1998 CHRYSLER VOYAGERS SERVICE MANUAL – PDF DOWNLOAD
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1998 CHRYSLER VOYAGERS SERVICE MANUAL – PDF DOWNLOAD
- The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations. This manual does not cover theory of operation, which is addressed in service training material.
- Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle. Information in this manual is divided into groups. These groups contain general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components.
- To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar after the group title is aligned to a solid tab on the first page of each group. The first page of the group has a contents section that lists major topics within the group. If you are not sure which Group contains the information you need, look up the Component/System in the alphabetical index located in the rear of this manual.
- Tightening torques are provided as a specific value throughout this manual. This value represents the midpoint of the acceptable engineering torque range for a given fastener application. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners. When replacing fasteners, always use the same type (part number) fastener as removed.
- Chrysler International reserves the right to change testing procedures, specifications, diagnosis, repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
TABLE OF CONTENTS:
1998 CHRYSLER VOYAGERS SERVICE MANUAL – PDF DOWNLOAD
INTRODUCTION NS............................................................................................................................ 4 GENERAL INFORMATION.................................................................................................................... 4 VEHICLE SAFETY CERTIFICATION LABEL................................................................................................. 4 VEHICLE IDENTIFICATION NUMBER...................................................................................................... 4 VIN CHECK DIGIT.................................................................................................................... 4 BODY CODE PLATE.................................................................................................................... 4 LOCATION AND DECODING.......................................................................................................... 4 VIN CODE BREAKDOWN CHART....................................................................................................... 5 BODY CODE PLATE – LINE 3....................................................................................................... 5 BODY CODE PLATE LINE 2......................................................................................................... 6 BODY CODE PLATE LINE 1......................................................................................................... 6 IF TWO BODY CODE PLATES ARE REQUIRED........................................................................................... 6 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS...................................................................................... 7 INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS................................ 7 FASTENER IDENTIFICATION............................................................................................................ 7 FASTENER IDENTIFICATION........................................................................................................ 7 FASTENER IDENTIFICATION........................................................................................................ 8 FASTENER STRENGTH.............................................................................................................. 9 METRIC SYSTEM...................................................................................................................... 10 CONVERSION FORMULAS AND EQUIVALENT VALUES...................................................................................... 10 TORQUE REFERENCES.................................................................................................................. 10 METRIC CONVERSION.............................................................................................................. 11 TORQUE SPECIFICATIONS.......................................................................................................... 12 INTRODUCTION NS/GS......................................................................................................................... 13 GENERAL INFORMATION.................................................................................................................... 13 E- MARK LABEL...................................................................................................................... 13 VEHICLE IDENTIFICATION NUMBER...................................................................................................... 13 VIN CHECK DIGIT................................................................................................................ 13 BODY CODE PLATE.................................................................................................................... 13 LOCATION AND DECODING.......................................................................................................... 13 BODY CODE PLATE— LINE 3........................................................................................................ 13 VIN DECODING INFORMATION....................................................................................................... 14 BODY CODE PLATE— LINE 2........................................................................................................ 14 BODY CODE PLATE LINE 1......................................................................................................... 15 IF TWO BODY CODE PLATES ARE REQUIRED........................................................................................... 15 MANUFACTURER PLATE................................................................................................................. 15 LUBRICATION AND MAINTENANCE................................................................................................................ 17 GENERAL INFORMATION.................................................................................................................... 17 INTRODUCTION....................................................................................................................... 17 PARTS AND LUBRICANT RECOMMENDATIONS............................................................................................... 17 INTERNATIONAL SYMBOLS.............................................................................................................. 17 CLASSIFICATION OF LUBRICANTS....................................................................................................... 17 ENGINE OIL..................................................................................................................... 18 FLUID CAPACITIES................................................................................................................... 18 GENERAL INFORMATION.................................................................................................................... 19 INTRODUCTION....................................................................................................................... 19 UNSCHEDULED INSPECTION............................................................................................................. 19 SCHEDULE – A....................................................................................................................... 19 SCHEDULE – B....................................................................................................................... 20 SERVICE PROCEDURES..................................................................................................................... 23 JUMP STARTING PROCEDURE............................................................................................................ 23 TO JUMP START A DISABLED VEHICLE:.............................................................................................. 23 TOWING RECOMMENDATIONS............................................................................................................. 24 WARNINGS AND CAUTIONS.......................................................................................................... 24 RECOMMENDED TOWING EQUIPMENT................................................................................................... 24 GROUND CLEARANCE............................................................................................................... 24 LOCKED VEHICLE TOWING.......................................................................................................... 24 FLAT TOWING WITH TOW BAR....................................................................................................... 24 FLAT BED TOWING TIE DOWNS...................................................................................................... 24 TOWING—FRONT WHEEL LIFT........................................................................................................ 25 TOWING—REAR WHEEL LIFT......................................................................................................... 25 HOISTING RECOMMENDATIONS........................................................................................................... 25 LUBRICATION AND MAINTENANCE 1.............................................................................................................. 27 GENERAL INFORMATION.................................................................................................................... 27 GENERAL INFORMATION................................................................................................................ 27 ENGINE OIL — GASOLINE ENGINES.................................................................................................. 27 SAE VISCOSITY GRADE........................................................................................................ 27 ENGINE OIL— DIESEL ENGINES..................................................................................................... 27 SAE VISCOSITY GRADE........................................................................................................ 27 MANUAL TRANSMISSION FLUID (A- 558 and A-598 Models)............................................................................ 27 FLUID CAPACITIES............................................................................................................... 27 MAINTENANCE SCHEDULES.................................................................................................................. 28 GENERAL INFORMATION................................................................................................................ 28 MAINTENANCE SCHEDULE........................................................................................................... 28 MAINTENANCE SCHEDULE— DIESEL ENGINE............................................................................................ 28 UNSCHEDULED INSPECTION......................................................................................................... 28 SCHEDULE— A (DIESEL)........................................................................................................... 28 SCHEDULE— B (DIESEL)........................................................................................................... 29 JUMP STARTING, HOISTING AND TOWING..................................................................................................... 31 SERVICE PROCEDURES................................................................................................................. 31 TOWING RECOMMENDATIONS......................................................................................................... 31 WARNINGS AND CAUTIONS...................................................................................................... 31 RECOMMENDED TOWING EQUIPMENT............................................................................................... 31 GROUND CLEARANCE........................................................................................................... 31 LOCKED VEHICLE TOWING...................................................................................................... 31 FLAT TOWING WITH TOW BAR................................................................................................... 31 FLAT BED TOWING TIE DOWNS.................................................................................................. 31 TOWING— FRONT WHEEL LIFT................................................................................................... 32 TOWING— REAR WHEEL LIFT.................................................................................................... 32 TOWING— TOW HOOKS.......................................................................................................... 32 SUSPENSION................................................................................................................................. 33 WHEEL ALIGNMENT........................................................................................................................ 33 DESCRIPTION AND OPERATION.......................................................................................................... 33 GENERAL INFORMATION............................................................................................................ 33 DIAGNOSIS AND TESTING.............................................................................................................. 35 SUSPENSION AND STEERING DIAGNOSIS.............................................................................................. 35 PRE-WHEEL ALIGNMENT INSPECTION................................................................................................. 36 SERVICE PROCEDURES................................................................................................................. 36 WHEEL ALIGNMENT CHECK AND ADJUSTMENT PROCEDURE................................................................................. 36 CASTER AND CAMBER.......................................................................................................... 36 FRONT TOE SETTING PROCEDURE................................................................................................ 39 SPECIFICATIONS..................................................................................................................... 39 ALIGNMENT SPECIFICATIONS....................................................................................................... 39 FRONT SUSPENSION....................................................................................................................... 41 DESCRIPTION AND OPERATION.......................................................................................................... 41 FRONT SUSPENSION DESCRIPTION................................................................................................... 41 SUSPENSION CRADLE (CROSSMEMBER)................................................................................................ 41 Mc PHERSON STRUT ASSEMBLY...................................................................................................... 42 STEERING KNUCKLE............................................................................................................... 42 LOWER CONTROL ARM.............................................................................................................. 42 STABILIZER BAR................................................................................................................. 42 STABILIZER BAR ATTACHING LINK.................................................................................................. 42 HUB AND BEARING ASSEMBLY....................................................................................................... 42 COIL SPRING.................................................................................................................... 43 BALL JOINT..................................................................................................................... 43 WHEEL MOUNTING STUDS........................................................................................................... 43 DIAGNOSIS AND TESTING.............................................................................................................. 43 Mc PHERSON STRUT............................................................................................................... 43 STEERING KNUCKLE .............................................................................................................. 44 LOWER CONTROL ARM.............................................................................................................. 44 BALL JOINT (LOWER)............................................................................................................. 44 STABILIZER BAR................................................................................................................. 44 HUB AND BEARING ASSEMBLY....................................................................................................... 44 SERVICE PROCEDURES................................................................................................................. 44 SUSPENSION CRADLE THREAD REPAIR PROCEDURE..................................................................................... 44 TOOL REQUIREMENT FOR M8x1.25 Thread........................................................................................ 45 TOOL REQUIREMENT FOR M10x1.5 Thread........................................................................................ 45 REMOVAL AND INSTALLATION........................................................................................................... 45 Mc PHERSON STRUT............................................................................................................... 45 REMOVAL.................................................................................................................... 45 INSTALLATION............................................................................................................... 45 STEERING KNUCKLE............................................................................................................... 46 REMOVE..................................................................................................................... 46 INSTALL.................................................................................................................... 49 LOWER CONTROL ARM.............................................................................................................. 51 REMOVE..................................................................................................................... 51 INSTALL.................................................................................................................... 52 BALL JOINT..................................................................................................................... 54 REMOVE..................................................................................................................... 54 INSTALL.................................................................................................................... 54 STABILIZER BAR................................................................................................................. 55 REMOVE..................................................................................................................... 55 INSTALL.................................................................................................................... 56 HUB AND BEARING ASSEMBLY....................................................................................................... 57 REMOVE..................................................................................................................... 57 INSTALL.................................................................................................................... 59 FRONT WHEEL MOUNTING STUDS..................................................................................................... 60 REMOVE..................................................................................................................... 60 INSTALL.................................................................................................................... 60 REAR WHEEL MOUNTING STUDS...................................................................................................... 61 REMOVE..................................................................................................................... 61 INSTALL.................................................................................................................... 61 DISASSEMBLY AND ASSEMBLY........................................................................................................... 62 Mc PHERSON STRUT............................................................................................................... 62 DISASSEMBLY................................................................................................................ 62 ASSEMBLY................................................................................................................... 64 BALL JOINT SEAL BOOT........................................................................................................... 65 REMOVE..................................................................................................................... 65 INSTALL.................................................................................................................... 65 LOWER CONTROL ARM FRONT BUSHING................................................................................................ 66 REMOVE..................................................................................................................... 66 INSTALL.................................................................................................................... 66 LOWER CONTROL ARM REAR BUSHING................................................................................................. 67 REMOVE..................................................................................................................... 67 INSTALL.................................................................................................................... 67 STABILIZER BAR BUSHING......................................................................................................... 67 Disassembly/Assembly....................................................................................................... 67 SPECIFICATIONS..................................................................................................................... 68 FRONT SUSPENSION FASTENER TORQUES.............................................................................................. 68 REAR SUSPENSION........................................................................................................................ 70 SPECIAL TOOLS...................................................................................................................... 69 FRONT SUSPENSION............................................................................................................... 69 GENERAL INFORMATION................................................................................................................ 70 REAR SUSPENSION................................................................................................................ 70 DESCRIPTION AND OPERATION.......................................................................................................... 71 REAR WHEEL ALIGNMENT........................................................................................................... 71 REAR TRACK BAR................................................................................................................. 71 STABILIZER BAR................................................................................................................. 71 SHOCK ABSORBERS (REAR LOAD LEVELING)........................................................................................... 72 REMOVAL AND INSTALLATION........................................................................................................... 72 REAR SPRINGS (FWD)............................................................................................................. 72 REMOVAL.................................................................................................................... 72 FRONT BUSHING REPLACEMENT.................................................................................................. 74 INSTALLATION............................................................................................................... 74 REAR SPRINGS (AWD)............................................................................................................. 75 REMOVE..................................................................................................................... 75 FRONT BUSHING REPLACEMENT.................................................................................................. 76 INSTALL.................................................................................................................... 76 SHOCK ABSORBER................................................................................................................. 77 REMOVE/INSTALL............................................................................................................. 77 REAR TRACK BAR................................................................................................................. 77 REMOVE..................................................................................................................... 77 INSTALL.................................................................................................................... 77 TRACK BAR MOUNT................................................................................................................ 77 REMOVE..................................................................................................................... 77 INSTALLATION............................................................................................................... 78 STABILIZER BAR................................................................................................................. 78 REMOVAL.................................................................................................................... 78 INSPECTION................................................................................................................. 78 INSTALLATION............................................................................................................... 78 JOUNCE BUMPER.................................................................................................................. 78 REMOVAL-STANDARD........................................................................................................... 78 INSTALLATION-STANDARD...................................................................................................... 78 REMOVAL-HEAVY DUTY......................................................................................................... 79 INSTALLATION-HEAVY DUTY ................................................................................................... 79 LEAF SPRING REAR MOUNT......................................................................................................... 79 REMOVE..................................................................................................................... 79 INSTALLATION............................................................................................................... 79 LEAF SPRING FRONT MOUNT........................................................................................................ 79 REMOVE..................................................................................................................... 79 INSTALL.................................................................................................................... 80 SPECIFICATIONS..................................................................................................................... 80 REAR SUSPENSION FASTENER TORQUES............................................................................................... 80 SUSPENSION 1 .............................................................................................................................. 81 SPECIFICATIONS......................................................................................................................... 81 ALIGNMENT SPECIFICATIONS........................................................................................................... 81 BRAKES..................................................................................................................................... 83 GENERAL INFORMATION.................................................................................................................... 83 GENERAL INFORMATION................................................................................................................ 83 GENERAL VEHICLE SERVICE CAUTIONS............................................................................................... 83 BASE BRAKE SYSTEM COMPONENT DESCRIPTION........................................................................................ 83 BASE BRAKE SYSTEM...................................................................................................................... 85 DESCRIPTION AND OPERATION.......................................................................................................... 86 FRONT DISC BRAKE SYSTEM........................................................................................................ 86 REAR DRUM BRAKES............................................................................................................... 87 REAR DISC BRAKES............................................................................................................... 87 PARKING BRAKE SYSTEM OPERATION................................................................................................. 87 PROPORTIONING VALVES........................................................................................................... 87 FIXED PROPORTIONING VALVE.................................................................................................. 87 HEIGHT SENSING PROPORTIONING VALVE......................................................................................... 88 CHASSIS TUBES AND HOSES........................................................................................................ 89 MASTER CYLINDER................................................................................................................ 89 POWER BRAKE VACUUM BOOSTER OPERATION........................................................................................... 90 RED BRAKE WARNING LAMP OPERATION............................................................................................... 90 STOP LAMP SWITCH............................................................................................................... 91 HUB/BEARING REAR WHEEL......................................................................................................... 91 DIAGNOSIS AND TESTING.............................................................................................................. 91 BRAKE SYSTEM BASIC DIAGNOSIS GUIDE............................................................................................. 91 BRAKE SYSTEM DIAGNOSIS CHARTS.................................................................................................. 92 MISCELLANEOUS BRAKE SYSTEM CONDITIONS...................................................................................... 92 RED BRAKE WARNING LAMP FUNCTION............................................................................................ 93 POWER BRAKE SYSTEM DIAGNOSTICS............................................................................................. 94 BRAKE NOISE................................................................................................................ 95 VEHICLE ROAD TEST.......................................................................................................... 95 ADJUSTER REAR DRUM BRAKE (AUTOMATIC)........................................................................................... 96 BRAKE ROTOR.................................................................................................................... 96 CHECKING ROTOR FOR RUNOUT AND THICKNESS.................................................................................... 96 PROPORTIONING VALVES........................................................................................................... 98 FIXED PROPORTIONING VALVE TEST PROCEDURE................................................................................... 98 HEIGHT SENSING PROPORTIONING VALVE......................................................................................... 99 BRAKE FLUID CONTAMINATION ..................................................................................................... 101 RED BRAKE WARNING LAMP TEST.................................................................................................... 101 TRACTION CONTROL LAMP TEST..................................................................................................... 101 STOP LAMP SWITCH TEST PROCEDURE................................................................................................ 101 SERVICE PROCEDURES................................................................................................................. 102 MASTER CYLINDER FLUID LEVEL CHECK.............................................................................................. 102 BLEEDING BASE BRAKE HYDRAULIC SYSTEM........................................................................................... 102 PRESSURE BLEEDING PROCEDURE................................................................................................ 102 BLEEDING WITHOUT A PRESSURE BLEEDER........................................................................................ 103 MASTER CYLINDER BLEEDING PROCEDURE............................................................................................. 104 ROTOR MACHINING (FRONT/REAR)................................................................................................... 104 BRAKE ROTOR MACHINING PROCEDURES........................................................................................... 104 REFACING BRAKE ROTOR....................................................................................................... 105 RESURFACNG BRAKE ROTOR..................................................................................................... 105 ROTOR REFINISHING LIMITS................................................................................................... 106 BRAKE DRUM MACHINING .......................................................................................................... 106 BRAKE TUBE REPAIR PROCEDURE.................................................................................................... 106 DOUBLE INVERTED TUBING FLARES.............................................................................................. 107 ISO TUBING FLARES.......................................................................................................... 107 PARK BRAKE AUTO ADJUSTER MECHANISM RELEASE..................................................................................... 108 REMOVAL AND INSTALLATION........................................................................................................... 109 WHEEL AND TIRE INSTALLATION.................................................................................................... 109 FRONT DISC BRAKE CALIPER....................................................................................................... 109 SERVICE PRECAUTIONS........................................................................................................ 109 REMOVE..................................................................................................................... 109 INSTALL.................................................................................................................... 110 REAR DISC BRAKE CALIPER........................................................................................................ 110 REMOVE..................................................................................................................... 111 INSTALL.................................................................................................................... 111 FRONT DISC BRAKE PADS.......................................................................................................... 112 REMOVE..................................................................................................................... 112 INSTALL.................................................................................................................... 112 REAR DISC BRAKE SHOES.......................................................................................................... 113 REMOVE..................................................................................................................... 113 CALIPER INSPECTION......................................................................................................... 114 INSTALL.................................................................................................................... 114 REAR BRAKE DRUM................................................................................................................ 115 REMOVE..................................................................................................................... 115 INSTALL.................................................................................................................... 115 REAR DRUM BRAKE SHOES.......................................................................................................... 116 REMOVE..................................................................................................................... 116 INSTALL.................................................................................................................... 118 BRAKE SUPPORT PLATE (REAR DRUM BRAKES)......................................................................................... 119 REMOVE..................................................................................................................... 119 INSTALL.................................................................................................................... 121 REAR BRAKE WHEEL CYLINDER...................................................................................................... 121 REMOVE..................................................................................................................... 121 INSTALL.................................................................................................................... 122 HUB/BEARING.................................................................................................................... 122 FRONT WHEEL DRIVE.......................................................................................................... 122 ALL WHEEL DRIVE............................................................................................................ 123 MASTER CYLINDER................................................................................................................ 126 REMOVE..................................................................................................................... 126 BLEEDING MASTER CYLINDER................................................................................................... 127 INSTALL.................................................................................................................... 128 VACUUM BOOSTER 2.4 LITER ENGINE................................................................................................ 129 REMOVE..................................................................................................................... 129 INSTALL.................................................................................................................... 130 VACUUM BOOSTER 3.0 LITER ENGINE................................................................................................ 131 REMOVE..................................................................................................................... 131 INSTALL.................................................................................................................... 133 VACUUM BOOSTER 3.3/3.8 LITER ENGINE............................................................................................ 134 REMOVE..................................................................................................................... 134 INSTALL.................................................................................................................... 136 JUNCTION BLOCK................................................................................................................. 137 REMOVE..................................................................................................................... 137 INSTALL.................................................................................................................... 137 PROPORTIONING VALVE (W/ABS BRAKES)............................................................................................. 138 REMOVE..................................................................................................................... 138 INSTALL.................................................................................................................... 139 PROPORTIONING VALVE (W/O ABS BRAKES)........................................................................................... 139 REMOVE..................................................................................................................... 139 INSTALL.................................................................................................................... 140 HYDRAULIC BRAKE TUBES AND HOSES................................................................................................ 140 PARK BRAKE PEDAL MECHANISM..................................................................................................... 140 REMOVE..................................................................................................................... 140 INSTALL.................................................................................................................... 141 PARK BRAKE SHOES (WITH REAR DISC BRAKES)....................................................................................... 142 REMOVE..................................................................................................................... 142 INSTALL.................................................................................................................... 145 FRONT PARK BRAKE CABLE......................................................................................................... 147 REMOVE..................................................................................................................... 147 INSTALL.................................................................................................................... 147 INTERMEDIATE PARK BRAKE CABLE.................................................................................................. 148 REMOVE..................................................................................................................... 148 INSTALL.................................................................................................................... 148 RIGHT REAR PARK BRAKE CABLE.................................................................................................... 148 REMOVE..................................................................................................................... 148 INSTALL.................................................................................................................... 149 LEFT REAR PARK BRAKE CABLE..................................................................................................... 149 REMOVE..................................................................................................................... 149 INSTALL.................................................................................................................... 150 STOP LAMP SWITCH............................................................................................................... 151 REMOVE..................................................................................................................... 151 INSTALL.................................................................................................................... 151 DISASSEMBLY AND ASSEMBLY........................................................................................................... 151 MASTER CYLINDER TO POWER BRAKE BOOSTER VACUUM SEAL............................................................................. 151 MASTER CYLINDER FLUID RESERVOIR................................................................................................ 152 MASTER CYLINDER FLUID RESERVOIR FILL TUBE...................................................................................... 153 REMOVE..................................................................................................................... 153 INSTALL.................................................................................................................... 153 MASTER CYLINDER BRAKE FLUID LEVEL SWITCH....................................................................................... 153 FRONT DISC BRAKE CALIPER....................................................................................................... 153 CLEANING AND INSPECTION.................................................................................................... 153 CALIPER GUIDE PIN BUSHING SERVICE.......................................................................................... 154 CALIPER DISASSEMBLY........................................................................................................ 155 CALIPER ASSEMBLY........................................................................................................... 157 WHEEL CYLINDER REAR DRUM BRAKE................................................................................................. 158 DISASSEMBLE................................................................................................................ 158 ASSEMBLE................................................................................................................... 158 CLEANING AND INSPECTION............................................................................................................ 158 FRONT DISC BRAKE PAD LINING INSPECTION......................................................................................... 158 REAR DISC BRAKES............................................................................................................... 158 BRAKE PAD LINING WEAR...................................................................................................... 158 CALIPER INSPECTION......................................................................................................... 159 REAR DRUM BRAKE SHOE LINING INSPECTION......................................................................................... 159 REAR DRUM BRAKE WHEEL CYLINDER................................................................................................. 160 BRAKE HOSE AND BRAKE LINES INSPECTION.......................................................................................... 160 REAR WHEEL HUB AND BEARING ASSEMBLY............................................................................................ 160 ADJUSTMENTS........................................................................................................................ 160 STOP LAMP SWITCH............................................................................................................... 160 REAR DRUM BRAKE SHOE ADJUSTMENT................................................................................................ 161 PARK BRAKE SHOES (WITH REAR DISC BRAKES)....................................................................................... 161 PARK BRAKE CABLE ADJUSTMENT.................................................................................................... 163 PROPORTIONING VALVE (HEIGHT SENSING)........................................................................................... 163 SPECIFICATIONS..................................................................................................................... 164 BRAKE FLUID.................................................................................................................... 164 VEHICLE BRAKE SYSTEM COMPONENT SPECIFICATIONS.................................................................................. 164 BRAKE ACTUATION SYSTEM S....................................................................................................... 165 BRAKE FASTENER TORQUE SPECIFICATION............................................................................................ 165 SPECIAL TOOLS...................................................................................................................... 166 SPECIAL TOOLS—BASE BRAKES...................................................................................................... 166 ANTILOCK BRAKE SYSTEM ± TEVES MARK-20.................................................................................................. 167 DESCRIPTION AND OPERATION.......................................................................................................... 167 ANTILOCK BRAKES OPERATION DESCRIPTION.......................................................................................... 167 ABS BRAKES COMPONENT ABBREVIATION LIST......................................................................................... 167 ABS BRAKES OPERATION AND VEHICLE PERFORMANCE................................................................................... 168 NORMAL BRAKING SYSTEM FUNCTION............................................................................................. 168 ABS SYSTEM OPERATION....................................................................................................... 168 VEHICLE HANDLING PERFORMANCE DURING ABS BRAKING............................................................................ 168 NOISE AND BRAKE PEDAL FEEL................................................................................................. 168 TIRE NOISE AND MARKS....................................................................................................... 168 START UP CYCLE............................................................................................................. 168 PREMATURE ABS CYCLING...................................................................................................... 169 ABS BRAKE SYSTEM COMPONENTS.................................................................................................... 169 ABS MASTER CYLINDER AND POWER BRAKE BOOSTER.................................................................................... 169 INTEGRATED CONTROL UNIT (ICU).................................................................................................. 169 INLET VALVES AND SOLENOIDS..................................................................................................... 170 OUTLET VALVES AND SOLENOIDS.................................................................................................... 170 ASR VALVE (ABS WITH TRACTION CONTROL ONLY)..................................................................................... 170 HCU BRAKE FLUID ACCUMULATORS AND NOISE DAMPING CHAMBER......................................................................... 170 HCU PUMP/MOTOR................................................................................................................. 171 ABS FUSES...................................................................................................................... 171 ABS RELAYS..................................................................................................................... 171 PROPORTIONING VALVES........................................................................................................... 171 WHEEL SPEED SENSORS............................................................................................................ 171 CONTROLLER ANTILOCK BRAKES (CAB)............................................................................................... 172 CONTROLLER ANTILOCK BRAKE INPUTS........................................................................................... 173 CONTROLLER ANTILOCK BRAKE OUTPUTS.......................................................................................... 173 ABS WARNING LAMP (YELLOW)...................................................................................................... 173 HYDRAULIC CIRCUITS AND VALVE OPERATION......................................................................................... 174 NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION ............................................................. 174 TEVES MARK 20 ABS CIRCUIT AND SOLENOID VALVE FUNCTION...................................................................... 174 TEVES MARK 20 SECONDARY ABS CIRCUIT AND SOLENOID VALVE FUNCTION............................................................ 174 TEVES MARK 20 ABS WITH TRACTION CONTROL NORMAL BRAKING HYDRAULIC CIRCUIT – SOLENOID AND SHUTTLE VALVE FUNCTION............. 175 TEVES MARK 20 ABS WITH TRACTION CONTROL ABS BRAKING HYDRAULIC CIRCUIT – SOLENOID AND SHUTTLE VALVE FUNCTION................ 175 TEVES MARK 20 ABS WITH TRACTION CONTROL– TRACTION CONTROL HYDRAULIC CIRCUIT – SOLENOID AND SHUTTLE VALVE FUNCTION.......... 177 DIAGNOSIS AND TESTING.............................................................................................................. 177 ABS GENERAL DIAGNOSTICS INFORMATION............................................................................................ 177 ABS WIRING DIAGRAM INFORMATION................................................................................................. 177 ABS DIAGNOSTICS MANUAL......................................................................................................... 178 DRB DIAGNOSTIC SCAN TOOL USAGE................................................................................................. 178 ABS BRAKE DIAGNOSTIC TOOL CONNECTOR ........................................................................................... 178 ABS SYSTEM SELF DIAGNOSTICS.................................................................................................... 178 START-UP CYCLE............................................................................................................. 179 DRIVE-OFF CYCLE............................................................................................................ 179 ONGOING TESTS.............................................................................................................. 179 ABS DIAGNOSTIC TROUBLE CODES................................................................................................... 179 LATCHING VERSUS NON-LATCHING DIAGNOSTIC TROUBLE CODES...................................................................... 179 INTERMITTENT DIAGNOSTIC TROUBLE CODES.......................................................................................... 179 TONEWHEEL INSPECTION........................................................................................................... 180 PROPORTIONING VALVE............................................................................................................ 180 BRAKE FLUID CONTAMINATION...................................................................................................... 180 TEST DRIVING ABS COMPLAINT VEHICLE............................................................................................. 180 ABS SERVICE PRECAUTIONS........................................................................................................ 181 SERVICE PROCEDURES................................................................................................................. 181 BRAKE FLUID LEVEL INSPECTION................................................................................................... 181 BLEEDING TEVES MARK 20 HYDRAULIC SYSTEM........................................................................................ 181 ABS BLEEDING PROCEDURE..................................................................................................... 181 REMOVAL AND INSTALLATION........................................................................................................... 182 ABS GENERAL SERVICE PRECAUTIONS................................................................................................ 182 HYDRAULIC CONTROL UNIT ........................................................................................................ 182 REMOVE..................................................................................................................... 182 INSTALL.................................................................................................................... 184 CONTROLLER ANTILOCK BRAKES (CAB)............................................................................................... 185 REMOVE..................................................................................................................... 185 INSTALL.................................................................................................................... 186 WHEEL SPEED SENSOR (FRONT)..................................................................................................... 187 REMOVE..................................................................................................................... 187 INSTALL.................................................................................................................... 188 WHEEL SPEED SENSOR (REAR FWD).................................................................................................. 188 REMOVE..................................................................................................................... 188 INSTALL.................................................................................................................... 190 WHEEL SPEED SENSOR (REAR AWD).................................................................................................. 190 REMOVE..................................................................................................................... 190 INSTALL.................................................................................................................... 191 TONE WHEEL (REAR FWD).......................................................................................................... 192 REMOVE..................................................................................................................... 192 INSTALL.................................................................................................................... 193 TONE WHEEL (REAR AWD).......................................................................................................... 193 SPECIFICATIONS..................................................................................................................... 194 SPEED SENSOR TONE WHEEL RUNOUT................................................................................................. 194 WHEEL SPEED SENSOR TO TONE WHEEL CLEARANCE..................................................................................... 194 FRONT WHEEL................................................................................................................ 194 REAR WHEEL................................................................................................................. 194 BRAKE FASTENER TORQUE SPECIFICATIONS........................................................................................... 194 BRAKES 1 .................................................................................................................................. 195 GENERAL INFORMATION.................................................................................................................... 195 BASE BRAKE SYSTEM COMPONENT DESCRIPTION............................................................................................ 195 DESCRIPTION AND OPERATION.............................................................................................................. 195 MASTER CYLINDER.................................................................................................................... 195 DIAGNOSIS AND TESTING.................................................................................................................. 195 REAR DRUM BRAKE ADJUSTMENT......................................................................................................... 195 MASTER CYLINDER FLUID LEVEL CHECK.................................................................................................. 196 REMOVAL AND INSTALLATION............................................................................................................... 196 FRONT PARK BRAKE CABLE AND LEVER ASSEMBLY- RHD& LHD VEHICLES....................................................................... 196 REMOVE......................................................................................................................... 196 INSTALL........................................................................................................................ 197 BRAKE PEDAL TORQUE SHAFT ASSEMBLY.................................................................................................. 198 REMOVE......................................................................................................................... 198 INSTALL........................................................................................................................ 198 CLUTCH..................................................................................................................................... 199 GENERAL INFORMATION.................................................................................................................... 199 CLUTCH COMPONENTS.................................................................................................................. 199 CLUTCH CABLE AND PEDAL — LHD................................................................................................... 199 HYDRAULIC LINKAGE AND COMPONENTS — RHD......................................................................................... 200 CLUTCH DISC AND COVER APPLICATION.................................................................................................. 201 CLUTCH REPLACEMENT................................................................................................................. 201 DESCRIPTION AND OPERATION.............................................................................................................. 202 CLUTCH RELEASE SYSTEM.............................................................................................................. 202 CLUTCH CABLE — LHD............................................................................................................. 202 HYDRAULIC CLUTCH — RHD......................................................................................................... 202 CLUTCH PEDAL POSITION SWITCH....................................................................................................... 202 DIAGNOSIS AND TESTING.................................................................................................................. 202 CLUTCH PEDAL POSITION SWITCH....................................................................................................... 202 CLUTCH PEDAL POSITION SWITCH– ELECTRICAL TEST.................................................................................. 202 CLUTCH PEDAL POSITION SWITCH– MECHANICAL TEST.................................................................................. 203 SERVICE DIAGNOSIS– CLUTCH PEDAL POSITION SWITCH................................................................................ 203 CLUTCH DIAGNOSIS................................................................................................................... 204 SERVICE DIAGNOSIS– CLUTCH GRAB/ CHATTER........................................................................................ 204 SERVICE DIAGNOSIS– CLUTCH SLIPS................................................................................................ 204 SERVICE DIAGNOSIS– IMPROPER CLUTCH RELEASE..................................................................................... 205 SERVICE DIAGNOSIS– CLUTCH PEDAL NOISE.......................................................................................... 205 DRIVE PLATE MISALIGNMENT........................................................................................................... 205 CLUTCH COVER AND DISC RUNOUT....................................................................................................... 206 CLUTCH CHATTER COMPLAINTS.......................................................................................................... 206 CLASH– INTO– REVERSE COMPLAINTS.................................................................................................... 206 REMOVAL AND INSTALLATION............................................................................................................... 206 CLUTCH CABLE SYSTEM — LHD.......................................................................................................... 206 REMOVAL........................................................................................................................ 206 INSTALLATION................................................................................................................... 208 CLUTCH PEDAL POSITION SWITCH....................................................................................................... 208 REMOVAL........................................................................................................................ 208 INSTALLATION................................................................................................................... 208 HYDRAULIC CLUTCH LINKAGE SYSTEM — RHD.............................................................................................. 209 REMOVAL........................................................................................................................ 209 INSTALLATION................................................................................................................... 209 QUICK CONNECT COUPLING — RHD....................................................................................................... 210 REMOVAL........................................................................................................................ 210 INSTALLATION................................................................................................................... 210 MASTER CYLINDER SYSTEM — RHD....................................................................................................... 210 REMOVAL........................................................................................................................ 210 INSTALLATION................................................................................................................... 210 SLAVE CYLINDER ASSEMBLY — RHD...................................................................................................... 210 REMOVAL........................................................................................................................ 210 INSTALLATION................................................................................................................... 211 MODULAR CLUTCH ASSEMBLY (2.0L AND 2.4L GASOLINE)................................................................................... 211 CLUTCH ASSEMBLY (2.5L DIESEL)...................................................................................................... 211 REMOVAL........................................................................................................................ 211 INSPECTION..................................................................................................................... 211 INSTALLATION................................................................................................................... 212 CLUTCH RELEASE BEARING AND FORK.................................................................................................... 212 REMOVAL........................................................................................................................ 212 INSTALLATION................................................................................................................... 213 CLEANING AND INSPECTION................................................................................................................ 213 CLUTCH CONTAMINATION............................................................................................................... 213 OIL CONTAMINATION.............................................................................................................. 213 GREASE CONTAMINATION........................................................................................................... 213 ROAD SPLASH/ WATER CONTAMINATION............................................................................................... 213 CLEANING PRECAUTIONS............................................................................................................... 213 ADJUSTMENTS............................................................................................................................ 214 CLUTCH CABLE — LHD................................................................................................................. 214 ADJUSTER MECHANISM FUNCTION CHECK — LHD........................................................................................ 214 CLUTCH PEDAL POSITION SWITCH....................................................................................................... 214 SPECIFICATIONS......................................................................................................................... 214 CLUTCH TIGHTENING REFERENCE........................................................................................................ 214 COOLING SYSTEM............................................................................................................................. 215 GENERAL INFORMATION.................................................................................................................... 215 ACCESSORY DRIVE BELTS.............................................................................................................. 215 COOLING SYSTEM..................................................................................................................... 216 COOLANT RECOVERY SYSTEM (CRS)...................................................................................................... 217 AUTOMATIC TRANSMISSION OIL COOLER 2.4L............................................................................................. 217 ENGINE THERMOSTAT.................................................................................................................. 217 WATER PUMPS........................................................................................................................ 217 COOLANT ........................................................................................................................... 217 RADIATOR........................................................................................................................... 217 RADIATOR PRESSURE CAP.............................................................................................................. 218 ENGINE BLOCK HEATER................................................................................................................ 219 DESCRIPTION AND OPERATION.............................................................................................................. 220 WATER PIPES—3.0L ENGINE............................................................................................................ 220 COOLANT PERFORMANCE................................................................................................................ 220 RADIATOR HOSES AND CLAMPS.......................................................................................................... 220 WATER PUMP 2.4L ENGINE ............................................................................................................ 220 WATER PUMP—3.0L ENGINE............................................................................................................. 220 WATER PUMP—3.3/3.8L ENGINES........................................................................................................ 221 DIAGNOSIS AND TESTING.................................................................................................................. 221 ACCESSORY DRIVE BELT............................................................................................................... 221 COOLING SYSTEM DIAGNOSIS........................................................................................................... 222 RADIATOR COOLANT FLOW TEST......................................................................................................... 228 RADIATOR FAN CONTROL............................................................................................................... 228 ELECTRIC FAN MOTOR TEST............................................................................................................ 228 TESTING COOLING SYSTEM FOR LEAKS................................................................................................... 228 RADIATOR FAN OPERATION......................................................................................................... 228 RADIATOR CAP TO FILLER NECK SEAL PRESSURE RELIEF CHECK............................................................................. 229 PRESSURE TESTING RADIATOR CAP...................................................................................................... 229 LOW COOLANT LEVEL AERATION......................................................................................................... 229 DEAERATION......................................................................................................................... 230 TEMPERATURE GAUGE INDICATION....................................................................................................... 230 SERVICE PROCEDURES..................................................................................................................... 230 COOLANT LEVEL CHECK—ROUTINE........................................................................................................ 230 COOLANT—ADDING ADDITIONAL.......................................................................................................... 230 COOLANT LEVEL SERVICE.............................................................................................................. 230 COOLING SYSTEM DRAINING ........................................................................................................... 230 COOLING SYSTEM—REFILLING........................................................................................................... 230 REMOVAL AND INSTALLATION............................................................................................................... 231 WATER PUMP—2.4L ENGINE............................................................................................................. 231 REMOVAL........................................................................................................................ 231 INSTALLATION................................................................................................................... 231 WATER PUMP INLET TUBE—2.4L ENGINE.................................................................................................. 231 REMOVAL........................................................................................................................ 231 INSTALLATION .................................................................................................................. 231 WATER PUMP—3.0L ENGINE............................................................................................................. 232 REMOVAL........................................................................................................................ 232 INSPECTION..................................................................................................................... 232 INSTALLATION................................................................................................................... 233 WATER PUMP—3.3/3.8L ENGINES........................................................................................................ 233 REMOVAL........................................................................................................................ 233 INSTALLATION................................................................................................................... 233 THERMOSTAT—2.4L ENGINE............................................................................................................. 233 REMOVAL........................................................................................................................ 233 INSTALLATION—2.4L ENGINE....................................................................................................... 234 THERMOSTAT—3.0L ENGINE............................................................................................................. 234 REMOVAL........................................................................................................................ 234 INSTALLATION—3.0L ENGINE....................................................................................................... 234 THERMOSTAT—3.3/3.8L ENGINES........................................................................................................ 234 REMOVAL........................................................................................................................ 234 INSTALLATION................................................................................................................... 235 RADIATOR........................................................................................................................... 235 REMOVAL ....................................................................................................................... 235 INSTALLATION................................................................................................................... 235 RADIATOR DRAINCOCK................................................................................................................. 235 REMOVAL........................................................................................................................ 235 INSTALLATION................................................................................................................... 236 FAN MODULE......................................................................................................................... 236 REMOVAL........................................................................................................................ 236 INSTALLATION................................................................................................................... 236 ENGINE BLOCK HEATER................................................................................................................ 237 REMOVAL........................................................................................................................ 237 INSTALLATION................................................................................................................... 237 ACCESSORY DRIVE BELTS—2.4L......................................................................................................... 237 REMOVAL/INSTALLATION-ADJUST.................................................................................................... 237 ACCESSORY DRIVE BELTS—3.0L......................................................................................................... 238 GENERATOR/POWER STEERING PUMP BELT............................................................................................. 238 AIR CONDITIONING BELT.......................................................................................................... 238 ACCESSORY DRIVE BELT—3.3/3.8L...................................................................................................... 238 REMOVE/INSTALL................................................................................................................. 238 CLEANING AND INSPECTION................................................................................................................ 238 WATER PUMP......................................................................................................................... 238 ACCESSORY DRIVE BELT .............................................................................................................. 239 RADIATOR PRESSURE CAP.............................................................................................................. 239 INSPECTION..................................................................................................................... 239 COOLING SYSTEM CLEANING............................................................................................................ 239 REVERSE FLUSHING THE RADIATOR...................................................................................................... 239 REVERSE FLUSHING THE ENGINE........................................................................................................ 239 CHEMICAL CLEANING.................................................................................................................. 239 ADJUSTMENTS............................................................................................................................ 239 PROPER BELT TENSION................................................................................................................ 239 BELT TENSION GAUGE METHOD.......................................................................................................... 240 BELT TENSION CHART................................................................................................................. 240 SPECIFICATIONS......................................................................................................................... 240 COOLING SYSTEM CAPACITY ........................................................................................................... 240 TORQUE CHART....................................................................................................................... 240 SPECIAL TOOLS.......................................................................................................................... 240 COOLING............................................................................................................................ 240 COOLING SYSTEM 1 .......................................................................................................................... 241 GENERAL INFORMATION.................................................................................................................... 241 COOLING SYSTEM — 2.0L GASOLINE..................................................................................................... 241 COOLING SYSTEM — 2.5L VM DIESEL.................................................................................................... 241 COOLANT PRESSURE BOTTLE............................................................................................................ 241 2.5L VM DIESEL................................................................................................................. 241 LOW COOLANT LEVEL SENSOR........................................................................................................... 241 RADIATOR........................................................................................................................... 242 DESCRIPTION AND OPERATION.............................................................................................................. 243 WATER PUMP......................................................................................................................... 243 2.0L GASOLINE.................................................................................................................. 243 2.5L VM DIESEL................................................................................................................. 243 THERMOSTAT OPERATION............................................................................................................... 244 2.5 VM DIESEL.................................................................................................................. 244 PRESSURE/ VENT CAP................................................................................................................. 244 COOLANT PERFORMANCE................................................................................................................ 245 ETHYLENE- GLYCOL MIXTURES...................................................................................................... 245 BELT TENSION....................................................................................................................... 245 AUTOMATIC BELT TENSIONER........................................................................................................... 246 THERMOSTAT......................................................................................................................... 246 DIAGNOSIS...................................................................................................................... 246 TESTING........................................................................................................................ 246 SERVICE PROCEDURES..................................................................................................................... 247 ADDING ADDITIONAL COOLANT.......................................................................................................... 247 2.5L VM DIESEL................................................................................................................. 247 DRAINING COOLING SYSTEM............................................................................................................ 247 2.0L GASOLINE.................................................................................................................. 247 2.5L VM DIESEL................................................................................................................. 247 REFILLING COOLING SYSTEM........................................................................................................... 247 2.0L GASOLINE.................................................................................................................. 247 2.5L VM DIESEL................................................................................................................. 247 REMOVAL AND INSTALLATION............................................................................................................... 247 WATER PUMP — 2.0L GASOLINE......................................................................................................... 247 REMOVAL........................................................................................................................ 247 INSTALLATION................................................................................................................... 248 WATER PUMP — 2.5L VM DIESEL........................................................................................................ 248 REMOVAL........................................................................................................................ 248 INSTALLATION................................................................................................................... 248 ENGINE THERMOSTAT— 2.0L GASOLINE................................................................................................... 249 REMOVAL........................................................................................................................ 249 INSTALLATION................................................................................................................... 249 THERMOSTAT — 2.5L VM DIESEL........................................................................................................ 249 REMOVAL........................................................................................................................ 249 INSTALLATION................................................................................................................... 249 RADIATOR — 2.5L VM DIESEL.......................................................................................................... 249 REMOVAL........................................................................................................................ 249 INSTALLATION................................................................................................................... 250 WATER PUMP BELT — 2.5L VM DIESEL................................................................................................... 250 REMOVAL........................................................................................................................ 250 INSTALLATION................................................................................................................... 250 GENERATOR/ POWER STEERING BELT — 2.5L VM DIESEL.................................................................................... 250 REMOVAL........................................................................................................................ 250 INSTALLATION................................................................................................................... 250 CLEANING AND INSPECTION................................................................................................................ 250 WATER PUMP......................................................................................................................... 250 ADJUSTMENTS............................................................................................................................ 251 BELT TENSION GAUGE METHOD.......................................................................................................... 251 BELT TENSION CHART................................................................................................................. 251 SPECIFICATIONS......................................................................................................................... 252 COOLING SYSTEM CAPACITY TORQUE CHART............................................................................................... 252 SPECIAL TOOLS.......................................................................................................................... 252 COOLING............................................................................................................................ 252 BATTERY.................................................................................................................................... 253 GENERAL INFORMATION.................................................................................................................... 253 INTRODUCTION....................................................................................................................... 253 SAFETY PRECAUTIONS AND WARNINGS.................................................................................................... 253 DESCRIPTION AND OPERATION.............................................................................................................. 253 BATTERY IGNITION OFF DRAW (IOD).................................................................................................... 253 CHARGING TIME REQUIRED............................................................................................................. 254 SIZE OF BATTERY................................................................................................................ 254 BATTERY CHARGING TIMETABLE..................................................................................................... 254 TEMPERATURE.................................................................................................................... 254 CHARGER CAPACITY............................................................................................................... 254 STATE OF CHARGE................................................................................................................ 254 DIAGNOSIS AND TESTING.................................................................................................................. 254 BATTERY BUILT-IN TEST INDICATOR.................................................................................................... 254 USING TEST INDICATOR........................................................................................................... 254 CAUSES OF BATTERY DISCHARGING.................................................................................................. 255 ABNORMAL BATTERY DISCHARGING................................................................................................... 255 BATTERY IGNITION OFF DRAW (IOD).................................................................................................... 255 BATTERY DIAGNOSIS AND TESTING.................................................................................................. 256 BATTERY LOAD TEST.................................................................................................................. 256 BATTERY LOAD TEST TEMPERATURE.................................................................................................. 257 BATTERY OPEN CIRCUIT VOLTAGE TEST.................................................................................................. 258 BATTERY OPEN CIRCUIT VOLTAGE................................................................................................... 258 SERVICE PROCEDURES..................................................................................................................... 258 BATTERY CHARGING................................................................................................................... 258 CHARGING COMPLETELY DISCHARGED BATTERY............................................................................................. 259 BATTERY CHARGING RATE.......................................................................................................... 259 VISUAL INSPECTION.................................................................................................................. 259 REMOVAL AND INSTALLATION............................................................................................................... 260 BATTERY............................................................................................................................ 260 REMOVAL........................................................................................................................ 260 INSTALLATION................................................................................................................... 260 BATTERY TRAY....................................................................................................................... 261 REMOVAL........................................................................................................................ 261 INSTALLATION................................................................................................................... 261 SPECIFICATIONS......................................................................................................................... 262 BATTERY SPECIFICATIONS............................................................................................................. 262 CRANKING RATING.................................................................................................................... 262 RESERVE CAPACITY RATING............................................................................................................ 262 TORQUE............................................................................................................................. 262 BATTERY 1 ................................................................................................................................. 263 GENERAL INFORMATION.................................................................................................................... 263 INTRODUCTION....................................................................................................................... 263 SAFETY PRECAUTIONS AND WARNINGS.................................................................................................... 263 DESCRIPTION AND OPERATION.............................................................................................................. 264 BATTERY IGNITION OFF DRAW (IOD).................................................................................................... 264 CHARGING TIME REQUIRED............................................................................................................. 264 SIZE OF BATTERY................................................................................................................ 264 TEMPERATURE.................................................................................................................... 264 CHARGER CAPACITY............................................................................................................... 264 STATE OF CHARGE................................................................................................................ 264 USING HYDROMETER............................................................................................................... 264 DIAGNOSIS AND TESTING.................................................................................................................. 265 BATTERY DISCHARGING................................................................................................................ 265 CAUSE OF BATTERY DISCHARGING................................................................................................... 265 ABNORMAL BATTERY DISCHARGING................................................................................................... 265 BATTERY IGNITION OFF DRAW.......................................................................................................... 265 BATTERY LOAD TEST.................................................................................................................. 267 BATTERY OPEN CIRCUIT VOLTAGE TEST.................................................................................................. 268 SERVICE PROCEDURES..................................................................................................................... 268 BATTERY CHARGING................................................................................................................... 268 CHARGING COMPLETELY DISCHARGED BATTERY............................................................................................. 269 VISUAL INSPECTION.................................................................................................................. 269 REMOVAL AND INSTALLATION............................................................................................................... 270 BATTERY............................................................................................................................ 270 REMOVAL........................................................................................................................ 270 INSTALLATION................................................................................................................... 270 BATTERY TRAY....................................................................................................................... 271 REMOVAL........................................................................................................................ 271 INSTALLATION................................................................................................................... 271 SPECIFICATIONS......................................................................................................................... 271 BATTERY SPECIFICATIONS............................................................................................................. 271 CRANKING RATING................................................................................................................ 271 TORQUE............................................................................................................................. 272 STARTER.................................................................................................................................... 273 GENERAL INFORMATION.................................................................................................................... 273 INTRODUCTION....................................................................................................................... 273 DESCRIPTION AND OPERATION.............................................................................................................. 273 SUPPLY CIRCUIT AND CONTROL CIRCUIT................................................................................................. 273 DIAGNOSIS AND TESTING.................................................................................................................. 273 CONTROL CIRCUIT TEST............................................................................................................... 273 STARTER SOLENOID............................................................................................................... 274 STARTER RELAY.................................................................................................................. 274 RELAY TEST..................................................................................................................... 274 RELAY CIRCUIT TEST............................................................................................................. 274 SAFETY SWITCHES................................................................................................................ 275 IGNITION SWITCH................................................................................................................ 275 BATTERY........................................................................................................................ 275 ALL RELATED WIRING AND CONNECTORS.............................................................................................. 275 FEED CIRCUIT RESISTANCE TEST....................................................................................................... 275 FEED CIRCUIT TEST.................................................................................................................. 276 REMOVAL AND INSTALLATION............................................................................................................... 277 STARTER—2.4L ENGINE................................................................................................................ 277 REMOVAL........................................................................................................................ 277 INSTALLATION................................................................................................................... 278 STARTER—3.0L ENGINE................................................................................................................ 278 REMOVAL........................................................................................................................ 278 INSTALLATION................................................................................................................... 278 STARTER—3.3/3.8L ENGINE............................................................................................................ 278 REMOVAL........................................................................................................................ 278 INSTALLATION................................................................................................................... 278 SPECIFICATIONS......................................................................................................................... 279 STARTER............................................................................................................................ 279 TORQUE............................................................................................................................. 279 STARTING SYSTEM............................................................................................................................ 281 REMOVAL AND INSTALLATION............................................................................................................... 281 STARTER............................................................................................................................ 281 2.0L ENGINE.................................................................................................................... 281 2.4L ENGINE - With Manual Transaxle............................................................................................ 282 2.4L ENGINE - With Automatic Transaxle......................................................................................... 282 3.0L ENGINE.................................................................................................................... 283 3.3/3.8L ENGINE................................................................................................................ 284 2.5L DIESEL ENGINE............................................................................................................. 285 CHARGING SYSTEM............................................................................................................................ 287 GENERAL INFORMATION ................................................................................................................... 287 OVERVIEW .......................................................................................................................... 287 DESCRIPTION AND OPERATION.............................................................................................................. 287 CHARGING SYSTEM OPERATION.......................................................................................................... 287 GENERATOR.......................................................................................................................... 288 BATTERY TEMPERATURE SENSOR......................................................................................................... 288 ELECTRONIC VOLTAGE REGULATOR....................................................................................................... 288 DIAGNOSIS AND TESTING.................................................................................................................. 288 CHARGING SYSTEM.................................................................................................................... 288 INSPECTION..................................................................................................................... 288 CHARGING SYSTEM RESISTANCE TESTS................................................................................................... 290 PREPARATION.................................................................................................................... 290 TEST........................................................................................................................... 290 CURRENT OUTPUT TEST................................................................................................................ 290 PREPARATION.................................................................................................................... 290 CHAR GING SYSTEM TEST.......................................................................................................... 291 OVERCHAR GE TEST............................................................................................................... 292 TEST........................................................................................................................... 293 ON-BOARD DIAGNOSTIC SYSTEM TEST.................................................................................................... 293 GENERAL INFORMATION............................................................................................................ 293 DIAGNOSTIC TROUBLE CODES....................................................................................................... 293 ERASING DIAGNOSTIC TROUBLE CODES............................................................................................... 293 VOLTAGE DROP TEST.............................................................................................................. 294 REMOVAL AND INSTALLATION............................................................................................................... 295 GENERATOR—2.4L ENGINE.............................................................................................................. 295 REMOVAL........................................................................................................................ 295 INSTALLATION................................................................................................................... 295 GENERATOR—3.0L ENGINE.............................................................................................................. 295 REMOVAL........................................................................................................................ 295 INSTALLATION................................................................................................................... 295 GENERATOR—3.3/3.8 L ENGINE......................................................................................................... 296 REMOVAL........................................................................................................................ 296 INSTALLATION................................................................................................................... 296 SPECIFICATIONS......................................................................................................................... 297 GENERATOR.......................................................................................................................... 297 TORQUE............................................................................................................................. 297 IGNITION SYSTEM............................................................................................................................ 299 GENERAL INFORMATION.................................................................................................................... 299 GENERAL INFORMATION................................................................................................................ 299 INTRODUCTION................................................................................................................... 299 POWERTRAIN CONTROL MODULE...................................................................................................... 299 IGNITION SYSTEM................................................................................................................ 300 SPARK PLUGS 2.4/3.0L .......................................................................................................... 300 SPARK PLUGS 3.3/3.8L........................................................................................................... 300 3.3/3.8L SPARK PLUG GAP MEASUREMENT........................................................................................ 301 SPARK PLUG CABLE............................................................................................................... 301 SPARK PLUG CABLES—3.3/3.8L................................................................................................. 302 IGNITION COIL.................................................................................................................. 302 AUTOMATIC SHUTDOWN (ASD) RELAY................................................................................................. 302 CRANKSHAFT POSITION SENSOR..................................................................................................... 303 CAMSHAFT POSITION SENSOR....................................................................................................... 303 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR........................................................................................ 304 ENGINE COOLANT TEMPERATURE (ECT) SENSOR........................................................................................ 304 THROTTLE POSITION SENSOR (TPS)................................................................................................. 305 LOCK KEY CYLINDER.............................................................................................................. 305 KNOCK SENSOR................................................................................................................... 305 DIAGNOSIS AND TESTING.............................................................................................................. 306 TESTING FOR SPARK AT COIL—2.4/3.3/3.8L ENGINES................................................................................. 306 TESTING FOR SPARK AT COIL—3.0L................................................................................................. 306 CHECK COIL TEST—2.4L........................................................................................................... 307 CHECK COIL TEST—3.3/3.8L....................................................................................................... 307 FAILURE TO START TEST.......................................................................................................... 308 IGNITION TIMING PROCEDURE...................................................................................................... 309 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST................................................................................... 309 CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR........................................................................ 309 ENGINE COOLANT TEMPERATURE SENSOR.............................................................................................. 309 INTAKE AIR TEMPERATURE SENSOR.................................................................................................. 309 SPARK PLUG CONDITION........................................................................................................... 309 NORMAL OPERATING CONDITIONS................................................................................................ 309 COLD FOULING (CARBON FOULING).............................................................................................. 309 FUEL FOULING .............................................................................................................. 309 OIL FOULING................................................................................................................ 309 OIL OR ASH ENCRUSTED....................................................................................................... 309 HIGH SPEED MISS............................................................................................................ 310 ELECTRODE GAP BRIDGING .................................................................................................... 310 SCAVENGER DEPOSITS......................................................................................................... 310 CHIPPED ELECTRODE INSULATOR................................................................................................ 310 PREIGNITION DAMAGE......................................................................................................... 310 SPARK PLUG OVERHEATING..................................................................................................... 310 THROTTLE POSITION SENSOR....................................................................................................... 311 SERVICE PROCEDURES................................................................................................................. 311 SPARK PLUG GAP ADJUSTMENT...................................................................................................... 311 POWERTRAIN CONTROL MODULE...................................................................................................... 311 REMOVAL.................................................................................................................... 311 INSTALLATION............................................................................................................... 312 IGNITION TIMING PROCEDURE...................................................................................................... 313 2.4L ENGINE............................................................................................................................ 314 DESCRIPTION AND OPERATION.......................................................................................................... 314 FIRING ORDER—2.4L.............................................................................................................. 314 CRANKSHAFT POSITION SENSOR..................................................................................................... 314 CAMSHAFT POSITION SENSOR....................................................................................................... 315 INTAKE AIR TEMPERATURE SENSOR 2.4L ............................................................................................ 315 REMOVAL AND INSTALLATION........................................................................................................... 316 SPARK PLUG CABLE SERVICE—2.4L.................................................................................................. 316 REMOVAL.................................................................................................................... 316 INSTALLATION............................................................................................................... 316 IGNITION COIL—2.4L............................................................................................................. 316 REMOVAL.................................................................................................................... 316 INSTALLATION............................................................................................................... 316 SPARK PLUG SERVICE............................................................................................................. 316 CRANKSHAFT POSITION SENSOR..................................................................................................... 317 REMOVAL.................................................................................................................... 317 INSTALLATION............................................................................................................... 317 CAMSHAFT POSITION SENSOR....................................................................................................... 317 REMOVAL.................................................................................................................... 317 INSTALLATION............................................................................................................... 317 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR—2.4/3.3/3.8L........................................................................... 318 REMOVAL.................................................................................................................... 318 INSTALLATION............................................................................................................... 318 THROTTLE POSITION SENSOR....................................................................................................... 318 ENGINE COOLANT TEMPERATURE SENSOR—2.4L......................................................................................... 318 REMOVAL.................................................................................................................... 319 INSTALLATION............................................................................................................... 319 KNOCK SENSOR—2.4L.............................................................................................................. 319 REMOVAL.................................................................................................................... 319 INSTALLATION .............................................................................................................. 319 INTAKE AIR TEMPERATURE SENSOR—2.4L............................................................................................. 319 REMOVAL.................................................................................................................... 319 INSTALLATION............................................................................................................... 319 SPECIFICATIONS..................................................................................................................... 320 IGNITION COIL.................................................................................................................. 320 SPARK PLUG..................................................................................................................... 320 TORQUE ........................................................................................................................ 320 SPARK PLUG CABLE RESISTANCE 2.4L............................................................................................... 320 3.0L ENGINE............................................................................................................................ 321 DESCRIPTION AND OPERATION.......................................................................................................... 321 FIRING ORDER—3.0L.............................................................................................................. 321 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR........................................................................................ 321 CAMSHAFT POSITION SENSOR....................................................................................................... 321 REMOVAL AND INSTALLATION........................................................................................................... 322 SPARK PLUG SERVICE............................................................................................................. 322 REMOVAL.................................................................................................................... 322 INSTALLATION............................................................................................................... 322 IGNITION COIL—3.OL................................................................................................................. 322 REMOVAL........................................................................................................................ 322 INSTALLATION................................................................................................................... 322 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR—3.0L................................................................................... 322 REMOVAL.................................................................................................................... 322 INSTALLATION............................................................................................................... 323 ENGINE COOLANT TEMPERATURE SENSOR—3.0L......................................................................................... 323 REMOVAL.................................................................................................................... 323 INSTALLATION............................................................................................................... 323 CRANKSHAFT POSITION SENSOR..................................................................................................... 323 REMOVAL.................................................................................................................... 323 INSTALLATION............................................................................................................... 323 THROTTLE POSITION SENSOR....................................................................................................... 323 DISASSEMBLY AND ASSEMBLY........................................................................................................... 324 DISTRIBUTOR—3.0L............................................................................................................... 324 REMOVAL.................................................................................................................... 324 INSTALLATION............................................................................................................... 324 CLEANING AND INSPECTION............................................................................................................ 324 DISTRIBUTOR CAP................................................................................................................ 324 DISTRIBUTOR ROTOR—3.0L......................................................................................................... 325 SPECIFICATIONS..................................................................................................................... 325 SPARK PLUG..................................................................................................................... 325 TORQUE ........................................................................................................................ 325 SPARK PLUG CABLE RESISTANCE 3.0L............................................................................................... 325 3.3/3.8L ENGINE........................................................................................................................ 326 DESCRIPTION AND OPERATION ......................................................................................................... 326 FIRING ORDER 3.3/3.8L ......................................................................................................... 326 REMOVAL AND INSTALLATION........................................................................................................... 326 SPARK PLUG CABLE SERVICE 3.3/3.8L ENGINES...................................................................................... 326 SPARK PLUG CABLES #3 AND #5.................................................................................................... 327 SPARK PLUG CABLE #1........................................................................................................ 327 SPARK PLUG SERVICE—3.3/3.8L ENGINES............................................................................................ 327 SPARK PLUG #3 AND #5....................................................................................................... 327 SPARK PLUG #1.............................................................................................................. 328 IGNITION COIL.................................................................................................................. 328 REMOVAL.................................................................................................................... 328 INSTALLATION............................................................................................................... 328 CRANKSHAFT POSITION SENSOR..................................................................................................... 328 REMOVAL.................................................................................................................... 328 INSTALLATION............................................................................................................... 328 CAMSHAFT POSITION SENSOR....................................................................................................... 329 REMOVAL.................................................................................................................... 329 INSTALLATION............................................................................................................... 329 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR........................................................................................ 330 REMOVAL.................................................................................................................... 330 INSTALLATION............................................................................................................... 330 ENGINE COOLANT TEMPERATURE SENSOR.............................................................................................. 330 REMOVAL.................................................................................................................... 330 INSTALLATION............................................................................................................... 330 THROTTLE POSITION SENSOR....................................................................................................... 330 KNOCK SENSOR—3.3/3.8L.......................................................................................................... 330 REMOVAL.................................................................................................................... 331 INSTALLATION............................................................................................................... 331 SPECIFICATIONS..................................................................................................................... 331 IGNITION COIL.................................................................................................................. 331 SPARK PLUG..................................................................................................................... 332 TORQUE ........................................................................................................................ 332 SPARK PLUG CABLE RESISTANCE 3.3/3.8L........................................................................................... 332 IGNITION SWITCH AND LOCK CYLINDER...................................................................................................... 333 DESCRIPTION AND OPERATION.......................................................................................................... 333 IGNITION INTERLOCK............................................................................................................. 333 LOCK KEY CYLINDER.............................................................................................................. 333 REMOVAL AND INSTALLATION........................................................................................................... 333 IGNITION SWITCH................................................................................................................ 333 REMOVAL.................................................................................................................... 334 INSTALLATION............................................................................................................... 335 LOCK KEY CYLINDER.............................................................................................................. 336 REMOVAL.................................................................................................................... 336 INSTALLATION............................................................................................................... 336 IGNITION INTERLOCK............................................................................................................. 336 LOCK CYLINDER HOUSING.......................................................................................................... 336 INSTRUMENT PANEL AND SYSTEMS............................................................................................................... 337 GENERAL INFORMATION ................................................................................................................... 337 INTRODUCTION....................................................................................................................... 337 DESCRIPTION AND OPERATION.............................................................................................................. 337 INSTRUMENT CLUSTER ................................................................................................................ 337 DIAGNOSIS AND TESTING.................................................................................................................. 338 DIAGNOSTIC PROCEDURES.............................................................................................................. 338 HEADLAMP SWITCH.................................................................................................................... 338 SELF DIAGNOSTIC TEST............................................................................................................... 338 DIM TEST....................................................................................................................... 338 INSTRUMENT CLUSTER DTC TABLE .................................................................................................. 339 CLUSTER CALIBRATION TABLE...................................................................................................... 339 CALIBRATION TEST............................................................................................................... 339 ODOMETER SEGMENT TEST ......................................................................................................... 339 ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST........................................................................... 339 CONDITIONS..................................................................................................................... 339 INSTRUMENT CLUSTER DIAGNOSIS................................................................................................... 339 SPEEDOMETER DIAGNOSIS.......................................................................................................... 340 TACHOMETER DIAGNOSIS........................................................................................................... 343 FUEL GAUGE DIAGNOSIS........................................................................................................... 345 TEMPERATURE GAUGE DIAGNOSIS.................................................................................................... 347 ODOMETER DIAGNOSIS............................................................................................................. 349 ELECTRONIC GEAR INDICATOR DISPLAY DIAGNOSIS.................................................................................... 351 TRACTION CONTROL SWITCH............................................................................................................ 353 MECHANICAL TRANSMISSION RANGE INDICATOR (PRND21) DIAGNOSIS..................................................................... 353 SWITCH CONTINUITY TABLE........................................................................................................ 353 REMOVAL AND INSTALLATION............................................................................................................... 353 CONVENIENCE BIN - CUP HOLDER....................................................................................................... 353 REMOVAL ....................................................................................................................... 353 INSTALLATION................................................................................................................... 353 CONVENIENCE BIN LAMP............................................................................................................... 353 REMOVAL........................................................................................................................ 353 INSTALLATION .................................................................................................................. 354 CONVENIENCE BIN TRACK ............................................................................................................. 354 REMOVAL ....................................................................................................................... 354 INSTALLATION................................................................................................................... 354 BODY CONTROL MODULE (BCM).......................................................................................................... 354 REMOVAL........................................................................................................................ 354 INSTALLATION................................................................................................................... 355 INSTRUMENT CLUSTER LENS - MECHANICAL TRANSMISSION RANGE INDICATOR (PRND21)......................................................... 355 REMOVAL........................................................................................................................ 355 INSTALLATION................................................................................................................... 355 INSTRUMENT CLUSTER ELECTRONIC ODOMETER AND TRANSMISSION RANGE INDICATOR............................................................ 355 REMOVAL........................................................................................................................ 355 INSTALLATION................................................................................................................... 355 GLOVE BOX.......................................................................................................................... 355 REMOVAL (FIG. 4)............................................................................................................... 355 INSTALLATION................................................................................................................... 355 GLOVE BOX LAMP AND SWITCH.......................................................................................................... 355 REMOVAL........................................................................................................................ 355 INSTALLATION................................................................................................................... 356 GLOVE BOX LOCK STRIKER............................................................................................................. 356 REMOVAL........................................................................................................................ 356 INSTALLATION................................................................................................................... 356 HEADLAMP SWITCH.................................................................................................................... 356 REMOVAL........................................................................................................................ 356 INSTALLATION .................................................................................................................. 356 HEADLAMP SWITCH LAMP(S)............................................................................................................ 357 REMOVAL........................................................................................................................ 357 INSTALLATION................................................................................................................... 357 HVAC CONTROL LAMP ................................................................................................................. 357 REMOVAL ....................................................................................................................... 357 INSTALLATION................................................................................................................... 357 INSTRUMENT CLUSTER BACK PANEL...................................................................................................... 357 REMOVAL........................................................................................................................ 357 INSTALLATION .................................................................................................................. 357 INSTRUMENT CLUSTER BEZEL........................................................................................................... 357 REMOVAL........................................................................................................................ 357 INSTALLATION................................................................................................................... 358 INSTRUMENT CLUSTER LAMPS........................................................................................................... 358 REMOVAL........................................................................................................................ 358 INSTALLATION................................................................................................................... 358 INSTRUMENT CLUSTER LENS............................................................................................................ 358 REMOVAL........................................................................................................................ 358 INSTALLATION................................................................................................................... 358 INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD........................................................................................... 359 REMOVAL........................................................................................................................ 359 INSTALLATION................................................................................................................... 359 INSTRUMENT CLUSTER SUBDIAL......................................................................................................... 359 REMOVAL........................................................................................................................ 359 INSTALLATION................................................................................................................... 359 INSTRUMENT CLUSTER SUBDIAL—MECHANICAL TRANSMISSION RANGE INDICATOR................................................................. 359 REMOVAL........................................................................................................................ 359 INSTALLATION................................................................................................................... 359 INSTRUMENT CLUSTER WITH ELECTRONIC TRANSMISSION RANGE INDICATOR.................................................................... 359 REMOVAL........................................................................................................................ 359 INSTALLATION .................................................................................................................. 359 INSTRUMENT CLUSTER WITH MECHANICAL TRANSMISSION RANGE INDICATOR.................................................................... 360 REMOVAL........................................................................................................................ 360 INSTALLATION................................................................................................................... 360 INSTRUMENT PANEL................................................................................................................... 361 REMOVAL........................................................................................................................ 361 INSTALLATION................................................................................................................... 362 INSTRUMENT PANEL LEFT END COVER.................................................................................................... 363 REMOVAL........................................................................................................................ 363 INSTALLATION................................................................................................................... 363 INSTRUMENT PANEL LOUVERS........................................................................................................... 363 CENTER LOUVER HOUSING.......................................................................................................... 363 LEFT LOUVER HOUSING............................................................................................................ 363 PASSENGER SIDE LOUVERS......................................................................................................... 364 PASSENGER SIDE LOUVER OUTER HOUSINGS........................................................................................... 364 INSTRUMENT PANEL TOP COVER......................................................................................................... 365 REMOVAL........................................................................................................................ 365 INSTALLATION................................................................................................................... 365 INSTRUMENT PANEL RIGHT END COVER................................................................................................... 365 REMOVAL........................................................................................................................ 365 INSTALLATION................................................................................................................... 366 JUNCTION BLOCK..................................................................................................................... 366 REMOVAL........................................................................................................................ 366 INSTALLATION................................................................................................................... 366 KNEE BLOCKER REINFORCEMENT......................................................................................................... 366 REMOVAL........................................................................................................................ 366 INSTALLATION................................................................................................................... 366 LOWER CONSOLE...................................................................................................................... 366 REMOVAL........................................................................................................................ 366 INSTALLATION................................................................................................................... 367 LOWER INSTRUMENT PANEL............................................................................................................. 367 REMOVAL........................................................................................................................ 367 INSTALLATION .................................................................................................................. 367 LOWER STEERING COLUMN COVER........................................................................................................ 367 REMOVAL........................................................................................................................ 367 INSTALLATION................................................................................................................... 368 MECHANICAL TRANSMISSION RANGE INDICATOR............................................................................................ 368 REMOVAL........................................................................................................................ 368 INSTALLATION .................................................................................................................. 368 MESSAGE CENTER..................................................................................................................... 368 REMOVAL........................................................................................................................ 368 INSTALLATION................................................................................................................... 368 MESSAGE CENTER LAMP................................................................................................................ 368 REMOVAL........................................................................................................................ 368 INSTALLATION................................................................................................................... 368 OUTLET (12 VOLT) BASE.............................................................................................................. 368 REMOVAL ....................................................................................................................... 368 INSTALLATION................................................................................................................... 368 OVER STEERING COLUMN BEZEL......................................................................................................... 368 REMOVAL........................................................................................................................ 368 INSTALLATION................................................................................................................... 369 POWER MIRROR SWITCH................................................................................................................ 370 REMOVAL........................................................................................................................ 370 INSTALLATION................................................................................................................... 370 POWER MIRROR SWITCH LAMP........................................................................................................... 370 REMOVAL........................................................................................................................ 370 INSTALLATION................................................................................................................... 370 RADIO BEZEL AND HVAC CONTROL....................................................................................................... 370 REMOVAL........................................................................................................................ 370 INSTALLATION................................................................................................................... 371 REAR HEATER-A/C SWITCH............................................................................................................. 371 REMOVAL ....................................................................................................................... 371 INSTALLATION................................................................................................................... 371 REAR HEATER-A/C SWITCH LAMP........................................................................................................ 371 REMOVAL........................................................................................................................ 371 INSTALLATION................................................................................................................... 371 TRACTION CONTROL SWITCH............................................................................................................ 371 REMOVAL........................................................................................................................ 371 INSTALLATION................................................................................................................... 371 INSTRUMENT PANEL AND SYSTEMS 1 ............................................................................................................ 373 GENERAL INFORMATION.................................................................................................................... 373 INTRODUCTION....................................................................................................................... 373 DESCRIPTION AND OPERATION.............................................................................................................. 373 HEADLAMP AND POWER MIRROR SWITCH LAMP( S).......................................................................................... 373 INSTRUMENT CLUSTER................................................................................................................. 374 DIAGNOSIS AND TESTING.................................................................................................................. 374 DIAGNOSTIC PROCEDURES.............................................................................................................. 374 HEADLAMP SWITCH.................................................................................................................... 374 SELF DIAGNOSTIC TEST............................................................................................................... 375 INSTRUMENT CLUSTER DTC CHART................................................................................................... 375 DIM TEST....................................................................................................................... 375 CLUSTER CALIBRATION TABLE...................................................................................................... 375 CALIBRATION TEST............................................................................................................... 376 ODOMETER SEGMENT TEST.......................................................................................................... 376 CONDITIONS..................................................................................................................... 376 REMOVAL AND INSTALLATION............................................................................................................... 387 CONVENIENCE BIN - CUP HOLDER....................................................................................................... 387 REMOVAL........................................................................................................................ 387 INSTALLATION................................................................................................................... 387 ASH RECEIVER – CONVENIENCE BIN LAMP MODULE......................................................................................... 387 REMOVAL........................................................................................................................ 387 INSTALLATION................................................................................................................... 387 CONVENIENCE BIN.................................................................................................................... 387 REMOVAL........................................................................................................................ 387 INSTALLATION................................................................................................................... 388 BODY CONTROL MODULE (BCM).......................................................................................................... 388 REMOVAL........................................................................................................................ 388 INSTALLATION................................................................................................................... 388 CIGAR LIGHTER BASE................................................................................................................. 388 REMOVAL........................................................................................................................ 388 INSTALLATION................................................................................................................... 388 GLOVE BOX.......................................................................................................................... 389 REMOVAL (FIG. 4)............................................................................................................... 389 INSTALLATION................................................................................................................... 389 GLOVE BOX LAMP AND SWITCH.......................................................................................................... 389 REMOVAL........................................................................................................................ 389 INSTALLATION................................................................................................................... 389 GLOVE BOX LOCK STRIKER............................................................................................................. 389 REMOVAL........................................................................................................................ 389 INSTALLATION................................................................................................................... 389 HEADLAMP SWITCH.................................................................................................................... 390 REMOVAL........................................................................................................................ 390 INSTALLATION................................................................................................................... 390 HEADLAMP SWITCH LAMP( S)........................................................................................................... 390 REMOVAL........................................................................................................................ 390 INSTALLATION................................................................................................................... 390 HVAC CONTROL LAMP.................................................................................................................. 390 REMOVAL........................................................................................................................ 390 INSTALLATION................................................................................................................... 390 INSTRUMENT CLUSTER BACK PANEL...................................................................................................... 390 REMOVAL........................................................................................................................ 390 INSTALLATION................................................................................................................... 390 INSTRUMENT CLUSTER BEZEL........................................................................................................... 390 REMOVAL........................................................................................................................ 390 INSTALLATION................................................................................................................... 391 INSTRUMENT CLUSTER LENS............................................................................................................ 391 REMOVAL........................................................................................................................ 391 INSTALLATION................................................................................................................... 391 INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD........................................................................................... 391 REMOVAL........................................................................................................................ 391 INSTALLATION................................................................................................................... 392 INSTRUMENT CLUSTER SUBDIAL......................................................................................................... 392 REMOVAL........................................................................................................................ 392 INSTALLATION................................................................................................................... 392 INSTRUMENT CLUSTER................................................................................................................. 392 REMOVAL........................................................................................................................ 392 INSTALLATION................................................................................................................... 392 INSTRUMENT PANEL................................................................................................................... 392 REMOVAL........................................................................................................................ 392 INSTALLATION................................................................................................................... 394 INSTRUMENT PANEL LEFT END COVER.................................................................................................... 394 REMOVAL........................................................................................................................ 394 INSTALLATION................................................................................................................... 394 INSTRUMENT PANEL LOUVERS........................................................................................................... 394 CENTER LOUVER HOUSING.......................................................................................................... 394 LEFT LOUVER HOUSING............................................................................................................ 395 PASSENGER SIDE LOUVERS......................................................................................................... 395 PASSENGER SIDE LOUVER OUTER HOUSINGS........................................................................................... 396 INSTRUMENT PANEL TOP COVER......................................................................................................... 396 REMOVAL........................................................................................................................ 396 INSTALLATION................................................................................................................... 397 INSTRUMENT PANEL RIGHT END COVER................................................................................................... 397 REMOVAL........................................................................................................................ 397 INSTALLATION................................................................................................................... 397 JUNCTION BLOCK..................................................................................................................... 397 REMOVAL........................................................................................................................ 397 INSTALLATION................................................................................................................... 397 KNEE BLOCKER REINFORCEMENT......................................................................................................... 397 REMOVAL........................................................................................................................ 397 INSTALLATION................................................................................................................... 398 LOWER CONSOLE...................................................................................................................... 398 REMOVAL........................................................................................................................ 398 INSTALLATION................................................................................................................... 398 LOWER INSTRUMENT PANEL............................................................................................................. 398 REMOVAL........................................................................................................................ 398 INSTALLATION................................................................................................................... 399 LOWER STEERING COLUMN COVER........................................................................................................ 399 REMOVAL........................................................................................................................ 399 INSTALLATION................................................................................................................... 399 MESSAGE CENTER..................................................................................................................... 399 REMOVAL........................................................................................................................ 399 INSTALLATION................................................................................................................... 400 OVER STEERING COLUMN BEZEL......................................................................................................... 400 REMOVAL........................................................................................................................ 400 INSTALLATION................................................................................................................... 400 POWER MIRROR SWITCH................................................................................................................ 400 REMOVAL........................................................................................................................ 400 INSTALLATION................................................................................................................... 400 POWER MIRROR SWITCH LAMP........................................................................................................... 400 REMOVAL........................................................................................................................ 400 INSTALLATION................................................................................................................... 401 RADIO BEZEL AND HVAC CONTROL....................................................................................................... 401 REMOVAL........................................................................................................................ 401 INSTALLATION................................................................................................................... 401 REAR HEATER- A/ C SWITCH........................................................................................................... 401 REMOVAL........................................................................................................................ 401 INSTALLATION................................................................................................................... 401 REAR HEATER- A/ C SWITCH LAMP...................................................................................................... 401 REMOVAL........................................................................................................................ 401 INSTALLATION................................................................................................................... 401 AUDIO SYSTEMS.............................................................................................................................. 403 GENERAL INFORMATION.................................................................................................................... 403 INTRODUCTION ...................................................................................................................... 403 DESCRIPTION AND OPERATION.............................................................................................................. 403 ANTENNA............................................................................................................................ 403 INTERFERENCE ELIMINATION........................................................................................................... 403 RADIOS............................................................................................................................. 403 RADIO IGNITION INTERFERENCE........................................................................................................ 404 CHOKE—INFINITY SPEAKERS............................................................................................................ 404 REMOTE RADIO SWITCHES.............................................................................................................. 405 NAME BRAND SPEAKER RELAY........................................................................................................... 405 DIAGNOSIS AND TESTING.................................................................................................................. 405 ANTENNA............................................................................................................................ 405 TEST 1......................................................................................................................... 405 TEST 2......................................................................................................................... 406 TEST 3......................................................................................................................... 406 TEST 4......................................................................................................................... 406 AUDIO SYSTEM....................................................................................................................... 406 RADIO.............................................................................................................................. 406 AUDIO SYSTEM DIAGNOSIS......................................................................................................... 407 REMOTE RADIO SWITCHES.............................................................................................................. 408 REMOTE RADIO SWITCH TEST....................................................................................................... 408 REMOVAL AND INSTALLATION............................................................................................................... 409 ANTENNA MAST AND CABLE LEAD........................................................................................................ 409 REMOVAL........................................................................................................................ 409 INSTALLATION................................................................................................................... 409 ANTENNA EXTENSION CABLE............................................................................................................ 409 REMOVAL........................................................................................................................ 409 INSTALLATION .................................................................................................................. 409 RADIO/TAPE/CD PLAYER............................................................................................................... 410 REMOVAL........................................................................................................................ 410 INSTALLATION................................................................................................................... 410 INSTRUMENT PANEL SPEAKER........................................................................................................... 410 INSTALLATION................................................................................................................... 410 INSTALLATION................................................................................................................... 410 FRONT DOOR SPEAKER................................................................................................................. 411 REMOVAL........................................................................................................................ 411 INSTALLATION................................................................................................................... 411 REMOTE RADIO SWITCHES.............................................................................................................. 411 REMOVAL........................................................................................................................ 411 INSTALLATION................................................................................................................... 411 QUARTER PANEL SPEAKER ............................................................................................................. 412 REMOVAL ....................................................................................................................... 412 INSTALLATION .................................................................................................................. 412 D PILLAR SPEAKER................................................................................................................... 412 REMOVAL........................................................................................................................ 412 INSTALLATION................................................................................................................... 412 HORNS...................................................................................................................................... 413 DESCRIPTION AND OPERATION ............................................................................................................. 413 INTRODUCTION ...................................................................................................................... 413 DIAGNOSIS AND TESTING.................................................................................................................. 413 HORN............................................................................................................................... 413 HORN RELAY......................................................................................................................... 413 HORNS WILL NOT SOUND............................................................................................................... 414 FUSE BLOWN..................................................................................................................... 414 FUSE OK........................................................................................................................ 414 HORNS SOUND CONTINUOUSLY .......................................................................................................... 415 HORN SYSTEM........................................................................................................................ 415 HORN SYSTEM TEST............................................................................................................... 415 REMOVAL AND INSTALLATION............................................................................................................... 416 HORN SWITCH........................................................................................................................ 416 HORNS.............................................................................................................................. 416 REMOVAL........................................................................................................................ 416 INSTALLATION................................................................................................................... 416 VEHICLE SPEED CONTROL SYSTEM............................................................................................................... 417 GENERAL INFORMATION ................................................................................................................... 417 INTRODUCTION ...................................................................................................................... 417 DESCRIPTION AND OPERATION.............................................................................................................. 417 SPEED CONTROL SERVO................................................................................................................ 417 SPEED CONTROL SWITCHES............................................................................................................. 417 AUTOMATIC SPEED CONTROL OVERSPEED REDUCTION........................................................................................ 418 STOP LAMP SWITCH................................................................................................................... 418 SERVO CABLE........................................................................................................................ 418 POWERTRAIN CONTROL MODULE.......................................................................................................... 418 VACUUM RESERVOIR................................................................................................................... 419 VEHICLE SPEED AND DISTANCE......................................................................................................... 419 DIAGNOSIS AND TESTING.................................................................................................................. 419 ROAD TEST.......................................................................................................................... 419 OVERSHOOT/UNDERSHOOT FOLLOWING SPEED CONTROL SET................................................................................... 419 CHECKING FOR DIAGNOSTIC CODES...................................................................................................... 419 SPEED CONTROL DIAGNOSTIC TROUBLE CODES......................................................................................... 420 SPEED CONTROL SLOWS DOWN BY ITSELF............................................................................................. 420 SPEED CONTROL ELECTRICAL TEST...................................................................................................... 420 SERVO VACUUM TEST.................................................................................................................. 422 SPEED CONTROL SWITCH TEST.......................................................................................................... 422 STOP LAMP SWITCH TEST.............................................................................................................. 422 ELECTRICAL TESTS AT POWERTRAIN CONTROL MODULE...................................................................................... 422 VACUUM SUPPLY TEST................................................................................................................. 424 VEHICLE SPEED SENSOR............................................................................................................... 424 REMOVAL AND INSTALLATION............................................................................................................... 424 SPEED CONTROL SERVO................................................................................................................ 424 REMOVAL........................................................................................................................ 424 INSTALLATION................................................................................................................... 425 SPEED CONTROL SWITCHES............................................................................................................. 425 REMOVAL........................................................................................................................ 425 INSTALLATION................................................................................................................... 425 STOP LAMP SWITCH................................................................................................................... 425 REMOVAL........................................................................................................................ 425 INSTALLATION................................................................................................................... 425 SPEED CONTROL CABLE................................................................................................................ 425 REMOVAL........................................................................................................................ 425 INSTALLATION................................................................................................................... 425 POWERTRAIN CONTROL MODULE.......................................................................................................... 425 VACUUM RESEROIR.................................................................................................................... 426 REMOVAL........................................................................................................................ 426 INSTALLATION................................................................................................................... 426 VEHICLE SPEED SENSOR............................................................................................................... 426 VEHICLE SPEED CONTROL SYSTEM 1 ............................................................................................................ 427 GENERAL INFORMATION.................................................................................................................... 427 INTRODUCTION....................................................................................................................... 427 TURN SIGNAL AND FLASHERS................................................................................................................... 429 GENERAL INFORMATION.................................................................................................................... 429 INTRODUCTION....................................................................................................................... 429 COMBINATION FLASHER................................................................................................................ 429 DESCRIPTION AND OPERATION.............................................................................................................. 429 COMBINATION FLASHER FUNCTION....................................................................................................... 429 COMBINATION FLASHER / DAYTIME RUNNING LAMPS (DRL) MODULE........................................................................... 430 DIAGNOSIS AND TESTING.................................................................................................................. 430 TURN SIGNAL MULTI-FUNCTION SWITCH.................................................................................................. 430 TURN SIGNAL MULTI-FUNCTION SWITCH TEST......................................................................................... 431 COMBINATION FLASHER WITH / WITHOUT DAYTIME RUNNING LAMPS MODULE—CIRCUIT DIAGNOSTICS................................................ 431 JUNCTION BLOCK TERMINAL CALL-OUT............................................................................................... 432 JUNCTION BLOCK TERMINAL CALL-OUT WITH DRL...................................................................................... 433 COMBINATION FLASHER DIAGNOSIS.................................................................................................. 434 COMBINATION FLASHER DIAGNOSIS WITH DRL......................................................................................... 436 REMOVAL AND INSTALLATION............................................................................................................... 439 MULTI-FUNCTION SWITCH.............................................................................................................. 439 REMOVAL........................................................................................................................ 439 INSTALLATION................................................................................................................... 439 COMBINATION FLASHER WITH / WITHOUT DRL MODULE...................................................................................... 439 REMOVAL........................................................................................................................ 439 INSTALLATION................................................................................................................... 439 WINDSHIELD WIPERS AND WASHERS.............................................................................................................. 441 WINDSHIELD WIPERS AND WASHER........................................................................................................... 441 GENERAL INFORMATION................................................................................................................ 441 INTRODUCTION................................................................................................................... 441 DIAGNOSIS AND TESTING.............................................................................................................. 441 DIAGNOSTIC PROCEDURES.......................................................................................................... 441 FAILED PARK SWITCH............................................................................................................. 442 WIPER SYSTEM DIAGNOSIS..................................................................................................... 442 MULTI-FUNCTION SWITCH.......................................................................................................... 444 REMOVAL AND INSTALLATION........................................................................................................... 444 MULTI-FUNCTION SWITCH.......................................................................................................... 444 REMOVAL.................................................................................................................... 444 INSTALLATION............................................................................................................... 444 WINDSHIELD WASHER BOTTLE....................................................................................................... 444 REMOVAL.................................................................................................................... 444 INSTALLATION............................................................................................................... 445 WINDSHIELD WIPER BLADE......................................................................................................... 445 REMOVAL.................................................................................................................... 445 INSTALLATION............................................................................................................... 445 WINDSHIELD WIPER BLADE ELEMENT................................................................................................. 446 REMOVAL.................................................................................................................... 446 INSTALLATION............................................................................................................... 446 WINDSHIELD WIPER MOTOR......................................................................................................... 446 REMOVAL.................................................................................................................... 446 INSTALLATION............................................................................................................... 446 WIPER ARM...................................................................................................................... 447 REMOVAL.................................................................................................................... 447 INSTALLATION............................................................................................................... 447 WIPER UNIT..................................................................................................................... 447 REMOVAL.................................................................................................................... 447 INSTALLATION............................................................................................................... 447 WIPER LINKAGE.................................................................................................................. 447 REMOVAL.................................................................................................................... 447 INSTALLATION............................................................................................................... 448 CLEANING AND INSPECTION............................................................................................................ 448 WIPER BLADES................................................................................................................... 448 ADJUSTMENTS........................................................................................................................ 448 WIPER ARM ALIGNMENT............................................................................................................ 448 REAR WIPER AND WASHER.................................................................................................................. 448 DESCRIPTION AND OPERATION ......................................................................................................... 449 INTRODUCTION .................................................................................................................. 449 REAR WINDOW WIPER/WASHER SWITCHES.............................................................................................. 449 DIAGNOSIS AND TESTING.............................................................................................................. 449 DIAGNOSTIC PROCEDURES.......................................................................................................... 449 REMOVAL AND INSTALLATION........................................................................................................... 449 REAR GLASS RUBBER GROMMET...................................................................................................... 449 REMOVAL.................................................................................................................... 449 INSTALLATION............................................................................................................... 449 REAR WINDOW WIPER MOTOR........................................................................................................ 450 REMOVAL.................................................................................................................... 450 INSTALLATION............................................................................................................... 450 REAR WIPER ARM................................................................................................................. 450 REMOVAL.................................................................................................................... 450 INSTALLATION............................................................................................................... 450 REAR WIPER BLADE............................................................................................................... 450 REMOVAL.................................................................................................................... 450 INSTALLATION............................................................................................................... 450 REAR WIPER BLADE ELEMENT....................................................................................................... 450 WIPER AND WASHER SYSTEMS 1 ................................................................................................................ 451 HEADLAMP WASHERS....................................................................................................................... 451 GENERAL INFORMATION................................................................................................................ 451 INTRODUCTION................................................................................................................... 451 REMOVAL AND INSTALLATION........................................................................................................... 451 WINDSHIELD/ HEADLAMP WASHER RESERVOIR.......................................................................................... 451 HEADLAMP WASHER NOZZLE......................................................................................................... 451 HEADLAMP WASHER PUMP........................................................................................................... 452 LAMPS...................................................................................................................................... 453 LAMP DIAGNOSIS......................................................................................................................... 453 GENERAL INFORMATION................................................................................................................ 453 GENERAL INFORMATION............................................................................................................ 453 SAFETY PRECAUTIONS............................................................................................................. 453 ELECTRONIC DAYTIME RUNNING LIGHT (DRL)......................................................................................... 453 SYSTEM FUNCTION............................................................................................................ 454 DIAGNOSIS AND TESTING.............................................................................................................. 454 DIAGNOSTIC PROCEDURES.......................................................................................................... 454 HEADLAMP DIAGNOSIS......................................................................................................... 455 FOG LAMP DIAGNOSIS......................................................................................................... 456 HEADLAMP ALIGNMENT..................................................................................................................... 457 GENERAL INFORMATION ............................................................................................................... 457 HEADLAMP ALIGNMENT ............................................................................................................ 457 SERVICE PROCEDURES................................................................................................................. 457 HEADLAMP ALIGNMENT PREPARATION................................................................................................. 457 ADJUSTMENTS........................................................................................................................ 457 HEADLAMP/FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN............................................................................ 457 ALIGNMENT SCREEN PREPARATION............................................................................................... 457 HEADLAMP ADJUSTMENT........................................................................................................ 458 HEADLAMP ADJUSTMENT – TOWN AND COUNTRY..................................................................................... 458 BUBBLE LEVEL CALIBRATION (VERTICAL AIM) ................................................................................... 459 MAGNIFYING WINDOW CALIBRATION (HORIZONTAL AIM)............................................................................. 459 FOG LAMP ALIGNMENT......................................................................................................... 460 REMOVAL AND INSTALLATION........................................................................................................... 461 HEADLAMP BULB.................................................................................................................. 461 REMOVAL.................................................................................................................... 461 INSTALLATION .............................................................................................................. 461 HEADLAMP BULB – TOWN & COUNTRY................................................................................................. 461 HEADLAMP HIGH BEAM......................................................................................................... 461 HEADLAMP LOW BEAM.......................................................................................................... 461 FOG LAMP BULB.................................................................................................................. 462 REMOVAL.................................................................................................................... 462 INSTALLATION............................................................................................................... 462 FOG LAMP BULB – TOWN and COUNTRY............................................................................................... 463 REMOVAL.................................................................................................................... 463 INSTALLATION............................................................................................................... 463 FRONT SIDE MARKER LAMP BULB TOWN and COUNTRY................................................................................... 463 REMOVAL.................................................................................................................... 463 INSTALLATION............................................................................................................... 463 PARKING AND TURN SIGNAL BULB................................................................................................... 463 REMOVAL.................................................................................................................... 463 INSTALLATION............................................................................................................... 463 FRONT PARKING AND TURN SIGNAL LAMP BULB TOWN and COUNTRY .................................................................... 464 REMOVAL ................................................................................................................... 464 INSTALLATION............................................................................................................... 464 TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP BULB.................................................................................. 464 REMOVAL.................................................................................................................... 464 INSTALLATION............................................................................................................... 464 LICENSE PLATE LAMP BULB........................................................................................................ 465 REMOVAL.................................................................................................................... 465 INSTALLATION .............................................................................................................. 465 CENTER HIGH MOUNTED STOP LAMP (CHMSL) BULB..................................................................................... 465 REMOVAL.................................................................................................................... 465 INSTALLATION............................................................................................................... 465 EXTERIOR LAMP SERVICE.................................................................................................................. 466 GENERAL INFORMATION................................................................................................................ 466 HEADLAMP MODULE................................................................................................................ 466 HEADLAMP SWITCH................................................................................................................ 466 HEADLAMP DIMMER SWITCH......................................................................................................... 466 REMOVAL AND INSTALLATION........................................................................................................... 466 HEADLAMP MODULE................................................................................................................ 466 REMOVAL.................................................................................................................... 466 INSTALLATION............................................................................................................... 466 FOG LAMP....................................................................................................................... 466 REMOVAL.................................................................................................................... 466 INSTALLATION............................................................................................................... 467 FOG LAMP – TOWN and COUNTRY.................................................................................................... 467 REMOVAL.................................................................................................................... 467 INSTALLATION............................................................................................................... 467 FRONT SIDE MARKER LAMP TOWN and COUNTRY........................................................................................ 467 REMOVAL.................................................................................................................... 467 INSTALLATION............................................................................................................... 467 FRONT PARKING AND TURN SIGNAL LAMP – TOWN and COUNTRY.......................................................................... 467 REMOVAL.................................................................................................................... 467 INSTALLATION............................................................................................................... 468 TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP....................................................................................... 468 REMOVAL.................................................................................................................... 468 INSTALLATION............................................................................................................... 468 LICENSE PLATE LAMP............................................................................................................. 468 REMOVAL.................................................................................................................... 468 INSTALLATION............................................................................................................... 469 CENTER HIGH MOUNTED STOP LAMP (CHMSL).......................................................................................... 469 REMOVAL.................................................................................................................... 469 INSTALLATION............................................................................................................... 469 INTERIOR LAMPS......................................................................................................................... 470 REMOVAL AND INSTALLATION........................................................................................................... 470 HEADER READING/COURTESY LAMP BULB.............................................................................................. 470 REMOVAL ................................................................................................................... 470 INSTALLATION .............................................................................................................. 470 OVERHEAD CONSOLE READING/COURTESY LAMP......................................................................................... 470 REMOVAL.................................................................................................................... 470 INSTALLATION............................................................................................................... 470 HEADER READING/COURTESY LAMP BULB.............................................................................................. 471 REMOVAL.................................................................................................................... 471 INSTALLATION............................................................................................................... 471 GLOVE BOX LAMP AND SWITCH...................................................................................................... 471 REMOVAL.................................................................................................................... 471 INSTALLATION............................................................................................................... 471 GLOVE BOX LAMP BULB............................................................................................................ 471 REMOVAL.................................................................................................................... 471 INSTALLATION............................................................................................................... 471 IGNITION HALO LAMP BULB........................................................................................................ 471 REMOVAL.................................................................................................................... 471 INSTALLATION............................................................................................................... 472 CONVENIENCE BIN LAMP........................................................................................................... 472 REMOVAL.................................................................................................................... 472 INSTALLATION............................................................................................................... 472 INSTRUMENT PANEL LAMPS AND SWITCHES............................................................................................ 472 DOME LAMP...................................................................................................................... 473 REMOVAL.................................................................................................................... 473 INSTALLATION............................................................................................................... 473 DOME LAMP BULB................................................................................................................. 473 REMOVAL.................................................................................................................... 473 INSTALLATION............................................................................................................... 473 FRONT DOOR COURTESY LAMP....................................................................................................... 473 REMOVAL.................................................................................................................... 473 INSTALLATION............................................................................................................... 474 FRONT DOOR COURTESY LAMP BULB.................................................................................................. 474 REMOVAL.................................................................................................................... 474 INSTALLATION............................................................................................................... 475 RAIL LAMP MODULE BULB.......................................................................................................... 475 REMOVAL.................................................................................................................... 475 INSTALLATION............................................................................................................... 475 LIFTGATE COURTESY LAMP......................................................................................................... 475 REMOVAL.................................................................................................................... 475 INSTALLATION............................................................................................................... 475 LIFTGATE COURTESY LAMP BULB.................................................................................................... 476 REMOVAL.................................................................................................................... 476 INSTALLATION............................................................................................................... 476 BULB APPLICATION....................................................................................................................... 477 GENERAL INFORMATION................................................................................................................ 477 INTRODUCTION................................................................................................................... 477 SPECIFICATIONS..................................................................................................................... 477 EXTERIOR LAMP BULBS............................................................................................................ 477 INTERIOR LAMP BULBS............................................................................................................ 477 LAMPS 1 ................................................................................................................................... 479 LAMP DIAGNOSIS......................................................................................................................... 479 GENERAL INFORMATION................................................................................................................ 479 INTRODUCTION................................................................................................................... 479 HEADLAMP LEVELING MOTOR........................................................................................................ 480 DIAGNOSIS AND TESTING.............................................................................................................. 480 DIAGNOSTIC PROCEDURES.......................................................................................................... 480 HEADLAMP DIAGNOSIS......................................................................................................... 480 FOG LAMP DIAGNOSIS......................................................................................................... 481 HEADLAMP LEVELING MOTOR DIAGNOSIS.......................................................................................... 482 SERVICE PROCEDURES................................................................................................................. 483 HEADLAMP ALIGNMENT PREPARATION................................................................................................. 483 ADJUSTMENTS........................................................................................................................ 483 HEADLAMP/ FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN........................................................................... 483 ALIGNMENT SCREEN PREPARATION............................................................................................... 483 HEADLAMP ADJUSTMENT........................................................................................................ 484 FOG LAMP ALIGNMENT......................................................................................................... 485 REMOVAL AND INSTALLATION........................................................................................................... 486 HEADLAMP BULB.................................................................................................................. 486 REMOVAL.................................................................................................................... 486 INSTALLATION............................................................................................................... 486 FRONT TURN SIGNAL LAMP BULB.................................................................................................... 486 REMOVAL.................................................................................................................... 486 INSTALLATION............................................................................................................... 487 CITYLIGHT LAMP BULB............................................................................................................ 487 REMOVAL.................................................................................................................... 487 INSTALLATION............................................................................................................... 487 FOG LAMP BULB.................................................................................................................. 487 REMOVAL.................................................................................................................... 487 INSTALLATION............................................................................................................... 488 SIDE REPEATER LAMP BULB........................................................................................................ 488 REMOVAL.................................................................................................................... 488 INSTALLATION............................................................................................................... 488 TAIL LAMP BULB................................................................................................................. 488 REMOVAL.................................................................................................................... 489 INSTALLATION............................................................................................................... 489 LICENSE PLATE LAMP BULB........................................................................................................ 490 REMOVAL.................................................................................................................... 490 INSTALLATION............................................................................................................... 490 CENTER HIGH MOUNTED STOP LAMP (CHMSL) BULB..................................................................................... 490 REMOVAL.................................................................................................................... 490 INSTALLATION............................................................................................................... 490 LAMP SERVICE........................................................................................................................... 491 GENERAL INFORMATION................................................................................................................ 491 HEADLAMP SWITCH................................................................................................................ 491 HEADLAMP DIMMER SWITCH......................................................................................................... 491 REMOVAL AND INSTALLATION........................................................................................................... 491 HEADLAMP MODULE................................................................................................................ 491 REMOVAL.................................................................................................................... 491 INSTALLATION............................................................................................................... 491 HEADLAMP LEVELING MOTOR........................................................................................................ 492 REMOVAL.................................................................................................................... 492 INSTALLATION............................................................................................................... 492 FOG LAMP....................................................................................................................... 492 REMOVAL.................................................................................................................... 492 INSTALLATION............................................................................................................... 492 SIDE REPEATER LAMP............................................................................................................. 492 REMOVAL.................................................................................................................... 492 INSTALLATION............................................................................................................... 492 TAIL LAMP...................................................................................................................... 493 REMOVAL.................................................................................................................... 493 INSTALLATION............................................................................................................... 493 LICENSE PLATE LAMP............................................................................................................. 493 REMOVAL.................................................................................................................... 493 INSTALLATION............................................................................................................... 494 CENTER HIGH MOUNTED STOP LAMP (CHMSL).......................................................................................... 494 REMOVAL.................................................................................................................... 494 INSTALLATION............................................................................................................... 494 BULB APPLICATION....................................................................................................................... 495 GENERAL INFORMATION................................................................................................................ 495 INTRODUCTION................................................................................................................... 495 CLEANING AND INSPECTION............................................................................................................ 495 HEADLAMP CLEANING.............................................................................................................. 495 SPECIFICATIONS..................................................................................................................... 495 EXTERIOR LAMP BULBS............................................................................................................ 495 INTERIOR LAMP BULBS............................................................................................................ 495 RESTRAINT SYSTEM........................................................................................................................... 497 GENERAL INFORMATION.................................................................................................................... 497 WARNINGS AND PRECAUTIONS........................................................................................................... 497 DESCRIPTION AND OPERATION.............................................................................................................. 497 AIRBAG CONTROL MODULE (ACM)........................................................................................................ 497 CLOCKSPRING........................................................................................................................ 498 DRIVER AND PASSENGER AIRBAG MODULES................................................................................................ 498 DIAGNOSIS AND TESTING.................................................................................................................. 498 AIRBAG SYSTEM TEST................................................................................................................. 498 SERVICE PROCEDURES..................................................................................................................... 499 CLEANUP PROCEDURE ................................................................................................................. 499 SERVICE OF DEPLOYED AIRBAG MODULE.............................................................................................. 499 HANDLING AIRBAG MODULE............................................................................................................. 499 DEPLOYED MODULE................................................................................................................ 499 UNDEPLOYED..................................................................................................................... 499 REMOVAL AND INSTALLATION............................................................................................................... 499 AIRBAG CONTROL MODULE.............................................................................................................. 499 REMOVAL........................................................................................................................ 499 INSTALLATION................................................................................................................... 500 CLOCKSPRING........................................................................................................................ 501 REMOVAL........................................................................................................................ 501 INSTALLATION................................................................................................................... 501 DRIVER AIRBAG MODULE............................................................................................................... 501 DEPLOYED MODULE................................................................................................................ 502 UNDEPLOYED..................................................................................................................... 502 PASSENGER AIRBAG................................................................................................................... 502 DEPLOYED MODULE................................................................................................................ 502 UNDEPLOYED..................................................................................................................... 503 ADJUSTMENTS............................................................................................................................ 503 CLOCKSPRING CENTERING PROCEDURE.................................................................................................... 503 ELECTRICALLY HEATED SYSTEMS................................................................................................................ 505 DESCRIPTION AND OPERATION.............................................................................................................. 505 INTRODUCTION....................................................................................................................... 505 HVAC MOUNTED SWITCH................................................................................................................ 505 DIAGNOSIS AND TESTING.................................................................................................................. 506 SYSTEM TEST........................................................................................................................ 506 GRID LINE TEST..................................................................................................................... 506 SERVICE PROCEDURES..................................................................................................................... 507 GRID LINE AND TERMINAL REPAIR...................................................................................................... 507 POWER DOOR LOCKS........................................................................................................................... 509 POWER DOOR LOCKS....................................................................................................................... 509 GENERAL INFORMATION................................................................................................................ 509 INTRODUCTION................................................................................................................... 509 DESCRIPTION AND OPERATION.......................................................................................................... 509 AUTOMATIC DOOR LOCK FEATURE.................................................................................................... 509 DOOR LOCK CIRCUIT PROTECTION................................................................................................... 509 DOOR LOCK INHIBIT FEATURE...................................................................................................... 510 SLIDING DOOR LOCK MEMORY FEATURE............................................................................................... 510 DIAGNOSIS AND TESTING.............................................................................................................. 510 AUTOMATIC DOOR LOCK SYSTEM TEST................................................................................................ 510 DOOR LOCK MOTOR................................................................................................................ 510 DOOR LOCK SWITCH TEST.......................................................................................................... 510 DOOR LOCK SWITCH TEST...................................................................................................... 511 SERVICE PROCEDURES................................................................................................................. 511 AUTOMATIC DOOR LOCKS DISABLE OR ENABLE......................................................................................... 511 REMOVAL AND INSTALLATION........................................................................................................... 511 FRONT DOOR LOCK MOTOR/LATCH.................................................................................................... 511 LIFTGATE LOCK MOTOR............................................................................................................ 511 REMOVAL.................................................................................................................... 511 INSTALLATION............................................................................................................... 511 SLIDING DOOR LOCK CONTACTS..................................................................................................... 511 REMOVAL.................................................................................................................... 511 INSTALLATION............................................................................................................... 511 SLIDING DOOR LOCK MOTOR........................................................................................................ 512 REMOVAL.................................................................................................................... 512 INSTALLATION............................................................................................................... 512 SLIDING DOOR LOCK PLUNGER...................................................................................................... 512 REMOVAL.................................................................................................................... 512 INSTALLATION............................................................................................................... 512 REMOTE KEYLESS ENTRY................................................................................................................... 513 DESCRIPTION AND OPERATION.......................................................................................................... 513 INTRODUCTION................................................................................................................... 513 VEHICLE ACCESS CODE (VAC) PROGRAMMING.......................................................................................... 513 DIAGNOSIS AND TESTING.............................................................................................................. 513 RKE DIAGNOSTICS................................................................................................................ 513 SERVICE PROCEDURES ................................................................................................................ 514 HORN CHIRP DISABLE OR ENABLE .................................................................................................. 514 ADJUSTMENTS........................................................................................................................ 514 PROGRAMMING RKE MODULE......................................................................................................... 514 REMOVAL AND INSTALLATION........................................................................................................... 514 RKE MODULE..................................................................................................................... 514 REMOVAL.................................................................................................................... 514 INSTALLATION............................................................................................................... 514 SPECIFICATIONS..................................................................................................................... 514 RKE TRANSMITTER BATTERY........................................................................................................ 514 RKE TRANSMITTER RANGE.......................................................................................................... 514 VEHICLE THEFT SECURITY SYSTEM.............................................................................................................. 515 GENERAL INFORMATION.................................................................................................................... 515 INTRODUCTION....................................................................................................................... 515 ENABLING....................................................................................................................... 515 DESCRIPTION AND OPERATION.............................................................................................................. 515 ARMING PROCEDURE................................................................................................................... 515 METHOD-A....................................................................................................................... 515 METHOD-B....................................................................................................................... 515 TIME-OUT PERIOD.................................................................................................................... 516 TRIGGERING THE VTSS................................................................................................................ 516 DIAGNOSIS AND TESTING.................................................................................................................. 516 DIAGNOSTIC PROCEDURES.............................................................................................................. 516 REMOVAL AND INSTALLATION............................................................................................................... 516 BODY CONTROL MODULE................................................................................................................ 516 REMOVAL ....................................................................................................................... 516 INSTALLATION................................................................................................................... 516 DOOR LOCK CYLINDER SWITCH.......................................................................................................... 516 REMOVAL........................................................................................................................ 516 INSTALLATION................................................................................................................... 516 FRONT DOOR AJAR (VTSS TRIGGER) SWITCH ............................................................................................. 516 REMOVAL ....................................................................................................................... 516 INSTALLATION................................................................................................................... 517 HOOD AJAR (VTSS TRIGGER) SWITCH.................................................................................................... 517 REMOVAL........................................................................................................................ 517 INSTALLATION................................................................................................................... 517 LIFTGATE AJAR (VTSS TRIGGER) SWITCH................................................................................................ 517 REMOVAL........................................................................................................................ 517 INSTALLATION................................................................................................................... 517 LIFTGATE LOCK CYLINDER SWITCH...................................................................................................... 517 REMOVAL ....................................................................................................................... 517 INSTALLATION................................................................................................................... 517 SLIDING DOOR AJAR (VTSS TRIGGER) SWITCH............................................................................................ 518 REMOVAL........................................................................................................................ 518 INSTALLATION................................................................................................................... 518 VEHICLE THEFT/ SECURITY SYSTEMS............................................................................................................ 519 GENERAL INFORMATION.................................................................................................................... 519 INTRODUCTION....................................................................................................................... 519 SMART KEY IMMOBILIZER SYSTEM....................................................................................................... 519 DESCRIPTION AND OPERATION.............................................................................................................. 519 SMART KEY IMMOBILIZER MODULE....................................................................................................... 519 SMART KEY IMMOBILIZER TRANSPONDER.................................................................................................. 520 SMART KEY IMMOBILIZER SYSTEM INDICATOR LAMP........................................................................................ 521 DIAGNOSIS AND TESTING.................................................................................................................. 521 SMART KEY IMMOBILIZER SYSTEM....................................................................................................... 521 SERVICE PROCEDURES..................................................................................................................... 522 SMART KEY IMMOBILIZER SYSTEM TRANSPONDER PROGRAMMING............................................................................... 522 PROGRAMMING THE SKIM MODULE WITH THE DRBIII.................................................................................... 522 PROGRAMMING IGNITION KEYS WITH THE DRBIII...................................................................................... 522 REMOVAL AND INSTALLATION............................................................................................................... 522 SMART KEY IMMOBILIZER MODULE....................................................................................................... 522 POWER WINDOWS.............................................................................................................................. 525 GENERAL INFORMATION.................................................................................................................... 525 INTRODUCTION....................................................................................................................... 525 DIAGNOSIS AND TESTING.................................................................................................................. 525 POWER VENT WINDOW MOTOR TEST....................................................................................................... 525 POWER WINDOW AND VENT SWITCH TEST.................................................................................................. 526 DRIVER DOOR POWER WINDOW SWITCH TEST........................................................................................... 526 POWER WINDOW MOTOR TEST............................................................................................................ 526 WIRING VOLTAGE TEST................................................................................................................ 527 REMOVAL AND INSTALLATION............................................................................................................... 527 POWER VENT WINDOW MOTOR............................................................................................................ 527 REMOVAL........................................................................................................................ 527 INSTALLATION................................................................................................................... 527 POWER WINDOW SWITCH................................................................................................................ 527 POWER WINDOW MOTOR................................................................................................................. 527 REMOVAL........................................................................................................................ 527 INSTALLATION................................................................................................................... 527 POWER SEATS................................................................................................................................ 529 POWER SEATS............................................................................................................................ 529 GENERAL INFORMATION................................................................................................................ 529 INTRODUCTION................................................................................................................... 529 DIAGNOSIS AND TESTING.............................................................................................................. 529 DIAGNOSTIC PROCEDURES.......................................................................................................... 529 SEAT MOTORS.................................................................................................................... 529 POWER SEAT SWITCH.............................................................................................................. 529 MEMORY SEAT AND MIRROR SYSTEM.......................................................................................................... 531 GENERAL INFORMATION................................................................................................................ 531 INTRODUCTION................................................................................................................... 531 DESCRIPTION AND OPERATION.......................................................................................................... 531 POWER SIDE VIEW MIRROR POSITION SENSING........................................................................................ 531 MEMORY SELECTOR SWITCHES....................................................................................................... 531 DEFINITION OF: MOMENTARILY AND RELEASE..................................................................................... 532 SEAT AND RECLINER SWITCHES..................................................................................................... 532 POSITION SENSING SEAT AND RECLINER POTENTIOMETERS.............................................................................. 532 DIAGNOSIS AND TESTING.............................................................................................................. 532 MEMORY SELECTOR SWITCHES....................................................................................................... 532 SIDE VIEW MIRROR SWITCH STUCK.................................................................................................. 532 DIAGNOSTIC MODE................................................................................................................ 533 MODE 1..................................................................................................................... 533 MIRROR MECHANIZATION TABLE................................................................................................. 533 MODE 2..................................................................................................................... 534 CIRCUIT DESCRIPTION............................................................................................................ 535 SEAT AND RECLINER POSITION SENSING............................................................................................. 537 SERVICE PROCEDURES................................................................................................................. 537 REMOTE KEYLESS ENTRY (RKE) DATA LINK........................................................................................... 537 SEAT ACTUATIONS TABLE...................................................................................................... 538 REMOVAL AND INSTALLATION........................................................................................................... 538 MEMORY SWITCHES................................................................................................................ 538 REMOVAL.................................................................................................................... 538 INSTALLATION............................................................................................................... 538 SEAT TRACK ASSEMBLY............................................................................................................ 538 POWER MIRRORS.............................................................................................................................. 539 GENERAL INFORMATION.................................................................................................................... 539 INTRODUCTION....................................................................................................................... 539 HEATED MIRROR ..................................................................................................................... 539 MEMORY MIRRORS..................................................................................................................... 539 DIAGNOSIS AND TESTING.................................................................................................................. 539 MIRROR MOTOR TEST.................................................................................................................. 539 MIRROR SWITCH TEST................................................................................................................. 539 HEATED MIRROR TEST................................................................................................................. 539 TEST PROCEDURE................................................................................................................. 539 REMOVAL AND INSTALLATION............................................................................................................... 541 POWER MIRROR....................................................................................................................... 541 REMOVAL........................................................................................................................ 541 INSTALLATION................................................................................................................... 541 POWER MIRROR SWITCH................................................................................................................ 541 CHIME WARNING/REMINDER SYSTEM.............................................................................................................. 543 GENERAL INFORMATION.................................................................................................................... 543 INTRODUCTION....................................................................................................................... 543 DIAGNOSIS AND TESTING.................................................................................................................. 543 CHIME SYSTEM DIAGNOSIS............................................................................................................. 543 NO TONE WHEN IGNITION SWITCH IS TURNED ON AND DRIVER’S SEAT BELT IS NOT BUCKLED................................................ 543 NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS TURNED ON..................................................................... 543 FASTEN SEAT BELT LAMP OR TONE CONTINUES FOR MORE THAN 10 SECONDS AFTER SEAT BELTS ARE FASTENED AND DRIVER’S DOOR IS CLOSED..... 543 NO TONE WHEN PARK OR HEADLAMPS ARE ON AND DRIVER’S DOOR IS OPEN................................................................ 543 DOME LAMP ON CHIME................................................................................................................. 544 ENGINE TEMPERATURE CRITICAL CHIME ................................................................................................. 544 EXTERIOR LAMPS ON CHIME............................................................................................................ 544 KEY-IN IGNITION CHIME.............................................................................................................. 544 LOW OIL PRESSURE CHIME OPERATION................................................................................................... 544 SEAT BELT CHIME.................................................................................................................... 544 SEAT BELT LAMP..................................................................................................................... 544 TURN SIGNAL ON CHIME............................................................................................................... 545 WARNING LAMP ANNOUNCEMENT CHIME.................................................................................................... 545 CHIME WARNING/ REMINDER SYSTEM 1 .......................................................................................................... 547 GENERAL INFORMATION.................................................................................................................... 547 INTRODUCTION....................................................................................................................... 547 DIAGNOSIS AND TESTING.................................................................................................................. 547 CATALYST OVERHEAT WARNING CHIME.................................................................................................... 547 CHIME SYSTEM DIAGNOSIS............................................................................................................. 547 NO TONE WHEN IGNITION SWITCH IS TURNED ON AND DRIVER’S SEAT BELT IS NOT BUCKLED................................................ 547 NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS TURNED ON..................................................................... 547 FASTEN SEAT BELT LAMP OR TONE CONTINUES FOR MORE THAN 10 SECONDS AFTER SEAT BELTS ARE FASTENED AND DRIVER’S DOOR IS CLOSED..... 548 NO TONE WHEN PARK OR HEADLAMPS ARE ON AND DRIVER’S DOOR IS OPEN................................................................ 548 DOME LAMP ON CHIME................................................................................................................. 548 ENGINE TEMPERATURE CRITICAL CHIME.................................................................................................. 548 EXTERIOR LAMPS ON CHIME............................................................................................................ 548 KEY- IN IGNITION CHIME............................................................................................................. 548 LOW OIL PRESSURE CHIME OPERATION................................................................................................... 548 SEAT BELT CHIME.................................................................................................................... 549 SEAT BELT LAMP..................................................................................................................... 549 TURN SIGNAL ON CHIME............................................................................................................... 549 WARNING LAMP ANNOUNCEMENT CHIME.................................................................................................... 549 OVERHEAD CONSOLE........................................................................................................................... 551 DESCRIPTION AND OPERATION.............................................................................................................. 551 COMPASS/TEMPERATURE MINI TRIP COMPUTER SELF-DIAGNOSTIC TEST........................................................................ 551 COMPASS MINI-TRIP COMPUTER (CMTC).................................................................................................. 551 THERMOMETER AND COMPASS............................................................................................................ 552 THERMOMETER.................................................................................................................... 552 COMPASS........................................................................................................................ 552 UNIVERSAL TRANSMITTER ............................................................................................................. 552 DIAGNOSIS AND TESTING.................................................................................................................. 553 READING/DOME LAMP DIAGNOSIS........................................................................................................ 553 TRAVELER MESSAGES.................................................................................................................. 553 UNIVERSAL TRANSMITTER.............................................................................................................. 553 SERVICE PROCEDURES..................................................................................................................... 554 COMPASS CALIBRATION PROCEDURE...................................................................................................... 554 COMPASS CALIBRATION PROCEDURE (FAST METHOD)........................................................................................ 554 DEMAGNETIZING PROCEDURE............................................................................................................ 554 UNIVERSAL TRANSMITTER.............................................................................................................. 555 TRAINING....................................................................................................................... 555 ERASING........................................................................................................................ 555 REMOVAL AND INSTALLATION............................................................................................................... 555 AMBIENT TEMPERATURE SENSOR......................................................................................................... 555 REMOVAL........................................................................................................................ 555 INSTALLATION................................................................................................................... 555 COMPASS MINI-TRIP COMPUTER (CMTC) MODULE........................................................................................... 556 REMOVAL........................................................................................................................ 556 INSTALLATION................................................................................................................... 556 COMPASS MINI-TRIP COMPUTER (CMTC) LAMP BULBS....................................................................................... 556 REMOVAL........................................................................................................................ 556 INSTALLATION .................................................................................................................. 556 FRONT HEADER READING/COURTESY LAMP................................................................................................. 556 REMOVAL........................................................................................................................ 556 INSTALLATION................................................................................................................... 556 OVERHEAD CONSOLE................................................................................................................... 556 REMOVAL........................................................................................................................ 556 INSTALLATION................................................................................................................... 556 READING/COURTESY LAMP.............................................................................................................. 556 Removal........................................................................................................................ 556 Installation................................................................................................................... 557 READING/COURTESY LAMP ASSEMBLY..................................................................................................... 557 Removal........................................................................................................................ 557 Installation................................................................................................................... 557 UNIVERSAL TRANSMITTER.............................................................................................................. 557 REMOVAL........................................................................................................................ 557 INSTALLATION................................................................................................................... 558 SPECIAL TOOLS.......................................................................................................................... 559 SPECIAL TOOL....................................................................................................................... 559 WIRING DIAGRAMS............................................................................................................................ 561 8W- 01 GENERAL INFORMATION............................................................................................................. 563 DESCRIPTION AND OPERATION.......................................................................................................... 563 INTRODUCTION................................................................................................................... 563 CIRCUIT INFORMATION............................................................................................................ 566 CIRCUIT FUNCTIONS.............................................................................................................. 566 SECTION IDENTIFICATION......................................................................................................... 567 SYMBOLS........................................................................................................................ 567 TERMINOLOGY.................................................................................................................... 569 CONNECTOR INFORMATION.......................................................................................................... 569 IDENTIFICATION............................................................................................................. 569 LOCATIONS.................................................................................................................. 569 SPLICE LOCATIONS............................................................................................................... 569 NOTES, CAUTIONS, and WARNINGS.................................................................................................. 569 TAKE OUTS...................................................................................................................... 570 ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES................................................................................ 570 POSITIVE TEMPERATURE COEFFICIENT............................................................................................... 570 DIAGNOSIS AND TESTING.............................................................................................................. 570 TROUBLESHOOTING TOOLS.......................................................................................................... 570 INTERMITTENT AND POOR CONNECTIONS.............................................................................................. 571 TROUBLESHOOTING TESTS.......................................................................................................... 571 TESTING FOR VOLTAGE POTENTIAL.............................................................................................. 571 TESTING FOR CONTINUITY..................................................................................................... 571 TESTING FOR A SHORT TO GROUND.............................................................................................. 571 TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS.............................................................. 572 TESTING FOR A VOLTAGE DROP................................................................................................. 572 TROUBLESHOOTING WIRING PROBLEMS................................................................................................ 572 SERVICE PROCEDURES................................................................................................................. 572 WIRING REPAIR.................................................................................................................. 572 TERMINAL/ CONNECTOR REPAIR- MOLEX CONNECTORS................................................................................... 573 CONNECTOR REPLACEMENT.......................................................................................................... 573 CONNECTOR AND TERMINAL REPLACEMENT............................................................................................. 574 TERMINAL/ CONNECTOR REPAIR- AUGAT CONNECTORS................................................................................... 574 TERMINAL REPLACEMENT........................................................................................................... 575 DIODE REPLACEMENT.............................................................................................................. 576 SPECIAL TOOLS...................................................................................................................... 576 WIRING/ TERMINAL............................................................................................................... 576 8W- 02 COMPONENT INDEX................................................................................................................. 577 8W- 10 POWER DISTRIBUTION.............................................................................................................. 581 8W- 12 JUNCTION BLOCK.................................................................................................................. 617 8W- 15 GROUND DISTRIBUTION............................................................................................................. 643 8W- 20 CHARGING SYSTEM................................................................................................................. 657 8W- 21 STARTING SYSTEM................................................................................................................. 661 8W- 30 FUEL/ IGNITION SYSTEM........................................................................................................... 665 8W- 31 TRANSMISSION CONTROL SYSTEM..................................................................................................... 705 8W- 33 VEHICLE SPEED CONTROL........................................................................................................... 713 8W- 35 ANTI- LOCK BRAKES............................................................................................................... 719 8W- 39 VEHICLE THEFT SECURITY SYSTEM................................................................................................... 723 8W- 40 INSTRUMENT CLUSTER.............................................................................................................. 729 8W- 41 HORN/ CIGAR LIGHTER/ POWER OUTLET............................................................................................... 741 8W- 42 AIR CONDITIONING- HEATER........................................................................................................ 745 8W- 43 AIRBAG SYSTEM................................................................................................................... 755 8W- 44 INTERIOR LIGHTING............................................................................................................... 759 8W- 45 BODY CONTROL MODULE............................................................................................................. 769 8W- 46 MESSAGE CENTER.................................................................................................................. 779 8W- 47 AUDIO SYSTEM.................................................................................................................... 785 8W- 48 WINDOW DEFOGGERS................................................................................................................ 793 8W- 49 OVERHEAD CONSOLE................................................................................................................ 797 8W- 50 FRONT LIGHTING.................................................................................................................. 801 8W- 51 REAR LIGHTING................................................................................................................... 815 8W- 52 TURN SIGNALS.................................................................................................................... 823 8W- 53 WIPERS.......................................................................................................................... 827 8W- 54 TRAILER TOW..................................................................................................................... 833 8W- 60 POWER WINDOWS................................................................................................................... 837 8W- 61 POWER DOOR LOCKS................................................................................................................ 841 8W- 62 POWER MIRRORS................................................................................................................... 849 8W- 63 POWER SEAT...................................................................................................................... 857 8W- 70 SPLICE INFORMATION.............................................................................................................. 865 8W- 80 CONNECTOR PIN- OUTS............................................................................................................. 877 8W- 90 CONNECTOR/ GROUND LOCATIONS..................................................................................................... 965 DESCRIPTION AND OPERATION.......................................................................................................... 965 INTRODUCTION................................................................................................................... 965 CONNECTOR/ GROUND LOCATIONS.................................................................................................... 965 CONNECTOR/ GROUND LOCATIONS.................................................................................................... 995 8W- 95 SPLICE LOCATIONS................................................................................................................1025 DESCRIPTION AND OPERATION..........................................................................................................1025 INTRODUCTION...................................................................................................................1025 SPLICE LOCATION INDEX..........................................................................................................1025 SPLICE LOCATIONS (RHD).........................................................................................................1039 ENGINE.....................................................................................................................................1051 STANDARD SERVICE PROCEDURES............................................................................................................1051 GENERAL INFORMATION................................................................................................................1051 FORM- IN- PLACE GASKETS........................................................................................................1051 MOPART SILICONE RUBBER ADHESIVE SEALANT....................................................................................1051 MOPART GASKET MAKER........................................................................................................1051 MOPART TORQUE CURE GASKET MAKER............................................................................................1051 GASKET DISASSEMBLY.........................................................................................................1052 SURFACE PREPARATION........................................................................................................1052 FORM- IN- PLACE GASKET APPLICATION.........................................................................................1052 CRANKSHAFT SPROCKET BOLT ACCESS PLUG...........................................................................................1052 ENGINE CORE PLUGS..............................................................................................................1052 REMOVAL....................................................................................................................1052 INSTALLATION...............................................................................................................1052 ENGINE PERFORMANCE.............................................................................................................1052 HONING CYLINDER BORES..........................................................................................................1053 MEASURING MAIN BEARING AND CONNECTING ROD BEARING CLEARANCES...................................................................1053 PREFERRED METHOD...........................................................................................................1053 ALTERNATIVE METHOD.........................................................................................................1054 PLASTIGAGE PROCEDURE.......................................................................................................1054 CONNECTING ROD BEARING CLEARANCE...........................................................................................1054 REPAIR OF DAMAGED OR WORN THREADS..............................................................................................1054 HYDROSTATIC LOCKED ENGINE......................................................................................................1055 ENGINE OIL.....................................................................................................................1055 ENGINE OIL SERVICE.............................................................................................................1055 ENGINE OIL SPECIFICATION...................................................................................................1055 API SERVICE GRADE CERTIFIED................................................................................................1056 SAE VISCOSITY..............................................................................................................1056 ENERGY CONSERVING OIL......................................................................................................1056 CONTAINER IDENTIFICATION...................................................................................................1056 ENGINE OIL CHANGE..........................................................................................................1056 ENGINE DIAGNOSIS.......................................................................................................................1057 DIAGNOSIS AND TESTING..............................................................................................................1057 GENERAL INFORMATION............................................................................................................1057 INTAKE MANIFOLD LEAKAGE DIAGNOSIS..............................................................................................1057 CYLINDER COMPRESSION PRESSURE TEST.............................................................................................1057 CYLINDER COMBUSTION PRESSURE LEAKAGE TEST......................................................................................1058 LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS.........................................................................................1058 INSPECTION (ENGINE OIL LEAKS IN GENERAL).......................................................................................1058 INSPECTION FOR REAR SEAL AREA LEAKS........................................................................................1059 ENGINE DIAGNOSIS— PERFORMANCE..................................................................................................1060 ENGINE DIAGNOSIS— MECHANICAL...................................................................................................1062 DESCRIPTION AND OPERATION..........................................................................................................1064 ENGINE IDENTIFICATION..........................................................................................................1064 ENGINE LUBRICATION SYSTEM......................................................................................................1064 OIL PAN....................................................................................................................1064 PRESSURE LUBRICATION.......................................................................................................1064 MAIN/ ROD BEARINGS.........................................................................................................1064 CAMSHAFT/ HYDRAULIC LASH ADJUSTERS.........................................................................................1064 BALANCE SHAFTS.............................................................................................................1065 SPLASH LUBRICATION.........................................................................................................1065 ENGINE COMPONENTS..............................................................................................................1065 DIAGNOSIS AND TESTING..............................................................................................................1066 CHECKING ENGINE OIL PRESSURE...................................................................................................1066 SERVICE PROCEDURES.................................................................................................................1066 FITTING PISTONS................................................................................................................1066 FITTING PISTON RINGS...........................................................................................................1066 PISTON RINGS— INSTALLATION.................................................................................................1067 CYLINDER BORE AND PISTON SPECIFICATION CHART...............................................................................1067 PISTON RING SPECIFICATION CHART............................................................................................1067 FITTING CONNECTING ROD BEARINGS................................................................................................1068 FITTING MAIN BEARINGS..........................................................................................................1069 CRANKSHAFT MAIN BEARINGS...................................................................................................1069 MAIN BEARING INSTALLATION..................................................................................................1069 CRANKSHAFT SPECIFICATION CHART.............................................................................................1069 CRANKSHAFT END PLAY............................................................................................................1070 CRANKSHAFT SPECIFICATION CHART.............................................................................................1070 OPTIONAL CRANKSHAFT END PLAY CHECK.........................................................................................1071 VALVE SERVICE RECONDITION......................................................................................................1071 VALVE REMOVAL..............................................................................................................1071 VALVE INSPECTION...........................................................................................................1071 VALVE GUIDES...............................................................................................................1071 TESTING VALVE SPRINGS......................................................................................................1071 REFACING VALVES AND VALVE SEATS............................................................................................1071 VALVE GUIDE SPECIFICATION CHART............................................................................................1071 VALVE SPECIFICATION CHART..................................................................................................1072 VALVE INSTALLATION.........................................................................................................1073 2.4L ENGINE............................................................................................................................1064 REMOVAL AND INSTALLATION...........................................................................................................1073 ENGINE MOUNT— FRONT............................................................................................................1073 REMOVAL....................................................................................................................1073 INSTALLATION...............................................................................................................1073 ENGINE MOUNT— LEFT.............................................................................................................1074 REMOVAL....................................................................................................................1074 INSTALLATION...............................................................................................................1074 ENGINE MOUNT— RIGHT............................................................................................................1074 REMOVAL....................................................................................................................1074 INSTALLATION...............................................................................................................1074 ENGINE MOUNT— REAR.............................................................................................................1075 REMOVAL....................................................................................................................1075 INSTALLATION...............................................................................................................1075 STRUCTURAL COLLAR..............................................................................................................1075 REMOVAL....................................................................................................................1075 INSTALLATION...............................................................................................................1075 ENGINE ASSEMBLY................................................................................................................1076 REMOVAL....................................................................................................................1076 INSTALLATION...............................................................................................................1076 CYLINDER HEAD COVER............................................................................................................1078 REMOVAL....................................................................................................................1078 INSTALLATION...............................................................................................................1078 CAMSHAFT.......................................................................................................................1078 REMOVAL....................................................................................................................1078 CAMSHAFT END PLAY..........................................................................................................1079 INSTALLATION...............................................................................................................1079 CAMSHAFT FOLLOWER..............................................................................................................1080 REMOVAL....................................................................................................................1080 INSTALLATION...............................................................................................................1080 BALANCE SHAFTS CARRIER ASSEMBLY................................................................................................1080 BALANCE SHAFTS.............................................................................................................1080 BALANCE SHAFT CARRIER......................................................................................................1081 BALANCE SHAFT INSTALLATION.................................................................................................1081 HYDRAULIC LASH ADJUSTER........................................................................................................1083 REMOVAL....................................................................................................................1083 INSTALLATION...............................................................................................................1083 VALVE SPRINGS AND VALVE SEALS IN VEHICLE.......................................................................................1083 REMOVAL....................................................................................................................1083 INSTALLATION...............................................................................................................1083 CYLINDER HEAD..................................................................................................................1084 REMOVAL....................................................................................................................1084 INSTALLATION...............................................................................................................1084 VALVES AND VALVE SPRINGS.......................................................................................................1085 REMOVAL....................................................................................................................1085 INSTALLATION...............................................................................................................1085 VIBRATION DAMPER...............................................................................................................1086 REMOVAL....................................................................................................................1086 INSTALLATION...............................................................................................................1086 TIMING BELT COVER..............................................................................................................1087 FRONT COVER................................................................................................................1087 REAR COVER.................................................................................................................1087 TIMING BELT....................................................................................................................1087 REMOVAL....................................................................................................................1087 INSTALLATION...............................................................................................................1089 TIMING BELT TENSIONER ASSEMBLY.................................................................................................1090 REMOVAL....................................................................................................................1090 INSTALLATION...............................................................................................................1090 CAMSHAFT OIL SEAL— FRONT.......................................................................................................1091 REMOVAL....................................................................................................................1091 INSTALLATION...............................................................................................................1091 CRANKSHAFT OIL SEAL— FRONT.....................................................................................................1092 REMOVAL....................................................................................................................1092 INSTALLATION...............................................................................................................1092 CRANKSHAFT OIL SEAL— REAR......................................................................................................1093 REMOVAL....................................................................................................................1093 INSTALLATION...............................................................................................................1094 OIL PAN........................................................................................................................1095 REMOVAL....................................................................................................................1095 INSTALLATION...............................................................................................................1095 CRANKSHAFT.....................................................................................................................1096 REMOVAL....................................................................................................................1096 INSTALLATION...............................................................................................................1096 OIL FILTER.....................................................................................................................1097 OIL PUMP.......................................................................................................................1097 REMOVAL....................................................................................................................1097 INSTALLATION...............................................................................................................1098 PISTON AND CONNECTING ROD......................................................................................................1099 REMOVAL....................................................................................................................1099 INSTALLATION...............................................................................................................1099 DISASSEMBLY AND ASSEMBLY...........................................................................................................1100 OIL PUMP.......................................................................................................................1100 DISASSEMBLY................................................................................................................1100 ASSEMBLY...................................................................................................................1101 CLEANING AND INSPECTION............................................................................................................1101 CYLINDER HEAD..................................................................................................................1101 CLEANING...................................................................................................................1101 INSPECTION.................................................................................................................1101 VALVE GUIDES...............................................................................................................1101 VALVE AND VALVE SPRING.........................................................................................................1101 VALVES.....................................................................................................................1101 VALVE GUIDE SPECIFICATION CHART............................................................................................1101 VALVE SPRINGS..............................................................................................................1102 CRANKSHAFT.....................................................................................................................1102 OIL PUMP.......................................................................................................................1102 CYLINDER BLOCK.................................................................................................................1104 CYLINDER BORE INSPECTION...................................................................................................1104 ADJUSTMENTS........................................................................................................................1104 ENGINE MOUNTS..................................................................................................................1104 ENGINE MOUNT INSULATOR ADJUSTMENT..........................................................................................1104 CYLINDER BORE AND PISTON SPECIFICATION CHART...............................................................................1104 SPECIFICATIONS.....................................................................................................................1105 2.4L ENGINE....................................................................................................................1105 TORQUE CHART 2.4L..............................................................................................................1107 SPECIAL TOOLS......................................................................................................................1108 2.4L ENGINE....................................................................................................................1108 3.0L ENGINE............................................................................................................................1111 DESCRIPTION AND OPERATION..........................................................................................................1111 ENGINE IDENTIFICATION NUMBER...................................................................................................1111 ENGINE LUBRICATION.............................................................................................................1111 ENGINE COMPONENTS..............................................................................................................1111 DIAGNOSIS AND TESTING..............................................................................................................1112 CHECKING ENGINE OIL PRESSURE...................................................................................................1112 SERVICE PROCEDURES.................................................................................................................1112 AUTO LASH ADJUSTER.............................................................................................................1112 FUNCTION CHECK.............................................................................................................1112 FITTING CONNECTING ROD BEARINGS................................................................................................1113 CONNECTING ROD CLEARANCE...................................................................................................1113 CONNECTING ROD SIDE CLEARANCE..............................................................................................1113 FITTING MAIN BEARING...........................................................................................................1113 INSPECTION.................................................................................................................1113 CRANKSHAFT OIL CLEARANCE— MECHANICAL MEASUREMENT...........................................................................1113 PLASTIGAGE MEASUREMENT.....................................................................................................1113 CONNECTING ROD SPECIFICATION CHART.........................................................................................1113 CRANKSHAFT BEARING INSTALLATION............................................................................................1114 CRANKSHAFT SPECIFICATION CHART.............................................................................................1114 CHECKING CRANKSHAFT END PLAY...................................................................................................1115 CRANKSHAFT SIZE CLASSIFICATION CHART.......................................................................................1115 CRANKSHAFT SPECIFICATION CHART.............................................................................................1115 VALVE SERVICE RECONDITION......................................................................................................1116 VALVES.....................................................................................................................1116 VALVE SEAT.................................................................................................................1117 INSTALLATION...............................................................................................................1117 VALVE SPECIFICATION CHART..................................................................................................1117 REMOVAL AND INSTALLATION...........................................................................................................1118 ENGINE MOUNTS..................................................................................................................1118 RIGHT SIDE MOUNT...........................................................................................................1118 FRONT MOUNT................................................................................................................1118 LEFT SIDE MOUNT............................................................................................................1118 REAR MOUNT.................................................................................................................1119 ENGINE MOUNT RUBBER INSULATORS.............................................................................................1119 ENGINE ASSEMBLY................................................................................................................1119 REMOVAL....................................................................................................................1119 INSTALLATION...............................................................................................................1120 CYLINDER HEAD COVER............................................................................................................1120 REMOVAL....................................................................................................................1120 INSTALLATION...............................................................................................................1121 CAMSHAFT.......................................................................................................................1121 REMOVAL....................................................................................................................1121 CAMSHAFT INSPECTION........................................................................................................1121 CAMSHAFT INSTALL...........................................................................................................1121 ROCKER ARMS....................................................................................................................1122 INSTALL ROCKER ARM SHAFT ASSEMBLY..........................................................................................1122 CAMSHAFT SEAL..................................................................................................................1122 CAMSHAFT END SEAL (PLUG)— IN VEHICLE SERVICE...............................................................................1122 CAMSHAFT OIL SEAL PLUG— OUT OF VEHICLE SERVICE.............................................................................1123 CAMSHAFT END SEAL (PLUG) SERVICE — OUT OF VEHICLE SERVICE..................................................................1123 CYLINDER HEAD..................................................................................................................1124 REMOVAL....................................................................................................................1124 INSTALLATION...............................................................................................................1124 TIMING BELT....................................................................................................................1125 REMOVAL....................................................................................................................1125 CAMSHAFT SPROCKETS.........................................................................................................1126 TIMING BELT TENSIONER......................................................................................................1126 INSTALLATION— TIMING BELT..................................................................................................1126 OIL PAN........................................................................................................................1127 PISTON AND CONNECTING ROD......................................................................................................1128 FITTING PISTONS............................................................................................................1128 FITTING PISTON RINGS.......................................................................................................1129 PISTON RINGS— INSTALLATION.................................................................................................1129 PISTON RING SPECIFICATION CHART............................................................................................1129 CRANKSHAFT.....................................................................................................................1131 REMOVAL....................................................................................................................1131 CRANKSHAFT BEARINGS— INSTALLATION..........................................................................................1132 REAR CRANKSHAFT SEAL...........................................................................................................1133 REAR CRANKSHAFT SEAL RETAINER..............................................................................................1133 FRONT CRANKSHAFT OIL SEAL......................................................................................................1133 OIL PUMP.......................................................................................................................1134 REMOVAL....................................................................................................................1134 INSTALLATION...............................................................................................................1134 OIL FILTER AND ADAPTOR.........................................................................................................1134 DISASSEMBLY AND ASSEMBLY...........................................................................................................1135 ROCKER ARMS AND SHAFTS.........................................................................................................1135 ROCKER ARM SHAFTS..........................................................................................................1135 REASSEMBLE.................................................................................................................1135 ASSEMBLE ROCKER ASSEMBLY...................................................................................................1135 CLEANING AND INSPECTION............................................................................................................1136 TIMING BELT....................................................................................................................1136 INSPECTION.................................................................................................................1136 CYLINDER HEAD..................................................................................................................1136 CLEANING AND INSPECTION....................................................................................................1136 CYLINDER BORE..................................................................................................................1137 INSPECTION.................................................................................................................1137 OIL PUMP.......................................................................................................................1137 OIL RELIEF PLUNGER.........................................................................................................1138 ADJUSTMENTS........................................................................................................................1138 ENGINE MOUNTS..................................................................................................................1138 ENGINE MOUNT INSULATOR ADJUSTMENT..........................................................................................1138 SPECIFICATIONS.....................................................................................................................1139 3.0L ENGINE....................................................................................................................1139 TORQUE CHART 3.0L..............................................................................................................1140 SPECIAL TOOLS......................................................................................................................1141 3.0L ENGINE....................................................................................................................1141 3.3/3.8L ENGINE........................................................................................................................1143 DESCRIPTION AND OPERATION..........................................................................................................1143 ENGINE IDENTIFICATION..........................................................................................................1143 ENGINE LUBRICATION SYSTEM......................................................................................................1143 ENGINE COMPONENTS..............................................................................................................1143 DIAGNOSIS AND TESTING..............................................................................................................1144 HYDRAULIC TAPPETS..............................................................................................................1144 PRELIMINARY STEP TO CHECKING THE HYDRAULIC TAPPETS.........................................................................1145 OIL LEVEL TOO HIGH.........................................................................................................1145 OIL LEVEL TOO LOW..........................................................................................................1145 VALVE TRAIN NOISE DIAGNOSIS................................................................................................1145 CHECKING ENGINE OIL PRESSURE...................................................................................................1146 SERVICE PROCEDURES.................................................................................................................1146 VALVE TIMING...................................................................................................................1146 MEASURING TIMING CHAIN FOR STRETCH.............................................................................................1146 FITTING PISTONS AND RINGS......................................................................................................1147 FITTING PISTONS............................................................................................................1147 FITTING RINGS..............................................................................................................1147 FITTING CONNECTING ROD BEARINGS................................................................................................1147 CYLINDER BORE AND PISTON SPECIFICATION CHART...............................................................................1147 FITTING MAIN BEARINGS..........................................................................................................1148 CRANKSHAFT OIL CLEARANCE...................................................................................................1148 PISTON RING SPECIFICATION CHART............................................................................................1148 PLASTIGAGE (OIL CLEARANCE) MEASUREMENT.....................................................................................1149 CRANKSHAFT END PLAY............................................................................................................1149 DIAL INDICATOR METHOD......................................................................................................1149 CONNECTING ROD SPECIFICATION CHART.........................................................................................1149 CRANKSHAFT SPECIFICATION CHART.............................................................................................1149 FEELER GAUGE METHOD........................................................................................................1150 VALVE SERVICE RECONDITION......................................................................................................1150 VALVE INSPECTION...........................................................................................................1150 REFACING VALVES AND VALVE SEATS............................................................................................1151 VALVE GUIDE SPECIFICATION CHART............................................................................................1151 VALVE SPECIFICATION CHART..................................................................................................1151 TESTING VALVE SPRINGS......................................................................................................1152 REMOVAL AND INSTALLATION...........................................................................................................1152 WIPER UNIT.....................................................................................................................1152 ENGINE MOUNTS..................................................................................................................1152 RIGHT SIDE MOUNT...........................................................................................................1152 FRONT MOUNT................................................................................................................1153 LEFT SIDE MOUNT............................................................................................................1153 REAR MOUNT.................................................................................................................1153 ENGINE MOUNT RUBBER INSULATORS.............................................................................................1154 ENGINE ASSEMBLY................................................................................................................1154 REMOVAL....................................................................................................................1154 INSTALLATION...............................................................................................................1155 CRANKSHAFT DAMPER..............................................................................................................1156 REMOVAL....................................................................................................................1156 INSTALLATION...............................................................................................................1156 ROCKER ARMS AND SHAFT ASSEMBLY.................................................................................................1156 REMOVAL....................................................................................................................1156 INSTALLATION...............................................................................................................1156 VALVE STEM SEALS OR SPRINGS, CYLINDER HEAD NOT REMOVED.........................................................................1156 CYLINDER HEAD COVER............................................................................................................1157 REMOVAL....................................................................................................................1157 INSTALLATION...............................................................................................................1157 CYLINDER HEAD..................................................................................................................1158 REMOVAL....................................................................................................................1158 INSTALLATION...............................................................................................................1158 INTAKE MANIFOLD SEALING....................................................................................................1159 VALVES AND VALVE SPRINGS.......................................................................................................1159 REMOVAL....................................................................................................................1159 VALVE INSTALLATION.........................................................................................................1160 TAPPET REMOVAL.................................................................................................................1160 INSTALLATION...............................................................................................................1160 TIMING CHAIN COVER.............................................................................................................1161 REMOVAL....................................................................................................................1161 INSTALLATION...............................................................................................................1161 TIMING CHAIN...................................................................................................................1162 REMOVAL....................................................................................................................1162 INSTALLATION...............................................................................................................1162 CAMSHAFT.......................................................................................................................1163 REMOVAL— ENGINE REMOVED FROM VEHICLE.......................................................................................1163 INSTALLATION...............................................................................................................1163 CAMSHAFT BEARINGS..............................................................................................................1164 REMOVAL....................................................................................................................1164 INSTALLATION...............................................................................................................1164 OIL PAN........................................................................................................................1164 REMOVAL....................................................................................................................1164 INSTALLATION...............................................................................................................1164 PISTON AND CONNECTING ROD......................................................................................................1165 REMOVAL....................................................................................................................1165 INSTALLING PISTON AND CONNECTING ROD ASSEMBLY..............................................................................1165 CRANKSHAFT.....................................................................................................................1166 MAIN BEARINGS..............................................................................................................1166 CRANKSHAFT MAIN JOURNALS...................................................................................................1166 REMOVAL....................................................................................................................1166 INSTALLATION...............................................................................................................1167 CRANKSHAFT OIL SEAL— FRONT.....................................................................................................1167 REMOVAL....................................................................................................................1167 INSTALLATION...............................................................................................................1167 CRANKSHAFT OIL SEAL— REAR......................................................................................................1168 REMOVAL....................................................................................................................1168 INSTALLATION...............................................................................................................1168 REAR CRANKSHAFT SEAL RETAINER..............................................................................................1168 OIL FILTER.....................................................................................................................1169 ENGINE OIL GALLERY PLUGS.......................................................................................................1169 REMOVAL....................................................................................................................1169 INSTALLATION...............................................................................................................1169 DISASSEMBLY AND ASSEMBLY...........................................................................................................1169 OIL PUMP.......................................................................................................................1169 DISASSEMBLY................................................................................................................1169 OIL PUMP ASSEMBLY..........................................................................................................1170 HYDRAULIC TAPPETS..............................................................................................................1170 DISASSEMBLY................................................................................................................1170 ASSEMBLY...................................................................................................................1170 CLEANING AND INSPECTION............................................................................................................1170 CYLINDER HEAD..................................................................................................................1170 OIL PAN........................................................................................................................1171 OIL PUMP.......................................................................................................................1171 INSPECTION AND REPAIR......................................................................................................1171 ENGINE BLOCK AND BORE..........................................................................................................1171 CLEANING AND INSPECTION....................................................................................................1171 CYLINDER BORE INSPECTION...................................................................................................1172 ADJUSTMENTS........................................................................................................................1173 ENGINE MOUNTS..................................................................................................................1173 ENGINE MOUNT INSULATOR ADJUSTMENT..........................................................................................1173 SPECIFICATIONS.....................................................................................................................1173 3.3/ 3.8L ENGINE...............................................................................................................1173 CYLINDER BORE AND PISTON SPECIFICATION CHART...............................................................................1173 TORQUE CHART...................................................................................................................1176 SPECIAL TOOLS......................................................................................................................1177 3.3/ 3.8L ENGINE...............................................................................................................1177 ENGINE 1 ..................................................................................................................................1179 2.0L SOHC ENGINE.......................................................................................................................1179 DESCRIPTION AND OPERATION..........................................................................................................1179 ENGINE IDENTIFICATION..........................................................................................................1179 GENERAL SPECIFICATION..........................................................................................................1180 ENGINE LUBRICATION SYSTEM......................................................................................................1180 ENGINE LUBRICATION.........................................................................................................1180 PRESSURE LUBRICATION.......................................................................................................1180 MAIN/ ROD BEARINGS.........................................................................................................1180 CAMSHAFT/ HYDRAULIC LASH ADJUSTERS.........................................................................................1180 SPLASH LUBRICATION.........................................................................................................1181 ENGINE COMPONENTS..............................................................................................................1181 DIAGNOSIS AND TESTING..............................................................................................................1181 CHECKING ENGINE OIL PRESSURE...................................................................................................1181 SERVICE PROCEDURES.................................................................................................................1182 CYLINDER BORE AND PISTON SIZING................................................................................................1182 SIZING PISTONS.............................................................................................................1182 CYLINDER BORE AND PISTON SPECIFICATION CHART...............................................................................1182 FITTING PISTON RINGS...........................................................................................................1182 FITTING CONNECTING RODS........................................................................................................1183 PISTON RING SPECIFICATION CHART............................................................................................1183 CONNECTING ROD SPECIFICATION CHART.........................................................................................1184 FITTING CRANKSHAFT BEARINGS....................................................................................................1184 CRANKSHAFT END PLAY............................................................................................................1184 DIAL INDICATOR METHOD......................................................................................................1184 REMOVAL AND INSTALLATION...........................................................................................................1184 CYLINDER HEAD COVER............................................................................................................1184 REMOVAL....................................................................................................................1184 INSTALLATION...............................................................................................................1184 CRANKSHAFT SPECIFICATION CHART.............................................................................................1184 SPARK PLUG TUBE................................................................................................................1185 SPARK PLUG TUBE SEALS......................................................................................................1185 CAMSHAFT.......................................................................................................................1185 REMOVAL....................................................................................................................1185 INSTALLATION...............................................................................................................1186 ROCKER ARM/ HYDRAULIC LASH ADJUSTER............................................................................................1186 REMOVAL....................................................................................................................1186 INSTALLATION...............................................................................................................1187 HYDRAULIC LASH ADJUSTER NOISE..............................................................................................1188 VALVE SEALS AND SPRINGS IN VEHICLE.............................................................................................1188 REMOVAL....................................................................................................................1188 INSTALLATION...............................................................................................................1188 CYLINDER HEAD..................................................................................................................1188 REMOVAL....................................................................................................................1188 INSTALLATION...............................................................................................................1189 TIMING BELT COVER..............................................................................................................1189 REMOVAL....................................................................................................................1189 INSTALLATION...............................................................................................................1190 CAMSHAFT OIL SEAL..............................................................................................................1190 REMOVAL....................................................................................................................1190 INSTALLATION...............................................................................................................1191 TIMING BELT SYSTEM.............................................................................................................1191 CHECKING BELT TIMING— COVER INSTALLED......................................................................................1191 REMOVAL— TIMING BELT.......................................................................................................1191 CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE AND BELT INSTALLATION —SOHC ENGINE................................................1192 TIMING BELT w/AUTO TENIONER IF EQUIPPED....................................................................................1194 OIL PAN........................................................................................................................1195 REMOVAL....................................................................................................................1195 INSTALLATION...............................................................................................................1196 FRONT CRANKSHAFT OIL SEAL......................................................................................................1196 REMOVAL....................................................................................................................1196 INSTALLATION...............................................................................................................1197 CRANKSHAFT OIL SEAL— REAR......................................................................................................1198 REMOVAL....................................................................................................................1198 INSTALLATION...............................................................................................................1198 CRANKSHAFT.....................................................................................................................1199 REMOVAL....................................................................................................................1199 CRANKSHAFT MAIN BEARINGS LOCATION..........................................................................................1200 CRANKSHAFT MAIN JOURNALS INSPECTION........................................................................................1200 INSTALLATION...............................................................................................................1200 OIL FILTER ADAPTER.............................................................................................................1202 REMOVE AND INSTALL.........................................................................................................1202 OIL FILTER.....................................................................................................................1202 REMOVE AND INSTALL.........................................................................................................1202 OIL PUMP.......................................................................................................................1203 REMOVAL....................................................................................................................1203 INSTALLATION...............................................................................................................1203 PISTON AND CONNECTING ROD......................................................................................................1203 REMOVAL....................................................................................................................1203 PISTON RING— REMOVAL.......................................................................................................1203 PISTON RINGS— INSTALLATION.................................................................................................1204 PISTON AND ROD —INSTALLATION...............................................................................................1206 VIBRATION DAMPER...............................................................................................................1206 REMOVAL....................................................................................................................1206 INSTALLATION...............................................................................................................1207 FEELER GAGE METHOD.............................................................................................................1184 DISASSEMBLY AND ASSEMBLY...........................................................................................................1207 OIL PUMP.......................................................................................................................1207 VALVE SERVICE WITH THE CYLINDER HEAD REMOVED...................................................................................1207 REMOVAL....................................................................................................................1207 VALVE INSPECTION...........................................................................................................1207 VALVE GUIDES...............................................................................................................1207 TESTING VALVE SPRINGS......................................................................................................1207 VALVE GUIDE SPECIFICATION CHART............................................................................................1208 REFACING VALVES AND VALVE SEATS............................................................................................1208 VALVE SPECIFICATION CHART..................................................................................................1209 CLEANING...................................................................................................................1209 VALVE INSTALLATION.........................................................................................................1209 CLEANING AND INSPECTION............................................................................................................1210 CYLINDER HEAD AND CAMSHAFT JOURNALS............................................................................................1210 INSPECTING CYLINDER HEAD...................................................................................................1210 CLEANING...................................................................................................................1210 OIL PUMP.......................................................................................................................1210 CYLINDER BLOCK AND BORE........................................................................................................1212 CYLINDER BORE INSPECTION...................................................................................................1212 CYLINDER BORE AND PISTON SPECIFICATION CHART...............................................................................1212 SPECIFICATIONS.....................................................................................................................1212 ENGINE 2.0L SOHC...............................................................................................................1212 TORQUE CHART 2.0L SOHC.........................................................................................................1214 SPECIAL TOOLS......................................................................................................................1214 ENGINE 2.0L SOHC...............................................................................................................1214 2.5L VM DIESEL.........................................................................................................................1218 GENERAL INFORMATION................................................................................................................1218 GENERAL SPECIFICATION..........................................................................................................1218 ENGINE IDENTIFICATION..........................................................................................................1219 DESCRIPTION AND OPERATION..........................................................................................................1219 LUBRICATION SYSTEM.............................................................................................................1219 DIAGNOSIS AND TESTING..............................................................................................................1221 ENGINE DIAGNOSIS— PERFORMANCE..................................................................................................1221 ENGINE DIAGNOSIS— MECHANICAL...................................................................................................1222 ENGINE DIAGNOSIS— MECHANICAL CONT..........................................................................................1223 ENGINE DIAGNOSIS— MECHANICAL CONT..........................................................................................1224 HYDRAULIC TAPPETS..............................................................................................................1225 OIL LEVEL HIGH.............................................................................................................1225 OIL LEVEL LOW..............................................................................................................1225 TAPPET NOISE DIAGNOSIS.....................................................................................................1225 SERVICE PROCEDURES.................................................................................................................1225 CHECKING OIL LEVEL.............................................................................................................1225 CHANGING ENGINE OIL AND FILTER.................................................................................................1225 ENGINE OIL CHANGE..........................................................................................................1226 ENGINE OIL.................................................................................................................1226 ENGINE OIL FILTER CHANGE...................................................................................................1226 TIMING PROCEDURE...............................................................................................................1227 VALVE AND SEAT REFACING........................................................................................................1227 VALVE REFACING.............................................................................................................1227 VALVE SEAT REFACING........................................................................................................1227 VALVE STAND DOWN...........................................................................................................1228 VALVE GUIDE HEIGHT.........................................................................................................1228 VALVE STEM- TO- GUIDE CLEARANCE MEASUREMENT................................................................................1228 FITTING PISTON RING............................................................................................................1228 CRANKSHAFT END PLAY............................................................................................................1228 REMOVAL AND INSTALLATION...........................................................................................................1229 ENGINE MOUNT— FRONT............................................................................................................1229 ENGINE MOUNT— RIGHT............................................................................................................1229 MOUNT— LEFT SIDE...............................................................................................................1229 ENGINE MOUNT— REAR.............................................................................................................1230 ENGINE ASSEMBLY................................................................................................................1231 REMOVAL....................................................................................................................1231 CYLINDER HEAD COVER............................................................................................................1232 REMOVAL....................................................................................................................1232 INSTALLATION...............................................................................................................1232 ROCKER ARMS AND PUSH RODS......................................................................................................1232 REMOVAL....................................................................................................................1232 INSTALLATION...............................................................................................................1232 VALVE SPRINGS— CYLINDER HEAD NOT REMOVED.......................................................................................1233 REMOVAL....................................................................................................................1233 INSTALLATION...............................................................................................................1233 CYLINDER HEAD..................................................................................................................1233 REMOVAL....................................................................................................................1233 CYLINDER HEAD GASKET.......................................................................................................1235 INSTALLATION CYLINDER HEAD.................................................................................................1236 VALVES AND VALVE SPRINGS— HEAD OFF.............................................................................................1238 REMOVAL....................................................................................................................1238 INSTALLATION...............................................................................................................1238 HYDRAULIC TAPPETS..............................................................................................................1238 REMOVAL....................................................................................................................1238 INSTALLATION...............................................................................................................1238 VIBRATION DAMPER...............................................................................................................1239 REMOVAL....................................................................................................................1239 INSTALLATION...............................................................................................................1239 TIMING GEAR COVER OIL SEAL.....................................................................................................1239 REMOVAL....................................................................................................................1239 INSTALLATION...............................................................................................................1239 INJECTION PUMP.................................................................................................................1239 TIMING GEAR COVER..............................................................................................................1239 REMOVAL....................................................................................................................1239 INSTALLATION...............................................................................................................1240 CAMSHAFT.......................................................................................................................1240 REMOVAL....................................................................................................................1240 THRUST PLATE INSPECTION....................................................................................................1241 INSTALLATION...............................................................................................................1241 CAMSHAFT BEARINGS..............................................................................................................1241 REMOVAL....................................................................................................................1241 INSTALLATION...............................................................................................................1241 CRANKSHAFT MAIN BEARINGS.......................................................................................................1241 REMOVAL....................................................................................................................1241 INSTALLATION...............................................................................................................1242 OIL PAN........................................................................................................................1244 REMOVAL....................................................................................................................1244 INSTALLATION...............................................................................................................1245 OIL PUMP.......................................................................................................................1245 REMOVAL....................................................................................................................1245 INSTALLATION...............................................................................................................1245 OIL PUMP PRESSURE RELIEF VALVE.................................................................................................1245 REMOVAL....................................................................................................................1245 INSTALLATION...............................................................................................................1245 OIL FILTER ADAPTER AND OIL COOLER..............................................................................................1246 REMOVAL....................................................................................................................1246 INSTALLATION...............................................................................................................1246 VACUUM PUMP....................................................................................................................1246 REMOVAL....................................................................................................................1246 INSTALLATION...............................................................................................................1246 PISTONS AND CONNECTING ROD.....................................................................................................1246 REMOVAL....................................................................................................................1246 PISTON PIN— REMOVAL........................................................................................................1247 PISTON RING— REMOVAL.......................................................................................................1248 FITTING PISTON RINGS.......................................................................................................1248 PISTON RINGS— INSTALLATION.................................................................................................1248 PISTON PIN— INSTALLATION...................................................................................................1249 PISTON— INSTALLATION.......................................................................................................1249 CYLINDER LINER.................................................................................................................1250 REMOVAL....................................................................................................................1250 INSTALLATION...............................................................................................................1250 CRANKSHAFT— REMOVAL............................................................................................................1250 REAR CRANKSHAFT OIL SEAL.......................................................................................................1250 REMOVAL....................................................................................................................1250 INSTALLATION...............................................................................................................1251 DISASSEMBLY AND ASSEMBLY...........................................................................................................1251 HYDRAULIC TAPPETS..............................................................................................................1251 DISASSEMBLE AND ASSEMBLE...................................................................................................1251 CLEANING AND INSPECTION............................................................................................................1252 CYLINDER HEAD COVERS...........................................................................................................1252 ROCKER ARMS AND PUSH RODS......................................................................................................1252 CLEANING...................................................................................................................1252 INSPECTION.................................................................................................................1252 CYLINDER HEAD..................................................................................................................1253 CLEANING...................................................................................................................1253 INSPECTION.................................................................................................................1253 VALVE GUIDE HEIGHT.........................................................................................................1253 VALVE STEM- TO- GUIDE CLEARANCE MEASUREMENT................................................................................1253 TIMING GEAR COVER..............................................................................................................1253 VALVES AND VALVE SPRINGS.......................................................................................................1254 VALVE CLEANING.............................................................................................................1254 INSPECTION.................................................................................................................1254 HYDRAULIC TAPPETS..............................................................................................................1254 OIL PUMP.......................................................................................................................1254 CLEANING...................................................................................................................1254 INSPECTION.................................................................................................................1254 PISTON AND CONNECTING ROD......................................................................................................1254 PISTONS....................................................................................................................1254 CONNECTING ROD.............................................................................................................1255 PISTON PIN.................................................................................................................1255 CRANKSHAFT.....................................................................................................................1255 CRANKSHAFT JOURNALS........................................................................................................1255 BEARING- TO- JOURNAL CLEARANCE.............................................................................................1255 CRANKSHAFT MAIN BEARING........................................................................................................1255 INSPECTION.................................................................................................................1255 OIL PAN........................................................................................................................1256 CYLINDER LINER.................................................................................................................1256 INSPECTION.................................................................................................................1256 SPECIFICATIONS.....................................................................................................................1256 2.5L VM DIESEL.................................................................................................................1256 SPECIAL TOOLS......................................................................................................................1259 2.5L VM DIESEL.................................................................................................................1259 TORQUE.........................................................................................................................1258 EXHAUST SYSTEM AND INTAKE MANIFOLD.........................................................................................................1263 GENERAL INFORMATION....................................................................................................................1263 EXHAUST SYSTEM.....................................................................................................................1263 CATALYTIC CONVERTERS...............................................................................................................1263 EXHAUST GAS RECIRCULATION (EGR)....................................................................................................1264 HEAT SHIELDS.......................................................................................................................1264 EXHAUST FLEX- JOINT COUPLING.......................................................................................................1264 DESCRIPTION AND OPERATION..............................................................................................................1265 INTAKE/ EXHAUST MANIFOLD— 2.4L ENGINE..............................................................................................1265 INTAKE/ EXHAUST MANIFOLD— 3.0L ENGINE..............................................................................................1265 INTAKE/ EXHAUST MANIFOLD— 3.3/ 3.8L ENGINES........................................................................................1265 DIAGNOSIS AND TESTING..................................................................................................................1265 EXHAUST SYSTEM.....................................................................................................................1265 REMOVAL AND INSTALLATION...............................................................................................................1266 EXHAUST PIPES, MUFFLERS AND TAILPIPES..............................................................................................1266 REMOVAL........................................................................................................................1266 INSTALLATION...................................................................................................................1266 UPPER INTAKE MANIFOLD— 2.4L ENGINE.................................................................................................1266 REMOVAL........................................................................................................................1266 INSTALLATION...................................................................................................................1268 INTAKE MANIFOLD LOWER— 2.4L ENGINE.................................................................................................1268 REMOVAL........................................................................................................................1268 INSTALLATION...................................................................................................................1269 EXHAUST MANIFOLD— 2.4L ENGINE......................................................................................................1270 REMOVAL........................................................................................................................1270 INSTALLATION...................................................................................................................1270 INTAKE MANIFOLD— 3.0L ENGINE.......................................................................................................1270 REMOVAL........................................................................................................................1270 INSTALLATION...................................................................................................................1272 EXHAUST MANIFOLD— 3.0L ENGINE......................................................................................................1273 REMOVAL........................................................................................................................1273 INSTALLATION...................................................................................................................1273 INTAKE MANIFOLD— 3.3/ 3.8L ENGINE..................................................................................................1274 REMOVAL........................................................................................................................1274 INSTALLATION...................................................................................................................1276 EXHAUST MANIFOLDS— 3.3/ 3.8L ENGINE................................................................................................1278 REMOVAL........................................................................................................................1278 INSTALLATION...................................................................................................................1278 CLEANING AND INSPECTION................................................................................................................1279 INTAKE MANIFOLD....................................................................................................................1279 INSPECTION.....................................................................................................................1279 CLEANING.......................................................................................................................1279 EXHAUST MANIFOLD...................................................................................................................1279 INSPECTION.....................................................................................................................1279 CLEANING.......................................................................................................................1279 SPECIFICATIONS.........................................................................................................................1280 TORQUE CHART.......................................................................................................................1280 FRAME AND BUMPERS..........................................................................................................................1281 BUMPERS AND FASCIA.....................................................................................................................1281 REMOVAL AND INSTALLATION...........................................................................................................1281 FRONT BUMPER FASCIA............................................................................................................1281 REMOVAL....................................................................................................................1281 INSTALLATION...............................................................................................................1281 FRONT BUMPER REINFORCEMENT.....................................................................................................1281 REMOVAL....................................................................................................................1281 INSTALLATION...............................................................................................................1282 REAR BUMPER FASCIA.............................................................................................................1282 REMOVAL....................................................................................................................1282 INSTALLATION...............................................................................................................1282 REAR BUMPER REINFORCEMENT......................................................................................................1282 REMOVAL....................................................................................................................1282 INSTALLATION...............................................................................................................1282 FRAME..................................................................................................................................1283 REMOVAL AND INSTALLATION...........................................................................................................1283 FRONT CROSSMEMBER..............................................................................................................1283 REMOVAL....................................................................................................................1283 INSTALLATION...............................................................................................................1284 FRONT CROSSMEMBER MOUNT BUSHINGS...............................................................................................1285 REMOVAL....................................................................................................................1285 INSTALLATION...............................................................................................................1285 SPECIFICATIONS.....................................................................................................................1285 FRAME AND BODY OPENING DIMENSIONS..............................................................................................1285 VEHICLE PREPARATION........................................................................................................1285 FRAME AND BUMPERS 1 .......................................................................................................................1293 FRAME..................................................................................................................................1293 REMOVAL AND INSTALLATION...........................................................................................................1293 FRONT TOW HOOK BRACKET.........................................................................................................1293 REMOVAL....................................................................................................................1293 INSTALLATION...............................................................................................................1293 REAR TOW HOOK BRACKET..........................................................................................................1293 REMOVAL....................................................................................................................1293 INSTALLATION...............................................................................................................1294 FUEL SYSTEM................................................................................................................................1295 GENERAL INFORMATION....................................................................................................................1295 GENERAL INFORMATION................................................................................................................1295 INTRODUCTION...................................................................................................................1295 PCM REPLACEMENT................................................................................................................1295 FUEL REQUIREMENTS..............................................................................................................1295 GASOLINE/ OXYGENATE BLENDS.....................................................................................................1296 E- 85 GENERAL INFORMATION......................................................................................................1296 ETHANOL FUEL (E- 85)...........................................................................................................1296 FUEL REQUIREMENTS..............................................................................................................1296 STARTING.......................................................................................................................1296 CRUISING RANGE.................................................................................................................1297 REPLACEMENT PARTS..............................................................................................................1297 FUEL DELIVERY SYSTEM...................................................................................................................1298 DESCRIPTION AND OPERATION..........................................................................................................1298 FUEL DELIVERY SYSTEM...........................................................................................................1298 FUEL PUMP MODULE...............................................................................................................1298 ELECTRIC FUEL PUMP.........................................................................................................1298 FUEL PUMP ELECTRICAL CONTROL...............................................................................................1299 ELECTRICAL PUMP REPLACEMENT................................................................................................1299 FUEL LEVEL SENSOR..............................................................................................................1299 FUEL PRESSURE REGULATOR........................................................................................................1299 FUEL INJECTORS.................................................................................................................1299 FUEL TANK......................................................................................................................1299 PRESSURE- VACUUM FILLER CAP....................................................................................................1300 QUICK- CONNECT FITTINGS........................................................................................................1300 DIAGNOSIS AND TESTING..............................................................................................................1300 FUEL PUMP PRESSURE TEST 2.4/ 3.3/ 3.8L.........................................................................................1300 FUEL PRESSURE BELOW SPECIFICATIONS.........................................................................................1302 FUEL LEVEL SENSOR..............................................................................................................1303 FUEL INJECTORS.................................................................................................................1303 SERVICE PROCEDURES.................................................................................................................1305 FUEL SYSTEM PRESSURE RELEASE PROCEDURE— 2.4/ 3.3/ 3.8L.........................................................................1305 FUEL SYSTEM PRESSURE RELEASE PROCEDURE— 3.0L ENGINE............................................................................1305 HOSES AND CLAMPS...............................................................................................................1306 QUICK- CONNECT FITTINGS........................................................................................................1306 REMOVAL....................................................................................................................1306 INSTALLATION...............................................................................................................1306 REMOVAL AND INSTALLATION...........................................................................................................1306 FUEL FILTER....................................................................................................................1306 REMOVAL....................................................................................................................1307 INSTALLATION...............................................................................................................1307 FUEL PUMP MODULE...............................................................................................................1307 REMOVAL....................................................................................................................1307 INSTALLATION...............................................................................................................1308 FUEL PRESSURE REGULATOR........................................................................................................1308 REMOVAL....................................................................................................................1308 INSTALLATION...............................................................................................................1308 FUEL PUMP INLET STRAINER.......................................................................................................1309 REMOVAL....................................................................................................................1309 INSTALLATION...............................................................................................................1309 FUEL LEVEL SENSOR..............................................................................................................1309 REMOVAL....................................................................................................................1309 INSTALLATION...............................................................................................................1310 FUEL TANK......................................................................................................................1311 REMOVAL....................................................................................................................1311 INSTALLATION...............................................................................................................1312 FUEL INJECTOR RAIL— 2.4L.......................................................................................................1312 REMOVAL....................................................................................................................1312 INSTALLATION...............................................................................................................1313 FUEL INJECTOR RAIL— 3.0L.......................................................................................................1313 REMOVAL....................................................................................................................1313 INSTALLATION...............................................................................................................1315 FUEL INJECTOR RAIL— 3.3/ 3.8L..................................................................................................1315 REMOVAL....................................................................................................................1315 INSTALLATION...............................................................................................................1317 FUEL INJECTOR— 2.4L............................................................................................................1318 REMOVAL....................................................................................................................1318 INSTALLATION...............................................................................................................1319 FUEL INJECTORS— 3.0L...........................................................................................................1319 REMOVAL....................................................................................................................1319 INSTALLATION...............................................................................................................1319 FUEL INJECTOR— 3.3/ 3.8L.......................................................................................................1320 REMOVAL....................................................................................................................1320 INSTALLATION...............................................................................................................1320 ACCELERATOR PEDAL..............................................................................................................1320 REMOVAL....................................................................................................................1320 INSTALLATION...............................................................................................................1320 THROTTLE CABLE.................................................................................................................1321 REMOVAL....................................................................................................................1321 INSTALLATION...............................................................................................................1321 SPECIFICATIONS.....................................................................................................................1322 TORQUE.........................................................................................................................1322 FUEL TANK CAPACITY.............................................................................................................1322 FUEL INJECTION SYSTEM..................................................................................................................1323 GENERAL INFORMATION................................................................................................................1324 INTRODUCTION...................................................................................................................1324 MODES OF OPERATION.............................................................................................................1324 IGNITION SWITCH ON (ZERO RPM) MODE.........................................................................................1324 ENGINE START- UP MODE......................................................................................................1324 ENGINE WARM- UP MODE.......................................................................................................1325 CRUISE OR IDLE MODE........................................................................................................1325 ACCELERATION MODE..........................................................................................................1325 DECELERATION MODE..........................................................................................................1325 WIDE OPEN THROTTLE (WOT) MODE..............................................................................................1325 IGNITION SWITCH OFF MODE...................................................................................................1326 DESCRIPTION AND OPERATION..........................................................................................................1326 SYSTEM DIAGNOSIS...............................................................................................................1326 CCD BUS........................................................................................................................1326 POWERTRAIN CONTROL MODULE (PCM)................................................................................................1326 AIR CONDITIONING PRESSURE TRANSDUCER— PCM INPUT................................................................................1327 AIR CONDITIONING SWITCH SENSE— PCM INPUT.......................................................................................1327 AUTOMATIC SHUTDOWN (ASD) SENSE— PCM INPUT......................................................................................1327 BATTERY VOLTAGE— PCM INPUT.....................................................................................................1327 BRAKE SWITCH— PCM INPUT........................................................................................................1327 CAMSHAFT POSITION SENSOR— PCM INPUT............................................................................................1327 3.3/ 3.8L..................................................................................................................1327 2.4L.......................................................................................................................1328 CRANKSHAFT POSITION SENSOR— PCM INPUT..........................................................................................1329 3.0/ 3.3/ 3.8L.............................................................................................................1329 2.4L.......................................................................................................................1330 ENGINE COOLANT TEMPERATURE SENSOR— PCM INPUT...................................................................................1330 3.0/ 3.3/ 3.8L.............................................................................................................1331 2.4L.......................................................................................................................1331 HEATED OXYGEN SENSOR (O2S SENSOR)— PCM INPUT...................................................................................1331 UPSTREAM HEATED OXYGEN SENSOR..............................................................................................1332 DOWNSTREAM HEATED OXYGEN SENSOR............................................................................................1332 KNOCK SENSOR— PCM INPUT........................................................................................................1332 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— PCM INPUT.............................................................................1333 SPEED CONTROL— PCM INPUT.......................................................................................................1333 TRANSAXLE PARK/ NEUTRAL SWITCH— PCM INPUT......................................................................................1334 THROTTLE POSITION SENSOR (TPS)— PCM INPUT......................................................................................1334 VEHICLE SPEED AND DISTANCE— PCM INPUT..........................................................................................1335 INTAKE AIR TEMPERATURE SENSOR— PCM INPUT (2.4L ONLY)...........................................................................1335 AIR CONDITIONING (A/ C) CLUTCH RELAY— PCM OUTPUT...............................................................................1335 GENERATOR FIELD— PCM OUTPUT....................................................................................................1336 AUTOMATIC SHUTDOWN RELAY— PCM OUTPUT...........................................................................................1336 FUEL PUMP RELAY— PCM OUTPUT....................................................................................................1336 STARTER RELAY— PCM OUTPUT......................................................................................................1336 IDLE AIR CONTROL MOTOR— PCM OUTPUT.............................................................................................1336 DUTY CYCLE EVAP CANISTER PURGE SOLENOID— PCM OUTPUT............................................................................1337 PROPORTIONAL PURGE SOLENOID....................................................................................................1337 ELECTRONIC EGR TRANSDUCER SOLENOID— PCM OUTPUT.................................................................................1337 DATA LINK CONNECTOR— PCM OUTPUT................................................................................................1338 AUTOMATIC TRANSAXLE CONTROL MODULE— PCM OUTPUT.................................................................................1338 FUEL INJECTORS— PCM OUTPUT.....................................................................................................1338 IGNITION COIL— PCM OUTPUT......................................................................................................1339 TORQUE CONVERTER CLUTCH SOLENOID— PCM OUTPUT...................................................................................1340 MALFUNCTION INDICATOR (CHECK ENGINE) LAMP— PCM OUTPUT..........................................................................1340 SOLID STATE FAN RELAY— PCM OUTPUT..............................................................................................1340 SPEED CONTROL SOLENOIDS— PCM OUTPUT............................................................................................1340 TACHOMETER— PCM OUTPUT.........................................................................................................1341 THROTTLE BODY..................................................................................................................1341 DIAGNOSIS AND TESTING..............................................................................................................1341 VISUAL INSPECTION— 2.4L ENGINE.................................................................................................1341 VISUAL INSPECTION— 3.0L ENGINE.................................................................................................1346 VISUAL INSPECTION— 3.3/ 3.8L ENGINES...........................................................................................1349 ASD AND FUEL PUMP RELAYS.......................................................................................................1353 OPERATION..................................................................................................................1353 TESTING....................................................................................................................1354 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR........................................................................................1354 HEATED OXYGEN SENSOR...........................................................................................................1355 KNOCK SENSOR...................................................................................................................1355 CAMSHAFT AND CRANKSHAFT POSITION SENSOR........................................................................................1355 ENGINE COOLANT TEMPERATURE SENSOR..............................................................................................1355 THROTTLE POSITION SENSOR.......................................................................................................1356 THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE.................................................................................1356 REMOVAL AND INSTALLATION...........................................................................................................1358 THROTTLE BODY..................................................................................................................1358 REMOVAL....................................................................................................................1358 INSTALLATION...............................................................................................................1358 FUEL PUMP RELAY................................................................................................................1358 AUTOMATIC SHUTDOWN (ASD) RELAY.................................................................................................1358 THROTTLE POSITION SENSOR.......................................................................................................1359 REMOVAL....................................................................................................................1359 INSTALLATION...............................................................................................................1359 IDLE AIR CONTROL MOTOR.........................................................................................................1359 REMOVAL....................................................................................................................1359 INSTALLATION...............................................................................................................1360 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— 2.4/ 3.3/ 3.8L........................................................................1360 REMOVAL....................................................................................................................1360 INSTALLATION...............................................................................................................1360 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— 3.0L..................................................................................1360 REMOVAL....................................................................................................................1360 INSTALLATION...............................................................................................................1360 PROPORTIONAL PURGE SOLENOID VALVE..............................................................................................1360 REMOVAL....................................................................................................................1360 INSTALLATION...............................................................................................................1360 POWERTRAIN CONTROL MODULE......................................................................................................1361 REMOVAL....................................................................................................................1361 INSTALLATION...............................................................................................................1362 CRANKSHAFT POSITION SENSOR.....................................................................................................1362 CAMSHAFT POSITION SENSOR.......................................................................................................1362 UPSTREAM OXYGEN SENSOR.........................................................................................................1362 REMOVAL....................................................................................................................1362 INSTALLATION...............................................................................................................1363 DOWNSTREAM OXYGEN SENSOR.......................................................................................................1363 REMOVAL....................................................................................................................1363 INSTALLATION...............................................................................................................1364 KNOCK SENSOR...................................................................................................................1364 AIR CLEANER ELEMENT............................................................................................................1364 REMOVAL....................................................................................................................1364 INSTALLATION...............................................................................................................1364 ENGINE COOLANT TEMPERATURE SENSOR— 2.4L........................................................................................1364 REMOVAL....................................................................................................................1365 INSTALLATION...............................................................................................................1365 ENGINE COOLANT TEMPERATURE SENSOR— 3.0L........................................................................................1365 REMOVAL....................................................................................................................1365 INSTALLATION...............................................................................................................1365 ENGINE COOLANT TEMPERATURE SENSOR— 3.3/ 3.8L...................................................................................1365 REMOVAL....................................................................................................................1365 INSTALLATION...............................................................................................................1365 INTAKE AIR TEMPERATURE SENSOR— 2.4L............................................................................................1366 REMOVAL....................................................................................................................1366 INSTALLATION...............................................................................................................1366 SPECIFICATIONS.....................................................................................................................1366 TORQUE.........................................................................................................................1366 SPECIAL TOOLS......................................................................................................................1366 FUEL...........................................................................................................................1366 FUEL SYSTEM— 2.5L DIESEL ENGINE/ 2.0L GAS ENGINE...........................................................................................1369 GENERAL INFORMATION....................................................................................................................1369 GENERAL INFORMATION................................................................................................................1369 INTRODUCTION— 2.5L DIESEL......................................................................................................1369 INTRODUCTION— 2.0L ENGINE......................................................................................................1370 FUEL REQUIREMENTS— 2.5L DIESEL.................................................................................................1370 FUEL REQUIREMENTS— 2.0L ENGINE.................................................................................................1370 GASOLINE/ OXYGENATE BLENDS.....................................................................................................1370 FUEL DELIVERY SYSTEM - 2.5L DIESEL ENGINE..............................................................................................1371 DESCRIPTION AND OPERATION..........................................................................................................1371 INTRODUCTION...................................................................................................................1371 FUEL SYSTEM PRESSURE WARNING...................................................................................................1371 FUEL TANK......................................................................................................................1371 FUEL TANK MODULE...............................................................................................................1372 FUEL GAUGE SENDING UNIT........................................................................................................1372 FUEL FILTER/ WATER SEPARATOR...................................................................................................1372 FUEL SHUTDOWN SOLENOID.........................................................................................................1373 FUEL INJECTION PUMP............................................................................................................1373 FUEL INJECTORS.................................................................................................................1374 FUEL TUBES/ LINES/ HOSES AND CLAMPS— LOW-PRESSURE TYPE.........................................................................1374 QUICK- CONNECT FITTINGS— LOW PRESSURE TYPE.....................................................................................1375 HIGH- PRESSURE FUEL LINES......................................................................................................1375 FUEL DRAIN TUBES...............................................................................................................1375 FUEL HEATER....................................................................................................................1376 FUEL HEATER RELAY..............................................................................................................1376 WASTEGATE (TURBOCHARGER).......................................................................................................1376 DIAGNOSIS AND TESTING..............................................................................................................1377 GENERAL INFORMATION............................................................................................................1377 VISUAL INSPECTION..............................................................................................................1377 AIR IN FUEL SYSTEM.............................................................................................................1379 FUEL HEATER RELAY TEST.........................................................................................................1380 FUEL INJECTOR TEST.............................................................................................................1380 FUEL INJECTOR SENSOR TEST......................................................................................................1380 FUEL INJECTION PUMP TEST.......................................................................................................1380 FUEL SUPPLY RESTRICTIONS.......................................................................................................1381 LOW– PRESSURE LINES........................................................................................................1381 HIGH– PRESSURE LINES.......................................................................................................1381 FUEL SHUTDOWN SOLENOID TEST....................................................................................................1381 HIGH- PRESSURE FUEL LINE LEAK TEST.............................................................................................1382 WASTEGATE (TURBOCHARGER).......................................................................................................1382 SERVICE PROCEDURES.................................................................................................................1382 AIR BLEED PROCEDURES...........................................................................................................1382 AIR BLEEDING AT FUEL FILTER................................................................................................1382 FUEL INJECTION PUMP BLEEDING...............................................................................................1383 HIGH– PRESSURE FUEL LINE BLEEDING..........................................................................................1383 FUEL INJECTION PUMP TIMING.....................................................................................................1383 REMOVAL AND INSTALLATION...........................................................................................................1384 ACCELERATOR PEDAL..............................................................................................................1384 REMOVAL....................................................................................................................1384 INSTALLATION...............................................................................................................1384 AIR CLEANER ELEMENT............................................................................................................1384 REMOVAL....................................................................................................................1384 INSTALLATION...............................................................................................................1384 FUEL DRAIN TUBES...............................................................................................................1384 FUEL FILTER/ WATER SEPARATOR...................................................................................................1384 DRAINING WATER FROM FILTER BOWL............................................................................................1384 FUEL FILTER REMOVAL........................................................................................................1385 FUEL FILTER INSTALLATION...................................................................................................1385 FUEL HEATER....................................................................................................................1385 FUEL HEATER RELAY..............................................................................................................1385 FUEL LEVEL SENSOR..............................................................................................................1386 REMOVAL....................................................................................................................1386 INSTALLATION...............................................................................................................1387 FUEL INJECTION PUMP............................................................................................................1387 REMOVAL....................................................................................................................1387 INSTALLATION/ ADJUSTING PUMP TIMING........................................................................................1389 FUEL INJECTORS.................................................................................................................1390 REMOVAL....................................................................................................................1390 INSTALLATION...............................................................................................................1391 FUEL SHUTDOWN SOLENOID.........................................................................................................1391 REMOVAL....................................................................................................................1391 INSTALLATION...............................................................................................................1391 FUEL TANK......................................................................................................................1391 REMOVAL....................................................................................................................1391 INSTALLATION...............................................................................................................1392 FUEL RESERVOIR MODULE..........................................................................................................1393 REMOVAL....................................................................................................................1393 INSTALLATION...............................................................................................................1393 HIGH- PRESSURE LINES...........................................................................................................1394 REMOVAL....................................................................................................................1394 INSTALLATION...............................................................................................................1394 SPECIFICATIONS.....................................................................................................................1395 FUEL TANK CAPACITY.............................................................................................................1395 IDLE SPEED.....................................................................................................................1395 FUEL INJECTOR FIRING SEQUENCE..................................................................................................1395 FUEL SYSTEM PRESSURE...........................................................................................................1395 FUEL DELIVERY SYSTEM-2.0L ENGINE.......................................................................................................1396 DESCRIPTION AND OPERATION..........................................................................................................1396 FUEL DELIVERY SYSTEM...........................................................................................................1396 FUEL PUMP MODULE...............................................................................................................1396 ELECTRIC FUEL PUMP.............................................................................................................1396 FUEL LEVEL SENSOR..............................................................................................................1396 FUEL PRESSURE REGULATOR........................................................................................................1396 FUEL INJECTORS.................................................................................................................1396 FUEL TANK......................................................................................................................1396 PRESSURE- VACUUM FILLER CAP— 2.0L ENGINE.......................................................................................1396 QUICK- CONNNECT FITTINGS— 2.0L ENGINE..........................................................................................1396 DIAGNOSIS AND TESTING..............................................................................................................1396 FUEL PUMP PRESSURE TEST— 2.0L ENGINE...........................................................................................1396 FUEL LEVEL SENSOR— 2.0L ENGINE.................................................................................................1396 FUEL INJECTORS— 2.0L ENGINE....................................................................................................1397 SERVICE PROCEDURES.................................................................................................................1397 FUEL SYSTEM PRESSURE RELEASE PROCEDURE— 2.0L ENGINE............................................................................1397 HOSES AND CLAMPS— 2.0L ENGINE..................................................................................................1397 QUICK- CONNNECT FITTINGS— 2.0L ENGINE..........................................................................................1397 REMOVAL AND INSTALLATION...........................................................................................................1397 FUEL FILTER— 2.0L ENGINE.......................................................................................................1397 FUEL PUMP MODULE— 2.0L ENGINE..................................................................................................1397 FUEL PRESSURE REGULATOR— 2.0L ENGINE...........................................................................................1397 FUEL PRESSURE REGULATOR— 2.0L ENGINE...........................................................................................1397 FUEL LEVEL SENSOR— 2.0L ENGINE.................................................................................................1398 FUEL TANK— 2.0L ENGINE.........................................................................................................1398 FUEL INJECTORS.................................................................................................................1398 REMOVAL....................................................................................................................1398 INSTALLATION...............................................................................................................1398 ACCELERATOR PEDAL..............................................................................................................1399 TORQUE SPECIFICATION...........................................................................................................1399 FUEL INJECTION SYSTEM-2.0L ENGINE......................................................................................................1400 GENERAL INFORMATION................................................................................................................1400 INTRODUCTION— 2.0L ENGINE......................................................................................................1400 MODES OF OPERATION— 2.0L ENGINE................................................................................................1400 DESCRIPTION AND OPERATION..........................................................................................................1401 SYSTEM DIAGNOSIS— 2.0L ENGINE..................................................................................................1401 POWERTRAIN CONTROL MODULE— 2.0L ENGINE.........................................................................................1401 AIR CONDITIONING PRESSURE TRANSDUCER— PCM INPUT— 2.0L ENGINE...................................................................1401 AIR CONDITIONING SWITCH SENSE— PCM INPUT— 2.0L ENGINE..........................................................................1401 AUTOMATIC SHUTDOWN (ASD) SENSE— PCM INPUT— 2.0L ENGINE.........................................................................1401 BATTERY VOLTAGE— PCM INPUT— 2.0L ENGINE........................................................................................1401 CAMSHAFT POSITION SENSOR— PCM INPUT— 2.0L ENGINE...............................................................................1401 CRANKSHAFT POSITION SENSOR— PCM INPUT— 2.0L ENGINE.............................................................................1401 ENGINE COOLANT TEMPERATURE SENSOR— PCM INPUT— 2.0L ENGINE......................................................................1401 HEATED OXYGEN SENSOR— PCM INPUT— 2.0L ENGINE...................................................................................1401 KNOCK SENSOR— PCM INPUT— 2.0L ENGINE...........................................................................................1402 MANIFOLD ABSOLUTE PRESSURE (MAP SENSOR)— PCM INPUT— 2.0L ENGINE................................................................1402 SPEED CONTROL— PCM INPUT— 2.0L ENGINE..........................................................................................1402 THROTTLE POSITION SENSOR/ IDLE AIR CONTROL MOTOR— PCM INPUT— 2.0L ENGINE.......................................................1403 AIR CONDITIONING (A/ C) RELAY— PCM OUTPUT— 2.0L ENGINE.........................................................................1403 GENERATOR FIELD— PCM OUTPUT— 2.0L ENGINE.......................................................................................1403 AUTOMATIC SHUTDOWN RELAY— PCM OUTPUT— 2.0L ENGINE..............................................................................1403 FUEL PUMP RELAY— PCM OUTPUT— 2.0L ENGINE.......................................................................................1403 STARTER RELAY— PCM OUTPUT— 2.0L ENGINE.........................................................................................1403 IDLE AIR CONTROL MOTOR— PCM OUTPUT— 2.0L ENGINE................................................................................1403 ELECTRONIC EGR TRANSDUCER— PCM OUTPUT— 2.0L ENGINE.............................................................................1403 DATA LINK CONNECTOR— PCM OUTPUT— 2.0L ENGINE...................................................................................1403 FUEL INJECTORS— PCM OUTPUT— 2.0L ENGINE........................................................................................1403 IGNITION COIL— PCM OUTPUT— 2.0L ENGINE.........................................................................................1404 MALFUNCTION INDICATOR (CHECK ENGINE) LAMP— PCM OUTPUT— 2.0L ENGINE.............................................................1404 RADIATOR FAN CONTROL MODULE— PCM OUTPUT— 2.0L ENGINE...........................................................................1404 SPEED CONTROL SOLENOIDS— PCM OUTPUT— 2.0L ENGINE...............................................................................1404 TACHOMETER— PCM OUTPUT— 2.0L ENGINE............................................................................................1404 THROTTLE BODY— 2.0L ENGINE.....................................................................................................1404 DIAGNOSIS AND TESTING..............................................................................................................1404 VISUAL INSPECTION— SOHC........................................................................................................1404 ASD AND FUEL PUMP RELAYS— 2.0L ENGINE..........................................................................................1407 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR— 2.0L ENGINE...........................................................................1407 KNOCK SENSOR— 2.0L ENGINE......................................................................................................1408 CAMSHAFT AND CRANKSHAFT POSITION SENSOR........................................................................................1408 ENGINE COOLANT TEMPERATURE SENSOR..............................................................................................1408 THROTTLE POSITION SENSOR.......................................................................................................1408 THROTTLE BODY MINIMUM AIR FLOW.................................................................................................1409 SPECIFICATIONS.....................................................................................................................1410 TORQUE.........................................................................................................................1410 FUEL INJECTION SYSTEM - 2.5L DIESEL ENGINE.............................................................................................1411 GENERAL INFORMATION................................................................................................................1411 INTRODUCTION...................................................................................................................1411 DESCRIPTION AND OPERATION..........................................................................................................1412 POWERTRAIN CONTROL MODULE (PCM)................................................................................................1412 BOOST PRESSURE SENSOR..........................................................................................................1413 VEHICLE THEFT ALARM............................................................................................................1413 BATTERY VOLTAGE— PCM INPUT.....................................................................................................1413 SENSOR RETURN— PCM INPUT (ANALOG GROUND).......................................................................................1413 SIGNAL GROUND— PCM INPUT.......................................................................................................1413 IGNITION CIRCUIT SENSE— PCM INPUT..............................................................................................1413 START SIGNAL— PCM INPUT........................................................................................................1413 POWER GROUND...................................................................................................................1413 NEEDLE MOVEMENT OR INSTRUMENTED FIRST INJECTOR— PCM INPUT......................................................................1413 FUEL INJECTOR SENSOR— GROUND...................................................................................................1414 ENGINE COOLANT TEMPERATURE SENSOR— PCM INPUT...................................................................................1414 ENGINE SPEED SENSOR— PCM INPUT.................................................................................................1414 AIR CONDITIONING (A/ C) CONTROLS— PCM INPUTS...................................................................................1415 BRAKE SWITCH— PCM INPUT........................................................................................................1415 DATA LINK CONNECTOR— PCM INPUT AND OUTPUT......................................................................................1415 VEHICLE SPEED SENSOR— PCM INPUT................................................................................................1415 SPEED CONTROL— PCM INPUTS......................................................................................................1416 DIESEL PCM RELAY— PCM INPUT....................................................................................................1416 FIVE VOLT POWER— PCM OUTPUT....................................................................................................1416 ENGINE COOLANT GAUGE— PCM OUTPUT...............................................................................................1416 ENGINE OIL PRESSURE GAUGE— PCM OUTPUT..........................................................................................1416 GLOW PLUG LAMP— PCM OUTPUT.....................................................................................................1416 SPEED CONTROL— PCM OUTPUTS.....................................................................................................1416 AIR CONDITIONING RELAY— PCM OUTPUT.............................................................................................1416 FUEL TIMING SOLENOID— PCM OUTPUT...............................................................................................1416 TACHOMETER— PCM OUTPUT.........................................................................................................1417 GLOW PLUG RELAY— PCM OUTPUT....................................................................................................1417 GLOW PLUGS.....................................................................................................................1417 GLOW PLUG CONTROL..........................................................................................................1417 EXHAUST GAS RECIRCULATION (EGR) SOLENOID— PCM OUTPUT...........................................................................1418 DIAGNOSIS AND TESTING..............................................................................................................1418 DIESEL DIAGONSTICS.............................................................................................................1418 DIESEL PCM RELAY TEST..........................................................................................................1418 ENGINE SPEED SENSOR TEST.......................................................................................................1418 ENGINE COOLANT TEMPERATURE SENSOR TEST.........................................................................................1418 SENSOR RESISTANCE (OHMS)...................................................................................................1418 GLOW PLUG TEST.................................................................................................................1419 GLOW PLUG RELAY TEST...........................................................................................................1419 RELAYS— OPERATION/ TESTING.....................................................................................................1420 OPERATION..................................................................................................................1420 GLOW PLUG CONTROL..........................................................................................................1420 TESTING....................................................................................................................1421 BOOST PRESSURE SENSOR..........................................................................................................1421 VEHICLE SPEED SENSOR TEST......................................................................................................1421 DIAGNOSTIC TROUBLE CODES.......................................................................................................1421 REMOVAL AND INSTALLATION...........................................................................................................1421 DIESEL PCM RELAY...............................................................................................................1421 A/ C CLUTCH RELAY..............................................................................................................1421 ENGINE SPEED SENSOR............................................................................................................1421 REMOVAL....................................................................................................................1421 INSTALLATION...............................................................................................................1422 ENGINE COOLANT TEMPERATURE SENSOR..............................................................................................1422 REMOVAL....................................................................................................................1422 INSTALLATION...............................................................................................................1422 GLOW PLUGS.....................................................................................................................1422 REMOVAL....................................................................................................................1422 INSTALLATION...............................................................................................................1423 GLOW PLUG RELAY................................................................................................................1423 REMOVAL....................................................................................................................1423 INSTALLATION...............................................................................................................1423 POWERTRAIN CONTROL MODULE (PCM)................................................................................................1423 REMOVAL....................................................................................................................1423 INSTALLATION...............................................................................................................1423 VEHICLE SPEED SENSOR...........................................................................................................1423 REMOVAL....................................................................................................................1424 INSTALLATION...............................................................................................................1424 SPECIFICATIONS.....................................................................................................................1424 GLOW PLUG CURRENT DRAW.........................................................................................................1424 TORQUE CHART— 2.5L DIESEL......................................................................................................1425 STEERING...................................................................................................................................1427 GENERAL INFORMATION....................................................................................................................1427 GENERAL INFORMATION................................................................................................................1427 STEERING SYSTEM AND COMPONENT DESCRIPTION......................................................................................1427 DIAGNOSIS AND TESTING..............................................................................................................1428 STEERING SYSTEM DIAGNOSIS CHARTS...............................................................................................1428 STEERING NOISE.............................................................................................................1428 BINDING STICKING SEIZED SHAKE SHUDDER VIBRATION............................................................................1430 LOW ASSIST, NO ASSIST, HARD STEERING POOR RETURN TO CENTER.................................................................1431 LOOSE STEERING.............................................................................................................1432 VEHICLE LEADS TO THE SIDE POWER STEERING FLUID LEAK........................................................................1433 FOAMY OR MILKY POWER STEERING FLUID........................................................................................1434 POWER STEERING PUMP....................................................................................................................1435 DESCRIPTION AND OPERATION..........................................................................................................1435 POWER STEERING PUMP OPERATION..................................................................................................1435 DIAGNOSIS AND TESTING..............................................................................................................1435 POWER STEERING PUMP FLOW RATE AND PRESSURE TEST................................................................................1435 POWER STEERING PUMP FLOW AND PRESSURE TEST PROCEDURE.......................................................................1436 SERVICE PROCEDURES.................................................................................................................1436 POWER STEERING SYSTEM FLUID LEVEL CHECK........................................................................................1436 POWER STEERING PUMP INITIAL OPERATION..........................................................................................1436 REMOVAL AND INSTALLATION...........................................................................................................1437 2.4 LITER POWER STEERING PUMP..................................................................................................1437 REMOVE.....................................................................................................................1437 INSTALL....................................................................................................................1439 3.0 LITER POWER STEERING PUMP..................................................................................................1439 REMOVE.....................................................................................................................1439 INSTALL....................................................................................................................1441 3.3/ 3.8 LITER POWER STEERING PUMP.............................................................................................1442 REMOVE.....................................................................................................................1442 INSTALL....................................................................................................................1443 POWER STEERING FLUID RESERVOIR TO PUMP SUPPLY HOSE.............................................................................1444 REMOVE.....................................................................................................................1444 INSTALL....................................................................................................................1445 POWER STEERING FLUID PRESSURE HOSE.............................................................................................1445 REMOVE.....................................................................................................................1445 INSTALL....................................................................................................................1446 POWER STEERING FLUID RETURN HOSE...............................................................................................1447 REMOVE.....................................................................................................................1447 INSTALL....................................................................................................................1447 REMOTE POWER STEERING FLUID RESERVOIR..........................................................................................1448 REMOVE.....................................................................................................................1448 INSTALL....................................................................................................................1448 DISASSEMBLY AND ASSEMBLY...........................................................................................................1449 POWER STEERING PUMP PULLEY.....................................................................................................1449 DISASSEMBLY................................................................................................................1449 ASSEMBLY...................................................................................................................1449 POWER STEERING PUMP FLOW CONTROL VALVE SEAL....................................................................................1449 DISASSEMBLE................................................................................................................1449 ASSEMBLE...................................................................................................................1450 SPECIFICATIONS.....................................................................................................................1450 POWER STEERING SYSTEM SPECIFICATIONS...........................................................................................1450 POWER STEERING PUMP FASTENER TORQUE SPECIFICATIONS.............................................................................1450 SPECIAL TOOLS......................................................................................................................1451 POWER STEERING PUMP............................................................................................................1451 POWER STEERING GEAR....................................................................................................................1452 DESCRIPTION AND OPERATION..........................................................................................................1452 STEERING GEAR OPERATION DESCRIPTION............................................................................................1452 DIAGNOSIS AND TESTING..............................................................................................................1453 POWER STEERING GEAR............................................................................................................1453 POWER STEERING PUMP FLOW AND PRESSURE TEST PROCEDURE.......................................................................1453 REMOVAL AND INSTALLATION...........................................................................................................1453 STEERING GEAR..................................................................................................................1453 REMOVE.....................................................................................................................1453 INSTALL....................................................................................................................1456 DISASSEMBLY AND ASSEMBLY...........................................................................................................1457 STEERING GEAR INNER TIE ROD BOOT...............................................................................................1457 DISASSEMBLE................................................................................................................1457 ASSEMBLE...................................................................................................................1458 OUTER TIE ROD END..............................................................................................................1459 DISASSEMBLE................................................................................................................1459 ASSEMBLE...................................................................................................................1460 SPECIFICATIONS.....................................................................................................................1460 STEERING GEAR FASTENER TORQUE SPECIFICATIONS...................................................................................1460 SPECIAL TOOLS......................................................................................................................1461 POWER STEERING GEAR............................................................................................................1461 STEERING COLUMN........................................................................................................................1462 DESCRIPTION AND OPERATION..........................................................................................................1462 STEERING COLUMN DESCRIPTION....................................................................................................1462 DIAGNOSIS AND TESTING..............................................................................................................1464 STEERING COLUMN................................................................................................................1464 SERVICE PROCEDURES.................................................................................................................1464 STEERING COLUMN SERVICE PROCEDURE WARNINGS.....................................................................................1464 REMOVAL AND INSTALLATION...........................................................................................................1464 STEERING COLUMN ASSEMBLY.......................................................................................................1464 REMOVE.....................................................................................................................1464 INSTALL....................................................................................................................1469 SPECIFICATIONS.....................................................................................................................1471 STEERING COLUMN FASTENER TORQUE SPECIFICATIONS.................................................................................1471 POWER STEERING - 2.5L VM DIESEL ...........................................................................................................1473 POWER STEERINGÐ 2.5L VM DIESEL.........................................................................................................1473 GENERAL INFORMATION................................................................................................................1473 POWER STEERING PUMP............................................................................................................1473 STEERING GEAR OPERATION— RHD & LHD VEHICLES....................................................................................1473 POWER STEERING GEAR............................................................................................................1473 SERVICE PROCEDURES.................................................................................................................1473 POWER STEERING PUMP – INITIAL OPERATION........................................................................................1473 REMOVAL AND INSTALLATION...........................................................................................................1474 POWER STEERING PUMP— 2.5L DIESEL...............................................................................................1474 REMOVAL....................................................................................................................1474 INSTALLATION...............................................................................................................1474 TRANSAXLE AND POWER TRANSFER UNIT..........................................................................................................1475 GENERAL INFORMATION....................................................................................................................1476 31TH TRANSAXLE.....................................................................................................................1476 FLUID LEVEL AND CONDITION..........................................................................................................1476 SELECTION OF LUBRICANT.............................................................................................................1477 SPECIAL ADDITIVES..................................................................................................................1477 DESCRIPTION AND OPERATION..............................................................................................................1477 TORQUE CONVERTER CLUTCH............................................................................................................1477 HYDRAULIC CONTROL SYSTEM...........................................................................................................1477 PRESSURE SUPPLY SYSTEM.............................................................................................................1477 PRESSURE REGULATING VALVES.........................................................................................................1477 FLOW CONTROL VALVES................................................................................................................1477 CLUTCHES, BAND SERVOS, AND ACCUMULATOR.............................................................................................1477 GEARSHIFT AND PARKING LOCK CONTROLS................................................................................................1478 TORQUE CONVERTER CLUTCH SOLENOID WIRING CONNECTOR..................................................................................1478 GOVERNOR...........................................................................................................................1478 DIAGNOSIS AND TESTING..................................................................................................................1478 THREE SPEED TRANSAXLE DIAGNOSIS AND TESTS..........................................................................................1478 31TH HYDRAULIC TROUBLE CODE CHARTS.............................................................................................1478 ROAD TEST..........................................................................................................................1478 HYDRAULIC PRESSURE TESTS...........................................................................................................1487 TEST ONE (SELECTOR IN 1).......................................................................................................1487 TEST TWO (SELECTOR IN 2).......................................................................................................1487 TEST THREE (SELECTOR IN D).....................................................................................................1487 TEST FOUR (SELECTOR IN REVERSE)................................................................................................1488 TEST RESULT INDICATIONS........................................................................................................1488 GOVERNOR PRESSURE..............................................................................................................1489 THROTTLE PRESSURE..............................................................................................................1489 CLUTCH AND SERVO AIR PRESSURE TESTS................................................................................................1489 FRONT CLUTCH...................................................................................................................1489 REAR CLUTCH....................................................................................................................1489 KICKDOWN SERVO (FRONT).........................................................................................................1489 LOW AND REVERSE SERVO (REAR)...................................................................................................1489 FLUID LEAKAGE- TRANSAXLE TORQUE CONVERTER HOUSING AREA.............................................................................1489 TORQUE CONVERTER LEAKAGE.......................................................................................................1489 SERVICE PROCEDURES.....................................................................................................................1490 FLUID AND FILTER CHANGE............................................................................................................1490 30,000 MILE TRANSAXLE OIL CHANGE...............................................................................................1490 SEVERE USAGE SERVICE...........................................................................................................1491 FLUID DRAIN AND REFILL.............................................................................................................1492 ALUMINUM THREAD REPAIR.............................................................................................................1492 FLUSHING COOLERS AND TUBES.........................................................................................................1492 COOLER FLUSH USING TOOL 6906A..................................................................................................1492 OIL PUMP VOLUME CHECK..............................................................................................................1493 REMOVAL AND INSTALLATION...............................................................................................................1493 VEHICLE SPEED SENSOR PINION GEAR...................................................................................................1493 REMOVAL........................................................................................................................1493 INSTALLATION...................................................................................................................1493 PARK/ NEUTRAL STARTING AND BACK- UP LAMP SWITCH....................................................................................1493 TEST...........................................................................................................................1493 REMOVAL........................................................................................................................1493 INSTALLATION...................................................................................................................1493 TRANSAXLE AND TORQUE CONVERTER REMOVAL.............................................................................................1494 REMOVAL........................................................................................................................1494 INSTALLATION...................................................................................................................1494 FRONT PUMP OIL SEAL................................................................................................................1495 REMOVAL........................................................................................................................1495 INSTALLATION...................................................................................................................1495 DISASSEMBLY AND ASSEMBLY...............................................................................................................1495 TRANSAXLE..........................................................................................................................1495 DISASSEMBLY....................................................................................................................1495 ASSEMBLY.......................................................................................................................1501 VALVE BODY RECONDITION.............................................................................................................1501 OIL PUMP- RECONDITION..............................................................................................................1505 FRONT CLUTCH- RECONDITION..........................................................................................................1506 INSPECTION.....................................................................................................................1506 DISASSEMBLY....................................................................................................................1506 ASSEMBLY.......................................................................................................................1507 REAR CLUTCH- RECONDITION...........................................................................................................1507 INSPECTION.....................................................................................................................1507 DISASSEMBLY....................................................................................................................1507 ASSEMBLY.......................................................................................................................1507 FRONT PLANETARY & ANNULUS GEAR-RECONDITION.........................................................................................1509 LOW/ REVERSE (REAR) SERVO- RECONDITION.............................................................................................1510 DISASSEMBLY ASSEMBLY...........................................................................................................1510 ACCUMULATOR- RECONDITION...........................................................................................................1510 DISASSEMBLY....................................................................................................................1510 ASSEMBLY.......................................................................................................................1511 KICKDOWN SERVO (CONTROLLED LOAD) -RECONDITION......................................................................................1511 DISASSEMBLY ASSEMBLY...........................................................................................................1511 TRANSFER SHAFT REPAIR..............................................................................................................1512 DISASSEMBLY....................................................................................................................1512 DETERMINING SHIM THICKNESS.....................................................................................................1516 ASSEMBLY.......................................................................................................................1516 PARKING PAWL.......................................................................................................................1516 DISASSEMBLY ASSEMBLY...........................................................................................................1516 OUTPUT SHAFT REPAIR................................................................................................................1517 DETERMINING SHIM THICKNESS.....................................................................................................1519 DIFFERENTIAL REPAIR................................................................................................................1520 DETERMINING SHIM THICKNESS.....................................................................................................1524 CLEANING AND INSPECTION................................................................................................................1524 VALVE BODY.........................................................................................................................1524 ADJUSTMENTS............................................................................................................................1525 GEARSHIFT CABLE ADJUSTMENT.........................................................................................................1525 THROTTLE PRESSURE LINKAGE ADJUSTMENT...............................................................................................1525 ROD ADJUSTMENT PROCEDURE.......................................................................................................1525 BAND ADJUSTMENT....................................................................................................................1525 KICKDOWN BAND (FRONT)..........................................................................................................1525 LOW/ REVERSE BAND (REAR).......................................................................................................1526 HYDRAULIC CONTROL PRESSURE ADJUSTMENTS.............................................................................................1526 LINE PRESSURE..................................................................................................................1526 THROTTLE PRESSURE..............................................................................................................1526 BEARING ADJUSTMENT PROCEDURES......................................................................................................1526 OUTPUT SHAFT BEARING...............................................................................................................1526 DIFFERENTIAL BEARING...............................................................................................................1527 TRANSFER SHAFT BEARING.............................................................................................................1528 DIFFERENTIAL BEARING SHIM CHART................................................................................................1528 SCHEMATICS AND DIAGRAMS................................................................................................................1530 31TH TRANSAXLE HYDRAULIC SCHEMATIC.................................................................................................1530 SPECIFICATIONS.........................................................................................................................1538 31TH AUTOMATIC TRANSAXLE...........................................................................................................1538 31TH TORQUE SPECIFICATIONS.........................................................................................................1539 SPECIAL TOOLS..........................................................................................................................1540 31TH AUTOMATIC TRANSAXLE...........................................................................................................1540 GENERAL INFORMATION....................................................................................................................1545 41TE FOUR SPEED AUTOMATIC TRANSAXLE................................................................................................1545 TRANSAXLE IDENTIFICATION.......................................................................................................1545 OPERATION......................................................................................................................1546 FLUID LEVEL AND CONDITION..........................................................................................................1546 SELECTION OF LUBRICANT.............................................................................................................1546 SPECIAL ADDITIVES..................................................................................................................1546 DESCRIPTION AND OPERATION..............................................................................................................1546 CLUTCH AND GEAR....................................................................................................................1546 HYDRAULICS.........................................................................................................................1547 SOLENOIDS..........................................................................................................................1547 SENSORS............................................................................................................................1547 ELECTRONICS........................................................................................................................1547 ADAPTIVE CONTROLS..................................................................................................................1547 TORQUE MANAGEMENT..................................................................................................................1548 ON- BOARD DIAGNOSTICS..............................................................................................................1548 TRANSMISSION CONTROL MODULE........................................................................................................1548 GEARSHIFT AND PARKING LOCK CONTROLS................................................................................................1548 TRANSMISSION RANGE SENSOR..........................................................................................................1548 SHIFT POSITION INDICATOR...........................................................................................................1548 DIAGNOSIS AND TESTING..................................................................................................................1549 41TE TRANSAXLE GENERAL DIAGNOSIS...................................................................................................1549 ROAD TEST..........................................................................................................................1549 HYDRAULIC PRESSURE TESTS...........................................................................................................1549 TEST ONE- SELECTOR IN LOW......................................................................................................1550 TEST TWO- SELECTOR IN DRIVE....................................................................................................1550 TEST THREE- OVERDRIVE CLUTCH CHECK.............................................................................................1550 TEST FOUR- SELECTOR IN CIRCLE DRIVE, OVERDRIVE GEAR............................................................................1550 TEST FIVE- SELECTOR IN CIRCLE DRIVE, OVERDRIVE.................................................................................1550 TEST SIX- SELECTOR IN REVERSE..................................................................................................1550 TEST RESULT INDICATIONS........................................................................................................1551 CLUTCH AIR PRESSURE TESTS..........................................................................................................1551 OVERDRIVE CLUTCH...............................................................................................................1551 REVERSE CLUTCH.................................................................................................................1552 2/ 4 CLUTCH....................................................................................................................1552 LOW/ REVERSE CLUTCH............................................................................................................1552 UNDERDRIVE CLUTCH..............................................................................................................1552 FLUID LEAKAGE- TORQUE CONVERTER HOUSING AREA.......................................................................................1552 TORQUE CONVERTER LEAKAGE.......................................................................................................1552 SHIFT POSITION INDICATOR...........................................................................................................1552 SERVICE PROCEDURES.....................................................................................................................1553 FLUID AND FILTER CHANGE............................................................................................................1553 30,000 MILE TRANSAXLE OIL CHANGE...............................................................................................1553 SEVERE USAGE SERVICE...........................................................................................................1554 FLUID DRAIN AND REFILL.............................................................................................................1555 ALUMINUM THREAD REPAIR.............................................................................................................1555 FLUSHING COOLERS AND TUBES.........................................................................................................1555 COOLER FLUSH USING TOOL 6906A..................................................................................................1556 OIL PUMP VOLUME CHECK..............................................................................................................1556 TRANSAXLE QUICK LEARN PROCEDURE....................................................................................................1556 PINION FACTOR PROCEDURE............................................................................................................1557 REMOVAL AND INSTALLATION...............................................................................................................1557 GEARSHIFT CABLE....................................................................................................................1557 REMOVAL........................................................................................................................1557 INSTALLATION...................................................................................................................1557 ADJUSTMENT.....................................................................................................................1558 MANUAL VALVE LEVER (SHIFT LEVER)...................................................................................................1558 REMOVAL........................................................................................................................1558 INSTALLATION...................................................................................................................1558 SOLENOID ASSEMBLY- REPLACE.........................................................................................................1559 TRANSMISSION RANGE SENSOR..........................................................................................................1559 REMOVAL........................................................................................................................1559 INSTALLATION...................................................................................................................1560 SPEED SENSOR- INPUT................................................................................................................1560 SPEED SENSOR- OUTPUT...............................................................................................................1560 TRANSMISSION CONTROL MODULE........................................................................................................1561 REMOVAL........................................................................................................................1561 INSTALLATION...................................................................................................................1561 VALVE BODY.........................................................................................................................1562 REMOVAL........................................................................................................................1562 INSTALLATION...................................................................................................................1563 TRANSAXLE..........................................................................................................................1563 REMOVAL........................................................................................................................1563 INSTALLATION...................................................................................................................1565 OIL PUMP SEAL......................................................................................................................1566 REMOVAL .......................................................................................................................1566 INSTALLATION...................................................................................................................1566 DISASSEMBLY AND ASSEMBLY...............................................................................................................1566 VALVE BODY RECONDITION.............................................................................................................1566 TRANSAXLE DISASSEMBLE..............................................................................................................1569 OIL PUMP INSPECTION............................................................................................................1572 INPUT CLUTCHES- RECONDITION........................................................................................................1584 DISASSEMBLY....................................................................................................................1584 ASSEMBLY.......................................................................................................................1589 TRANSAXLE ASSEMBLE.................................................................................................................1596 OUTPUT GEAR BEARING ADJUSTMENT.................................................................................................1599 OUTPUT GEAR BEARING SHIM CHART.................................................................................................1600 TRANSFER SHAFT BEARING.........................................................................................................1603 TRANSFER SHAFT BEARING SHIM CHART..............................................................................................1604 LOW/ REVERSE REACTION PLATE CHART..............................................................................................1607 DETERMINING No. 4 THRUST PLATE THICKNESS INPUT SHAFT END PLAY.................................................................1608 NO. 4 THRUST PLATE CHART.......................................................................................................1610 DIFFERENTIAL REPAIR................................................................................................................1613 DISASSEMBLE....................................................................................................................1613 CHECKING SIDE GEAR END PLAY....................................................................................................1615 ASSEMBLE.......................................................................................................................1615 DIFFERENTIAL SERVICE TOOLS.....................................................................................................1615 DIFFERENTIAL BEARING PRELOAD ADJUSTMENT........................................................................................1616 DIFFERENTIAL BEARING SHIM CHART................................................................................................1617 CLEANING AND INSPECTION................................................................................................................1618 CLEANING VALVE BODY................................................................................................................1618 ADJUSTMENTS............................................................................................................................1618 GEARSHIFT CABLE ADJUSTMENT.........................................................................................................1618 SCHEMATICS AND DIAGRAMS................................................................................................................1619 41TE TRANSAXLE HYDRAULIC SCHEMATICS................................................................................................1619 SPECIFICATIONS.........................................................................................................................1632 41TE AUTOMATIC TRANSAXLE...........................................................................................................1632 41TE TORQUE SPECIFICATIONS.........................................................................................................1632 SPECIAL TOOLS..........................................................................................................................1633 41TE AUTOMATIC TRANSAXLE...........................................................................................................1633 GENERAL INFORMATION....................................................................................................................1639 POWER TRANSFER UNIT................................................................................................................1639 DIAGNOSIS AND TESTING..................................................................................................................1639 SEAL IDENTIFICATION................................................................................................................1639 FLUID LEAK DIAGNOSIS...............................................................................................................1641 REMOVAL AND INSTALLATION...............................................................................................................1641 POWER TRANSFER UNIT (P. T. U.).....................................................................................................1641 REMOVAL........................................................................................................................1641 INSTALLATION...................................................................................................................1643 END COVER SEAL.....................................................................................................................1643 INPUT SHAFT SEAL...................................................................................................................1643 REMOVAL........................................................................................................................1643 INSTALLATION...................................................................................................................1644 DIFFERENTIAL CARRIER SEAL..........................................................................................................1644 REMOVAL........................................................................................................................1644 INSTALLATION...................................................................................................................1645 REAR COVER O- RING.................................................................................................................1645 REMOVAL........................................................................................................................1645 INSTALLATION...................................................................................................................1645 POWER TRANSFER UNIT OUTPUT SEAL....................................................................................................1645 REMOVAL........................................................................................................................1646 INSTALLATION...................................................................................................................1647 INPUT SHAFT COVER SEAL.............................................................................................................1648 REMOVAL........................................................................................................................1648 INSTALLATION...................................................................................................................1648 HALF SHAFT INNER SEAL..............................................................................................................1649 REMOVAL........................................................................................................................1649 INSTALLATION...................................................................................................................1650 INPUT SHAFT END SEAL...............................................................................................................1651 REMOVAL........................................................................................................................1651 INSTALLATION...................................................................................................................1651 OUTER HALF SHAFT SEAL..............................................................................................................1651 REMOVAL........................................................................................................................1652 INSTALLATION...................................................................................................................1652 END COVER BALL BEARING.............................................................................................................1652 REMOVAL........................................................................................................................1652 INSTALLATION...................................................................................................................1653 ADJUSTMENTS............................................................................................................................1654 OUTPUT FLANGE SHIM SELECTION.......................................................................................................1654 SPECIFICATIONS.........................................................................................................................1654 TORQUE.............................................................................................................................1654 SPECIAL TOOLS..........................................................................................................................1655 SDP POWER TRANSFER UNIT............................................................................................................1655 A– 598 MANUAL TRANSAXLE....................................................................................................................1657 GENERAL INFORMATION....................................................................................................................1658 A- 598 MANUAL TRANSAXLE............................................................................................................1658 A- 558 MANUAL TRANSAXLE— RHD VEHICLES..............................................................................................1658 TRANSAXLE IDENTIFICATION INFORMATION...............................................................................................1658 TRANSAXLE IDENTIFICATION INFORMATION— RHD VEHICLES.................................................................................1658 SELECTION OF LUBRICANT.............................................................................................................1658 SELECTION OF LUBRICANT— RHD VEHICLES...............................................................................................1658 SPECIAL ADDITIVES..................................................................................................................1658 SPECIAL ADDITIVES— RHD VEHICLES....................................................................................................1659 GEAR RATIOS........................................................................................................................1659 GEAR RATIOS— RHD VEHICLES..........................................................................................................1659 GEARSHIFT PATTERN..................................................................................................................1659 GEARSHIFT PATTERN— RHD VEHICLES....................................................................................................1659 DESCRIPTION AND OPERATION..............................................................................................................1659 GEARSHIFT LEVERS...................................................................................................................1659 AXLE SEALS.........................................................................................................................1659 DIAGNOSIS AND TESTING..................................................................................................................1659 COMMON PROBLEM CAUSES..............................................................................................................1659 HARD SHIFTING......................................................................................................................1660 NOISY OPERATION....................................................................................................................1660 SLIPS OUT OF GEAR..................................................................................................................1660 LOW LUBRICANT LEVEL................................................................................................................1660 CLUTCH PROBLEMS....................................................................................................................1660 SERVICE PROCEDURES.....................................................................................................................1660 FLUID DRAIN AND FILL...............................................................................................................1660 TRANSAXLE FLUID DRAIN..........................................................................................................1660 TRANSAXLE FLUID FILL...........................................................................................................1660 FLUID DRAIN AND FILL— RHD VEHICLES.................................................................................................1660 TRANSAXLE FLUID DRAIN..........................................................................................................1660 TRANSAXLE FLUID FILL...........................................................................................................1660 REMOVAL AND INSTALLATION...............................................................................................................1661 GEARSHIFT KNOB.....................................................................................................................1661 REMOVAL........................................................................................................................1661 INSTALLATION...................................................................................................................1661 GEARSHIFT BOOT.....................................................................................................................1661 REMOVAL........................................................................................................................1661 INSTALLATION...................................................................................................................1661 GEARSHIFT BOOT.....................................................................................................................1661 REMOVAL........................................................................................................................1661 INSTALLATION...................................................................................................................1661 GEARSHIFT CABLES...................................................................................................................1661 REMOVAL........................................................................................................................1661 INSTALLATION...................................................................................................................1663 GEARSHIFT CABLES— RHD VEHICLES.....................................................................................................1663 REMOVAL........................................................................................................................1663 INSTALLATION...................................................................................................................1663 GEARSHIFT MECHANISM REPLACEMENT....................................................................................................1663 REMOVAL........................................................................................................................1663 INSTALLATION...................................................................................................................1664 GEARSHIFT MECHANISM REPLACEMENT— RHD VEHICLES......................................................................................1664 REMOVAL........................................................................................................................1664 INSTALLATION...................................................................................................................1665 VEHICLE SPEED SENSOR DRIVE GEAR....................................................................................................1665 REMOVAL........................................................................................................................1665 INSTALLATION...................................................................................................................1665 BACK- UP LAMP SWITCH...............................................................................................................1665 REMOVAL........................................................................................................................1665 INSTALLATION...................................................................................................................1666 CRANKSHAFT POSITION SENSOR — 2.5L VM DIESEL........................................................................................1666 REMOVAL........................................................................................................................1667 INSTALLATION...................................................................................................................1667 CROSSOVER LEVER....................................................................................................................1667 REMOVAL........................................................................................................................1667 INSTALLATION...................................................................................................................1667 SELECTOR LEVER.....................................................................................................................1667 REMOVAL........................................................................................................................1667 INSTALLATION...................................................................................................................1667 AXLE SEALS.........................................................................................................................1667 EXTENSION HOUSING AXLE SEAL....................................................................................................1667 DIFFERENTIAL BEARING RETAINER AXLE SEAL........................................................................................1668 SHIFT SHAFT SEALS..................................................................................................................1668 REMOVAL........................................................................................................................1668 INSTALLATION...................................................................................................................1668 TRANSAXLE..........................................................................................................................1668 REMOVAL........................................................................................................................1668 INSTALLATION...................................................................................................................1670 INPUT SHAFT FRONT BEARING RETAINER.................................................................................................1671 REMOVAL........................................................................................................................1671 INSTALLATION...................................................................................................................1671 INPUT SHAFT SEAL...................................................................................................................1672 REMOVAL........................................................................................................................1672 INSTALLATION...................................................................................................................1672 A- 558 TRANSAXLE ASSEMBLY— RHD VEHICLES............................................................................................1672 REMOVAL........................................................................................................................1672 INSTALLATION...................................................................................................................1675 DISASSEMBLY AND ASSEMBLY...............................................................................................................1676 TRANSAXLE..........................................................................................................................1676 DISASSEMBLY....................................................................................................................1676 ASSEMBLY.......................................................................................................................1684 INPUT SHAFT........................................................................................................................1688 DISASSEMBLY....................................................................................................................1688 ASSEMBLY.......................................................................................................................1688 INTERMEDIATE SHAFT.................................................................................................................1689 DISASSEMBLY....................................................................................................................1689 ASSEMBLY.......................................................................................................................1693 DIFFERENTIAL.......................................................................................................................1695 DIFFERENTIAL BEARINGS..........................................................................................................1695 RING GEAR......................................................................................................................1698 DIFFERENTIAL GEARS.............................................................................................................1698 SYNCHRONIZER.......................................................................................................................1699 DISASSEMBLY....................................................................................................................1700 ASSEMBLY.......................................................................................................................1700 SHIFT COVER........................................................................................................................1701 DISASSEMBLY....................................................................................................................1701 ASSEMBLY.......................................................................................................................1703 TRANSAXLE CASE.....................................................................................................................1704 INTERMEDIATE SHAFT FRONT BEARING CUP...........................................................................................1704 INPUT SHAFT FRONT BEARING......................................................................................................1705 SHIFT RAIL BUSHINGS............................................................................................................1707 REVERSE SHIFT LEVER............................................................................................................1708 CLEANING AND INSPECTION................................................................................................................1708 TRANSAXLE..........................................................................................................................1708 SYNCHRONIZER.......................................................................................................................1708 CLEAN..........................................................................................................................1708 INSPECT........................................................................................................................1708 ADJUSTMENTS............................................................................................................................1708 GEARSHIFT CROSSOVER CABLE..........................................................................................................1708 GEARSHIFT CROSSOVER CABLE..........................................................................................................1711 BEARING ADJUSTMENT PROCEDURE.......................................................................................................1712 GENERAL RULES ON SERVICING BEARINGS............................................................................................1713 INTERMEDIATE SHAFT BEARING PRELOAD.................................................................................................1713 SPECIFICATIONS.........................................................................................................................1715 A- 598 (T- 750) MANUAL TRANSAXLE...................................................................................................1715 NV T750 (A- 598) MANUAL TRANSAXLE FLUID FILL...................................................................................1715 A- 558 MANUAL TRANSAXLE— RHD VEHICLES..............................................................................................1715 SPECIAL TOOLS..........................................................................................................................1716 A- 558 MANUAL TRANSAXLE FLUID FILL.................................................................................................1716 A- 598 (T- 750) MANUAL TRANSAXLE ..................................................................................................1716 A- 558 MANUAL TRANSAXLE RHD VEHICLES..............................................................................................1716 TIRES AND WHEELS...........................................................................................................................1719 DESCRIPTION AND OPERATION..............................................................................................................1719 TIRE INFORMATION...................................................................................................................1719 TIRE IDENTIFICATION............................................................................................................1719 TIRE CHAINS....................................................................................................................1719 RADIAL-PLY TIRES...................................................................................................................1720 SPARE TIRE (TEMPORARY).............................................................................................................1720 TIRE INFLATION PRESSURES...........................................................................................................1720 TIRE PRESSURE FOR HIGH-SPEED DRIVING...............................................................................................1721 REPLACEMENT TIRES..................................................................................................................1721 DIAGNOSIS AND TESTING..................................................................................................................1721 PRESSURE GAUGES....................................................................................................................1721 TREAD WEAR INDICATORS..............................................................................................................1721 TIRE WEAR PATTERNS.................................................................................................................1722 TIRE NOISE OR VIBRATION............................................................................................................1722 LEAD CORRECTION CHART..............................................................................................................1722 LEAD CORRECTION CHART..........................................................................................................1723 SERVICE PROCEDURES.....................................................................................................................1724 TIRE AND WHEEL ROTATION (NON-DIRECTIONAL THREAD PATTERN)...........................................................................1724 REPAIRING TIRE LEAKS...............................................................................................................1724 TIRE AND WHEEL MATCH MOUNTING......................................................................................................1724 CLEANING AND INSPECTION................................................................................................................1725 CLEANING TIRES.....................................................................................................................1725 SPECIFICATIONS.........................................................................................................................1726 TIRE SPECIFICATIONS................................................................................................................1726 DESCRIPTION AND OPERATION..............................................................................................................1727 WHEEL INFORMATION..................................................................................................................1727 DIAGNOSIS AND TESTING..................................................................................................................1727 WHEEL INSPECTION...................................................................................................................1727 TIRE AND WHEEL RUNOUT..............................................................................................................1728 METHOD 1 (RELOCATE WHEEL ON HUB)...............................................................................................1728 METHOD 2 (RELOCATE TIRE ON WHEEL)..............................................................................................1728 SERVICE PROCEDURES.....................................................................................................................1729 WHEEL INSTALLATION.................................................................................................................1729 TIRE AND WHEEL BALANCE.............................................................................................................1729 SPECIFICATIONS.........................................................................................................................1730 WHEEL SPECIFICATIONS...............................................................................................................1730 BODY.......................................................................................................................................1731 GENERAL INFORMATION....................................................................................................................1731 SAFETY PRECAUTIONS AND WARNINGS....................................................................................................1731 GENERAL INFORMATION....................................................................................................................1732 PAINT CODE.........................................................................................................................1732 BASE COAT/ CLEAR COAT FINISH.......................................................................................................1732 WET SANDING, BUFFING, AND POLISHING................................................................................................1732 PAINTED SURFACE TOUCH- UP..........................................................................................................1732 TOUCH- UP PROCEDURE............................................................................................................1732 AFTERMARKET PAINT REPAIR PRODUCTS..................................................................................................1733 EXTERIOR COLORS................................................................................................................1733 INTERIOR COLORS................................................................................................................1733 DESCRIPTION AND OPERATION..............................................................................................................1734 SAFETY PRECAUTIONS.................................................................................................................1734 REMOVAL AND INSTALLATION...............................................................................................................1734 WINDSHIELD.........................................................................................................................1734 WINDSHIELD REMOVAL – EXTERIOR METHOD...........................................................................................1734 WINDSHIELD REMOVAL – INTERIOR METHOD...........................................................................................1735 WINDSHIELD INSTALLATION........................................................................................................1735 BODY SIDE/ SLIDING DOOR STATIONARY GLASS...........................................................................................1736 REMOVAL........................................................................................................................1736 INSTALLATION...................................................................................................................1736 REAR WINDOW........................................................................................................................1737 REAR WINDOW REMOVAL – EXTERIOR METHOD..........................................................................................1737 REAR WINDOW REMOVAL – INTERIOR METHOD..........................................................................................1737 REAR WINDOW INSTALLATION.......................................................................................................1737 REMOVAL AND INSTALLATION...............................................................................................................1739 ARM REST...........................................................................................................................1739 REMOVAL........................................................................................................................1739 INSTALLATION...................................................................................................................1739 BENCH SEAT BACK COVER..............................................................................................................1739 REMOVAL........................................................................................................................1739 INSTALLATION...................................................................................................................1739 BENCH SEAT BACK HINGE..............................................................................................................1739 REMOVAL........................................................................................................................1739 INSTALLATION...................................................................................................................1740 SYNCHRONIZING CABLE ADJUSTMENT.................................................................................................1740 BENCH SEAT BACK HINGE COVERS.......................................................................................................1740 REMOVAL........................................................................................................................1740 INSTALLATION...................................................................................................................1740 BENCH SEAT RISER – FIRST REAR......................................................................................................1741 REMOVAL........................................................................................................................1741 INSTALLATION...................................................................................................................1741 BENCH SEAT RISER – SECOND REAR.....................................................................................................1741 REMOVAL........................................................................................................................1741 INSTALLATION...................................................................................................................1741 BENCH SEAT TRACK – SECOND REAR.....................................................................................................1741 REMOVAL........................................................................................................................1741 INSTALLATION...................................................................................................................1741 BUCKET SEAT BACK...................................................................................................................1742 REMOVAL........................................................................................................................1742 INSTALLATION...................................................................................................................1742 BUCKET SEAT BACK ASSIST STRAP......................................................................................................1742 REMOVAL........................................................................................................................1742 INSTALLATION...................................................................................................................1742 BUCKET SEAT CUSHION PAN............................................................................................................1742 REMOVAL........................................................................................................................1742 INSTALLATION...................................................................................................................1743 BUCKET SEAT CUSHION SIDE COVER.....................................................................................................1743 REMOVAL........................................................................................................................1743 INSTALLATION...................................................................................................................1743 BUCKET SEAT RECLINER – MANUAL......................................................................................................1743 REMOVAL........................................................................................................................1743 INSTALLATION...................................................................................................................1743 BUCKET SEAT RECLINER – POWER.......................................................................................................1744 REMOVAL........................................................................................................................1744 INSTALLATION...................................................................................................................1744 BUCKET SEAT RISER – MANUAL TRACK...................................................................................................1744 REMOVAL........................................................................................................................1744 INSTALLATION...................................................................................................................1744 BUCKET SEAT TRACK – MANUAL.........................................................................................................1744 REMOVAL........................................................................................................................1744 INSTALLATION...................................................................................................................1744 BUCKET SEAT TRACK – POWER..........................................................................................................1744 REMOVAL........................................................................................................................1744 INSTALLATION...................................................................................................................1745 BUCKET SEAT TRACK FRONT COVER – POWER..............................................................................................1745 REMOVAL........................................................................................................................1745 INSTALLATION...................................................................................................................1745 BUCKET SEAT TRACK REAR COVER – POWER...............................................................................................1745 REMOVAL........................................................................................................................1745 INSTALLATION...................................................................................................................1745 CHILD RESTRAINT SEAT MODULE........................................................................................................1746 REMOVAL........................................................................................................................1746 INSTALLATION...................................................................................................................1746 HEAD RESTRAINT – BENCH SEAT........................................................................................................1746 REMOVAL........................................................................................................................1746 INSTALLATION...................................................................................................................1747 HEAD RESTRAINT – BUCKET SEAT.......................................................................................................1747 REMOVAL........................................................................................................................1747 INSTALLATION...................................................................................................................1748 HEAD RESTRAINT SLEEVE..............................................................................................................1748 REMOVAL........................................................................................................................1748 INSTALLATION...................................................................................................................1748 HEATED SEAT HEATING ELEMENT........................................................................................................1748 HEATED SEAT MODULE.................................................................................................................1748 REMOVAL........................................................................................................................1748 INSTALLATION...................................................................................................................1749 HEATED SEAT SWITCH.................................................................................................................1749 REMOVAL........................................................................................................................1749 INSTALLATION...................................................................................................................1749 MECHANICAL LUMBAR HANDLE ASSEMBLY..................................................................................................1749 REMOVAL........................................................................................................................1749 INSTALLATION...................................................................................................................1749 PLASTIC GROCERY BAG RETAINER.......................................................................................................1749 REMOVAL........................................................................................................................1749 INSTALLATION...................................................................................................................1749 POWER SEAT SWITCH..................................................................................................................1750 REMOVAL........................................................................................................................1750 INSTALLATION...................................................................................................................1750 RECLINER HANDLE – MANUAL...........................................................................................................1750 REMOVAL........................................................................................................................1750 INSTALLATION...................................................................................................................1750 UNDER SEAT STORAGE BIN.............................................................................................................1750 REMOVAL........................................................................................................................1750 INSTALLATION...................................................................................................................1750 UNDER SEAT STORAGE BIN GUIDE.......................................................................................................1751 REMOVAL........................................................................................................................1751 INSTALLATION...................................................................................................................1751 UNDER SEAT STORAGE BIN LOCK/ LATCH.................................................................................................1751 REMOVAL........................................................................................................................1751 INSTALLATION...................................................................................................................1751 DIAGNOSIS AND TESTING..................................................................................................................1753 WATER LEAKS........................................................................................................................1753 VISUAL INSPECTION BEFORE WATER LEAK TESTS......................................................................................1753 WATER LEAK TESTS...............................................................................................................1753 WATER LEAK DETECTION...........................................................................................................1753 WIND NOISE.........................................................................................................................1754 VISUAL INSPECTION BEFORE TESTS.................................................................................................1754 SERVICE PROCEDURES.....................................................................................................................1754 HEAT STAKING.......................................................................................................................1754 REMOVAL AND INSTALLATION...............................................................................................................1755 A- PILLAR LOWER EXTENSION TRIM.....................................................................................................1755 REMOVAL........................................................................................................................1755 INSTALLATION...................................................................................................................1755 A- PILLAR TRIM PANEL...............................................................................................................1755 REMOVAL........................................................................................................................1755 INSTALLATION...................................................................................................................1755 COWL COVER.........................................................................................................................1755 REMOVAL........................................................................................................................1755 INSTALLATION...................................................................................................................1755 COWL TRIM..........................................................................................................................1755 REMOVAL........................................................................................................................1755 INSTALLATION...................................................................................................................1756 FLOOR CARPET.......................................................................................................................1756 REMOVAL........................................................................................................................1756 INSTALLATION...................................................................................................................1756 FRONT DOOR.........................................................................................................................1757 REMOVAL........................................................................................................................1757 INSTALLATION...................................................................................................................1757 FRONT DOOR APPLIQUE................................................................................................................1758 REMOVAL........................................................................................................................1758 INSTALLATION...................................................................................................................1758 FRONT DOOR CHECK STRAP.............................................................................................................1758 REMOVAL........................................................................................................................1758 INSTALLATION...................................................................................................................1759 FRONT DOOR FRAME CLOSEOUT MOLDINGS.................................................................................................1759 REMOVAL – A- PILLAR, HEADER, OR B- PILLAR......................................................................................1759 INSTALLATION – A- PILLAR, HEADER, OR B- PILLAR.................................................................................1759 FRONT DOOR GLASS...................................................................................................................1759 REMOVAL........................................................................................................................1759 INSTALLATION...................................................................................................................1759 FRONT DOOR GLASS RUN WEATHER- STRIP................................................................................................1760 REMOVAL........................................................................................................................1760 INSTALLATION...................................................................................................................1760 FRONT DOOR HINGE...................................................................................................................1760 REMOVAL........................................................................................................................1761 INSTALLATION...................................................................................................................1761 FRONT DOOR INNER BELT MOLDING......................................................................................................1761 REMOVAL........................................................................................................................1761 INSTALLATION...................................................................................................................1761 FRONT DOOR LATCH...................................................................................................................1761 REMOVAL........................................................................................................................1761 INSTALLATION...................................................................................................................1762 FRONT DOOR LATCH STRIKER...........................................................................................................1762 REMOVAL........................................................................................................................1762 INSTALLATION...................................................................................................................1762 FRONT DOOR LOCK CYLINDER...........................................................................................................1762 REMOVAL........................................................................................................................1762 INSTALLATION...................................................................................................................1763 FRONT DOOR OUTER BELT MOLDING......................................................................................................1763 REMOVAL........................................................................................................................1763 INSTALLATION...................................................................................................................1763 FRONT DOOR OUTSIDE HANDLE..........................................................................................................1763 REMOVAL........................................................................................................................1763 INSTALLATION...................................................................................................................1764 FRONT DOOR REFLECTOR...............................................................................................................1764 REMOVAL........................................................................................................................1764 INSTALLATION...................................................................................................................1764 FRONT DOOR SILL PLATE..............................................................................................................1764 REMOVAL........................................................................................................................1764 INSTALLATION...................................................................................................................1764 FRONT DOOR TRIM PANEL..............................................................................................................1764 REMOVAL........................................................................................................................1764 INSTALLATION...................................................................................................................1765 FRONT DOOR WEATHER- STRIP..........................................................................................................1766 REMOVAL........................................................................................................................1766 INSTALLATION...................................................................................................................1766 FRONT DOOR WINDOW CRANK............................................................................................................1766 REMOVAL........................................................................................................................1766 INSTALLATION...................................................................................................................1766 FRONT DOOR WINDOW REGULATOR........................................................................................................1766 REMOVAL........................................................................................................................1766 INSTALLATION...................................................................................................................1767 FRONT SEAT.........................................................................................................................1767 REMOVAL........................................................................................................................1767 INSTALLATION...................................................................................................................1767 FRONT WHEELHOUSE SPLASH SHIELD.....................................................................................................1767 REMOVAL........................................................................................................................1767 INSTALLATION...................................................................................................................1767 FUEL FILL DOOR BLOCKER LATCH.......................................................................................................1768 REMOVAL........................................................................................................................1768 INSTALLATION...................................................................................................................1768 FUEL FILL DOOR BLOCKER LATCH STRIKER...............................................................................................1768 REMOVAL........................................................................................................................1768 INSTALLATION...................................................................................................................1768 FUEL FILL DOOR BLOCKER LOCKOUT LINK................................................................................................1768 REMOVAL........................................................................................................................1768 INSTALLATION...................................................................................................................1769 FUEL FILLER HOUSING – WITH BLOCKER LATCH...........................................................................................1769 REMOVAL........................................................................................................................1769 INSTALLATION...................................................................................................................1769 GRILLE.............................................................................................................................1769 REMOVAL........................................................................................................................1769 INSTALLATION...................................................................................................................1769 HEADLINING......................................................................................................................... 0 REMOVAL........................................................................................................................1769 INSTALLATION...................................................................................................................1770 HOOD...............................................................................................................................1770 REMOVAL........................................................................................................................1770 INSTALLATION...................................................................................................................1770 HOOD HINGE.........................................................................................................................1771 REMOVAL........................................................................................................................1771 INSTALLATION................................................................................................................... 0 ADJUSTMENTS............................................................................................................................1810 SLIDING DOOR ADJUSTMENTS...........................................................................................................1810 PRELIMINARY CHECKS.............................................................................................................1810 UP/ DOWN ADJUSTMENT............................................................................................................1810 FORE/ AFT ADJUSTMENT...........................................................................................................1810 SEAL COMPRESSION...............................................................................................................1811 STABILIZER ADJUSTMENT..........................................................................................................1812 BODY 1 ....................................................................................................................................1813 REMOVAL AND INSTALLATION...............................................................................................................1813 HEAD RESTRAINT.....................................................................................................................1813 REMOVAL........................................................................................................................1813 INSTALLATION...................................................................................................................1813 HEAD RESTRAINT ESCUTCHEON..........................................................................................................1813 REMOVAL........................................................................................................................1813 INSTALLATION...................................................................................................................1813 HEAD RESTRAINT SLEEVE..............................................................................................................1814 REMOVAL........................................................................................................................1814 INSTALLATION...................................................................................................................1814 BENCH SEAT BACK COVER..............................................................................................................1814 REMOVAL........................................................................................................................1814 INSTALLATION...................................................................................................................1814 REMOVAL AND INSTALLATION...............................................................................................................1815 GEARSHIFT CONSOLE..................................................................................................................1815 REMOVAL........................................................................................................................1815 INSTALLATION...................................................................................................................1815 LIFTGATE CHMSL ACCESS PANEL........................................................................................................1815 REMOVAL........................................................................................................................1815 INSTALLATION...................................................................................................................1816 HEATING AND AIR CONDITIONING...............................................................................................................1817 GENERAL INFORMATION....................................................................................................................1818 INTRODUCTION.......................................................................................................................1818 SAFETY PRECAUTIONS AND WARNINGS....................................................................................................1818 DESCRIPTION AND OPERATION..............................................................................................................1818 AIR DISTRIBUTION DUCTS.............................................................................................................1818 A/ C PRESSURE TRANSDUCER...........................................................................................................1818 A/ C SERVICE PORTS.................................................................................................................1818 REAR BLOWER SPEED SWITCH...........................................................................................................1819 COMPRESSOR HIGH-PRESSURE RELIEF VALVE..............................................................................................1819 CONDENSATE DRAIN...................................................................................................................1819 ENGINE COOLING SYSTEM REQUIREMENTS.................................................................................................1819 EVAPORATOR PROBE...................................................................................................................1819 HANDLING TUBING AND FITTINGS.......................................................................................................1819 HVAC CONTROL MODULE................................................................................................................1820 SIDE DOOR HEATER A/ C OUTLETS......................................................................................................1820 SIDE WINDOW DEMISTER...............................................................................................................1820 SYSTEM AIRFLOW.....................................................................................................................1820 SYSTEM OIL LEVEL...................................................................................................................1821 REFRIGERANT OIL LEVEL CHECK....................................................................................................1821 SERVICING REFRIGERANT OIL LEVEL................................................................................................1822 DIAGNOSIS AND TESTING..................................................................................................................1822 ACTUATOR CALIBRATION/ DIAGNOSTICS AND COOLDOWN TEST................................................................................1822 GENERAL INFORMATION............................................................................................................1822 ACTUATOR CALIBRATION...........................................................................................................1822 REFRIGERANT OIL CAPACITIES.....................................................................................................1822 DIAGNOSTICS....................................................................................................................1823 COOLDOWN TEST..................................................................................................................1823 CALIBRATION/ COOLDOWN LED DISPLAY CODES........................................................................................1823 CALIBRATION/ DIAGNOSTICS TEST ENTRY............................................................................................1823 CALIBRATION/ COOLDOWN LED DISPLAY CODES........................................................................................1823 COOLDOWN TEST ENTRY............................................................................................................1824 CALIBRATION DIAGNOSTICS AND COOLDOWN ABORT.....................................................................................1824 EEPROM DATA....................................................................................................................1824 ACTUATOR CALIBRATION AND DIAGNOSTICS...........................................................................................1824 FAIL CODES/ LEVEL DISPLAY......................................................................................................1825 WIPE BUTTON LED................................................................................................................1825 LEVEL 1– FAILURE CODE VALUES (INTERMITTENT WIPE BUTTON LED)....................................................................1825 TEMPERATURE AND MODE POTENTIOMETER DIAGNOSTICS.................................................................................1825 POTENTIOMETER VS. POSITION AND FLASH RATE......................................................................................1825 EVAPORATOR PROBE TEMPERATURE DIAGNOSTICS.......................................................................................1825 HVAC CONTROL DIAGNOSTIC CONDITIONS.................................................................................................1825 A/ C PERFORMANCE TEST..............................................................................................................1828 PERFORMANCE TEST PROCEDURE.....................................................................................................1828 A/ C PRESSURE TRANSDUCER...........................................................................................................1828 A/ C PERFORMANCE TEMPERATURES..................................................................................................1828 A/ C PRESSURE TRANSDUCER VOLTAGE...............................................................................................1829 BLOWER MOTOR AND WHEEL ASSEMBLY....................................................................................................1829 VIBRATION AND/ OR NOISE DIAGNOSIS..............................................................................................1829 COMPRESSOR NOISE DIAGNOSIS.........................................................................................................1829 COMPRESSOR CLUTCH/ COIL............................................................................................................1829 TESTS..........................................................................................................................1829 EXPANSION VALVE....................................................................................................................1829 TESTS..........................................................................................................................1829 HEATER PERFORMANCE TEST............................................................................................................1831 PRE-DIAGNOSTIC PREPARATIONS....................................................................................................1831 MAXIMUM HEATER OUTPUT: TEST AND ACTION.........................................................................................1831 TEMPERATURE REFERENCE TABLE....................................................................................................1831 POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW.........................................................................1831 POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT................................................................................1831 TEMPERATURE CONTROL............................................................................................................1832 SYSTEM CHARGE LEVEL TEST...........................................................................................................1832 SERVICE PROCEDURES.....................................................................................................................1832 R-134a REFRIGERANT.................................................................................................................1832 CHARGING REFRIGERANT SYSTEM........................................................................................................1833 EVACUATING REFRIGERANT SYSTEM......................................................................................................1834 THERMOCOUPLE PROBE.................................................................................................................1835 STICKING HVAC CONTROL MODULE PUSH BUTTONS..........................................................................................1835 SYSTEM LEAK CHECKING...............................................................................................................1835 EMPTY REFRIGERANT SYSTEM LEAK TEST.............................................................................................1835 LOW REFRIGERANT LEVEL LEAK TEST................................................................................................1835 REMOVAL AND INSTALLATION...............................................................................................................1836 A/ C PRESSURE TRANSDUCER...........................................................................................................1836 REMOVAL........................................................................................................................1836 INSTALLATION...................................................................................................................1836 A/ C SERVICE PORTS.................................................................................................................1836 REMOVAL........................................................................................................................1836 INSTALLATION...................................................................................................................1836 BLEND-AIR DOOR ACTUATOR............................................................................................................1836 REMOVAL........................................................................................................................1836 INSTALLATION...................................................................................................................1836 BLOWER MOTOR AND WHEEL ASSEMBLY....................................................................................................1837 REMOVAL........................................................................................................................1837 INSTALLATION...................................................................................................................1837 BLOWER MOTOR RESISTOR BLOCK........................................................................................................1837 REMOVAL........................................................................................................................1837 INSTALLATION...................................................................................................................1838 BLOWER MOTOR WHEEL.................................................................................................................1838 COMPRESSOR.........................................................................................................................1839 REMOVAL........................................................................................................................1839 INSTALLATION...................................................................................................................1839 COMPRESSOR CLUTCH/ COIL............................................................................................................1839 REMOVAL........................................................................................................................1839 INSTALLATION...................................................................................................................1841 CLUTCH BREAK-IN................................................................................................................1841 CONDENSER ASSEMBLY.................................................................................................................1841 REMOVAL........................................................................................................................1841 INSTALLATION...................................................................................................................1842 DISCHARGE LINE.....................................................................................................................1842 REMOVAL........................................................................................................................1842 INSTALLATION...................................................................................................................1843 EVAPORATOR PROBE...................................................................................................................1843 REMOVAL........................................................................................................................1843 INSTALLATION...................................................................................................................1843 EXPANSION VALVE....................................................................................................................1844 REMOVAL........................................................................................................................1844 INSTALLATION...................................................................................................................1844 FILTER-DRIER ASSEMBLY..............................................................................................................1844 REMOVAL........................................................................................................................1844 INSTALLATION...................................................................................................................1845 HEATER A/ C UNIT HOUSING...........................................................................................................1845 REMOVAL........................................................................................................................1845 INSTALLATION...................................................................................................................1846 HEATER CORE........................................................................................................................1846 REMOVAL........................................................................................................................1846 INSTALLATION...................................................................................................................1847 HEATER HOSES.......................................................................................................................1847 REMOVAL........................................................................................................................1847 INSTALLATION...................................................................................................................1848 LIQUID LINE........................................................................................................................1848 REMOVAL........................................................................................................................1848 INSTALLATION...................................................................................................................1848 MODE DOOR ACTUATOR.................................................................................................................1848 REMOVAL........................................................................................................................1848 INSTALLATION...................................................................................................................1848 SIDE WINDOW DEMISTER DUCTS.........................................................................................................1849 LEFT SIDE......................................................................................................................1849 RIGHT SIDE.....................................................................................................................1849 SUCTION LINE.......................................................................................................................1849 REMOVAL........................................................................................................................1849 INSTALLATION...................................................................................................................1849 RECIRC DOOR ACTUATOR...............................................................................................................1850 REMOVAL........................................................................................................................1850 INSTALLATION...................................................................................................................1850 DISASSEMBLY AND ASSEMBLY...............................................................................................................1850 HEATER A/ C UNIT RECONDITION.......................................................................................................1850 DISASSEMBLY - EVAPORATOR HOUSING...............................................................................................1850 ASSEMBLY - EVAPORATOR HOUSING..................................................................................................1851 DISASSEMBLY - DISTRIBUTION HOUSING.............................................................................................1851 ASSEMBLY - DISTRIBUTION HOUSING................................................................................................1856 GENERAL INFORMATION....................................................................................................................1857 INTRODUCTION.......................................................................................................................1857 DESCRIPTION AND OPERATION..............................................................................................................1857 REAR BLOWER RESISTOR BLOCK.........................................................................................................1857 REAR HEATER AND A/ C LINES.........................................................................................................1857 SYSTEM OPERATION...................................................................................................................1857 DIAGNOSIS AND TESTING..................................................................................................................1859 DIAGNOSTIC PROCEDURES..............................................................................................................1859 REMOVAL AND INSTALLATION...............................................................................................................1859 AIR DISTRIBUTION DUCT- A/ C........................................................................................................1859 REMOVAL........................................................................................................................1859 INSTALLATION...................................................................................................................1859 AIR DISTRIBUTION DUCT- HEATER......................................................................................................1859 REMOVAL........................................................................................................................1859 INSTALLATION...................................................................................................................1859 EVAPORATOR AND EXPANSION VALVE.....................................................................................................1860 REMOVAL........................................................................................................................1860 INSTALLATION...................................................................................................................1860 REAR AIR CONDITIONING LINES........................................................................................................1861 REMOVAL........................................................................................................................1861 INSTALLATION...................................................................................................................1861 REAR HEATER A/ C AIR OUTLETS.......................................................................................................1861 REMOVAL........................................................................................................................1861 INSTALLATION...................................................................................................................1861 REAR HEATER- A/ C AUXILIARY CONDENSER..............................................................................................1861 REMOVAL........................................................................................................................1861 INSTALLATION...................................................................................................................1861 REAR HEATER A/ C BLOWER MOTOR......................................................................................................1862 REMOVAL........................................................................................................................1862 INSTALLATION...................................................................................................................1862 REAR HEATER- A/ C CONTROL ILLUMINATION BULB........................................................................................1862 REMOVAL........................................................................................................................1862 INSTALLATION...................................................................................................................1862 REAR HEATER A/ C UNIT..............................................................................................................1862 REMOVAL........................................................................................................................1862 INSTALLATION...................................................................................................................1863 REAR HEATER CORE...................................................................................................................1864 REMOVAL........................................................................................................................1864 INSTALLATION...................................................................................................................1864 REAR HEATER LINES..................................................................................................................1865 REMOVAL........................................................................................................................1865 INSTALLATION...................................................................................................................1865 MODE DOOR..........................................................................................................................1865 REMOVAL........................................................................................................................1865 INSTALLATION...................................................................................................................1865 MODE DOOR ACTUATOR.................................................................................................................1865 REMOVAL........................................................................................................................1865 INSTALLATION...................................................................................................................1865 HEATING AND AIR CONDITIONING 1 ............................................................................................................1867 GENERAL INFORMATION....................................................................................................................1867 INTRODUCTION.......................................................................................................................1867 SAFETY PRECAUTIONS AND WARNINGS....................................................................................................1868 DESCRIPTION AND OPERATION..............................................................................................................1868 AIR DISTRIBUTION DUCTS.............................................................................................................1868 A/ C PRESSURE TRANSDUCER...........................................................................................................1868 A/ C SERVICE PORTS.................................................................................................................1868 COMPRESSOR.........................................................................................................................1868 COMPRESSOR HIGH- PRESSURE RELIEF VALVE.............................................................................................1869 CONDENSATE DRAIN...................................................................................................................1869 ENGINE COOLING SYSTEM REQUIREMENTS.................................................................................................1869 EVAPORATOR PROBE...................................................................................................................1869 HANDLING TUBING AND FITTINGS.......................................................................................................1869 HVAC CONTROL MODULE................................................................................................................1869 SIDE DOOR HEATER A/ C OUTLETS......................................................................................................1870 SIDE WINDOW DEMISTER...............................................................................................................1870 SYSTEM AIRFLOW.....................................................................................................................1870 SYSTEM OIL LEVEL...................................................................................................................1870 REFRIGERANT OIL LEVEL CHECK....................................................................................................1871 REFRIGERANT OIL CAPACITIES.....................................................................................................1871 SERVICING REFRIGERANT OIL LEVEL................................................................................................1871 DIAGNOSIS AND TESTING..................................................................................................................1871 ACTUATOR CALIBRATION/ DIAGNOSTICS AND COOLDOWN TEST................................................................................1871 GENERAL INFORMATION............................................................................................................1871 ACTUATOR CALIBRATION...........................................................................................................1871 REFRIGERANT OIL CAPACITIES.....................................................................................................1871 DIAGNOSTICS....................................................................................................................1872 COOLDOWN TEST..................................................................................................................1872 CALIBRATION/ COOLDOWN LED DISPLAY CODES........................................................................................1872 CALIBRATION/ DIAGNOSTICS TEST ENTRY............................................................................................1872 COOLDOWN TEST ENTRY............................................................................................................1873 CALIBRATION DIAGNOSTICS AND COOLDOWN ABORT.....................................................................................1873 EEPROM DATA....................................................................................................................1873 ACTUATOR CALIBRATION AND DIAGNOSTICS...........................................................................................1873 FAIL CODES/ LEVEL DISPLAY......................................................................................................1874 TEMPERATURE AND MODE POTENTIOMETER DIAGNOSTICS.................................................................................1874 EVAPORATOR PROBE TEMPERATURE DIAGNOSTICS.......................................................................................1874 WIPE BUTTON LED................................................................................................................1874 LEVEL 1– FAILURE CODE VALUES (INTERMITTENT WIPE BUTTON LED)....................................................................1874 POTENTIOMETER VS. POSITION AND FLASH RATE......................................................................................1874 HVAC CONTROL DIAGNOSTIC CONDITIONS.................................................................................................1875 A/ C PERFORMANCE TEST..............................................................................................................1877 PERFORMANCE TEST PROCEDURE.....................................................................................................1877 A/ C PRESSURE TRANSDUCER...........................................................................................................1877 BLOWER MOTOR AND WHEEL ASSEMBLY....................................................................................................1878 VIBRATION AND/ OR NOISE DIAGNOSIS..............................................................................................1878 COMPRESSOR NOISE DIAGNOSIS.........................................................................................................1878 COMPRESSOR CLUTCH/ COIL............................................................................................................1878 TESTS..........................................................................................................................1878 EXPANSION VALVE....................................................................................................................1880 TESTS..........................................................................................................................1880 HEATER PERFORMANCE TEST............................................................................................................1880 PRE- DIAGNOSTIC PREPARATIONS...................................................................................................1880 MAXIMUM HEATER OUTPUT: TEST AND ACTION.........................................................................................1880 TEMPERATURE REFERENCE CHART....................................................................................................1880 POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW.........................................................................1881 POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT................................................................................1881 TEMPERATURE CONTROL............................................................................................................1881 SYSTEM CHARGE LEVEL TEST...........................................................................................................1881 SERVICE PROCEDURES.....................................................................................................................1882 R-134a REFRIGERANT.................................................................................................................1882 CHARGING REFRIGERANT SYSTEM........................................................................................................1883 EVACUATING REFRIGERANT SYSTEM......................................................................................................1883 THERMOCOUPLE PROBE.................................................................................................................1884 STICKING HVAC CONTROL MODULE PUSH BUTTONS..........................................................................................1884 SYSTEM LEAK CHECKING...............................................................................................................1885 EMPTY REFRIGERANT SYSTEM LEAK TEST.............................................................................................1885 LOW REFRIGERANT LEVEL LEAK TEST................................................................................................1885 REMOVAL AND INSTALLATION...............................................................................................................1885 A/ C PRESSURE TRANSDUCER...........................................................................................................1885 REMOVAL........................................................................................................................1885 INSTALLATION...................................................................................................................1885 A/ C SERVICE PORTS.................................................................................................................1885 REMOVAL........................................................................................................................1886 INSTALLATION...................................................................................................................1886 BLEND- AIR DOOR ACTUATOR...........................................................................................................1886 REMOVAL........................................................................................................................1886 INSTALLATION...................................................................................................................1886 BLOWER MOTOR AND WHEEL ASSEMBLY....................................................................................................1886 REMOVAL........................................................................................................................1886 INSTALLATION...................................................................................................................1887 BLOWER MOTOR RESISTOR BLOCK........................................................................................................1887 REMOVAL........................................................................................................................1887 INSTALLATION...................................................................................................................1888 BLOWER MOTOR WHEEL.................................................................................................................1888 COMPRESSOR (2.5L TURBO DIESEL).....................................................................................................1888 REMOVAL........................................................................................................................1888 INSTALLATION...................................................................................................................1888 CONDENSER ASSEMBLY.................................................................................................................1889 REMOVAL........................................................................................................................1889 INSTALLATION...................................................................................................................1889 DISCHