................................................... 188 NORMAL BRAKING SYSTEM FUNCTION..................................................................................................... 188 PEDAL FEEL......................................................................................................................... 188 ANTI- LOCK OPERATION............................................................................................................... 188 TIRE NOISE & MARKS................................................................................................................. 188 ABS EQUIPPED VEHICLE PERFORMANCE....................................................................................................... 188 ABS SYSTEM SELF- DIAGNOSTICS........................................................................................................... 189 WARNING SYSTEMS OPERATION.............................................................................................................. 189 RED BRAKE WARNING LAMP............................................................................................................. 189 ANTI- LOCK WARNING LAMP............................................................................................................ 189 NORMAL OPERATION OF WARNING LAMPS.................................................................................................. 189 ANTI- LOCK BRAKE SYSTEM COMPONENTS..................................................................................................... 190 HYDRAULIC ASSEMBLY................................................................................................................. 190 HYDRAULIC ASSEMBLY BRAKE FLUID RES-ERVOIR.......................................................................................... 190 BOOSTER/ MASTER CYLINDER........................................................................................................... 190 HYDRAULIC BLADDER ACCUMULATOR...................................................................................................... 191 DUAL FUNCTION PRESSURE SWITCH...................................................................................................... 191 PRESSURE TRANSDUCERS............................................................................................................... 192 DIFFERENTIAL PRESSURE SWITCH....................................................................................................... 192 PROPORTIONING VALVES............................................................................................................... 192 FILTERS- SERVICEABILITY............................................................................................................ 192 FLUID LEVEL SWITCH................................................................................................................. 192 DUAL FUNCTION PRESSURE SWITCH WIRING DIAGRAM....................................................................................... 192 PUMP/ MOTOR ASSEMBLY............................................................................................................... 193 WHEEL SPEED SENSORS................................................................................................................ 193 PRESSURE SWITCH AND PRESSURE TRANSDUCER WIRING..................................................................................... 193 CONTROLLER ANTI- LOCK BRAKE (CAB)...................................................................................................... 195 CONTROLLER ANTI- LOCK BRAKE (INPUTS)............................................................................................... 195 CONTROLLER ANTI- LOCK BRAKE (OUTPUTS).............................................................................................. 195 ABS SYSTEM DIAGNOSTIC CONNECTOR........................................................................................................ 195 ABS SYSTEM WIRING SCHEMATIC........................................................................................................ 196 ANTI- LOCK SYSTEM RELAYS AND WARNING LAMPS............................................................................................. 197 PUMP/ MOTOR RELAY.................................................................................................................. 197 SYSTEM RELAY....................................................................................................................... 197 ANTI- LOCK WARNING LAMP RELAY...................................................................................................... 197 ANTI- LOCK WARNING LAMP OFF........................................................................................................ 197 ANTI- LOCK WARNING LAMP ON......................................................................................................... 197 ANTI- LOCK SYSTEM RELAY WIRING SCHEMATIC........................................................................................... 198 ABS HYDRAULIC CIRCUITS AND VALVE OPERA-TION............................................................................................ 199 NORMAL BRAKING..................................................................................................................... 199 ABS BRAKING- BUILD PRESSURE........................................................................................................ 199 ABS BRAKING- HOLD PRESSURE......................................................................................................... 200 ABS BRAKING- DECAY PRESSURE........................................................................................................ 200 ABS BRAKING SYSTEM DIAGNOSIS........................................................................................................... 201 GENERAL INFORMATION................................................................................................................ 201 DEFINITIONS........................................................................................................................ 202 ABS CONTROLLER ANTI- LOCK BRAKE (CAB) SERVICE PRECAUTIONS.............................................................................. 202 ABS SYSTEM GENERAL SERVICE PRECAUTIONS................................................................................................. 202 TEST DRIVING ABS COMPLAINT VEHICLES................................................................................................ 202 DE- PRESSURIZING HYDRAULIC ACCUMULATOR............................................................................................. 203 WHEEL SPEED SENSOR CABLES.......................................................................................................... 203 MECHANICAL DIAGNOSTICS AND SERVICE PROCEDURES.......................................................................................... 203 SPECIAL SERVICE TOOLS.............................................................................................................. 203 INTERMITTENT FAULTS................................................................................................................ 204 ABS SYSTEM DIAGNOSTIC FEATURES......................................................................................................... 205 SYSTEM SELF DIAGNOSIS.............................................................................................................. 205 CONTROLLER ANTI- LOCK BRAKE (CAB).................................................................................................. 205 START- UP CYCLE.................................................................................................................... 205 DRIVE- OFF CYCLE................................................................................................................... 205 LATCHING VERSUS NON- LATCHING FAULTS............................................................................................... 205 BENDIX ABS SYSTEMS DIAGNOSTICS..................................................................................................... 205 ON CAR HYDRAULIC ABS COMPONENT SERVICE................................................................................................. 205 GENERAL SERVICE PRECAUTIONS............................................................................................................ 205 DE- PRESSURIZING HYDRAULIC ACCUMULATOR............................................................................................. 206 CHECKING BRAKE FLUID LEVEL......................................................................................................... 206 BLEEDING BRAKE SYSTEM.............................................................................................................. 206 PUMP/ MOTOR SERVICE (FIG. 4)....................................................................................................... 208 BRAKE FLUID PRESSURE AND RETURN HOSES (FIG. 6)..................................................................................... 209 INSTALL............................................................................................................................ 209 HYDRAULIC ASSEMBLY................................................................................................................. 210 BRAKE FLUID RESERVOIR.............................................................................................................. 211 HYDRAULIC BLADDER ACCUMULATOR...................................................................................................... 213 PROPORTIONING VALVES (FIG. 17)..................................................................................................... 214 ON CAR ELECTRONIC ABS COMPONENT SERVICE................................................................................................ 215 CONTROLLER ANTI- LOCK BRAKE (FIG. 1)............................................................................................... 215 SYSTEM RELAY, ANTI- LOCK WARNING LAMP RELAY AND PUMP/ MOTOR RELAYS (FIG. 2)........................................................ 215 DUAL FUNCTION PRESSURE SWITCH...................................................................................................... 216 WHEEL SPEED SENSORS................................................................................................................ 216 REAR WHEEL SPEED SENSOR............................................................................................................ 218 SPECIFICATIONS............................................................................................................................. 220 BRAKE SYSTEM COMPONENTS BRAKE ACTUATION SYSTEM......................................................................................... 220 TIGHTENING REFERENCE............................................................................................................... 221 92AS_6............................................................................................................................................. 223 MANUAL TRANSAXLE CLUTCH........................................................................................................................ 223 CONTENTS................................................................................................................................... 223 GENERAL INFORMATION.................................................................................................................... 223 CLUTCH CHATTER COMPLAINTS.............................................................................................................. 223 EXCESSIVE CLUTCH SPIN TIME/ CLASH INTO REVERSE COMPLAINTS.............................................................................. 223 CLUTCH CABLE MECHANISM................................................................................................................. 223 SERVICE DIAGNOSIS— CLUTCH SLIPS.................................................................................................... 224 SERVICE DIAGNOSIS— IMPROPER CLUTCH RELEASE......................................................................................... 225 SERVICE DIAGNOSIS— CLUTCH NOISE.................................................................................................... 226 CLUTCH CABLE REPLACEMENT............................................................................................................... 227 SERVICE DIAGNOSIS— CLUTCH GRAB/ CHATTER............................................................................................ 227 CLUTCH/ STARTER INTERLOCK SWITCH....................................................................................................... 229 DIAGNOSIS.......................................................................................................................... 229 REMOVAL............................................................................................................................ 229 INSTALLATION....................................................................................................................... 229 ADJUSTMENT PROCEDURE............................................................................................................... 229 CLUTCH DISC REPLACEMENT................................................................................................................ 230 REMOVAL............................................................................................................................ 230 INSPECTION......................................................................................................................... 230 INSTALLATION....................................................................................................................... 231 RELEASE BEARING AND FORK............................................................................................................... 231 REMOVAL AND INSTALLATION........................................................................................................... 231 CLEANING PRECAUTIONS................................................................................................................... 231 92AS_7............................................................................................................................................. 233 COOLING SYSTEM................................................................................................................................. 233 GENERAL INFORMATION........................................................................................................................ 233 COOLING SYSTEM......................................................................................................................... 233 3.0L WATER PIPES................................................................................................................... 234 COOLING SYSTEM DIAGNOSIS........................................................................................................... 236 COOLING SYSTEM DIAGNOSIS........................................................................................................... 237 COOLING SYSTEM DIAGNOSIS........................................................................................................... 238 COOLING SYSTEM DIAGNOSIS........................................................................................................... 239 COOLING SYSTEM DIAGNOSIS........................................................................................................... 240 COOLING SYSTEM DIAGNOSIS........................................................................................................... 241 SERVICE PROCEDURES......................................................................................................................... 242 WATER PUMPS............................................................................................................................ 242 WATER PUMP 2.5L ENGINE............................................................................................................. 242 WATER PUMP 3.0L ENGINE............................................................................................................. 243 WATER PUMP 3.3L ENGINE............................................................................................................. 243 ENGINE THERMOSTAT...................................................................................................................... 244 DESCRIPTION AND OPERATION.......................................................................................................... 244 OPERATION AND TESTING.............................................................................................................. 244 REMOVAL............................................................................................................................ 245 INSTALLATION— 2.5L ENGINE.......................................................................................................... 245 INSTALLATION— 3.0L ENGINE.......................................................................................................... 245 INSTALLATION— 3.3L................................................................................................................. 245 COOLANT................................................................................................................................ 246 PERFORMANCE........................................................................................................................ 246 SELECTION AND ADDITIVES............................................................................................................ 246 SERVICE............................................................................................................................ 246 ROUTINE LEVEL CHECK................................................................................................................ 246 ADDING ADDITIONAL COOLANT.............................................................................................................. 246 SERVICE COOLANT LEVEL.............................................................................................................. 246 LOW COOLANT LEVEL AERATION......................................................................................................... 246 DEAERATION......................................................................................................................... 246 COOLING SYSTEM DRAIN, CLEAN FLUSH AND REFILL........................................................................................... 247 DRAINING COOLING SYSTEM............................................................................................................ 247 CLEANING........................................................................................................................... 247 REVERSE FLUSHING................................................................................................................... 247 CHEMICAL CLEANING.................................................................................................................. 247 REFILLING.......................................................................................................................... 248 TESTING SYSTEM FOR LEAKS............................................................................................................... 248 COOLANT RECOVERY SYSTEM (CRS).......................................................................................................... 248 RADIATOR PRESSURE CAP.................................................................................................................. 249 RADIATOR CAP TO FILLER NECK SEAL PRESSURE RELIEF CHECK............................................................................. 249 PRESSURE TESTING RADIATOR CAP.......................................................................................................... 249 INSPECTION......................................................................................................................... 249 RADIATORS.............................................................................................................................. 250 RADIATOR DRAINCOCK SERVICE......................................................................................................... 250 RADIATOR COOLANT FLOW CHECK........................................................................................................ 251 RADIATOR HOSES......................................................................................................................... 251 FANS................................................................................................................................... 251 FAN SERVICE............................................................................................................................ 251 REMOVAL............................................................................................................................ 251 INSTALLATION....................................................................................................................... 251 RADIATOR FAN CONTROL............................................................................................................... 252 TEMPERATURE GAUGE INDICATION....................................................................................................... 252 ELECTRIC FAN MOTOR..................................................................................................................... 252 ELECTRIC FAN MOTOR TEST................................................................................................................ 253 TEST PROCEDURE..................................................................................................................... 253 FAN SHROUD............................................................................................................................. 253 AUTOMATIC TRANSMISSION OIL COOLERS..................................................................................................... 253 ACCESSORY DRIVE BELTS...................................................................................................................... 255 GENERAL INFORMATION.................................................................................................................... 255 PROPER BELT TENSION................................................................................................................ 255 BELT TENSION GAUGE METHOD.......................................................................................................... 255 TORQUE EQUIVALENT METHOD........................................................................................................... 255 2.5L ENGINE BELTS REMOVE/ INSTALL-ADJUST............................................................................................... 255 AIR CONDITIONING COMPRESSOR........................................................................................................ 255 ACCESSORY DRIVE BELTS DIAGNOSIS.................................................................................................... 255 POWER STEERING PUMP— S TYPE........................................................................................................ 256 ALTERNATOR BELT.................................................................................................................... 256 3.0L ENGINE BELTS REMOVE/ INSTALL- ADJUST.............................................................................................. 256 AIR CONDITIONING BELT.............................................................................................................. 256 ALTERNATOR/ POWER STEERING PUMP BELT............................................................................................... 257 3.3L ENGINE ACCESSORY DRIVE BELT REMOVE/ INSTALL....................................................................................... 257 ALTERNATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER PUMP DRIVE BELT............................................. 257 BELT TENSION CHART................................................................................................................. 258 ENGINE BLOCK HEATER........................................................................................................................ 259 DESCRIPTION AND OPERATION.............................................................................................................. 259 REMOVAL............................................................................................................................ 259 INSTALLATION....................................................................................................................... 259 SPECIFICATIONS............................................................................................................................. 261 TORQUE ................................................................................................................................ 261 COOLING SYSTEM CAPACITY................................................................................................................ 261 92AS_8A............................................................................................................................................ 263 BATTERY/ STARTING/ CHARGING SYSTEMS DIAGNOSTICS................................................................................................ 0 BATTERY TEST PROCEDURES ON- VEHICLE........................................................................................................ 264 GENERAL INFORMATION.................................................................................................................... 264 TEST INDICATOR......................................................................................................................... 265 STATE OF CHARGE TESTS.................................................................................................................. 265 USING TEST INDICATOR............................................................................................................... 265 CAUSES OF BATTERY DISCHARGING.......................................................................................................... 265 ABNORMAL BATTERY DISCHARGING....................................................................................................... 266 BATTERY OPEN CIRCUIT VOLTAGE TEST...................................................................................................... 266 BATTERY LOAD TEST...................................................................................................................... 266 BATTERY CHARGING....................................................................................................................... 268 CHARGING TIME REQUIRED............................................................................................................. 268 CHARGING COMPLETELY DISCHARGED BATTERY............................................................................................. 269 IGNITION OFF DRAW (IOD).................................................................................................................... 269 GENERAL INFORMATION.................................................................................................................... 269 IGNITION OFF DRAW (IOD) TESTS...................................................................................................... 270 STARTER TEST PROCEDURES ON VEHICLE......................................................................................................... 271 GENERAL INFORMATION.................................................................................................................... 271 DIAGNOSTIC PREPARATION................................................................................................................. 271 STARTER FEED CIRCUIT TESTS............................................................................................................. 271 STARTER FEED CIRCUIT RESISTANCE TEST................................................................................................... 273 STARTER CONTROL CIRCUIT TESTS.......................................................................................................... 274 STARTER SOLENOID TEST.............................................................................................................. 275 STARTER RELAY TEST................................................................................................................. 275 NEUTRAL STARTING AND BACK- UP SWITCH............................................................................................... 275 IGNITION SWITCH TEST............................................................................................................... 275 BENCH TESTING STARTER SOLENOID..................................................................................................... 275 ALTERNATOR TEST PROCEDURES ON VEHICLE...................................................................................................... 277 OUTPUT WIRE RESISTANCE TEST............................................................................................................ 277 PREPARATION........................................................................................................................ 277 TEST............................................................................................................................... 278 RESULTS............................................................................................................................ 279 CURRENT OUTPUT TEST.................................................................................................................... 279 PREPARATION........................................................................................................................ 279 TEST............................................................................................................................... 280 RESULTS............................................................................................................................ 280 FAULT CODES— ON BOARD DIAGNOSTICS.......................................................................................................... 280 GENERAL DESCRIPTION/ INFORMATION....................................................................................................... 280 EXAMPLES:.......................................................................................................................... 280 DIAGNOSTIC TESTING USING FAULT CODES................................................................................................... 281 DRB II DIAGNOSTIC TESTER............................................................................................................... 284 TESTING FAULT CODES................................................................................................................ 284 SPECIFICATIONS............................................................................................................................. 285 SPECIFICATIONS STARTER/ BATTERY ...................................................................................................... 285 SPECIFICATIONS ALTERNATOR AMPERAGE/ IDENTIFICATION NUMBERS............................................................................ 285 TORQUE SPECIFICATIONS ................................................................................................................. 286 SPECIFICATIONS ALTERNATOR OUTPUT VOLTAGE.............................................................................................. 286 92AS_8B............................................................................................................................................ 287 BATTERY/ STARTER/ ALTERNATOR SERVICE........................................................................................................... 287 BATTERY.................................................................................................................................... 287 GENERAL INFORMATION.................................................................................................................... 287 BATTERY VISUAL INSPECTION AND SERVICE.................................................................................................. 287 STARTER.................................................................................................................................... 289 GENERAL INFORMATION.................................................................................................................... 289 STARTING SYSTEM........................................................................................................................ 289 BOSCH STARTERS..................................................................................................................... 289 NIPPONDENSO STARTERS............................................................................................................... 289 SUPPLY CIRCUIT AND CONTROL CIRCUIT..................................................................................................... 289 STARTER MOTOR REPLACEMENT.............................................................................................................. 289 BOSCH STARTER 2.5L ENGINE.......................................................................................................... 289 BOSCH OR NIPPONDENSO STARTER— 3.0L OR 3.3L ENGINE.................................................................................. 290 STARTER COMPONENT REPLACEMENT.......................................................................................................... 291 NIPPONDENSO STARTER GEAR AND CLUTCH................................................................................................ 291 BOSCH STARTER SOLENOID REPLACEMENT................................................................................................. 292 BOSCH STARTER GEAR AND CLUTCH REPLACEMENT.......................................................................................... 293 NEUTRAL STARTING AND BACK- UP SWITCH................................................................................................... 293 ALTERNATOR SERVICE PROCEDURES.............................................................................................................. 294 GENERAL INFORMATION.................................................................................................................... 294 ALTERNATOR REPLACEMENT— 2.5L ENGINE.................................................................................................... 294 ALTERNATOR REPLACEMENT— 3.0L ENGINE.................................................................................................... 295 ALTERNATOR REPLACEMENT— 3.3L ENGINE.................................................................................................... 296 SPECIFICATIONS............................................................................................................................. 296 STARTER/ BATTERY....................................................................................................................... 296 ALTERNATOR AMPERAGE/ IDENTIFICATION NUMBERS ....................................................................................... 297 TORQUE SPECIFICATIONS ALTERNATOR/ STARTER......................................................................................... 297 92AS_8C............................................................................................................................................ 299 OVERHEAD CONSOLE............................................................................................................................... 299 CONTENTS................................................................................................................................... 299 MAP/ READING LAMPS..................................................................................................................... 299 LAMP HOUSING REPLACEMENT........................................................................................................... 299 LENS/ LAMP REPLACEMENT............................................................................................................. 299 LAMP TEST.......................................................................................................................... 299 REAR VENT WINDOWS SWITCHES............................................................................................................. 299 SWITCH VOLTAGE TEST................................................................................................................ 299 SWITCH MODULE TEST................................................................................................................. 300 SWITCH REMOVAL..................................................................................................................... 300 COMPASS MINI- TRIP COMPUTER (CMTC)..................................................................................................... 300 THERMOMETER AND COMPASS............................................................................................................ 300 VARIANCE PROCEDURE................................................................................................................. 301 TRAVELER MESSAGES.................................................................................................................. 301 DEMAGNETIZING PROCEDURE............................................................................................................ 301 SELF- DIAGNOSTIC TEST.............................................................................................................. 302 OVERHEAD CONSOLE REPLACEMENT........................................................................................................... 302 COMPASS MODULE REPLACEMENT............................................................................................................. 302 FRONT HEADER READING LAMP.............................................................................................................. 302 FRONT HEADER READING LAMP REPLACEMENT/ LAMP REPLACEMENT................................................................................ 302 92AS_8D............................................................................................................................................ 305 IGNITION SYSTEMS............................................................................................................................... 305 2.5L AND 3.0L IGNITION SYSTEMS— SYSTEM OPERATION........................................................................................... 305 GENERAL INFORMATION.................................................................................................................... 305 DISTRIBUTOR CAP........................................................................................................................ 305 ROTOR— 2.5L AND 3.0L ENGINES........................................................................................................... 306 SPARK PLUG CABLES...................................................................................................................... 306 SPARK PLUGS............................................................................................................................ 307 SPARK PLUG CONDITION............................................................................................................... 307 CABLE RESISTANCE CHART............................................................................................................. 307 SPARK PLUG SERVICE................................................................................................................. 310 ENGINE CONTROLLER...................................................................................................................... 310 HALL EFFECT PICK- UP— 2.5L ENGINES..................................................................................................... 310 DISTRIBUTOR PICK- UP— 3.0L ENGINE...................................................................................................... 311 COOLANT TEMPERATURE SENSOR............................................................................................................. 311 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR................................................................................................ 311 AUTO SHUTDOWN (ASD) RELAY AND FUEL PUMP RELAY.......................................................................................... 312 IGNITION COIL.......................................................................................................................... 313 2.5L AND 3.0L IGNITION SYSTEMS— DIAGNOSTIC PROCEDURES...................................................................................... 314 GENERAL INFORMATION.................................................................................................................... 314 SPARK PLUGS............................................................................................................................ 314 IGNITION COIL.......................................................................................................................... 314 TESTING FOR SPARK AT COIL.............................................................................................................. 314 COIL RESISTANCE.................................................................................................................... 314 FAILURE TO START TEST— 2.5L TBI AND 3.0L ENGINES....................................................................................... 315 POOR PERFORMANCE TEST.................................................................................................................. 316 COOLANT TEMPERATURE SENSOR TEST........................................................................................................ 316 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST........................................................................................... 316 2.5L AND 3.0L IGNITION SYSTEMS— SERVICE PROCEDURES......................................................................................... 317 ENGINE CONTROLLER...................................................................................................................... 317 REMOVAL............................................................................................................................ 317 INSTALLATION....................................................................................................................... 317 COOLANT TEMPERATURE SENSOR............................................................................................................. 317 REMOVAL............................................................................................................................ 317 INSTALLATION....................................................................................................................... 317 IGNITION COIL— 2.5L TBI ENGINES........................................................................................................ 318 REMOVAL............................................................................................................................ 318 INSTALLATION....................................................................................................................... 318 IGNITION COIL— 3.0L ENGINES............................................................................................................ 318 REMOVAL............................................................................................................................ 318 INSTALLATION....................................................................................................................... 318 SPARK PLUG SERVICE..................................................................................................................... 318 SPARK PLUG REMOVAL................................................................................................................. 318 SPARK PLUG GAP ADJUSTMENT.......................................................................................................... 319 IDLE RPM TEST— 2.5L AND 3.0L ENGINES................................................................................................... 319 THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE— 2.5L ENGINE........................................................................ 319 IDLE SPECIFICATIONS................................................................................................................ 319 THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE— 3.0L ENGINE........................................................................ 320 IDLE SPECIFICATIONS— 3.0L ENGINE................................................................................................... 320 IGNITION TIMING PROCEDURE— 2.5L TBI AND 3.0L ENGINES................................................................................... 321 DISTRIBUTOR— 2.5L ENGINE............................................................................................................... 322 REMOVAL............................................................................................................................ 322 INSTALLATION....................................................................................................................... 322 DISTRIBUTOR PICK- UP— 2.5L ENGINE...................................................................................................... 323 REMOVAL............................................................................................................................ 323 INSTALLATION....................................................................................................................... 323 DISTRIBUTOR SERVICE— 3.0L ENGINE....................................................................................................... 323 REMOVAL............................................................................................................................ 323 INSTALLATION....................................................................................................................... 324 DISASSEMBLY........................................................................................................................ 324 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR SERVICE— 2.5L TBI AND 3.0L ENGINES............................................................. 328 3.3L IGNITION SYSTEM— SYSTEM OPERATION..................................................................................................... 329 GENERAL INFORMATION.................................................................................................................... 329 FIRING ORDER....................................................................................................................... 329 ENGINE CONTROLLER...................................................................................................................... 329 SPARK PLUG CABLES...................................................................................................................... 330 SPARK PLUGS............................................................................................................................ 330 SPARK PLUG CONDITION............................................................................................................... 331 CAMSHAFT SENSOR........................................................................................................................ 332 CRANKSHAFT TIMING SENSOR............................................................................................................... 333 IGNITION COIL.......................................................................................................................... 334 COOLANT TEMPERATURE SENSOR ENGINE CONTROLLER INPUT.................................................................................... 334 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR................................................................................................ 335 AUTO SHUTDOWN (ASD) RELAY ENGINE CONTROLLER OUTPUT.................................................................................... 335 3.3L IGNITION SYSTEM— DIAGNOSTIC PROCEDURES................................................................................................ 336 TESTING FOR SPARK AT COIL.............................................................................................................. 336 CHECK COIL TEST— 3.3L ENGINE........................................................................................................... 336 FAILURE TO START TEST.................................................................................................................. 337 COOLANT TEMPERATURE SENSOR TEST........................................................................................................ 337 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST........................................................................................... 338 CRANKSHAFT SENSOR AND CAMSHAFT SENSOR TESTS............................................................................................ 338 3.3L IGNITION SYSTEMS— SERVICE PROCEDURES.................................................................................................. 339 ENGINE CONTROLLER...................................................................................................................... 339 REMOVAL............................................................................................................................ 339 INSTALLATION....................................................................................................................... 339 COOLANT TEMPERATURE SENSOR............................................................................................................. 339 REMOVAL............................................................................................................................ 339 INSTALLATION....................................................................................................................... 340 SPARK PLUG CABLE SERVICE............................................................................................................... 340 SPARK PLUG SERVICE..................................................................................................................... 340 SPARK PLUG REMOVAL................................................................................................................. 340 SPARK PLUG GAP ADJUSTMENT.......................................................................................................... 340 IDLE RPM TEST.......................................................................................................................... 340 CABLE RESISTANCE CHART............................................................................................................. 340 THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE..................................................................................... 341 IDLE SPECIFICATIONS................................................................................................................ 341 IGNITION TIMING PROCEDURE.............................................................................................................. 342 CRANKSHAFT TIMING SENSOR............................................................................................................... 342 REMOVAL............................................................................................................................ 342 INSTALLATION....................................................................................................................... 342 CAMSHAFT SENSOR........................................................................................................................ 342 REMOVAL............................................................................................................................ 342 INSTALLATION....................................................................................................................... 342 IGNITION COIL.......................................................................................................................... 343 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR................................................................................................ 343 IGNITION SWITCH............................................................................................................................ 344 IGNITION SWITCH AND KEY CYLINDER SERVICE............................................................................................... 344 REMOVAL............................................................................................................................ 344 IGNITION SWITCH DESIGNATIONS....................................................................................................... 344 INSTALLATION....................................................................................................................... 345 SPECIFICATIONS............................................................................................................................. 346 GENERAL INFORMATION.................................................................................................................... 346 SPARK PLUG WIRE ROUTING 2.5L ENGINES ............................................................................................. 346 SPARK PLUG WIRE ROUTING 3.0L ENGINE .............................................................................................. 346 SPARK PLUG WIRE ROUTING -3.3L ENGINES............................................................................................. 346 3.3L ENGINE DIRECT IGNITION SYSTEM................................................................................................. 346 DISTRIBUTORS ...................................................................................................................... 347 IGNITION COILS .................................................................................................................... 347 SPARK PLUGS ....................................................................................................................... 347 TORQUE............................................................................................................................. 347 92AS_8E............................................................................................................................................ 349 INSTRUMENT PANEL AND GAUGES.................................................................................................................... 349 CONTENTS................................................................................................................................... 349 GENERAL INFORMATION.................................................................................................................... 349 INSTRUMENT CLUSTERS................................................................................................................ 349 MAGNETIC GAUGES.................................................................................................................... 349 ELECTRONIC DIGITAL CLOCK........................................................................................................... 349 MAINTENANCE REQUIRED REMINDER...................................................................................................... 350 SEAT BELT WARNING SYSTEM........................................................................................................... 350 SEAT BELT WARNING LAMP............................................................................................................. 350 CLUSTER AND GAUGE SERVICE.............................................................................................................. 350 MECHANICAL CLUSTER SERVICE......................................................................................................... 350 ELECTRONIC CLUSTER SERVICE......................................................................................................... 350 SELF DIAGNOSTIC SYSTEM............................................................................................................. 350 CONDITION: MECHANICAL CLUSTER IS NOT FUNCTIONAL WITH ENGINE RUNNING................................................................ 350 WARNING INDICATOR MODULE REPLACE-MENT OR LAMP REPLACEMENT.......................................................................... 350 INSTRUMENT PANEL CLUSTER BEZEL RE-PLACEMENT........................................................................................ 350 INSTRUMENT PANEL CLUSTER LENS RE-PLACEMENT......................................................................................... 353 INSTRUMENT PANEL CLUSTER REPLACE-MENT.............................................................................................. 353 CLUSTER PRINTED CIRCUIT BOARD RE-PLACEMENT......................................................................................... 354 CLUSTER LAMPS BULB REPLACEMENT MECHANIAL CLUSTER ONLY.............................................................................. 355 GAUGES................................................................................................................................. 355 FUEL GAUGE REPLACEMENT............................................................................................................. 355 VOLTMETER REPLACEMENT.............................................................................................................. 355 TEMPERATURE GAUGE REPLACEMENT...................................................................................................... 356 OIL PRESSURE GAUGE REPLACEMENT..................................................................................................... 356 TACHOMETER REPLACEMENT............................................................................................................. 356 SPEEDOMETER ASSEMBLY REPLACEMENT................................................................................................... 356 ODOMETER ASSEMBLY REPLACEMENT...................................................................................................... 356 DISTANCE SENSOR REPLACEMENT........................................................................................................ 357 DISTANCE SENSOR TEST............................................................................................................... 357 SENDING UNIT TEST.................................................................................................................. 357 FUEL TANK SENDING UNIT TEST........................................................................................................ 357 CONDITION.......................................................................................................................... 357 WARNING LAMP SYSTEM TESTS.............................................................................................................. 358 BRAKE SYSTEM WARNING LAMP TEST..................................................................................................... 358 TEMPERATURE WARNING LAMP TEST...................................................................................................... 358 LOW OIL PRESSURE WARNING LAMP TEST................................................................................................. 358 COMBINATION OIL SENDING UNIT TESTS................................................................................................. 358 SWITCH AND PANEL COMPONENT SERVICE..................................................................................................... 360 HEADLAMP SWITCH.................................................................................................................... 360 SWITCH TEST........................................................................................................................ 360 SWITCH/ LAMP REPLACEMENT........................................................................................................... 360 REAR WIPER/ WASHER CONTROL POD SWITCH REPLACEMENT...................................................................................... 360 ACCESSORY SWITCH CARRIER............................................................................................................... 360 ACCESSORY SWITCH CARRIER TEST.......................................................................................................... 362 ACCESSORY SWITCH CARRIER REPLACEMENT................................................................................................... 362 A/ C AND HEATER CONTROL/ BLOWER SWITCH REPLACEMENT................................................................................. 362 A/ C AND HEATER CONTROL LAMP REPLACEMENT........................................................................................... 362 REAR A/ C- HEATER SWITCH REPLACEMENT............................................................................................... 363 CIGAR LIGHTER REPLACEMENT.......................................................................................................... 363 FORWARD CONSOLE REMOVAL............................................................................................................ 363 CENTER STORAGE MODULE REMOVAL...................................................................................................... 364 ASH RECEIVER ASSEMBLY.............................................................................................................. 364 BODY CONTROLLER REPLACEMENT........................................................................................................ 364 LOWER RIGHT INSTRUMENT PANEL REPLACEMENT............................................................................................... 364 INSTRUMENT PANEL REPLACEMENT........................................................................................................... 365 DOOR COURTESY LAMP/ REFLECTOR REPLACEMENT.......................................................................................... 366 DOOR COURTESY LAMP BULB REPLACEMENT................................................................................................ 366 DOME LAMP.......................................................................................................................... 366 LIFTGATE LAMP BULBS REPLACEMENT.................................................................................................... 366 GLOVEBOX LIGHT SWITCH REPLACEMENT.................................................................................................. 366 PRNDL REPLACEMENT.................................................................................................................. 366 92AS_8F............................................................................................................................................ 369 AUDIO SYSTEM................................................................................................................................... 369 CONTENTS................................................................................................................................... 369 RADIOS................................................................................................................................. 369 INTERFERENCE ELIMINATION........................................................................................................... 369 TEST............................................................................................................................... 369 REPLACEMENT........................................................................................................................ 369 MANUAL ANTENNAS........................................................................................................................ 369 TESTING............................................................................................................................ 369 REMOVAL............................................................................................................................ 369 INSTALLATION....................................................................................................................... 370 BENCH TEST FOR ANTENNA MALFUNCTION................................................................................................. 370 SPEAKERS............................................................................................................................... 370 FRONT SPEAKER REPLACEMENT.......................................................................................................... 370 FRONT DOOR SPEAKERS REPLACEMENT.................................................................................................... 370 REAR SPEAKERS REPLACEMENT.......................................................................................................... 372 RELAY/ CHOKE— INFINITY SPEAKERS........................................................................................................ 372 92AS_8G............................................................................................................................................ 375 HORNS.......................................................................................................................................... 375 CONTENTS................................................................................................................................... 375 GENERAL INFORMATION.................................................................................................................... 375 HORNS WILL NOT SOUND................................................................................................................... 375 HORNS SOUND CONTINUOUSLY............................................................................................................... 376 DIAGNOSIS TESTING...................................................................................................................... 376 HORN SWITCH REPLACEMENT................................................................................................................ 376 92AS_8H............................................................................................................................................ 379 SPEED CONTROL SYSTEM........................................................................................................................... 379 CONTENTS................................................................................................................................... 379 GENERAL INFORMATION.................................................................................................................... 379 DIAGNOSIS PROCEDURES................................................................................................................... 380 ROAD TEST.............................................................................................................................. 380 INOPERATIVE SYSTEM..................................................................................................................... 380 CHECKING FOR FAULT CODE................................................................................................................ 380 SYSTEM DIAGNOSIS................................................................................................................... 381 SYSTEM DIAGNOSIS— CONTINUED........................................................................................................ 382 ELECTRICAL TEST:....................................................................................................................... 383 SERVO ELECTRICAL TESTS................................................................................................................. 383 ENGINE CONTROLLER ELECTRICAL TEST...................................................................................................... 384 SPEED CONTROL SWITCH TEST.............................................................................................................. 385 STOP LAMP SPEED CONTROL SWITCH TEST.................................................................................................... 385 VACUUM SUPPLY TEST..................................................................................................................... 385 SERVO VACUUM TEST...................................................................................................................... 386 SERVO UNIT............................................................................................................................. 386 REMOVAL............................................................................................................................ 386 INSTALLATION....................................................................................................................... 386 SPEED CONTROL SWITCH................................................................................................................... 386 REMOVAL............................................................................................................................ 386 INSTALLATION....................................................................................................................... 386 92AS_8J............................................................................................................................................ 387 TURN SIGNALS AND HAZARD WARNING FLASHER........................................................................................................ 387 CONTENTS................................................................................................................................... 387 GENERAL INFORMATION.................................................................................................................... 387 HAZARD WARNING SWITCH.................................................................................................................. 387 CHIME FUNCTION......................................................................................................................... 387 MULTI- FUNCTION SWITCH................................................................................................................. 387 SWITCH TEST........................................................................................................................ 387 REMOVAL............................................................................................................................ 387 INSTALLATION....................................................................................................................... 387 ELECTRONIC COMBINATION FLASHER......................................................................................................... 387 FLASHER SYSTEM DIAGNOSIS............................................................................................................... 389 92AS_8K............................................................................................................................................ 391 WINDSHIELD WIPER AND WASHER SYSTEMS............................................................................................................ 391 WINDSHIELD WIPER BLADE AND ARM............................................................................................................. 391 GENERAL INFORMATION.................................................................................................................... 391 WIPER BLADES........................................................................................................................... 391 WIPER BLADE ELEMENT CHANGE REPLACEMENT................................................................................................. 391 WIPER ARM REPLACEMENT.................................................................................................................. 391 WIPER ARM ADJUSTMENT................................................................................................................... 393 WINDSHIELD WIPER MOTOR AND LINKAGE......................................................................................................... 394 MOTOR TESTS............................................................................................................................ 394 CONDITION: MOTOR WILL NOT RUN IN ANY SWITCH POSITION............................................................................... 394 CONDITION: MOTOR RUNS SLOWLY AT ALL SPEEDS......................................................................................... 394 CONDITION: MOTOR WILL RUN AT HIGH SPEED, BUT NOT AT LOW SPEED OR................................................................... 394 CONDITION: MOTOR KEEP RUNNING WITH SWITCH IN OFF POSITION.......................................................................... 396 CONDITION: MOTOR WILL STOP, WHEN SWITCH IS SET IN OFF POSITION. WIPERS DO NOT CONTINUE RUNNING TO PARK POSI-TION................... 396 WIPER MOTOR REPLACEMENT................................................................................................................ 397 INTERMITTENT WINDSHIELD WIPER MOTOR AND SWITCH............................................................................................. 397 INTERMITTENT WIPER MOTOR TEST.......................................................................................................... 397 CONDITION: EXCESSIVE DELAY OF MORE THAN 30 SECONDS OR INADEQUATE VARIA-TION IN DELAY............................................... 397 CONDITION: IN DELAY MODE WIPERS RUN CONTINUALLY WHEN WASH IS OPERATED BUT DO NOT PROVIDE AN EXTRA WIPE WHEN THE WASH CONTROL....... 397 INTERMITTENT WINDSHIELD WIPER SWITCH................................................................................................... 398 INTERMITTENT FUNCTION TESTS............................................................................................................ 398 CONDITION: EXCESSIVE DELAY, MORE THAN 30 SECONDS OR INADEQUATE VARIATION IN DELAY.................................................. 398 CONDITION: IN DELAY MODE WIPERS RUN CONTINUALLY WHEN WASH IS OPERATED BUT DO NOT PROVIDE AN EXTRA WIPE WHEN THE WASH CONTROL....... 398 CONDITION: WIPERS START ERRATICALLY DURING DELAY MODE.............................................................................. 398 WINDSHIELD WASHERS......................................................................................................................... 399 GENERAL INFORMATION.................................................................................................................... 399 WASHER RESERVOIR REMOVAL............................................................................................................... 399 WASHER RESERVOIR PUMP REPLACEMENT...................................................................................................... 399 WASHER NOZZLE.......................................................................................................................... 400 REAR WINDOW WIPER/ WASHER SYSTEM........................................................................................................... 400 REAR ARM ADJUSTMENT.................................................................................................................... 400 REAR WINDOW INTERMITTENT WIPE MODULE LOCATION.......................................................................................... 400 MODULE TEST............................................................................................................................ 401 REAR WIPER/ WASHER CONTROL POD SWITCH.................................................................................................. 401 REAR WIPER/ WASHER CONTROL POD SWITCH REPLACEMENT...................................................................................... 401 LIFTGATE WIPER MOTOR TEST.............................................................................................................. 401 LIFTGATE MOTOR REPLACEMENT............................................................................................................. 402 LIFTGATE WASHER RESERVOIR REMOVAL...................................................................................................... 402 LIFTGATE WASHER RESERVOIR PUMP REPLACE-MENT............................................................................................ 403 WASHER NOZZLE.......................................................................................................................... 403 92AS_8L............................................................................................................................................ 405 LAMPS.......................................................................................................................................... 405 GENERAL INFORMATION........................................................................................................................ 405 DIAGNOSTIC PROCEDURES.................................................................................................................. 405 HEADLAMP DIAGNOSIS................................................................................................................. 405 EXTERIOR LAMPS, SWITCHES AND SYSTEMS....................................................................................................... 406 HEADLAMP SWITCH........................................................................................................................ 406 HEADLAMP DIMMER SWITCH................................................................................................................. 406 HEADLAMP ALIGNMENT..................................................................................................................... 406 HEADLAMP ALIGNMENT PREPARATION......................................................................................................... 406 HEADLAMP ADJUSTMENT USING ALIGNMENT SCREEN............................................................................................. 406 ALIGNMENT SCREEN PREPARATION (FIG. 1).............................................................................................. 406 HEADLAMP ADJUSTMENT (FIG. 2 OR 3).................................................................................................. 406 FOG LAMP ALIGNMENT (FIG. 4)........................................................................................................ 406 AERO HEADLAMP BULB..................................................................................................................... 407 REMOVAL (FIG. 5)................................................................................................................... 407 INSTALLATION....................................................................................................................... 407 AERO HEADLAMP LENS/ HOUSING............................................................................................................ 408 REMOVAL............................................................................................................................ 408 INSTALLATION....................................................................................................................... 408 PARK/ TURN SIGNAL AND SIDE MARKER LAMP— AERO HEADLAMPS................................................................................. 409 LAMP OR BULB REMOVAL............................................................................................................... 409 LAMP OR BULB INSTALLATION.......................................................................................................... 409 PARK/ TURN SIGNAL AND SIDE MARKER LAMP................................................................................................. 410 LAMP OR BULB REMOVAL............................................................................................................... 410 LAMP OR BULB INSTALLATION.......................................................................................................... 410 FOG LAMP............................................................................................................................... 410 BULB REMOVAL....................................................................................................................... 410 BULB INSTALLATION.................................................................................................................. 410 TAIL LAMP.............................................................................................................................. 410 BULB REPLACEMENT (FIG. 16)......................................................................................................... 410 REMOVAL (FIG. 16).................................................................................................................. 410 INSTALLATION....................................................................................................................... 411 LICENSE PLATE LAMP/ BULB............................................................................................................... 411 REMOVAL (FIG. 17).................................................................................................................. 411 INSTALLATION....................................................................................................................... 411 CENTER HIGH- MOUNTED STOP LAMP (CHMSL)................................................................................................. 411 BULB OR LAMP REMOVAL (FIG. 18)..................................................................................................... 411 BULB OR LAMP INSTALLATION.......................................................................................................... 411 DAYTIME RUNNING LAMPS— CANADA ONLY..................................................................................................... 412 DIAGNOSTICS........................................................................................................................ 412 RELAY REMOVAL (FIG. 19)............................................................................................................ 412 RELAY INSTALLATION................................................................................................................. 412 HEADLAMP TIME DELAY SYSTEM............................................................................................................. 412 DIAGNOSTICS........................................................................................................................ 412 ILLUMINATED ENTRY SYSTEM................................................................................................................... 413 GENERAL INFORMATION.................................................................................................................... 413 DIAGNOSTIC PROCEDURES.................................................................................................................. 413 BODY CONTROLLER........................................................................................................................ 413 BODY CONTROLLER REMOVAL (FIG. 21).................................................................................................. 413 ILLUMINATED ENTRY SWITCH............................................................................................................... 413 REMOVAL (FIG. 20).................................................................................................................. 413 INSTALLATION....................................................................................................................... 413 INSTRUMENT PANEL LAMPS AND SWITCHES.................................................................................................... 413 ILLUMINATED ENTRY DIAGNOSIS........................................................................................................ 414 BULB APPLICATION TABLE..................................................................................................................... 415 GENERAL INFORMATION.................................................................................................................... 415 EXTERIOR LAMPS......................................................................................................................... 415 INTERIOR LAMPS......................................................................................................................... 415 DIMMER CONTROLLED LAMPS............................................................................................................ 415 INDICATOR LAMPS.................................................................................................................... 415 NON- DIMMING LAMPS................................................................................................................. 415 92AS_8M............................................................................................................................................ 417 RESTRAINT SYSTEMS.............................................................................................................................. 417 CONTENTS................................................................................................................................... 417 AIR BAG SERVICE AND TEST PROCEDURES.................................................................................................... 417 GENERAL INFORMATION.................................................................................................................... 417 AIR BAG MODULE..................................................................................................................... 417 FRONT IMPACT SENSORS............................................................................................................... 417 CLOCKSPRING........................................................................................................................ 418 DIAGNOSTIC MODULE.................................................................................................................. 418 STORAGE............................................................................................................................ 418 HANDLING LIVE MODULE............................................................................................................... 418 DEPLOYED MODULE.................................................................................................................... 418 CLEANUP PROCEDURE.................................................................................................................. 418 SERVICE OF DEPLOYED AIR BAG MODULE................................................................................................. 419 AIR BAG SYSTEM CHECK................................................................................................................... 419 AIR BAG MODULE......................................................................................................................... 419 REMOVAL............................................................................................................................ 419 INSTALLATION....................................................................................................................... 419 LEFT FRONT IMPACT SENSOR............................................................................................................... 420 REMOVAL............................................................................................................................ 420 INSTALLATION....................................................................................................................... 420 RIGHT FRONT IMPACT SENSOR.............................................................................................................. 420 REMOVAL............................................................................................................................ 420 INSTALLATION....................................................................................................................... 420 AIR BAG SYSTEM DIAGNOSTIC MODULE (ASDM)................................................................................................ 421 REMOVAL............................................................................................................................ 421 INSTALLATION....................................................................................................................... 421 CLOCKSPRING............................................................................................................................ 421 REMOVAL............................................................................................................................ 421 INSTALLATION....................................................................................................................... 422 CLOCKSPRING CENTERING PROCEDURE........................................................................................................ 422 STEERING WHEEL......................................................................................................................... 423 REMOVAL............................................................................................................................ 423 INSTALLATION....................................................................................................................... 423 STEERING COLUMN SWITCHES............................................................................................................... 423 REMOVAL............................................................................................................................ 423 INSTALLATION....................................................................................................................... 423 92AS_8N............................................................................................................................................ 425 REAR WINDOW DEFOGGER........................................................................................................................... 425 CONTENTS................................................................................................................................... 425 GENERAL INFORMATION.................................................................................................................... 425 ACCESSORY SWITCH CARRIER............................................................................................................... 425 SYSTEM TEST............................................................................................................................ 425 REAR WINDOW GRID LINES TEST............................................................................................................ 426 ACCESSORY SWITCH CARRIER TEST.......................................................................................................... 426 REPAIR GRID LINES, TERMINALS AND PIGTAILS.............................................................................................. 427 92AS_8P............................................................................................................................................ 429 POWER LOCKS.................................................................................................................................... 429 CONTENTS................................................................................................................................... 429 GENERAL INFORMATION.................................................................................................................... 429 DOOR LOCK INHIBIT...................................................................................................................... 429 POWER DOOR LOCKS....................................................................................................................... 429 DOOR LOCK SYSTEM TEST.................................................................................................................. 429 SWITCH VOLTAGE TEST.................................................................................................................... 429 CIRCUIT BREAKER TEST................................................................................................................... 430 SWITCH TEST............................................................................................................................ 430 CIRCUIT TEST SLIDING DOOR.............................................................................................................. 430 ELECTRIC MOTOR TEST.................................................................................................................... 430 LIFT GATE OPERATION.................................................................................................................... 431 TEST............................................................................................................................... 431 ADJUSTMENT......................................................................................................................... 431 DOOR LATCH WITH INTEGRAL LOCK— FRONT DOOR.............................................................................................. 431 REMOVAL............................................................................................................................ 431 INSTALLATION....................................................................................................................... 431 LOCK MOTOR REPLACEMENT SLIDING DOOR.................................................................................................... 431 REMOVAL............................................................................................................................ 431 INSTALLATION....................................................................................................................... 431 LOCK MOTOR REPLACEMENT LIFTGATE DOOR................................................................................................... 431 REMOVAL............................................................................................................................ 431 INSTALLATION....................................................................................................................... 432 92AS_8R............................................................................................................................................ 433 POWER SEATS.................................................................................................................................... 433 CONTENTS................................................................................................................................... 433 GENERAL INFORMATION.................................................................................................................... 433 TEST PROCEDURES........................................................................................................................ 433 CIRCUIT BREAKER TEST................................................................................................................... 433 HARNESS VOLTAGE TEST................................................................................................................... 433 MOTOR TESTS............................................................................................................................ 433 SWITCH TEST............................................................................................................................ 434 SEAT ASSEMBLY.......................................................................................................................... 434 REMOVAL............................................................................................................................ 434 INSTALLATION....................................................................................................................... 434 MOTOR CABLE AND HOUSING................................................................................................................ 434 REMOVAL............................................................................................................................ 434 INSTALLATION....................................................................................................................... 434 HORIZONTAL AND VERTICAL TRANSMISSIONS.................................................................................................. 435 ADJUSTER............................................................................................................................... 435 REMOVAL............................................................................................................................ 435 INSTALLATION....................................................................................................................... 435 MOTOR.................................................................................................................................. 435 REMOVAL............................................................................................................................ 435 INSTALLATION....................................................................................................................... 435 92AS_8S............................................................................................................................................ 437 POWER WINDOWS.................................................................................................................................. 437 CONTENTS................................................................................................................................... 437 GENERAL INFORMATION.................................................................................................................... 437 SWITCH VOLTAGE TEST.................................................................................................................... 437 SWITCH CONTINUITY TEST................................................................................................................. 437 WINDOW MOTOR TEST...................................................................................................................... 438 POWER WINDOW CABLE HOUSING/ MOTOR RE-PLACEMENT......................................................................................... 438 MOTOR REPLACEMENT...................................................................................................................... 438 REMOVAL............................................................................................................................ 438 INSTALLATION....................................................................................................................... 438 POWER VENT WINDOWS..................................................................................................................... 439 VENT WINDOW SWITCH TEST................................................................................................................ 439 VENT WINDOW MOTOR TEST................................................................................................................. 439 VENT CABLE AND CRANK MECHANISM......................................................................................................... 440 REMOVAL............................................................................................................................ 440 INSTALLATION....................................................................................................................... 440 VENT WINDOW MOTOR REPLACEMENT.......................................................................................................... 441 REMOVAL............................................................................................................................ 441 INSTALLATION....................................................................................................................... 441 92AS_8T............................................................................................................................................ 443 POWER MIRRORS.................................................................................................................................. 443 CONTENTS................................................................................................................................... 443 GENERAL INFORMATION.................................................................................................................... 443 MIRROR MOTOR TEST...................................................................................................................... 443 MIRROR SWITCH TEST..................................................................................................................... 443 HEATED MIRROR.......................................................................................................................... 443 TEST PROCEDURES.................................................................................................................... 444 MIRROR SWITCH REPLACEMENT.............................................................................................................. 444 MIRROR ASSEMBLY REPLACEMENT............................................................................................................ 444 92AS_8U............................................................................................................................................ 445 CHIME WARNING/ REMINDER SYSTEM................................................................................................................. 445 FASTEN SEAT BELTS.......................................................................................................................... 445 TURN SIGNAL WARNING........................................................................................................................ 445 EXTERIOR LAMPS LEFT ON................................................................................................................. 445 KEY LEFT IN IGNITION................................................................................................................... 445 FASTEN SEAT BELTS.......................................................................................................................... 445 TURN SIGNAL WARNING........................................................................................................................ 445 EXTERIOR LAMPS LEFT ON..................................................................................................................... 445 KEY LEFT IN IGNITION....................................................................................................................... 445 CHIME SYSTEM DIAGNOSIS..................................................................................................................... 445 CONDITION: NO TONE WHEN IGNITION SWITCH IS TURNED ON AND DRIVERS SEAT BELT IS UNBUCKLED................................................ 445 CONDITION: NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS TURNED ON.................................................................. 445 CONDITION: FASTEN SEAT BELT LAMP OR TONE CONTINUE FOR MORE THAN 10 SEC-ONDS AFTER SEAT BELTS ARE FASTENED AND DRIVERS DOOR I........... 445 CONDITION: NO TONE WHEN HEADLAMPS ARE ON AND DRIVERS DOOR IS OPEN...................................................................... 445 CONDITION: NO TONE WHEN KEY IS LEFT IN IGNITION AND DRIVERS DOOR IS OPEN............................................................... 446 CONDITION: CHIMES CONTINUE WHEN HEADLAMPS ARE TURNED OFF AND/ OR KEY IS REMOVED FROM IGNITION.......................................... 446 HEADLAMP SWITCH REPLACEMENT................................................................................................................ 446 SEAT BELT BUCKLE REPLACEMENT............................................................................................................... 446 KEY- IN SWITCH............................................................................................................................. 446 92as_8w............................................................................................................................................ 447 WIRING DIAGRAMS................................................................................................................................ 447 GENERAL INFORMATION........................................................................................................................ 447 DISTRIBUTOR SECONDARY WIRING........................................................................................................... 447 WIRING DIAGRAM SHEETS AND INDEXES...................................................................................................... 447 WIRE CODE IDENTIFICATION............................................................................................................... 448 MAIN CIRCUIT IDENTIFICATION............................................................................................................ 448 LOCATING A SYSTEM...................................................................................................................... 448 COMPONENT IDENTIFICATION............................................................................................................... 449 SPLICE LOCATIONS....................................................................................................................... 449 CONNECTORS............................................................................................................................. 450 TROUBLESHOOTING WIRING PROBLEMS........................................................................................................ 450 FUSIBLE LINKS.......................................................................................................................... 450 HARNESS REPAIR......................................................................................................................... 450 FUSIBLE LINK REPLACEMENT........................................................................................................... 450 WIRING REPAIR...................................................................................................................... 451 CONNECTOR REPLACEMENT.............................................................................................................. 451 CONNECTOR AND TERMINAL ASSEMBLY REPLACEMENT........................................................................................ 451 TERMINAL REPLACEMENT............................................................................................................... 452 SYMBOLS, FUSES AND ABBREVIATIONS....................................................................................................... 452 COMPONENT IDENTIFICATION................................................................................................................... 457 SPLICE LOCATION............................................................................................................................ 479 WIRING DIAGRAMS AS- BODY H- K.............................................................................................................. 493 ALPHABETICAL INDEX..................................................................................................................... 493 92AS_9............................................................................................................................................. 683 ENGINE......................................................................................................................................... 683 STANDARD SERVICE PROCEDURES................................................................................................................ 683 FORM- IN- PLACE GASKETS................................................................................................................ 683 MOPAR SILICONE RUBBER ADHESIVE SEAL-ANT............................................................................................ 683 MOPAR GASKET MAKER................................................................................................................. 683 GASKET DISASSEMBLY................................................................................................................. 683 SURFACE PREPARATION................................................................................................................ 683 FORM- IN- PLACE GASKET APPLICATION................................................................................................. 683 CRANKSHAFT SPROCKET BOLT ACCESS PLUG................................................................................................... 684 ENGINE PERFORMANCE..................................................................................................................... 684 HONING CYLINDER BORES.................................................................................................................. 684 MEASURING MAIN BEARING CLEARANCE AND CONNECTING ROD BEARING CLEARANCE.................................................................. 685 PLASTIGAGE METHOD.................................................................................................................. 685 CONNECTING ROD BEARING CLEARANCE................................................................................................... 686 LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS................................................................................................. 686 REPAIR OF DAMAGED OR WORN THREADS...................................................................................................... 686 HYDROSTATIC LOCKED ENGINE.............................................................................................................. 687 ENGINE DIAGNOSIS— PERFORMANCE...................................................................................................... 688 ENGINE DIAGNOSIS— MECHANICAL....................................................................................................... 689 2.5L ENGINE................................................................................................................................ 690 GENERAL INFORMATION.................................................................................................................... 690 ENGINE IDENTIFICATION NUMBER OR CODE............................................................................................... 690 SPECIFICATIONS..................................................................................................................... 690 ENGINE MOUNTS.......................................................................................................................... 691 REMOVAL AND INSTALLATION RIGHT SIDE MOUNT.......................................................................................... 691 FRONT MOUNT........................................................................................................................ 692 LEFT SIDE MOUNT.................................................................................................................... 692 ENGINE MOUNT RUBBER INSULATORS..................................................................................................... 692 ENGINE MOUNT INSULATOR ADJUSTMENT.................................................................................................. 692 ENGINE ASSEMBLY........................................................................................................................ 693 REMOVAL............................................................................................................................ 693 INSTALLATION....................................................................................................................... 694 SOLID MOUNT COMPRESSOR BRACKET SERVICE................................................................................................. 695 ACCESSORIES REMOVAL................................................................................................................ 695 SOLID MOUNT BRACKET— REMOVAL (FIG. 7).............................................................................................. 695 SOLID MOUNT BRACKET— INSTALLATION.................................................................................................. 695 TIMING SYSTEM AND SEALS SERVICE........................................................................................................ 696 TIMING BELT SERVICE................................................................................................................ 696 SERVICING FRONT OIL SEALS— REPLACEMENT............................................................................................. 697 CAMSHAFT, CRANKSHAFT AND INTERMEDIATE SHAFTS TIMING PROCEDURE.......................................................................... 699 CYLINDER HEAD AND VALVE ASSEMBLY SERVICE............................................................................................... 700 CYLINDER HEAD COVER AND CURTAIN.................................................................................................... 701 REMOVAL............................................................................................................................ 701 CLEANING........................................................................................................................... 701 CURTAIN INSTALLATION............................................................................................................... 701 COVER SEALING AND INSTALLATION..................................................................................................... 701 CYLINDER HEAD COMPONENTS— IN- VEHICLE SERVICE.......................................................................................... 701 CAMSHAFT SERVICE................................................................................................................... 702 REMOVAL............................................................................................................................ 702 INSPECTION......................................................................................................................... 702 CAMSHAFT END PLAY.................................................................................................................. 703 INSTALLATION....................................................................................................................... 703 LASH ADJUSTER (TAPPET) NOISE....................................................................................................... 703 VALVE COMPONENTS REPLACE— CYLINDER HEAD NOT REMOVED ROCKER ARM AND HYDRAULIC LASH AD-JUSTER REMOVAL................................ 703 INSTALLATION....................................................................................................................... 703 VALVE SPRINGS AND VALVE STEM SEALS REMOVAL......................................................................................... 704 INSTALLATION....................................................................................................................... 704 CYLINDER HEAD.......................................................................................................................... 704 REMOVAL............................................................................................................................ 704 INSPECT HEAD AND CAMSHAFT BEARING JOURNALS......................................................................................... 704 CLEANING........................................................................................................................... 705 INSTALLATION....................................................................................................................... 705 VALVE SERVICE— CYLINDER HEAD REMOVED................................................................................................... 705 VALVES AND VALVE SPRINGS REMOVAL................................................................................................... 705 VALVE INSPECTION................................................................................................................... 705 VALVE GUIDES....................................................................................................................... 705 TESTING VALVE SPRINGS.............................................................................................................. 706 REFACING VALVES AND VALVE SEATS.................................................................................................... 707 CLEANING........................................................................................................................... 707 VALVE GEAR REASSEMBLY AFTER VALVE SERVICE.......................................................................................... 707 CYLINDER BLOCK, PISTON AND CONNECTING ROD ASSEMBLY SERVICE............................................................................. 709 PISTON AND CONNECTING ROD— REMOVAL................................................................................................. 709 CYLINDER BLOCK CLEANING AND INSPEC- TION........................................................................................... 710 CYLINDER BORE INSPECTION........................................................................................................... 710 SIZING PISTONS..................................................................................................................... 710 PISTON RING— REMOVAL............................................................................................................... 711 FITTING RINGS...................................................................................................................... 711 PISTON RINGS— INSTALLATION......................................................................................................... 711 PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION.................................................................................... 712 CONNECTING RODS.................................................................................................................... 713 ENGINE CORE PLUGS...................................................................................................................... 713 REMOVAL............................................................................................................................ 713 INSTALLATION....................................................................................................................... 714 CRANKSHAFT, INTERMEDIATE AND BALANCE SHAFT ASSEMBLIES SERVICE.......................................................................... 715 CRANKSHAFT OIL SEALS SERVICE........................................................................................................... 716 REAR CRANKSHAFT SEAL RETAINER AND OIL SEAL......................................................................................... 716 FRONT CRANKSHAFT SEAL RETAINER..................................................................................................... 716 CRANKSHAFT SERVICE..................................................................................................................... 717 CRANKSHAFT MAIN BEARINGS........................................................................................................... 717 CRANKSHAFT MAIN JOURNALS........................................................................................................... 717 MAIN BEARING SERVICE— CRANKSHAFT NOT REMOVED....................................................................................... 717 CHECKING CRANKSHAFT END PLAY....................................................................................................... 717 OPTIONAL CRANKSHAFT END PLAY CHECK................................................................................................. 717 CRANKSHAFT BEARING CLEARANCE....................................................................................................... 718 BALANCE SHAFTS......................................................................................................................... 719 REMOVAL............................................................................................................................ 719 BALANCE SHAFTS CARRIER ASSEMBLY.................................................................................................... 720 CHAIN TENSIONING................................................................................................................... 721 INTERMEDIATE SHAFT SERVICE............................................................................................................. 721 REMOVAL............................................................................................................................ 721 INSTALLATION....................................................................................................................... 722 INTERMEDIATE SHAFT BUSHING SERVICE................................................................................................. 722 ENGINE LUBRICATION SYSTEM.............................................................................................................. 723 OIL PAN............................................................................................................................ 725 PRESSURE LUBRICATION............................................................................................................... 725 MAIN/ ROD BEARINGS................................................................................................................. 725 ACCESSORY SHAFT.................................................................................................................... 725 BALANCE SHAFTS..................................................................................................................... 725 CAMSHAFT/ HYDRAULIC LIFTERS........................................................................................................ 725 SPLASH LUBRICATION................................................................................................................. 725 OIL PAN................................................................................................................................ 725 REMOVAL............................................................................................................................ 725 OIL PAN RAIL TO BLOCK SEALING...................................................................................................... 725 INSTALLATION....................................................................................................................... 725 OIL PUMP SERVICE....................................................................................................................... 725 OIL PICKUP......................................................................................................................... 725 REMOVAL............................................................................................................................ 726 INSTALLATION....................................................................................................................... 726 INSPECTION......................................................................................................................... 726 CHECKING ENGINE OIL PRESSURE........................................................................................................... 728 OIL FILTER............................................................................................................................. 728 ANTI- DRAIN BACK VALVE............................................................................................................. 728 FILTER............................................................................................................................. 728 ENGINE SPECIFICATIONS.................................................................................................................. 729 ENGINE SPECIFICATIONS (CONT.).......................................................................................................... 730 TORQUE............................................................................................................................. 731 3.0L ENGINE................................................................................................................................ 732 GENERAL INFORMATION.................................................................................................................... 732 ENGINE IDENTIFICATION NUMBER OR CODE............................................................................................... 732 3.0L ENGINE........................................................................................................................ 732 SPECIFICATIONS..................................................................................................................... 733 ENGINE MOUNTS.......................................................................................................................... 734 REMOVAL AND INSTALLATION RIGHT SIDE MOUNT.......................................................................................... 734 FRONT MOUNT........................................................................................................................ 734 LEFT SIDE MOUNT.................................................................................................................... 735 ENGINE MOUNT RUBBER INSULATORS..................................................................................................... 735 ENGINE MOUNT INSULATOR ADJUSTMENT.................................................................................................. 735 ENGINE ASSEMBLY........................................................................................................................ 735 REMOVAL............................................................................................................................ 735 INSTALLATION....................................................................................................................... 736 ACCESSORY DRIVE BELT SERVICE........................................................................................................... 736 REMOVAL............................................................................................................................ 736 ENGINE MOUNT BRACKET REMOVAL....................................................................................................... 737 TIMING BELT INSPECTION— IN VEHICLE..................................................................................................... 737 TIMING BELT SERVICE.................................................................................................................... 738 REMOVAL............................................................................................................................ 738 CAMSHAFT SPROCKETS REMOVAL......................................................................................................... 738 INSTALLATION....................................................................................................................... 738 TIMING BELT TENSIONER.............................................................................................................. 738 INSTALLATION— TIMING BELT.......................................................................................................... 740 CYLINDER HEAD AND CAMSHAFT SERVICE..................................................................................................... 741 CYLINDER HEAD COVER REMOVAL........................................................................................................ 741 INSTALLATION....................................................................................................................... 741 AUTO LASH ADJUSTER..................................................................................................................... 741 FUNCTION CHECK..................................................................................................................... 741 CAMSHAFT SERVICE....................................................................................................................... 742 SEE AUTO LASH ADJUSTER FUNCTION CHECK BEFORE DISASSEMBLY REMOVAL................................................................... 742 CAMSHAFT INSPECTION................................................................................................................ 742 CAMSHAFT INSTALL................................................................................................................... 742 ROCKER ARMS........................................................................................................................ 742 ROCKER ARM SHAFTS.................................................................................................................. 742 REASSEMBLE......................................................................................................................... 743 ASSEMBLE ROCKER ASSEMBLY........................................................................................................... 743 INSTALL ROCKER ARM SHAFT ASSEMBLY.................................................................................................. 743 CAMSHAFT OIL SEAL — ENGINE OUT OF VE- HICLE........................................................................................ 743 CAMSHAFT END SEAL (PLUG) — ENGINE IN VEHICLE....................................................................................... 743 CAMSHAFT END SEAL (PLUG) — ENGINE OUT OF VEHICLE................................................................................... 744 REMOVAL............................................................................................................................ 744 INSPECTION......................................................................................................................... 745 INSTALLATION....................................................................................................................... 745 VALVE SERVICE.......................................................................................................................... 746 VALVE AND VALVE SPRINGS............................................................................................................ 746 VALVES............................................................................................................................. 746 VALVE SEAT INSPECTION.............................................................................................................. 746 PISTON AND CONNECTING ROD ASSEMBLY SER-VICE............................................................................................ 748 CYLINDER BORE INSPECTION........................................................................................................... 748 FITTING PISTONS.................................................................................................................... 748 FITTING PISTON RINGS............................................................................................................... 748 PISTON RINGS— INSTALLATION......................................................................................................... 749 CONNECTING ROD CLEARANCE........................................................................................................... 750 CONNECTING ROD SIDE CLEARANCE...................................................................................................... 751 CRANKSHAFT AND CYLINDER BLOCK, ASSEMBLY SERVICE........................................................................................ 752 CRANKSHAFT SERVICE................................................................................................................. 752 CRANKSHAFT— REMOVAL................................................................................................................ 752 INSPECTION......................................................................................................................... 752 CRANKSHAFT OIL CLEARANCE MECHANICAL MEASUREMENT.................................................................................... 752 PLASTIGAGE MEASUREMENT............................................................................................................. 753 CRANKSHAFT BEARINGS INSTALLATION................................................................................................... 753 CHECKING CRANKSHAFT END PLAY....................................................................................................... 754 CRANKSHAFT OIL SEALS SERVICE REAR CRANKSHAFT SEAL RETAINER......................................................................... 754 FRONT CRANKSHAFT OIL PUMP AND OIL SEAL............................................................................................. 755 CYLINDER BLOCK......................................................................................................................... 755 BORING CYLINDER.................................................................................................................... 756 ENGINE LUBRICATION SYSTEM.............................................................................................................. 757 OIL PAN................................................................................................................................ 758 OIL PAN SEALING AND INSTALLATION................................................................................................... 758 OIL PUMP SERVICE....................................................................................................................... 758 REMOVAL............................................................................................................................ 758 INSPECTION OIL PUMP................................................................................................................ 758 OIL RELIEF PLUNGER................................................................................................................. 759 INSTALLATION....................................................................................................................... 759 CHECKING ENGINE OIL PRESSURE........................................................................................................... 759 OIL FILTER AND BRACKET................................................................................................................. 760 BRACKET INSPECTION................................................................................................................. 760 OIL FILTER......................................................................................................................... 760 ENGINE SPECIFICATIONS.................................................................................................................. 761 ENGINE SPECIFICATIONS (CONT.).......................................................................................................... 762 TORQUE............................................................................................................................. 763 3.3L ENGINE................................................................................................................................ 764 GENERAL INFORMATION.................................................................................................................... 764 ENGINE IDENTIFICATION NUMBER OR CODE............................................................................................... 764 SPECIFICATIONS..................................................................................................................... 764 ENGINE MOUNTS.......................................................................................................................... 765 REMOVAL AND INSTALLATION RIGHT SIDE MOUNT.......................................................................................... 765 FRONT MOUNT........................................................................................................................ 767 LEFT SIDE MOUNT.................................................................................................................... 767 ENGINE MOUNT RUBBER INSULATORS..................................................................................................... 767 ENGINE MOUNT INSULATOR ADJUSTMENT.................................................................................................. 767 ENGINE ASSEMBLY........................................................................................................................ 767 REMOVAL............................................................................................................................ 767 INSTALLATION....................................................................................................................... 768 ROCKER ARMS AND SHAFT ASSEMBLY......................................................................................................... 768 REMOVAL............................................................................................................................ 768 INSTALLATION....................................................................................................................... 768 CYLINDER HEADS......................................................................................................................... 768 REMOVAL............................................................................................................................ 769 INSPECTION......................................................................................................................... 769 INSTALLATION....................................................................................................................... 769 INTAKE MANIFOLD SEALING................................................................................................................ 770 VALVE SERVICE.......................................................................................................................... 771 VALVES AND VALVE SPRINGS........................................................................................................... 771 REMOVAL............................................................................................................................ 771 VALVE INSPECTION................................................................................................................... 771 VALVE GUIDES....................................................................................................................... 772 REFACING VALVES AND VALVE SEATS.................................................................................................... 772 VALVES............................................................................................................................. 772 VALVE SEATS........................................................................................................................ 772 TESTING VALVE SPRINGS.............................................................................................................. 773 VALVE INSTALLATION................................................................................................................. 773 REPLACE VALVE STEM SEALS OR VALVE SPRINGS, CYLINDER HEAD NOT REMOVED............................................................... 774 HYDRAULIC TAPPETS...................................................................................................................... 774 PRELIMINARY STEP TO CHECKING THE HYDRAULIC TAPPETS................................................................................. 774 OIL LEVEL TOO HIGH................................................................................................................. 774 OIL LEVEL TOO LOW.................................................................................................................. 774 TAPPET NOISE DIAGNOSIS............................................................................................................. 774 TAPPET REMOVAL..................................................................................................................... 775 DISASSEMBLY (FIG. 27).............................................................................................................. 775 CLEANING AND ASSEMBLY.............................................................................................................. 775 INSTALLATION....................................................................................................................... 775 VALVE TIMING........................................................................................................................... 775 TIMING CHAIN COVER, OIL SEAL AND CHAIN................................................................................................. 776 COVER.............................................................................................................................. 776 MEASURING TIMING CHAIN FOR STRETCH................................................................................................. 776 TIMING CHAIN COVER EXTERNAL OIL SEAL............................................................................................... 778 CAMSHAFT............................................................................................................................... 778 REMOVAL— ENGINE REMOVED FROM VE-HICLE.............................................................................................. 778 INSTALLATION....................................................................................................................... 778 CAMSHAFT BEARINGS— ENGINE REMOVED FROM VEHICLE......................................................................................... 779 REMOVAL............................................................................................................................ 779 INSTALLATION....................................................................................................................... 779 ENGINE CORE OIL AND CAM PLUGS.......................................................................................................... 780 REMOVAL............................................................................................................................ 780 INSTALLATION....................................................................................................................... 780 CYLINDER BLOCK, PISTON AND CONNECTING ROD ASSEMBLY SERVICE............................................................................. 781 CYLINDER BLOCK PISTON— REMOVAL..................................................................................................... 781 CLEANING AND INSPECTION............................................................................................................ 781 CYLINDER BORE INSPECTION........................................................................................................... 781 FINISHED PISTONS................................................................................................................... 782 FITTING PISTONS.................................................................................................................... 782 PISTON PINS........................................................................................................................ 782 FITTING RINGS...................................................................................................................... 782 PISTON RINGS— INSTALLATION......................................................................................................... 782 INSTALLING PISTON AND CONNECTING ROD AS-SEMBLY......................................................................................... 784 CONNECTING RODS........................................................................................................................ 785 INSTALLATION OF CONNECTING ROD BEAR-INGS........................................................................................... 785 CRANKSHAFT SERVICE..................................................................................................................... 785 CRANKSHAFT MAIN BEARINGS........................................................................................................... 785 CRANKSHAFT MAIN JOURNALS........................................................................................................... 785 CHECKING CRANKSHAFT END PLAY....................................................................................................... 786 CRANKSHAFT END PLAY CHECK— OPTIONAL................................................................................................ 786 CRANKSHAFT OIL CLEARANCE........................................................................................................... 787 PLASTIGAGE (OIL CLEARANCE) MEASURE-MENT............................................................................................ 787 CRANKSHAFT OIL SEALS SERVICE........................................................................................................... 788 REMOVAL............................................................................................................................ 788 INSTALLATION....................................................................................................................... 788 REAR CRANKSHAFT SEAL RETAINER...................................................................................................... 788 ENGINE LUBRICATION SYSTEM.............................................................................................................. 789 OIL PAN SERVICE........................................................................................................................ 789 REMOVAL............................................................................................................................ 789 CLEANING AND INSPECTION............................................................................................................ 789 INSTALLATION....................................................................................................................... 789 OIL PUMP SERVICE....................................................................................................................... 790 DISASSEMBLY........................................................................................................................ 790 INSPECTION AND REPAIR.............................................................................................................. 790 OIL PUMP ASSEMBLY AND INSTALLATION................................................................................................. 791 CHECKING ENGINE OIL PRESSURE........................................................................................................... 792 OIL FILTER............................................................................................................................. 792 ENGINE SPECIFICATIONS.................................................................................................................. 793 ENGINE SPECIFICATIONS (CONT.).......................................................................................................... 794 ENGINE SPECIFICATIONS (CONT.).......................................................................................................... 795 ENGINE SPECIFICATIONS (CONT.).......................................................................................................... 796 TORQUE............................................................................................................................. 797 92AS_11............................................................................................................................................ 799 EXHAUST SYSTEM AND INTAKE MANIFOLD............................................................................................................. 799 GENERAL INFORMATION........................................................................................................................ 799 EXHAUST SYSTEMS........................................................................................................................ 799 CATALYTIC CONVERTERS............................................................................................................... 799 SPECIAL EXHAUST BALL- JOINT COUPLING............................................................................................... 800 EXHAUST GAS RECIRCULATION (EGR).................................................................................................... 800 HEAT SHIELDS....................................................................................................................... 800 EXHAUST SYSTEM DIAGNOSIS........................................................................................................... 801 SERVICE PROCEDURES......................................................................................................................... 802 EXHAUST PIPES, MUFFLERS AND TAILPIPES.................................................................................................. 802 REMOVAL............................................................................................................................ 802 INSTALLATION....................................................................................................................... 802 INTAKE AND EXHAUST MANIFOLDS— TBI ENGINE............................................................................................... 802 INTAKE MANIFOLDS:.................................................................................................................. 802 EXHAUST MANIFOLDS:................................................................................................................. 802 THROTTLE BODY AIR HEATER........................................................................................................... 802 INTAKE AND EXHAUST MANIFOLDS SERVICE TBI ENGINE....................................................................................... 803 FUEL SYSTEM PRESSURE RELEASE PROCEDURE............................................................................................. 803 REMOVAL............................................................................................................................ 803 CLEANING AND INSPECTION............................................................................................................ 804 INSTALLATION....................................................................................................................... 804 INTAKE AND EXHAUST MANIFOLDS— 3.0L ENGINE.............................................................................................. 804 INTAKE PLENUM/ MANIFOLD............................................................................................................ 804 FUEL SYSTEM PRESSURE RELEASE PROCEDURE............................................................................................. 804 INSPECTION......................................................................................................................... 805 INSTALLATION....................................................................................................................... 806 EXHAUST MANIFOLDS.................................................................................................................. 809 INTAKE/ EXHAUST MANIFOLD 3.3L ENGINE................................................................................................... 810 REMOVAL............................................................................................................................ 810 FUEL SYSTEM PRESSURE RELEASE PROCEDURE............................................................................................. 810 INSPECTION......................................................................................................................... 812 EXHAUST MANIFOLDS.................................................................................................................. 814 TORQUE SPECIFICATION....................................................................................................................... 815 92AS_13............................................................................................................................................ 817 FRAME AND BUMPERS.............................................................................................................................. 817 CONTENTS................................................................................................................................... 817 GENERAL INFORMATIONA................................................................................................................... 817 LOW LINE FRONT BUMPER.................................................................................................................. 817 REMOVAL (FIG. 1)................................................................................................................... 817 INSTALLATION....................................................................................................................... 817 HIGH LINE FRONT BUMPER AND FASCIA...................................................................................................... 818 REMOVAL (FIG. 2)................................................................................................................... 818 INSTALLATION....................................................................................................................... 818 OVERHAUL (FIG. 3).................................................................................................................. 818 HIGH LINE FRONT BUMPER ASSEMBLY.................................................................................................... 818 FRONT BUMPER SUPPORT BRACKET........................................................................................................... 818 REMOVAL............................................................................................................................ 818 INSTALLATION....................................................................................................................... 818 REAR BUMPER............................................................................................................................ 819 REMOVAL (FIG. 4)................................................................................................................... 819 INSTALLATION....................................................................................................................... 819 HIGH LINE REAR BUMPER AND FASCIA....................................................................................................... 819 REMOVAL (FIG. 5)................................................................................................................... 819 INSTALLATION....................................................................................................................... 819 FRONT WHEEL DRIVE VAN/ WAGON CROSSMEM-BER.............................................................................................. 819 REMOVAL (FIG. 6)................................................................................................................... 819 INSTALLATION....................................................................................................................... 820 ALL WHEEL DRIVE VAN/ WAGON CROSSMEMBER................................................................................................. 820 REMOVAL (FIG. 7)................................................................................................................... 820 INSTALLATION....................................................................................................................... 820 FRAME DIMENSIONS....................................................................................................................... 820 VEHICLE PREPARATION................................................................................................................ 820 92AS_14............................................................................................................................................ 825 FUEL SYSTEM.................................................................................................................................... 825 GENERAL INFORMATION........................................................................................................................ 825 FUEL REQUIREMENTS...................................................................................................................... 825 GASOLINE/ OXYGENATE BLENDS......................................................................................................... 825 FUEL DELIVERY SYSTEM....................................................................................................................... 827 GENERAL INFORMATION.................................................................................................................... 827 FUEL SYSTEM PRESSURE RELEASE PROCEDURE................................................................................................. 827 FUEL HOSES, CLAMPS, AND QUICK CONNECT FITTINGS......................................................................................... 827 HOSES AND CLAMPS................................................................................................................... 827 QUICK CONNECT FITTINGS............................................................................................................. 827 TUBE/ FITTING DISASSEMBLY.......................................................................................................... 828 TUBE/ FITTING ASSEMBLY............................................................................................................. 828 TUBE/ FITTING SERVICE.............................................................................................................. 828 FUEL PUMP/ LEVEL UNIT ASSEMBLY......................................................................................................... 829 FUEL PUMP PRESSURE TEST— 2.5L and 3.0L EN-GINES........................................................................................ 829 FUEL SYSTEM PRESSURE— WITHOUT VACUUM APPLIED TO PRESSURE REGULATOR................................................................. 829 FUEL PUMP PRESSURE TEST— 3.3L ENGINE................................................................................................... 830 FUEL PUMP/ LEVEL SENDING UNIT ASSEMBLY REMOVAL— FRONT WHEEL DRIVE...................................................................... 832 FUEL PUMP INLET STRAINER REMOVAL— FRONT WHEEL DRIVE................................................................................ 832 FUEL PUMP INLET STRAINER INSTALLATION— FRONT WHEEL DRIVE........................................................................... 832 FUEL LEVEL SENDING UNIT DIAGNOSIS.................................................................................................. 832 FUEL LEVEL SENDING UNIT REMOVAL— FRONT WHEEL DRIVE................................................................................. 832 FUEL LEVEL SENDING UNIT INSTALLATION— FRONT WHEEL DRIVE............................................................................ 832 FUEL PUMP/ LEVEL UNIT ASSEMBLY INSTALLATION— FRONT WHEEL DRIVE......................................................................... 833 FUEL PUMP MODULE REMOVAL— ALL WHEEL DRIVE.............................................................................................. 833 FUEL PUMP INLET STRAINER REMOVAL— ALL WHEEL DRIVE.................................................................................. 833 FUEL PUMP INLET STRAINER INSTALLATION— ALL WHEEL DRIVE............................................................................. 833 FUEL LEVEL SENDING UNIT DIAGNOSIS.................................................................................................. 833 FUEL LEVEL SENDING UNIT REMOVAL— ALL WHEEL DRIVE................................................................................... 834 FUEL LEVEL SENDING UNIT INSTALLATION— ALL WHEEL DRIVE.............................................................................. 834 FUEL PUMP MODULE INSTALLATION— ALL WHEEL DRIVE......................................................................................... 834 FUEL FILTER— FRONT WHEEL DRIVE......................................................................................................... 834 REMOVAL............................................................................................................................ 834 INSTALLATION....................................................................................................................... 835 FUEL FILTER— ALL WHEEL DRIVE........................................................................................................... 835 REMOVAL............................................................................................................................ 835 INSTALLATION....................................................................................................................... 835 CHASSIS FUEL TUBES..................................................................................................................... 835 FUEL TANK.................................................................................................................................. 837 GENERAL INFORMATION.................................................................................................................... 837 NO- LEAD FUEL TANK FILLER TUBE......................................................................................................... 837 PRESSURE- VACUUM FILLER CAP— FRONT WHEEL DRIVE......................................................................................... 837 FUEL SYSTEM PRESSURE RELEASE PROCEDURE................................................................................................. 837 FUEL TANK CAPACITIES............................................................................................................... 837 FUEL TANK— FRONT WHEEL DRIVE........................................................................................................... 838 DRAINING FUEL TANK................................................................................................................. 838 FUEL TANK REMOVAL— FRONT WHEEL DRIVE............................................................................................... 838 FUEL TANK INSTALLATION— FRONT WHEEL DRIVE.......................................................................................... 840 FUEL TANK— ALL WHEEL DRIVE............................................................................................................. 840 DRAINING FUEL TANK— ALL WHEEL DRIVE................................................................................................ 840 FUEL TANK REMOVAL— ALL WHEEL DRIVE................................................................................................. 840 FUEL TANK INSTALLATION— ALL WHEEL DRIVE............................................................................................ 841 FUEL PUMP/ LEVEL UNIT— FRONT WHEEL DRIVE............................................................................................... 842 FUEL PUMP MODULE— ALL WHEEL DRIVE...................................................................................................... 842 FUEL TANK PRESSURE RELIEF/ ROLLOVER VALVE— FRONT WHEEL DRIVE........................................................................... 842 REMOVAL............................................................................................................................ 842 INSTALLATION....................................................................................................................... 842 FUEL TANK PRESSURE RELIEF/ ROLLOVER VALVE— ALL WHEEL DRIVE............................................................................. 843 REMOVAL............................................................................................................................ 843 INSTALLATION....................................................................................................................... 843 ACCELERATOR PEDAL AND THROTTLE CABLE....................................................................................................... 844 ACCELERATOR PEDAL SERVICE.............................................................................................................. 844 REMOVAL............................................................................................................................ 844 INSTALLATION....................................................................................................................... 844 THROTTLE CABLE SERVICE................................................................................................................. 844 REMOVAL............................................................................................................................ 844 INSTALLATION....................................................................................................................... 844 2.5L SINGLE POINT FUEL INJECTION— SYSTEM OPERATION......................................................................................... 846 GENERAL INFORMATION.................................................................................................................... 846 SYSTEM DIAGNOSIS................................................................................................................... 846 CCD BUS................................................................................................................................ 846 ENGINE CONTROLLER...................................................................................................................... 846 AIR CONDITIONING SWITCH SENSE— ENGINE CONTROLLER INPUT................................................................................. 848 BATTERY VOLTAGE— ENGINE CONTROLLER INPUT............................................................................................... 848 BRAKE SWITCH— ENGINE CONTROLLER INPUT.................................................................................................. 848 COOLANT TEMPERATURE SENSOR— ENGINE CON-TROLLER INPUT................................................................................... 848 DISTRIBUTOR (HALL EFFECT) PICK- UP— ENGINE CONTROLLER INPUT............................................................................ 848 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— ENGINE CONTROLLER INPUT....................................................................... 849 OXYGEN SENSOR (O2 SENSOR)— ENGINE CON-TROLLER INPUT.................................................................................... 849 SPEED CONTROL— ENGINE CONTROLLER INPUT................................................................................................. 850 TRANSMISSION PARK/ NEUTRAL SWITCH— ENGINE CONTROLLER INPUT............................................................................. 850 THROTTLE POSITION SENSOR (TPS)— ENGINE CONTROLLER INPUT................................................................................ 850 VEHICLE DISTANCE (SPEED) SENSOR— ENGINE CONTROLLER INPUT............................................................................... 850 AIR CONDITIONING (A/ C) CLUTCH RELAY— ENGINE CONTROLLER OUTPUT......................................................................... 850 ALTERNATOR FIELD— ENGINE CONTROLLER OUT-PUT............................................................................................ 851 AUTO SHUTDOWN (ASD) RELAY AND FUEL PUMP RELAY— ENGINE CONTROLLER OUTPUT................................................................ 851 AUTOMATIC IDLE SPEED (AIS) MOTOR— ENGINE CONTROLLER OUTPUT............................................................................. 851 CANISTER PURGE SOLENOID— ENGINE CONTROLLER OUTPUT...................................................................................... 852 CHECK ENGINE LAMP— ENGINE CONTROLLER OUTPUT............................................................................................ 852 DIAGNOSTIC CONNECTOR— ENGINE CONTROLLER OUTPUT......................................................................................... 852 EMISSION MAINTENANCE REMINDER (EMR) LAMP— ENGINE CONTROLLER OUTPUT..................................................................... 852 FUEL INJECTOR— ENGINE CONTROLLER OUTPUT................................................................................................ 853 IGNITION COIL— ENGINE CONTROLLER OUTPUT................................................................................................ 853 PART THROTTLE UNLOCK SOLENOID— ENGINE CONTROLLER OUTPUT................................................................................ 853 RADIATOR FAN RELAY— ENGINE CONTROLLER OUTPUT........................................................................................... 853 SPEED CONTROL SOLENOIDS— ENGINE CONTROL-LER OUTPUT..................................................................................... 853 TACHOMETER— ENGINE CONTROLLER OUTPUT................................................................................................... 853 MODES OF OPERATION..................................................................................................................... 854 FUEL PRESSURE REGULATOR................................................................................................................ 855 THROTTLE BODY.......................................................................................................................... 856 2.5L SINGLE POINT FUEL INJECTION— GENERAL DIAGNOSIS........................................................................................ 858 GENERAL INFORMATION.................................................................................................................... 858 VISUAL INSPECTION...................................................................................................................... 858 ON BOARD DIAGNOSTICS................................................................................................................... 862 MONITORED CIRCUITS................................................................................................................. 863 NON- MONITORED CIRCUITS............................................................................................................ 863 HIGH AND LOW LIMITS................................................................................................................ 864 FAULT CODE DESCRIPTION................................................................................................................. 864 SYSTEMS TEST........................................................................................................................... 864 OBTAINING FAULT CODES.............................................................................................................. 864 STATE DISPLAY TEST MODE................................................................................................................ 864 STATE DISPLAY INPUTS AND OUTPUTS................................................................................................... 864 STATE DISPLAY SENSORS.............................................................................................................. 864 FAULT CODE DESCRIPTION............................................................................................................. 865 CIRCUIT ACTUATION TEST MODE............................................................................................................ 866 OBTAINING CIRCUIT ACTUATION TEST................................................................................................... 866 FAULT CODE DESCRIPTION (CON’T)..................................................................................................... 866 THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE......................................................................................... 867 IGNITION TIMING PROCEDURE.......................................................................................................... 867 60- WAY ENGINE CONTROLLER WIRING CONNEC-TOR............................................................................................ 867 IDLE SPECIFICATIONS................................................................................................................ 867 2.5L SINGLE POINT FUEL INJECTION— SERVICE PROCEDURES....................................................................................... 869 FUEL LINES AND HOSES................................................................................................................... 869 FUEL SYSTEM PRESSURE RELEASE PROCEDURE................................................................................................. 869 THROTTLE BODY.......................................................................................................................... 869 REMOVAL............................................................................................................................ 869 INSTALLATION....................................................................................................................... 871 FUEL FITTING........................................................................................................................... 871 REMOVAL............................................................................................................................ 871 INSTALLATION....................................................................................................................... 871 FUEL PRESSURE REGULATOR................................................................................................................ 872 REMOVAL............................................................................................................................ 872 INSTALLATION....................................................................................................................... 872 FUEL INJECTOR.......................................................................................................................... 872 REMOVAL............................................................................................................................ 872 INSTALLATION....................................................................................................................... 873 THROTTLE POSITION SENSOR............................................................................................................... 873 REMOVAL............................................................................................................................ 873 INSTALLATION....................................................................................................................... 874 AUTOMATIC IDLE SPEED (AIS) MOTOR....................................................................................................... 874 REMOVAL............................................................................................................................ 874 INSTALLATION....................................................................................................................... 874 MANIFOLD ABSOLUTE PRESSURE SENSOR...................................................................................................... 874 REMOVAL............................................................................................................................ 874 CANISTER PURGE SOLENOID................................................................................................................ 874 ENGINE CONTROLLER...................................................................................................................... 874 OXYGEN SENSOR (O2 SENSOR).............................................................................................................. 875 3.0L MULTI- POINT FUEL INJECTION— SYSTEM OPERATION......................................................................................... 876 GENERAL INFORMATION.................................................................................................................... 876 SYSTEM DIAGNOSIS................................................................................................................... 876 CCD BUS................................................................................................................................ 876 ENGINE CONTROLLER...................................................................................................................... 877 AIR CONDITIONING SWITCH SENSE— ENGINE CONTROLLER INPUT................................................................................. 878 BATTERY VOLTAGE— ENGINE CONTROLLER INPUT............................................................................................... 878 BRAKE SWITCH— ENGINE CONTROLLER INPUT.................................................................................................. 878 COOLANT TEMPERATURE SENSOR— ENGINE CON-TROLLER INPUT................................................................................... 878 DISTRIBUTOR PICK- UP— ENGINE CONTROLLER INPUT.......................................................................................... 878 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— ENGINE CONTROLLER INPUT....................................................................... 879 OXYGEN SENSOR (O2 SENSOR)— ENGINE CON-TROLLER INPUT.................................................................................... 880 SPEED CONTROL— ENGINE CONTROLLER INPUT................................................................................................. 880 TRANSMISSION PARK/ NEUTRAL SWITCH— ENGINE CONTROLLER INPUT............................................................................. 880 THROTTLE POSITION SENSOR (TPS)— ENGINE CONTROLLER INPUT................................................................................ 880 VEHICLE DISTANCE (SPEED) SENSOR— ENGINE CONTROLLER INPUT............................................................................... 881 AIR CONDITIONING (A/ C) CLUTCH RELAY— ENGINE CONTROLLER OUTPUT......................................................................... 881 ALTERNATOR FIELD— ENGINE CONTROLLER OUT-PUT............................................................................................ 881 AUTO SHUTDOWN (ASD) RELAY AND FUEL PUMP RELAY— ENGINE CONTROLLER OUTPUT................................................................ 881 AUTOMATIC IDLE SPEED (AIS) MOTOR— ENGINE CONTROLLER OUTPUT............................................................................. 882 14 - 58 FUEL SYSTEM.................................................................................................................... 882 CHECK ENGINE LAMP— ENGINE CONTROLLER OUTPUT............................................................................................ 883 DIAGNOSTIC CONNECTOR— ENGINE CONTROLLER OUTPUT......................................................................................... 883 ELECTRONIC AUTOMATIC TRANSMISSION CONTROLLER— ENGINE CONTROLLER OUTPUT................................................................. 883 EMISSION MAINTENANCE REMINDER (EMR) LAMP— ENGINE CONTROLLER OUTPUT..................................................................... 883 FUEL INJECTORS— ENGINE CONTROLLER OUTPUT............................................................................................... 883 IGNITION COIL— ENGINE CONTROLLER OUTPUT................................................................................................ 884 PART THROTTLE UNLOCK SOLENOID— ENGINE CONTROLLER OUTPUT................................................................................ 884 RADIATOR FAN RELAY— ENGINE CONTROLLER OUTPUT........................................................................................... 884 SPEED CONTROL SOLENOIDS— ENGINE CONTROL-LER OUTPUT..................................................................................... 884 TACHOMETER— ENGINE CONTROLLER OUTPUT................................................................................................... 884 MODES OF OPERATION..................................................................................................................... 884 THROTTLE BODY.......................................................................................................................... 886 FUEL SUPPLY CIRCUIT.................................................................................................................... 886 FUEL PRESSURE REGULATOR................................................................................................................ 886 3.0L MULTI- POINT FUEL INJECTION— GENERAL DIAGNOSIS........................................................................................ 888 FUEL SYSTEM DIAGRAM.................................................................................................................... 888 VISUAL INSPECTION...................................................................................................................... 888 ON BOARD DIAGNOSTICS................................................................................................................... 891 MONITORED CIRCUITS................................................................................................................. 892 NON- MONITORED CIRCUITS............................................................................................................ 892 HIGH AND LOW LIMITS................................................................................................................ 893 FAULT CODE DESCRIPTION................................................................................................................. 893 SYSTEM TESTS........................................................................................................................... 893 OBTAINING FAULT CODES.............................................................................................................. 893 FAULT CODE DESCRIPTION............................................................................................................. 894 STATE DISPLAY TEST MODE................................................................................................................ 895 STATE DISPLAY INPUTS AND OUTPUTS................................................................................................... 895 FAULT CODE DESCRIPTION (CON’T)..................................................................................................... 895 STATE DISPLAY SENSORS.............................................................................................................. 896 CIRCUIT ACTUATION TEST MODE............................................................................................................ 896 OBTAINING CIRCUIT ACTUATION TEST................................................................................................... 896 THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE......................................................................................... 896 IGNITION TIMING PROCEDURE.......................................................................................................... 897 60- WAY ENGINE CONTROLLER WIRING CONNEC-TOR............................................................................................ 897 IDLE SPECIFICATIONS................................................................................................................ 897 3.0L MULTI- POINT FUEL INJECTION— SERVICE PROCEDURES....................................................................................... 899 THROTTLE BODY SERVICE.................................................................................................................. 899 THROTTLE BODY.......................................................................................................................... 899 FUEL SYSTEM PRESSURE RELEASE PROCEDURE................................................................................................. 900 THROTTLE POSITION SENSOR............................................................................................................... 900 REMOVAL............................................................................................................................ 900 INSTALLATION....................................................................................................................... 900 AUTOMATIC IDLE SPEED (AIS) MOTOR....................................................................................................... 900 REMOVAL............................................................................................................................ 900 INSTALLATION....................................................................................................................... 900 FUEL INJECTOR RAIL ASSEMBLY............................................................................................................ 901 REMOVAL............................................................................................................................ 901 FUEL INJECTOR RAIL ASSEMBLY............................................................................................................ 902 INSTALLATION....................................................................................................................... 902 FUEL PRESSURE REGULATOR SERVICE........................................................................................................ 902 REMOVAL............................................................................................................................ 902 INSTALLATION....................................................................................................................... 903 FUEL INJECTORS......................................................................................................................... 903 REMOVAL............................................................................................................................ 903 INSTALLATION....................................................................................................................... 903 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR................................................................................................ 904 CANISTER PURGE SOLENOID SERVICE........................................................................................................ 904 ENGINE CONTROLLER...................................................................................................................... 904 HEATED OXYGEN SENSOR (O2 SENSOR)....................................................................................................... 904 3.3L MULTI- POINT FUEL INJECTION— SYSTEM OPERATION......................................................................................... 905 GENERAL INFORMATION.................................................................................................................... 905 SYSTEM DIAGNOSIS................................................................................................................... 906 CCD BUS................................................................................................................................ 906 ENGINE CONTROLLER...................................................................................................................... 906 AIR CONDITIONING SWITCH SENSE— ENGINE CONTROLLER INPUT................................................................................. 907 BATTERY VOLTAGE— ENGINE CONTROLLER INPUT............................................................................................... 907 BRAKE SWITCH— ENGINE CONTROLLER INPUT.................................................................................................. 907 CAMSHAFT SENSOR— ENGINE CONTROLLER IN-PUT.............................................................................................. 908 COOLANT TEMPERATURE SENSOR— ENGINE CON-TROLLER INPUT................................................................................... 908 CRANKSHAFT SENSOR— ENGINE CONTROLLER INPUT............................................................................................. 908 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— ENGINE CONTROLLER INPUT....................................................................... 909 OXYGEN SENSOR (O2 SENSOR)— ENGINE CON-TROLLER INPUT.................................................................................... 910 SPEED CONTROL— ENGINE CONTROLLER INPUT................................................................................................. 910 TRANSMISSION PARK/ NEUTRAL SWITCH— ENGINE CONTROLLER INPUT............................................................................. 910 THROTTLE POSITION SENSOR (TPS)— ENGINE CONTROLLER INPUT................................................................................ 910 VEHICLE DISTANCE (SPEED) SENSOR— ENGINE CONTROLLER INPUT............................................................................... 911 AIR CONDITIONING (A/ C) CLUTCH RELAY— ENGINE CONTROLLER OUTPUT......................................................................... 911 ALTERNATOR FIELD— ENGINE CONTROLLER OUT-PUT............................................................................................ 911 AUTO SHUTDOWN (ASD) RELAY AND FUEL PUMP RELAY— ENGINE CONTROLLER OUTPUT................................................................ 912 AUTOMATIC IDLE SPEED (AIS) MOTOR— ENGINE CONTROLLER OUTPUT............................................................................. 912 CANISTER PURGE SOLENOID— ENGINE CONTROL-LER OUTPUT..................................................................................... 912 CHECK ENGINE LAMP— ENGINE CONTROLLER OUTPUT............................................................................................ 913 DIAGNOSTIC CONNECTOR— ENGINE CONTROLLER OUTPUT......................................................................................... 913 ELECTRONIC AUTOMATIC TRANSAXLE CONTROLLER— ENGINE CONTROLLER OUTPUT.................................................................... 913 EMISSION MAINTENANCE REMINDER (EMR) LAMP— ENGINE CONTROLLER OUTPUT..................................................................... 913 FUEL INJECTORS— ENGINE CONTROLLER OUTPUT............................................................................................... 913 IGNITION COIL— ENGINE CONTROLLER OUTPUT................................................................................................ 914 RADIATOR FAN RELAY— ENGINE CONTROLLER OUTPUT........................................................................................... 914 SPEED CONTROL SOLENOIDS— ENGINE CONTROL-LER OUTPUT..................................................................................... 914 TACHOMETER— ENGINE CONTROLLER OUTPUT................................................................................................... 914 MODES OF OPERATION..................................................................................................................... 914 THROTTLE BODY.......................................................................................................................... 916 FUEL SUPPLY CIRCUIT.................................................................................................................... 916 FUEL INJECTORS AND FUEL RAIL ASSEMBLY.................................................................................................. 916 FUEL PRESSURE REGULATOR................................................................................................................ 917 3.3L MULTI- POINT FUEL INJECTION— GENERAL DIAGNOSIS........................................................................................ 917 FUEL SYSTEM DIAGRAM.................................................................................................................... 917 VISUAL INSPECTION...................................................................................................................... 917 ON BOARD DIAGNOSTICS................................................................................................................... 921 MONITORED CIRCUITS................................................................................................................. 922 NON- MONITORED CIRCUITS............................................................................................................ 922 HIGH AND LOW LIMITS................................................................................................................ 923 FAULT CODE DESCRIPTION................................................................................................................. 923 SYSTEM TESTS........................................................................................................................... 923 OBTAINING FAULT CODES.............................................................................................................. 923 STATE DISPLAY TEST MODE................................................................................................................ 923 STATE DISPLAY INPUTS AND OUTPUTS................................................................................................... 923 FAULT CODE DESCRIPTION............................................................................................................. 924 FAULT CODE DESCRIPTION (CON’T)..................................................................................................... 925 STATE DISPLAY SENSORS.............................................................................................................. 926 CIRCUIT ACTUATION TEST MODE............................................................................................................ 926 OBTAINING CIRCUIT ACTUATION TEST................................................................................................... 926 THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE......................................................................................... 926 60- WAY ENGINE CONTROLLER WIRING CONNECTOR............................................................................................. 927 IDLE SPECIFICATIONS................................................................................................................ 927 3.3L MULTI- POINT FUEL INJECTION— SERVICE PROCEDURES....................................................................................... 929 THROTTLE BODY REMOVAL.................................................................................................................. 929 THROTTLE BODY.......................................................................................................................... 929 FUEL SYSTEM PRESSURE RELEASE PROCEDURE................................................................................................. 930 THROTTLE POSITION SENSOR............................................................................................................... 930 REMOVAL............................................................................................................................ 930 INSTALLATION....................................................................................................................... 930 AUTOMATIC IDLE SPEED (AIS) MOTOR....................................................................................................... 930 REMOVAL............................................................................................................................ 930 INSTALLATION....................................................................................................................... 930 FUEL INJECTOR RAIL ASSEMBLY............................................................................................................ 930 REMOVAL............................................................................................................................ 930 INSTALLATION....................................................................................................................... 932 FUEL PRESSURE REGULATOR................................................................................................................ 933 REMOVAL............................................................................................................................ 933 INSTALLATION....................................................................................................................... 934 FUEL INJECTOR.......................................................................................................................... 934 REMOVAL............................................................................................................................ 934 INSTALLATION....................................................................................................................... 934 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR................................................................................................ 934 CANISTER PURGE SOLENOID SERVICE........................................................................................................ 935 ENGINE CONTROLLER SERVICE.............................................................................................................. 935 CRANKSHAFT TIMING SENSOR............................................................................................................... 935 REMOVAL............................................................................................................................ 935 INSTALLATION....................................................................................................................... 935 CAMSHAFT SENSOR SERVICE................................................................................................................ 936 REMOVAL............................................................................................................................ 936 INSTALLATION....................................................................................................................... 936 HEATED OXYGEN SENSOR (O2 SENSOR) SERVICE............................................................................................... 936 SPECIFICATIONS............................................................................................................................. 937 TEMPERATURE SENSOR SPECIFICATIONS...................................................................................................... 937 TORQUE................................................................................................................................. 938 92AS_19............................................................................................................................................ 939 STEERING....................................................................................................................................... 939 GENERAL INFORMATION........................................................................................................................ 939 POWER STEERING PUMPS....................................................................................................................... 940 GENERAL INFORMATION.................................................................................................................... 940 STEERING COMPONENTS SERVICE DIAGNOSIS.................................................................................................. 941 POWER STEERING SERVICE DIAGNOSIS................................................................................................... 941 POWER STEERING SERVICE DIAGNOSIS................................................................................................... 942 POWER STEERING SERVICE DIAGNOSIS................................................................................................... 943 POWER STEERING SERVICE DIAGNOSIS................................................................................................... 944 POWER STEERING SERVICE DIAGNOSIS................................................................................................... 945 POWER STEERING SERVICE DIAGNOSIS................................................................................................... 946 POWER STEERING PUMP SERVICE............................................................................................................ 947 PUMP LEAKAGE DIAGNOSIS............................................................................................................. 947 CHECKING POWER STEERING FLUID LEVEL.................................................................................................... 948 POWER STEERING PUMP PRESSURE TEST...................................................................................................... 948 POWER STEERING HOSES................................................................................................................... 948 REMOVAL............................................................................................................................ 949 INSTALLATION....................................................................................................................... 949 POWER STEERING PUMP REMOVAL............................................................................................................ 950 2.5 LITER.......................................................................................................................... 950 3.0 LITER.......................................................................................................................... 951 3.3 LITER F. W. D. & A. W. D....................................................................................................... 953 POWER STEERING PUMP PULLEY............................................................................................................. 956 REMOVAL............................................................................................................................ 956 INSTALLATION....................................................................................................................... 956 POWER STEERING PUMP FLUID RESERVOIR.................................................................................................... 957 REMOVE............................................................................................................................. 957 INSTALL............................................................................................................................ 957 POWER STEERING PUMP— INITIAL OPERATION................................................................................................. 957 POWER STEERING GEAR........................................................................................................................ 958 GENERAL INFORMATION.................................................................................................................... 958 STEERING GEAR SERVICE (FRONT WHEEL DRIVE).............................................................................................. 959 REMOVAL............................................................................................................................ 959 INSTALLATION....................................................................................................................... 960 STEERING GEAR ALL WHEEL DRIVE...................................................................................................... 960 STEERING GEAR SERVICE (ALL WHEEL DRIVE)................................................................................................ 961 REMOVAL............................................................................................................................ 961 INSTALLATION....................................................................................................................... 964 OUTER TIE ROD.......................................................................................................................... 964 REMOVAL............................................................................................................................ 964 INSTALLATION....................................................................................................................... 964 STEERING GEAR BOOT SEAL................................................................................................................ 965 REMOVAL............................................................................................................................ 965 INSTALLATION....................................................................................................................... 965 ACUSTAR STANDARD AND TILT STEERING COLUMN.................................................................................................. 966 GENERAL INFORMATION.................................................................................................................... 966 STEERING COLUMN SERVICE PROCEDURES..................................................................................................... 966 STEERING COLUMN REMOVAL............................................................................................................ 968 STEERING COLUMN INSTALLATION....................................................................................................... 970 STEERING COLUMN COMPONENT SERVICE...................................................................................................... 971 GEAR SHIFT LEVER................................................................................................................... 971 IGNITION SWITCH SERVICE................................................................................................................ 972 TEST AND REPAIR.................................................................................................................... 972 SPECIFICATIONS AND TIGHTENING REFERENCE.................................................................................................... 973 TORQUE SPECIFICATIONS.................................................................................................................. 973 92AS_21............................................................................................................................................ 975 TRANSAXLE...................................................................................................................................... 975 A- 523 MANUAL TRANSAXLE.................................................................................................................... 975 GENERAL INFORMATION.................................................................................................................... 975 IDENTIFICATION......................................................................................................................... 975 GEARSHIFT LINKAGE ADJUSTMENT (CABLE OPER-ATED)......................................................................................... 976 IN- CAR TRANSAXLE DISASSEMBLE/ ASSEMBLE................................................................................................ 978 TRANSAXLE REMOVAL AND INSTALLATION..................................................................................................... 978 OUT OF CAR TRANSAXLE— DISASSEMBLE AND ASSEMBLE......................................................................................... 979 DIFFERENTIAL....................................................................................................................... 979 GEAR SET........................................................................................................................... 981 CLUTCH RELEASE BEARING INPUT SHAFT OIL SEAL........................................................................................ 988 REVERSE SHIFT LEVER................................................................................................................ 989 SUBASSEMBLY- RECONDITION............................................................................................................... 989 TRANSAXLE CASE..................................................................................................................... 989 INTERMEDIATE SHAFT ASSEMBLY........................................................................................................ 990 1- 2 SYNCHRONIZER (DUAL- CONE)..................................................................................................... 991 SYNCHRONIZERS...................................................................................................................... 993 GEARSHIFT HOUSING.................................................................................................................. 995 DIFFERENTIAL BEARING RETAINER...................................................................................................... 998 EXTENSION HOUSING.................................................................................................................. 999 INPUT SHAFT........................................................................................................................1000 A- 523 DIFFERENTIAL................................................................................................................1001 BEARING ADJUSTMENT PROCEDURE...........................................................................................................1003 GENERAL RULES ON SERVICING BEARINGS................................................................................................1003 INPUT SHAFT BEARING END PLAY ADJUSTMENT............................................................................................1003 DIFFERENTIAL BEARING PRELOAD ADJUSTMENT................................................................................................1004 INPUT SHAFT SHIM CHART.............................................................................................................1004 DIFFERENTIAL BEARING SHIM CHART....................................................................................................1005 THREE SPEED TORQUEFLITE AUTOMATIC TRANSAXLE................................................................................................1006 GENERAL INFORMATION....................................................................................................................1006 LOCKUP TORQUE CONVERTER............................................................................................................1007 HYDRAULIC CONTROL SYSTEM...........................................................................................................1007 PRESSURE SUPPLY SYSTEM.............................................................................................................1007 PRESSURE REGULATING VALVES.........................................................................................................1007 FLOW CONTROL VALVES................................................................................................................1007 CLUTCHES, BAND SERVOS, AND ACCUMULATOR.............................................................................................1007 GEARSHIFT AND PARKING LOCK CONTROLS................................................................................................1007 TORQUEFLITE DIAGNOSIS AND TESTS........................................................................................................1007 FLUID LEVEL AND CONDITION..............................................................................................................1010 DIAGNOSIS GUIDE— ABNORMAL NOISE....................................................................................................1010 SELECTION OF LUBRICANT.................................................................................................................1011 SPECIAL ADDITIVES......................................................................................................................1011 FLUID AND FILTER CHANGE................................................................................................................1011 FLUID DRAIN AND REFILL.................................................................................................................1011 LOCKUP SOLENOID WIRING CONNECTOR.......................................................................................................1011 ROAD TEST..............................................................................................................................1011 HYDRAULIC PRESSURE TESTS...............................................................................................................1012 TEST ONE (SELECTOR IN ‘‘ 1’’)......................................................................................................1012 ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER.............................................................................1012 TEST TWO (SELECTOR IN ‘‘ 2’’)......................................................................................................1013 TEST THREE (SELECTOR IN ‘‘ D’’)....................................................................................................1013 TEST FOUR (SELECTOR IN REVERSE)....................................................................................................1013 TEST RESULT INDICATIONS............................................................................................................1014 GOVERNOR PRESSURE..................................................................................................................1014 THROTTLE PRESSURE..................................................................................................................1014 CLUTCH AND SERVO AIR PRESSURE TESTS....................................................................................................1014 FRONT CLUTCH.......................................................................................................................1014 REAR CLUTCH........................................................................................................................1014 KICKDOWN SERVO (FRONT).............................................................................................................1014 LOW AND REVERSE SERVO (REAR).......................................................................................................1014 FLUID LEAKAGE- TRANSAXLE TORQUE CON-VERTER HOUSING AREA................................................................................1014 LEAKAGE TEST PROBE.................................................................................................................1015 TORQUE CONVERTER LEAKAGE...........................................................................................................1016 AIR PRESSURE TEST OF TRANSAXLE.....................................................................................................1016 GEARSHIFT LINKAGE ADJUSTMENT...........................................................................................................1017 THROTTLE PRESSURE LINKAGE ADJUSTMENT...................................................................................................1017 CABLE ADJUSTMENT PROCEDURE (4- CYL.)...............................................................................................1017 ROD ADJUSTMENT PROCEDURE (6- CYL.).................................................................................................1017 BAND ADJUSTMENT........................................................................................................................1018 KICKDOWN BAND (FRONT)..............................................................................................................1018 LOW/ REVERSE BAND (REAR)...........................................................................................................1018 HYDRAULIC CONTROL PRESSURE ADJUSTMENTS.................................................................................................1018 LINE PRESSURE......................................................................................................................1018 THROTTLE PRESSURE..................................................................................................................1018 DISTANCE SENSOR PINION GEAR............................................................................................................1018 REMOVAL AND INSTALLATION...........................................................................................................1018 NEUTRAL STARTING AND BACK- UP LAMP SWITCH..............................................................................................1018 REPLACEMENT AND TEST...............................................................................................................1018 GOVERNOR...............................................................................................................................1019 ALUMINUM THREAD REPAIR.................................................................................................................1019 OIL COOLERS AND TUBES REVERSE FLUSHING.................................................................................................1019 OIL COOLER FLOW CHECK..................................................................................................................1019 TRANSAXLE AND TORQUE CONVERTER REMOVAL.................................................................................................1020 TRANSAXLE DISASSEMBLY (SUBASSEMBLY REMOVAL)............................................................................................1022 TRANSAXLE ASSEMBLY (SUBASSEMBLY INSTALLATION)..........................................................................................1028 VALVE BODY RECONDITION.................................................................................................................1028 CLEANING AND INSPECTION............................................................................................................1028 PUMP OIL SEAL- REPLACEMENT.............................................................................................................1032 OIL PUMP- RECONDITION FRONT CLUTCH- RECONDITION........................................................................................1033 INSPECTION.........................................................................................................................1033 DISASSEMBLE/ ASSEMBLE MEASURING PLATE CLEARANCE....................................................................................1034 REAR CLUTCH- RECONDITION...............................................................................................................1035 INSPECTION.........................................................................................................................1035 DISASSEMBLE/ ASSEMBLE..............................................................................................................1035 MEASURING PLATE CLEARANCE..........................................................................................................1036 FRONT PLANETARY & ANNULUS GEAR- RECONDITION............................................................................................1036 LOW/ REVERSE (REAR) SERVO- RECONDITION.................................................................................................1037 ACCUMULATOR- RECONDITION...............................................................................................................1038 KICKDOWN SERVO (CONTROLLED LOAD) -RECONDITION..........................................................................................1038 TRANSFER SHAFT REPAIR..................................................................................................................1039 DETERMINING SHIM THICKNESS.........................................................................................................1043 PARKING PAWL...........................................................................................................................1043 OUTPUT SHAFT REPAIR....................................................................................................................1044 DETERMINING SHIM THICKNESS.........................................................................................................1046 DIFFERENTIAL REPAIR....................................................................................................................1047 DETERMINING SHIM THICKNESS.........................................................................................................1051 BEARING ADJUSTMENT PROCEDURES..........................................................................................................1053 GENERAL RULES ON SERVICING BEARINGS................................................................................................1053 OUTPUT SHAFT BEARING...............................................................................................................1053 DIFFERENTIAL BEARING...............................................................................................................1053 OUTPUT SHAFT BEARING SHIM CHART....................................................................................................1053 TRANSFER SHAFT BEARING.............................................................................................................1054 DIFFERENTIAL BEARING SHIM CHART....................................................................................................1054 TRANSFER BEARING SHIM CHART BEARING SHIM CHART.....................................................................................1055 4- SPEED ELECTRONIC AUTOMATIC TRANSAXLE....................................................................................................1056 GENERAL INFORMATION....................................................................................................................1056 TRANSAXLE IDENTIFICATION...........................................................................................................1056 OPERATION..........................................................................................................................1056 CLUTCH AND GEAR....................................................................................................................1058 HYDRAULICS.........................................................................................................................1058 SOLENOIDS..........................................................................................................................1058 SENSORS............................................................................................................................1058 ELECTRONICS........................................................................................................................1058 ADAPTIVE CONTROLS..................................................................................................................1058 ON- BOARD DIAGNOSTICS..............................................................................................................1059 GENERAL DIAGNOSIS......................................................................................................................1059 DIAGNOSIS GUIDE- VEHICLE WILL NOT MOVE.............................................................................................1059 FAULT CODE CHART ‘‘ A’’............................................................................................................1060 DIAGNOSIS CHART ‘‘ B’’.............................................................................................................1061 DIAGNOSIS GUIDE- ABNORMAL NOISE DIAGNOSIS GUIDE- FLUID LEAKS.......................................................................1062 FLUID LEVEL AND CONDITION..............................................................................................................1063 SELECTION OF LUBRICANT.................................................................................................................1063 SPECIAL ADDITIVES......................................................................................................................1063 FLUID AND FILTER CHANGE................................................................................................................1063 FLUID DRAIN AND REFILL.................................................................................................................1063 ROAD TEST..............................................................................................................................1064 ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER.............................................................................1064 HYDRAULIC PRESSURE TESTS...............................................................................................................1065 TEST ONE (SELECTOR IN ‘‘ L’’ 1ST GEAR).............................................................................................1065 TEST TWO (SELECTOR IN ‘‘ 3’’ 2ND GEAR).............................................................................................1065 TEST THREE (OVERDRIVE CLUTCH CHECK)................................................................................................1065 TEST FOUR (SELECTOR IN ‘‘ CIRCLE D’’ OVER-DRIVE GEAR)..............................................................................1065 TEST FIVE (SELECTOR IN ‘‘ CIRCLE D’’ OVER-DRIVE LOCKUP)............................................................................1065 TEST SIX (SELECTOR IN REVERSE).....................................................................................................1065 TEST RESULT INDICATIONS............................................................................................................1066 CLUTCH AIR PRESSURE TESTS..............................................................................................................1066 OVERDRIVE CLUTCH...................................................................................................................1066 REVERSE CLUTCH.....................................................................................................................1066 PRESSURE CHECK SPECIFICATIONS......................................................................................................1066 2/ 4 CLUTCH........................................................................................................................1067 LOW/ REVERSE CLUTCH................................................................................................................1067 UNDERDRIVE CLUTCH..................................................................................................................1067 FLUID LEAKAGE- TRANSAXLE TORQUE CON-VERTER HOUSING AREA................................................................................1067 TORQUE CONVERTER LEAKAGE...........................................................................................................1067 LEAKAGE TEST PROBE.................................................................................................................1067 AIR PRESSURE TEST OF TRANSAXLE.....................................................................................................1068 GEARSHIFT LINKAGE ADJUSTMENT...........................................................................................................1068 DISTANCE SENSOR GEAR...................................................................................................................1069 REMOVAL AND INSTALL................................................................................................................1069 ALUMINUM THREAD REPAIR.................................................................................................................1069 OIL COOLERS AND TUBES REVERSE FLUSHING.................................................................................................1069 OIL COOLER FLOW CHECK..................................................................................................................1069 TRANSAXLE REMOVAL AND INSTALLATION.....................................................................................................1070 SOLENOID ASSEMBLY- REPLACE.............................................................................................................1072 PRNDL SWITCH...........................................................................................................................1073 NEUTRAL SAFETY SWITCH..................................................................................................................1073 SPEED SENSOR- INPUT....................................................................................................................1073 SPEED SENSOR- OUTPUT...................................................................................................................1073 TRANSAXLE- RECONDITION.................................................................................................................1074 DETERMINING No. 4 THRUST PLATE THICKNESS (Input Shaft End Play)........................................................................1089 LOW/ REVERSE REACTION PLATE CHART..................................................................................................1089 INPUT CLUTCHES- RECONDITION............................................................................................................1090 DISASSEMBLY........................................................................................................................1090 NO. 4 THRUST PLATE CHART...........................................................................................................1090 ASSEMBLY...........................................................................................................................1095 UNDERDRIVE REACTION PLATE CHART....................................................................................................1099 REVERSE CLUTCH SNAP RING CHART.....................................................................................................1101 VALVE BODY- RECONDITION................................................................................................................1102 OIL PUMP SEAL- REPLACE DIFFERENTIAL REPAIR.............................................................................................1106 DETERMINING SHIM THICKNESS.........................................................................................................1110 BEARING ADJUSTMENT PROCEDURES..........................................................................................................1111 GENERAL RULES ON SERVICING BEARINGS................................................................................................1111 OUTPUT GEAR BEARING................................................................................................................1111 DIFFERENTIAL BEARING...............................................................................................................1112 OUTPUT GEAR BEARING SHIM CHART DIFFERENTIAL BEARING SHIM CHART.....................................................................1112 TRANSFER SHAFT BEARING.............................................................................................................1113 TRANSFER BEARING SHIM CHART........................................................................................................1113 BEARING SHIM CHART.................................................................................................................1114 ALL WHEEL DRIVE POWER TRANSFER UNIT (P. T. U.).............................................................................................1115 GENERAL INFORMATION....................................................................................................................1115 SEAL IDENTIFICATION....................................................................................................................1115 FLUID LEAK DIAGNOSIS...................................................................................................................1115 POWER TRANSFER UNIT (P. T. U.).........................................................................................................1116 REMOVAL AND INSTALLATION...........................................................................................................1116 POWER TRANSFER UNIT END COVER— RESEAL..................................................................................................1119 POWER TRANSFER UNIT INPUT SHAFT SEAL...................................................................................................1120 REMOVAL............................................................................................................................1120 INSTALLATION.......................................................................................................................1120 TRANSAXLE DIFFERENTIAL CARRIER SEAL....................................................................................................1121 REMOVAL............................................................................................................................1121 INSTALLATION.......................................................................................................................1121 POWER TRANSFER UNIT REAR COVER O- RING.................................................................................................1122 REMOVAL............................................................................................................................1122 POWER TRANSFER UNIT OUTPUT SEAL........................................................................................................1122 REMOVAL............................................................................................................................1122 INSTALLATION.......................................................................................................................1123 OUTPUT FLANGE SHIM SELECTION...........................................................................................................1124 POWER TRANSFER UNIT INPUT SHAFT COVER SEAL.............................................................................................1124 REMOVAL............................................................................................................................1124 INSTALLATION.......................................................................................................................1124 POWER TRANSFER UNIT HALF SHAFT INNER SEAL..............................................................................................1126 REMOVAL............................................................................................................................1126 INSTALLATION.......................................................................................................................1126 POWER TRANSFER UNIT INPUT SHAFT END SEAL...............................................................................................1127 REMOVAL............................................................................................................................1127 INSTALLATION.......................................................................................................................1128 POWER TRANSFER UNIT OUTER HALF SHAFT SEAL..............................................................................................1129 REMOVAL............................................................................................................................1129 INSTALLATION.......................................................................................................................1129 POWER TRANSFER UNIT END COVER BALL BEAR-ING............................................................................................1129 REMOVAL............................................................................................................................1129 INSTALLATION.......................................................................................................................1130 4- SPEED ELECTRONIC TRANSAXLE ON- BOARD DIAGNOSTICS........................................................................................1131 GENERAL INFORMATION....................................................................................................................1131 ON- BOARD DIAGNOSTICS INFORMATION......................................................................................................1131 CCD BUS................................................................................................................................1131 SYSTEM FAULT MESSAGES/ CODES...........................................................................................................1131 HARD FAULTS........................................................................................................................1131 SOFT FAULTS........................................................................................................................1131 LIMP- IN MODE..........................................................................................................................1131 DRBII (DIAGNOSTIC READ- OUT BOX).......................................................................................................1132 FAULT CODE CHARTS......................................................................................................................1132 FAULT CODE 11......................................................................................................................1132 FAULT CODE 12 FAULT CODE 13........................................................................................................1133 FAULT CODE 14 FAULT CODE 15........................................................................................................1134 FAULT CODE 16 FAULT CODE 17........................................................................................................1135 FAULT CODE 18 FAULT CODE 19........................................................................................................1136 FAULT CODE 20......................................................................................................................1137 FAULT CODE 21- 27..................................................................................................................1138 FAULT CODE 28......................................................................................................................1139 FAULT CODE 29 FAULT CODE 31- 32....................................................................................................1140 FAULT CODE 36 FAULT CODE 37........................................................................................................1141 FAULT CODE 38......................................................................................................................1142 FAULT CODE 41- 44..................................................................................................................1143 FAULT CODE 45 FAULT CODE 46........................................................................................................1144 FAULT CODE 47......................................................................................................................1145 FAULT CODE 50- 58..................................................................................................................1146 FAULT CODE 60- 63..................................................................................................................1147 4 SPEED ELECTRONIC TRANSAXLE WIRING DIAGRAM........................................................................................1148 ON BOARD DIAGNOSTICS GLOSSARY......................................................................................................1149 THREE SPEED TRANSAXLE HYDRAULIC SCHEMATICS ........................................................................................1150 THREE SPEED TRANSAXLE HYDRAULIC SCHEMATIC..........................................................................................1151 THREE SPEED TRANSAXLE HYDRAULIC SCHEMATIC..........................................................................................1152 THREE SPEED TRANSAXLE HYDRAULIC SCHEMATIC..........................................................................................1153 THREE SPEED TRANSAXLE HYDRAULIC SCHEMATIC..........................................................................................1154 THREE SPEED TRANSAXLE HYDRAULIC SCHEMATIC..........................................................................................1155 THREE SPEED TRANSAXLE HYDRAULIC SCHEMATIC..........................................................................................1156 THREE SPEED TRANSAXLE HYDRAULIC SCHEMATIC..........................................................................................1157 4- SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC..................................................................................1158 4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATICS..........................................................................................1158 4- SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC......................................................................................1159 4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1160 4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1161 4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1162 4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1163 4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1164 4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1165 4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1166 4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1167 4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1168 4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1169 4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC SCHEMATIC.......................................................................................1170 3- SPEED AUTOMATIC TRANSAXLE...........................................................................................................1171 4- SPEED ELECTRONIC AUTOMATIC TRANSAXLE................................................................................................1172 SPECIFICATIONS.............................................................................................................................1173 THREE SPEED TRANSAXLE TIGHTENING REFERENCE.............................................................................................1173 4 SPEED ELECTRONIC TRANSAXLE TIGHTENING REFERENCE .....................................................................................1174 CONVERSION CHART...................................................................................................................1175 POWER TRANSFER UNIT TIGHTENING REFERENCE...............................................................................................1174 92AS_22............................................................................................................................................1177 WHEELS TIRES...................................................................................................................................1177 TIRE SERVICE PROCEDURES....................................................................................................................1177 GENERAL INFORMATION....................................................................................................................1177 RADIAL- PLY TIRES......................................................................................................................1177 SPARE TIRE (COMPACT)...............................................................................................................1177 TIRE CHAINS........................................................................................................................1177 CLEANING OF TIRES......................................................................................................................1177 PRESSURE GAUGES........................................................................................................................1178 TIRE INFLATION PRESSURES...............................................................................................................1178 TIRE PRESSURE FOR HIGH SPEED OPERATION............................................................................................1178 REPLACEMENT TIRES......................................................................................................................1178 ROTATION...............................................................................................................................1179 TREAD WEAR INDICATORS..................................................................................................................1179 REPAIRING LEAKS........................................................................................................................1179 TIRE NOISE OR VIBRATION................................................................................................................1179 TIRE WEAR PATTERNS.....................................................................................................................1179 LEAD CORRECTION CHART..............................................................................................................1181 WHEEL SERVICE PROCEDURES...................................................................................................................1182 GENERAL INFORMATION....................................................................................................................1182 WHEEL INSTALLATION.....................................................................................................................1182 WHEEL REPLACEMENT......................................................................................................................1182 TIRE AND WHEEL BALANCE.................................................................................................................1182 TIRE AND WHEEL RUN OUT.................................................................................................................1183 METHOD 1 (RELOCATE WHEEL ON HUB)...................................................................................................1183 METHOD 2 (RELOCATE TIRE ON WHEEL)..................................................................................................1183 SPECIFICATIONS.............................................................................................................................1184 TORQUE.................................................................................................................................1184 92AS_23............................................................................................................................................1185 BODY...........................................................................................................................................1185 GENERAL SERVICE INFORMATION................................................................................................................1185 VEHICLE IDENTIFICATION.................................................................................................................1185 SAFETY PRECAUTIONS AND WARNINGS........................................................................................................1185 BODY DIAGNOSTIC PROCEDURES.................................................................................................................1186 WATER LEAKS............................................................................................................................1186 VISUAL INSPECTION BEFORE WATER LEAK TESTS..........................................................................................1186 WATER LEAK TESTS...................................................................................................................1186 WATER LEAK DETECTION...............................................................................................................1186 MIRROR INSPECTION METHOD...........................................................................................................1186 BRIGHT LIGHT LEAK TEST METHOD......................................................................................................1186 PRESSURIZED LEAK TEST METHOD.......................................................................................................1186 WIND NOISE.............................................................................................................................1187 VISUAL INSPECTION BEFORE TESTS.....................................................................................................1187 ROAD TESTING WIND NOISE............................................................................................................1187 PAINT......................................................................................................................................1188 INTRODUCTION...........................................................................................................................1188 BASE COAT/ CLEAR COAT FINISH...........................................................................................................1188 WET SANDING, BUFFING AND POLISHING.....................................................................................................1188 PAINTED SURFACE TOUCH- UP..............................................................................................................1188 TOUCH- UP PROCEDURE................................................................................................................1188 PAINT AND TRIM CODE DESCRIPTIONS...................................................................................................1188 WINDSHIELD.................................................................................................................................1189 SAFETY PRECAUTIONS AND WARNINGS........................................................................................................1189 WINDSHIELD REPLACEMENT.................................................................................................................1189 REMOVAL............................................................................................................................1189 INSTALLATION.......................................................................................................................1189 SEAT COMPONENT SERVICE.....................................................................................................................1191 GENERAL INFORMATION....................................................................................................................1191 HEAD RESTRAINT.........................................................................................................................1191 REMOVAL (FIG. 1)...................................................................................................................1191 INSTALLATION (FIG. 2)..............................................................................................................1191 ARMREST................................................................................................................................1191 REMOVAL (FIG. 3)...................................................................................................................1191 INSTALLATION.......................................................................................................................1192 BUCKET SEAT BACK.......................................................................................................................1192 REMOVAL (FIG. 4 AND 5).............................................................................................................1192 INSTALLATION.......................................................................................................................1192 RECLINER HANDLE........................................................................................................................1192 REMOVAL (FIG. 6)...................................................................................................................1192 RECLINER HANDLE INSTALLATION.......................................................................................................1193 SEAT BACK RECLINER.....................................................................................................................1193 REMOVAL (FIG. 7)...................................................................................................................1193 INSTALLATION.......................................................................................................................1193 LUMBAR SUPPORT HANDLE..................................................................................................................1193 REMOVAL (FIG. 8)...................................................................................................................1193 LUMBAR SUPPORT HANDLE INSTALLATION.................................................................................................1193 SEAT BACK ASSIST STRAP.................................................................................................................1193 REMOVAL (FIG. 9)...................................................................................................................1193 INSTALLATION.......................................................................................................................1193 SEAT BACK FRAME........................................................................................................................1193 REMOVAL (FIG. 10 AND 11)...........................................................................................................1193 SEAT BACK FRAME INSTALLATION (FIG. 12, 13 AND 14)..................................................................................1194 BUCKET SEAT RISER TRIM COVER...........................................................................................................1195 REMOVAL (FIG. 15)..................................................................................................................1195 INSTALLATION.......................................................................................................................1195 BUCKET SEAT RISER......................................................................................................................1195 REMOVAL (FIG. 16)..................................................................................................................1195 INSTALLATION.......................................................................................................................1195 BUCKET SEAT CUSHION SIDE COVER.........................................................................................................1195 REMOVAL (FIG. 17)..................................................................................................................1195 INSTALLATION.......................................................................................................................1195 BUCKET SEAT CUSHION FRAME..............................................................................................................1195 REMOVAL (FIG. 18)..................................................................................................................1195 INSTALLATION.......................................................................................................................1195 BUCKET SEAT CUSHION PAD................................................................................................................1195 REMOVAL (FIG. 19)..................................................................................................................1195 BUCKET SEAT CUSHION PAD INSTALLATION (FIG. 20).....................................................................................1196 SECOND REAR SEAT BACK PANEL............................................................................................................1196 REMOVAL (FIG. 21)..................................................................................................................1196 INSTALLATION.......................................................................................................................1196 SECOND REAR SEAT BACK HINGE COVER......................................................................................................1196 REMOVAL (FIG. 22)..................................................................................................................1196 INSTALLATION.......................................................................................................................1196 SECOND REAR SEAT BACK..................................................................................................................1196 REMOVAL (FIG. 23)..................................................................................................................1196 SECOND REAR SEAT BACK INSTALLATION.................................................................................................1197 SECOND REAR SEAT BACK HINGE............................................................................................................1197 REMOVAL (FIG. 24)..................................................................................................................1197 INSTALLATION.......................................................................................................................1197 SECOND REAR SEAT TRACK.................................................................................................................1197 REMOVAL (FIG. 25)..................................................................................................................1197 INSTALLATION.......................................................................................................................1197 SECOND REAR SEAT RISER.................................................................................................................1197 REMOVAL (FIG. 26)..................................................................................................................1197 INSTALLATION.......................................................................................................................1197 SECOND REAR SEAT CUSHION PAD...........................................................................................................1198 REMOVAL............................................................................................................................1198 INSTALLATION.......................................................................................................................1198 SECOND REAR SEAT BACK PAD..............................................................................................................1198 REMOVAL............................................................................................................................1198 INSTALLATION.......................................................................................................................1198 CHILD RESTRAINT SEAT...................................................................................................................1198 CHILD SEAT MODULE......................................................................................................................1198 REMOVAL............................................................................................................................1198 INSTALLATION.......................................................................................................................1198 CHILD SEAT MODULE HEAD RESTRAINT.......................................................................................................1199 REMOVAL (FIG. 29)..................................................................................................................1199 INSTALLATION.......................................................................................................................1199 CHILD SEAT MODULE HEAD RESTRAINT COVER AND PAD.........................................................................................1199 REMOVAL............................................................................................................................1199 INSTALLATION.......................................................................................................................1199 CHILD SEAT MODULE CUSHION COVER AND PAD................................................................................................1199 REMOVAL............................................................................................................................1199 INSTALLATION.......................................................................................................................1199 CHILD SEAT BACK COVER AND PADS.........................................................................................................1200 REMOVAL............................................................................................................................1200 INSTALLATION.......................................................................................................................1200 CHILD SEAT CUSHION COVER AND PAD.......................................................................................................1200 REMOVAL............................................................................................................................1200 CHILD SEAT CUSHION COVER AND PAD INSTALLATION......................................................................................1201 CONVERTA- BED SEATS....................................................................................................................1201 CONVERTA- BED SEAT RISER...............................................................................................................1201 REMOVAL (FIG. 35)..................................................................................................................1201 INSTALLATION.......................................................................................................................1201 CONVERTA- BED FORWARD RAIL AND PIVOT...................................................................................................1201 REMOVAL (FIG. 36)..................................................................................................................1201 INSTALLATION.......................................................................................................................1201 CONVERTA- BED SEAT HINGE COVERS........................................................................................................1201 REMOVAL............................................................................................................................1201 INSTALLATION.......................................................................................................................1201 CONVERTA- BED LATCH HANDLE AND LINK BAR................................................................................................1202 REMOVAL............................................................................................................................1202 INSTALLATION.......................................................................................................................1202 CONVERTA- BED SEAT BACK HINGE..........................................................................................................1202 REMOVAL............................................................................................................................1202 INSTALLATION.......................................................................................................................1202 CONVERTA- BED SEAT BACK FRAME..........................................................................................................1202 REMOVAL............................................................................................................................1202 CONVERTA- BED SEAT BACK FRAME INSTALLATION.........................................................................................1203 CONVERTA- BED SEAT CUSHION FRAME.......................................................................................................1203 REMOVAL............................................................................................................................1203 INSTALLATION.......................................................................................................................1203 BODY COMPONENT SERVICE.....................................................................................................................1204 GRILLE.................................................................................................................................1204 REMOVAL (FIG. 1 OR 2)..............................................................................................................1204 INSTALLATION.......................................................................................................................1204 HOOD ORNAMENT..........................................................................................................................1204 REMOVAL (FIG. 3)...................................................................................................................1204 INSTALLATION.......................................................................................................................1204 HOOD AND HINGES........................................................................................................................1205 HOOD REMOVAL (FIG. 4)..............................................................................................................1205 HOOD INSTALLATION..................................................................................................................1205 HOOD HINGE REMOVAL (FIG. 4)........................................................................................................1205 HOOD HINGE INSTALLATION............................................................................................................1205 HOOD SAFETY CATCH......................................................................................................................1205 REMOVAL (FIG. 5)...................................................................................................................1205 INSTALLATION.......................................................................................................................1205 HOOD LATCH.............................................................................................................................1205 REMOVAL (FIG. 6)...................................................................................................................1205 HOOD LATCH INSTALLATION............................................................................................................1206 HOOD RELEASE CABLE.....................................................................................................................1206 REMOVAL (FIG. 7)...................................................................................................................1206 INSTALLATION.......................................................................................................................1206 SIGHT SHIELD...........................................................................................................................1206 REMOVAL (FIG. 8)...................................................................................................................1206 INSTALLATION.......................................................................................................................1206 COWL COVER.............................................................................................................................1206 REMOVAL (FIG. 9)...................................................................................................................1206 COWL COVER INSTALLATION............................................................................................................1207 FRONT END SPLASH SHIELDS...............................................................................................................1207 FRONT WHEELHOUSE SPLASH SHIELD RE-MOVAL (FIG. 10)..................................................................................1207 FRONT WHEELHOUSE SPLASH SHIELD IN-STALLATION.......................................................................................1207 ENGINE DRIVE BELT SPLASH SHIELD RE-MOVAL (FIG. 10).................................................................................1207 ENGINE DRIVE BELT SPLASH SHIELD INSTAL-LATION......................................................................................1207 REAR ENGINE COMPARTMENT SPLASH SHIELD..................................................................................................1207 REAR ENGINE COMPARTMENT SPLASH SHIELD REMOVAL (FIG. 10)............................................................................1207 REAR ENGINE COMPARTMENT SPLASH SHIELD INSTALLATION.................................................................................1207 TRANSAXLE SPLASH SHIELD................................................................................................................1207 REMOVAL (FIG. 11)..................................................................................................................1207 INSTALLATION.......................................................................................................................1207 FRONT FENDER...........................................................................................................................1207 REMOVAL (FIG. 12)..................................................................................................................1207 FRONT FENDER INSTALLATION..........................................................................................................1208 FRONT DOOR TRIM PANEL..................................................................................................................1208 REMOVAL (FIG. 13)..................................................................................................................1208 FRONT DOOR TRIM PANEL INSTALLATION.................................................................................................1208 FRONT DOOR AND HINGE...................................................................................................................1208 FRONT DOOR REMOVAL (FIG. 14).......................................................................................................1208 FRONT DOOR INSTALLATION............................................................................................................1209 FRONT DOOR HINGE REMOVAL (FIG. 14).................................................................................................1209 FRONT DOOR HINGE INSTALLATION......................................................................................................1209 OUTSIDE FRONT DOOR LATCH RELEASE HANDLE................................................................................................1209 REMOVAL (FIG. 15)..................................................................................................................1209 INSTALLATION.......................................................................................................................1209 FRONT DOOR LATCH.......................................................................................................................1209 REMOVAL (FIG. 16)..................................................................................................................1209 INSTALLATION.......................................................................................................................1209 FRONT DOOR SIDE VIEW MIRROR............................................................................................................1210 REMOVAL (FIG. 17)..................................................................................................................1210 INSTALLATION.......................................................................................................................1210 FRONT DOOR GLASS.......................................................................................................................1210 REMOVAL (FIG. 18)..................................................................................................................1210 INSTALLATION.......................................................................................................................1210 FRONT DOOR BELT MOLDING AND WEATHERSTRIP— VAN..........................................................................................1210 REMOVAL (FIG. 19)..................................................................................................................1210 INSTALLATION.......................................................................................................................1210 FRONT DOOR FRAME REAR MOLDING— VAN.....................................................................................................1210 REMOVAL (FIG. 19)..................................................................................................................1210 INSTALLATION.......................................................................................................................1210 FRONT DOOR BELT MOLDING AND WEATHERSTRIP— WAGON........................................................................................1211 REMOVAL (FIG. 20)..................................................................................................................1211 INSTALLATION.......................................................................................................................1211 FRONT DOOR GLASS CHANNEL AND RUN WEATH-ERSTRIP.........................................................................................1211 REMOVAL (FIG. 21)..................................................................................................................1211 INSTALLATION.......................................................................................................................1211 FRONT DOOR GLASS LOWER CHANNEL.........................................................................................................1211 REMOVAL (FIG. 22)..................................................................................................................1211 INSTALLATION.......................................................................................................................1211 FRONT DOOR WINDOW REGULATOR— MANUAL....................................................................................................1211 REMOVAL (FIG. 22)..................................................................................................................1211 MANUAL WINDOW REGULATOR INSTALLA-TION..............................................................................................1212 FRONT DOOR WINDOW REGULATOR— POWER.....................................................................................................1212 REMOVAL (FIG. 22)..................................................................................................................1212 INSTALLATION.......................................................................................................................1212 SLIDING DOOR TRIM PANEL................................................................................................................1212 REMOVAL (FIG. 23)..................................................................................................................1212 INSTALLATION.......................................................................................................................1212 SLIDING DOOR FRAME UPPER MOLDING.......................................................................................................1212 REMOVAL (FIG. 23)..................................................................................................................1212 INSTALLATION.......................................................................................................................1212 SLIDING DOOR PULL HANDLE...............................................................................................................1212 REMOVAL (FIG. 23)..................................................................................................................1212 INSTALLATION.......................................................................................................................1212 SLIDING DOOR...........................................................................................................................1212 REMOVAL............................................................................................................................1212 SLIDING DOOR INSTALLATION..........................................................................................................1213 SLIDING DOOR CENTER HINGE TRACK COVER..................................................................................................1213 REMOVAL (FIG. 24)..................................................................................................................1213 INSTALLATION.......................................................................................................................1213 SLIDING DOOR CENTER HINGE..............................................................................................................1213 REMOVAL (FIG. 25)..................................................................................................................1213 INSTALLATION.......................................................................................................................1213 SLIDING DOOR UPPER HINGE...............................................................................................................1213 REMOVAL (FIG. 26)..................................................................................................................1213 SLIDING DOOR UPPER HINGE INSTALLATION..............................................................................................1214 SLIDING DOOR LOWER HINGE...............................................................................................................1214 REMOVAL (FIG. 27)..................................................................................................................1214 INSTALLATION.......................................................................................................................1214 SLIDING DOOR INSIDE LATCH/ LOCK CONTROL................................................................................................1214 REMOVAL (FIG. 28)..................................................................................................................1214 INSTALLATION.......................................................................................................................1214 SLIDING DOOR LATCH/ LOCK LINKAGE.......................................................................................................1214 REMOVAL (FIG. 29)..................................................................................................................1214 SLIDING DOOR LATCH/ LOCK LINKAGE IN-STALLATION.....................................................................................1215 SLIDING DOOR POWER LOCK ACTUATOR.......................................................................................................1215 REMOVAL (FIG. 29)..................................................................................................................1215 INSTALLATION.......................................................................................................................1215 SLIDING DOOR OUTSIDE LATCH RELEASE HANDLE..............................................................................................1215 REMOVAL (FIG. 30)..................................................................................................................1215 INSTALLATION.......................................................................................................................1215 SLIDING DOOR REAR LATCH................................................................................................................1215 REMOVAL (FIG. 31)..................................................................................................................1215 INSTALLATION.......................................................................................................................1215 VENT WINDOW............................................................................................................................1216 REMOVAL (FIG. 32)..................................................................................................................1216 INSTALLATION.......................................................................................................................1216 VENT WINDOW WEATHERSTRIP...............................................................................................................1216 REMOVAL (FIG. 33)..................................................................................................................1216 INSTALLATION.......................................................................................................................1216 DOOR OPENING WEATHERSTRIPS.............................................................................................................1216 REMOVAL............................................................................................................................1216 INSTALLATION.......................................................................................................................1216 STICK- ON BODY SIDE MOLDING............................................................................................................1216 REMOVAL AND INSTALLATION...........................................................................................................1216 EXTERIOR MOLDINGS (FIG. 34)............................................................................................................1217 UPPER MOLDINGS.....................................................................................................................1217 LOWER MOLDINGS.....................................................................................................................1217 WHEEL LIP MOLDINGS.................................................................................................................1217 SILL MOLDINGS......................................................................................................................1217 BODY SIDE APPLIQUE (FIG. 35)...........................................................................................................1217 DOOR APPLIQUE......................................................................................................................1217 FRONT SILL APPLIQUE................................................................................................................1217 RIGHT REAR SILL APPLIQUE...........................................................................................................1217 LEFT QUARTER APPLIQUE..............................................................................................................1218 WOOD GRAIN OVERLAY.....................................................................................................................1219 REMOVAL............................................................................................................................1219 INSTALLATION.......................................................................................................................1219 RIGHT SIDE GRAB HANDLE.................................................................................................................1219 REMOVAL (FIG. 36)..................................................................................................................1219 INSTALLATION.......................................................................................................................1219 COWL TRIM AND SCUFF PLATES.............................................................................................................1219 REMOVAL (FIG. 37)..................................................................................................................1219 COWL TRIM AND SCUFF PLATE INSTALLA-TION............................................................................................1220 SLIDING DOOR SCUFF PLATE REMOVAL (FIG. 37).........................................................................................1220 SLIDING DOOR SCUFF PLATE INSTALLATION..............................................................................................1220 A- PILLAR AND ROOF RAIL MOLDINGS.......................................................................................................1220 REMOVAL (FIG. 37)..................................................................................................................1220 INSTALLATION.......................................................................................................................1220 RIGHT B- PILLAR TRIM COVER.............................................................................................................1220 REMOVAL (FIG. 37)..................................................................................................................1220 INSTALLATION.......................................................................................................................1220 UPPER TRACK COVER......................................................................................................................1220 REMOVAL (FIG. 37)..................................................................................................................1220 INSTALLATION.......................................................................................................................1220 RIGHT QUARTER TRIM PANEL...............................................................................................................1221 REMOVAL (FIG. 37)..................................................................................................................1221 INSTALLATION.......................................................................................................................1221 LEFT QUARTER TRIM PANEL................................................................................................................1221 REMOVAL (FIG. 38)..................................................................................................................1221 INSTALLATION.......................................................................................................................1221 LEFT QUARTER TRIM PANEL— WITH REAR A/ C................................................................................................1222 REMOVAL (FIG. 39)..................................................................................................................1222 INSTALLATION.......................................................................................................................1222 FRONT SEAT BELTS.......................................................................................................................1222 OUTBOARD SHOULDER HARNESS/ LAP BELT REMOVAL (FIG. 40 OR 41)........................................................................1222 OUTBOARD SHOULDER HARNESS/ LAP BELT INSTALLATION...................................................................................1222 INBOARD BUCKLE REMOVAL (FIG. 42)...................................................................................................1222 INBOARD BUCKLE INSTALLATION........................................................................................................1222 REAR SEAT BELTS........................................................................................................................1223 OUTBOARD SHOULDER HARNESS/ LAP BELT REMOVAL (FIG. 43 OR 44)........................................................................1223 OUTBOARD SHOULDER HARNESS/ LAP BELT INSTALLATION...................................................................................1223 SEATS..................................................................................................................................1223 FRONT SEAT REMOVAL (FIG. 45).......................................................................................................1223 FRONT SEAT INSTALLATION............................................................................................................1223 FRONT CENTER CONSOLE...................................................................................................................1224 REMOVAL (FIG. 46)..................................................................................................................1224 INSTALLATION.......................................................................................................................1224 FLOOR CARPET...........................................................................................................................1224 REMOVAL (FIG. 47)..................................................................................................................1224 INSTALLATION.......................................................................................................................1224 OVERHEAD CONSOLE.......................................................................................................................1224 REMOVAL (FIG. 48)..................................................................................................................1224 OVERHEAD CONSOLE INSTALLATION......................................................................................................1225 HEAD LINING............................................................................................................................1225 REMOVAL (FIG. 49)..................................................................................................................1225 INSTALLATION.......................................................................................................................1225 LIFTGATE...............................................................................................................................1225 REMOVAL (FIG. 50)..................................................................................................................1225 INSTALLATION.......................................................................................................................1225 LIFTGATE TRIM PANEL....................................................................................................................1225 REMOVAL (FIG. 51)..................................................................................................................1225 INSTALLATION.......................................................................................................................1225 LIFTGATE LATCH.........................................................................................................................1226 REMOVAL (FIG. 52)..................................................................................................................1226 INSTALLATION.......................................................................................................................1226 ROOF TOP LUGGAGE RACK..................................................................................................................1226 REMOVAL (FIG. 53)..................................................................................................................1226 INSTALLATION.......................................................................................................................1226 FUEL FILL DOOR RELEASE CABLE...........................................................................................................1226 REMOVAL (FIG. 54)..................................................................................................................1226 FUEL FILL DOOR CABLE INSTALLATION..................................................................................................1227 REAR WINDOW GLASS......................................................................................................................1227 92AS_24............................................................................................................................................1229 HEATING AND AIR CONDITIONING...................................................................................................................1229 GENERAL INFORMATION........................................................................................................................1229 A/ C SYSTEM IDENTIFICATION.............................................................................................................1229 DESCRIPTION AND OPERATION..............................................................................................................1229 SYSTEM AIRFLOW.........................................................................................................................1229 SIDE WINDOW DEMISTERS..................................................................................................................1230 ENGINE COOLING SYSTEM REQUIREMENTS.....................................................................................................1230 SAFETY PRECAUTIONS AND WARNINGS........................................................................................................1230 COOLING SYSTEM PRECAUTIONS.............................................................................................................1231 HANDLING TUBING AND FITTINGS...........................................................................................................1231 VARIABLE COMPRESSOR AND COMPONENTS DIAGNOSTIC PROCEDURES...................................................................................1232 GENERAL INFORMATION....................................................................................................................1232 COMPRESSOR IDENTIFICATION..............................................................................................................1232 VARIABLE DISPLACEMENT COMPRESSOR DIAG-NOSIS............................................................................................1232 COMPRESSOR NOISE.......................................................................................................................1232 COMPRESSOR CLUTCH INOPERATIVE..........................................................................................................1232 VARIABLE DISPLACEMENT COMPRESSOR DIAGNOSIS.........................................................................................1233 REFRIGERANT SYSTEM DIAGNOSIS— VARIABLE DISPLACEMENT COMPRESSOR.....................................................................1234 COMPRESSOR NOISE AND COMPRESSOR CLUTCH DIAGNOSIS...................................................................................1235 CLUTCH COIL TESTS......................................................................................................................1236 DIFFERENTIAL PRESSURE CUT- OUT SWITCH DI-AGNOSIS.......................................................................................1236 DPCO SWITCH TEST...................................................................................................................1236 AMBIENT SWITCH DIAGNOSIS...............................................................................................................1236 AMBIENT SWITCH TEST................................................................................................................1236 CONDENSER FAN CONTROL SWITCH DIAGNOSIS.................................................................................................1236 FAN CONTROL SWITCH TEST............................................................................................................1236 COMPRESSOR CLUTCH DIAGNOSIS— VARIABLE DISPLACEMENT COMPRESSOR— MODEL 6C17..........................................................1237 HIGH PRESSURE CUT- OUT SWITCH DIAGNOSIS................................................................................................1238 HPCO SWITCH TESTS..................................................................................................................1238 BLACK EXPANSION VALVE TEST.............................................................................................................1239 HIGH PRESSURE RELIEF VALVE (HPR) DIAGNOSIS.............................................................................................1239 HPR VALVE LOCATION.................................................................................................................1239 FIXED DISPLACEMENT COMPRESSOR AND COMPONENTS DIAGNOSTIC PROCE-DURES........................................................................1241 GENERAL INFORMATION COMPRESSOR IDENTIFICATION COMPRESSOR NOISE.........................................................................1241 COMPRESSOR CLUTCH INOPERATIVE..........................................................................................................1241 CLUTCH COIL TESTS......................................................................................................................1241 LOW- PRESSURE CUT- OFF SWITCH DIAGNOSIS................................................................................................1241 COMPRESSOR NOISE AND COMPRESSOR CLUTCH DIAGNOSIS...................................................................................1242 LPCO SWITCH TEST...................................................................................................................1243 ELECTRONIC CYCLING CLUTCH SWITCH.......................................................................................................1243 TEST PROCEDURE.....................................................................................................................1243 FIXED DISPLACEMENT COMPRESSOR REFRIGER-ANT SYSTEM......................................................................................1243 SILVER EXPANSION VALVE TESTS...........................................................................................................1243 REFRIGERANT SYSTEM DIAGNOSIS.......................................................................................................1244 HIGH PRESSURE RELIEF VALVE (HPR) DIAGNOSIS.............................................................................................1245 HPR VALVE LOCATION.................................................................................................................1245 VACUUM CONTROL SYSTEM DIAGNOSIS............................................................................................................1246 GENERAL INFORMATION....................................................................................................................1246 VACUUM TESTING THE ONE- WAY CHECK VALVE................................................................................................1246 VACUUM TESTING THE HEATER- A/ C CONTROLS...............................................................................................1246 LOCATING VACUUM LEAKS..................................................................................................................1246 HEATER AND A/ C PERFORMANCE TESTS..........................................................................................................1247 VACUUM CIRCUITS— HEATER OR HEATER A/ C CONTROL.........................................................................................1247 HEATER OUTPUT TEST.....................................................................................................................1248 PRE- DIAGNOSTIC PREPARATIONS.......................................................................................................1248 MAXIMUM HEATER OUTPUT: TEST AND AC-TION............................................................................................1248 A/ C PERFORMANCE TEST..................................................................................................................1248 PERFORMANCE TEST PROCEDURE.........................................................................................................1248 TEMPERATURE REFERENCE CHART........................................................................................................1248 A/ C PERFORMANCE TEMPERATURES......................................................................................................1249 REFRIGERANT SERVICE PROCEDURES.............................................................................................................1250 SIGHT GLASS REFRIGERANT LEVEL INSPECTION...............................................................................................1250 R- 12 REFRIGERANT EQUIPMENT............................................................................................................1250 REFRIGERANT RECYCLING..................................................................................................................1251 MANIFOLD GAUGE SET CONNECTIONS.........................................................................................................1251 GENERAL INFORMATION................................................................................................................1251 TESTING FOR REFRIGERANT LEAKS..........................................................................................................1252 EMPTY REFRIGERANT SYSTEM LEAK TEST.................................................................................................1252 LOW REFRIGERANT LEVEL LEAK TEST....................................................................................................1252 ADDING PARTIAL REFRIGERANT CHARGE......................................................................................................1252 DISCHARGING REFRIGERANT SYSTEM.........................................................................................................1253 EVACUATING REFRIGERANT SYSTEM..........................................................................................................1253 CHARGING REFRIGERANT SYSTEM— EMPTY SYS-TEM.............................................................................................1254 REFRIGERANT CAPACITIES:............................................................................................................1254 OIL LEVEL..............................................................................................................................1254 REFRIGERANT OIL LEVEL CHECK........................................................................................................1254 VERIFY REFRIGERANT OIL LEVEL.......................................................................................................1254 REFRIGERANT OIL CAPACITIES.........................................................................................................1254 VARIABLE DISPLACEMENT COMPRESSOR SERVICE PROCEDURES........................................................................................1255 COMPRESSOR REMOVAL AND INSTALLATION....................................................................................................1255 COMPRESSOR CLUTCH/ COIL ASSEMBLY.......................................................................................................1255 REMOVAL AND INSTALLATION...........................................................................................................1255 COMPRESSOR FRONT SHAFT SEAL............................................................................................................1256 REMOVAL............................................................................................................................1256 INSTALLATION.......................................................................................................................1258 COMPRESSOR HIGH PRESSURE CUT- OUT SWITCH...............................................................................................1258 REMOVAL AND INSTALLATION...........................................................................................................1258 COMPRESSOR HIGH PRESSURE RELIEF VALVE..................................................................................................1259 REMOVAL AND INSTALLATION...........................................................................................................1259 COMPRESSOR MAIN OR SUB CONTROL VALVES..................................................................................................1259 REMOVAL AND INSTALLATION...........................................................................................................1259 FIXED DISPLACEMENT COMPRESSOR SERVICE PROCEDURES...........................................................................................1260 COMPRESSOR REMOVAL AND INSTALLATION....................................................................................................1260 COMPRESSOR CLUTCH/ COIL— MODEL 10PA17..................................................................................................1260 REMOVAL............................................................................................................................1260 INSTALLATION.......................................................................................................................1261 CLUTCH BREAK- IN...................................................................................................................1262 COMPRESSOR FRONT SHAFT SEAL— MODEL 10PA17..............................................................................................1262 REMOVAL............................................................................................................................1262 INSTALLATION.......................................................................................................................1263 COMPRESSOR HIGH- PRESSURE RELIEF VALVE.................................................................................................1264 REMOVAL AND INSTALLATION...........................................................................................................1264 COMPONENT DIAGNOSIS........................................................................................................................1266 CONDENSATE WATER DRAINAGE..............................................................................................................1266 BLOWER MOTOR VIBRATION AND/ OR NOISE DI-AGNOSIS........................................................................................1266 BLOWER MOTOR ELECTRICAL DIAGNOSIS......................................................................................................1266 BLOWER MOTOR NOISE/ VIBRATION DIAGNOSIS............................................................................................1267 BLOWER MOTOR ELECTRICAL SYSTEM DIAGNOSIS...........................................................................................1268 COMPONENT SERVICE PROCEDURES...............................................................................................................1269 TEMPERATURE CONTROL CABLE..............................................................................................................1269 REMOVAL AND INSTALLATION...........................................................................................................1269 BLOWER RESISTOR BLOCK..................................................................................................................1269 REMOVAL AND INSTALLATION...........................................................................................................1269 VACUUM ACTUATOR— FRESH/ RECIRC DOOR....................................................................................................1270 REMOVAL AND INSTALLATION...........................................................................................................1270 VACUUM ACTUATORS— MODE DOORS...........................................................................................................1270 REMOVAL............................................................................................................................1270 INSTALLATION.......................................................................................................................1270 AIR DISTRIBUTION DUCT..................................................................................................................1270 REMOVAL AND INSTALLATION...........................................................................................................1270 DEFROSTER DUCTS/ DEMISTER DUCTS AND HOSES..............................................................................................1271 REMOVAL AND INSTALLATION...........................................................................................................1271 HEATER HOSES...........................................................................................................................1271 REMOVAL AND INSTALLATION...........................................................................................................1271 WATER CONTROL VALVE....................................................................................................................1272 REMOVAL AND INSTALLATION...........................................................................................................1272 AMBIENT SWITCH.........................................................................................................................1272 REMOVAL AND INSTALLATION...........................................................................................................1272 ELECTRONIC CYCLING CLUTCH SWITCH (ECCS)................................................................................................1272 REMOVAL AND INSTALLATION...........................................................................................................1272 CONDENSER FAN CONTROL SWITCH— VARIABLE DISPLACEMENT COMPRESSOR SYSTEM..................................................................1272 REMOVAL AND INSTALLATION...........................................................................................................1273 LOW OR DIFFERENTIAL PRESSURE CUT- OFF SWITCH...........................................................................................1273 REMOVAL AND INSTALLATION...........................................................................................................1273 EXPANSION VALVE........................................................................................................................1273 REMOVAL............................................................................................................................1273 INSTALLATION.......................................................................................................................1273 FILTER- DRIER ASSEMBLY.................................................................................................................1274 REMOVAL AND INSTALLATION...........................................................................................................1274 CONDENSER ASSEMBLY.....................................................................................................................1274 REMOVAL AND INSTALLATION...........................................................................................................1274 BLOWER MOTOR AND WHEEL ASSEMBLY........................................................................................................1274 REMOVAL AND INSTALLATION...........................................................................................................1274 BLOWER MOTOR WHEEL.....................................................................................................................1275 REMOVAL AND INSTALLATION...........................................................................................................1275 HEATER CORE............................................................................................................................1275 REMOVAL AND INSTALLATION...........................................................................................................1275 EVAPORATOR COIL........................................................................................................................1275 REMOVAL AND INSTALLATION...........................................................................................................1275 HEATER- A/ C UNIT HOUSING..............................................................................................................1275 REMOVAL AND INSTALLATION...........................................................................................................1275 HEATER A/ C UNIT RECONDITION...........................................................................................................1275 DISASSEMBLY........................................................................................................................1275 ASSEMBLY...........................................................................................................................1276 CONDENSATE DRAIN TUBE..................................................................................................................1277 REMOVAL AND INSTALLATION...........................................................................................................1277 AUXILIARY REAR HEATING OR HEATING- AIR/ CONDITIONING.......................................................................................1278 GENERAL INFORMATION....................................................................................................................1278 DIAGNOSTIC PROCEDURES..................................................................................................................1278 REAR HEATER A/ C CONTROL...............................................................................................................1278 REMOVE AND INSTALL.................................................................................................................1278 REAR HEATER A/ C CONTROL ILLUMINATION BULB.............................................................................................1278 REMOVE AND INSTALL.................................................................................................................1278 REAR HEATER A/ C AIR OUTLETS...........................................................................................................1278 REMOVAL AND INSTALL................................................................................................................1278 REAR BLOWER RESISTOR BLOCK.............................................................................................................1279 REMOVE AND INSTALL.................................................................................................................1279 REAR HEATER A/ C BLOWER MOTOR..........................................................................................................1279 REMOVE AND INSTALL.................................................................................................................1279 REAR HEATER- A/ C UNIT.................................................................................................................1279 REMOVE AND INSTALL.................................................................................................................1279 AIR DISTRIBUTION DUCT..................................................................................................................1279 REMOVE AND INSTALL.................................................................................................................1279 HEATER CORE............................................................................................................................1279 REMOVE AND INSTALL.................................................................................................................1279 EVAPORATOR AND EXPANSION VALVE.........................................................................................................1279 REMOVE.............................................................................................................................1279 INSTALL............................................................................................................................1280 AUXILIARY UNDER BODY HEATER PLUMBING...................................................................................................1280 REMOVAL AND INSTALLATION...........................................................................................................1280 AUXILIARY UNDER BODY REFRIGERANT PLUMBING..............................................................................................1280 REMOVAL............................................................................................................................1280 INSTALL............................................................................................................................1280 92AS_25............................................................................................................................................1283 EMISSION CONTROL SYSTEMS.......................................................................................................................1283 CONTENTS...................................................................................................................................1283 GENERAL INFORMATION....................................................................................................................1283 EMISSION MAINTENANCE REMINDER (EMR) SYSTEM.............................................................................................1283 RESETTING EMR LAMP.................................................................................................................1283 EVAPORATIVE EMISSION CONTROLS..............................................................................................................1284 VEHICLE EMISSION CONTROL INFORMATION LABEL.............................................................................................1284 FEDERAL EMISSION CONTROL INFORMATION LABEL— TYPICAL................................................................................1284 VACUUM SCHEMATICS......................................................................................................................1285 CALIFORNIA VEHICLE CONTROL INFORMATION LABEL— TYPICAL CANADA VEHICLE EMISSION CONTROL INFORMATION LABEL— TYPICAL...................1285 ENGINE VACUUM SCHEMATIC— 2.5L ENGINE ENGINE VACUUM SCHEMATIC— 3.0L ENGINE..........................................................1286 EVAPORATION CONTROL SYSTEM.............................................................................................................1287 PRESSURE RELIEF/ ROLLOVER VALVE....................................................................................................1287 EVAPORATIVE CANISTER...............................................................................................................1287 CANISTER PURGE SOLENOID................................................................................................................1287 ENGINE VACUUM SCHEMATIC— 3.3L ENGINE...............................................................................................1287 PRESSURE- VACUUM FILLER CAP........................................................................................................1288 POSITIVE CRANKCASE VENTILATION (PCV) SYSTEMS.......................................................................................1288 PCV VALVE TEST.....................................................................................................................1288 CRANKCASE VENT FILTER..............................................................................................................1289 EXHAUST EMISSION CONTROLS..................................................................................................................1290 HEATED INLET AIR SYSTEM................................................................................................................1290 HEATED INLET AIR SYSTEM SERVICE....................................................................................................1290 HEATED AIR TEMPERATURE SENSOR SER- VICE............................................................................................1291 HEATED OXYGEN SENSOR (O2 SENSOR).......................................................................................................1291 REMOVAL............................................................................................................................1292 EXHAUST GAS RECIRCULATION (EGR) SYSTEM.................................................................................................1292 EGR SYSTEM ON- BOARD DIAGNOSTICS (CALIFORNIA VEHICLES).............................................................................1293 EXHAUST GAS RECIRCULATION (EGR) SYS-TEM TEST.......................................................................................1293 EGR DIAGNOSIS CHART................................................................................................................1294 EGR GAS FLOW TEST..................................................................................................................1295 EGR SYSTEM SERVICE.....................................................................................................................1295 EGR VALVE REMOVAL..................................................................................................................1295 INSTALLATION.......................................................................................................................1295 EGR TUBE REMOVAL...................................................................................................................1295 INSTALLATION.......................................................................................................................1295 92AS_FR............................................................................................................................................1297 92AS_IN............................................................................................................................................1301 INTRODUCTION...................................................................................................................................1301 CONTENTS...................................................................................................................................1301 VEHICLE FAMILY IDENTIFICATION..........................................................................................................1301 VEHICLE IDENTIFICATION NUMBER..........................................................................................................1301 VEHICLE SAFETY CERTIFICATION LABEL.....................................................................................................1301 VEHICLE IDENTIFICATION NUMBER DECODING CHART.......................................................................................1302 BODY CODE PLATE LOCATION AND DECODING INFORMATION......................................................................................1303 BODY CODE PLATE LINE 3.............................................................................................................1303 BODY CODE PLATE LINE 2.............................................................................................................1303 BODY CODE PLATE LINE 1.............................................................................................................1303 BODY CODE PLATE....................................................................................................................1303 IF TWO BODY CODE PLATES ARE REQUIRED...............................................................................................1304 TORQUE REFERENCES......................................................................................................................1304 STANDARD BODY DIMENSIONS...........................................................................................................1304 METRIC THREAD AND GRADE IDENTIFICATION.................................................................................................1305 INTERNATIONAL SYMBOLS..................................................................................................................1305 METRIC SYSTEM..........................................................................................................................1306 CONVERSION TABLES..................................................................................................................1307 CONVERSION TABLES..................................................................................................................1308 92AS_IX............................................................................................................................................1309
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer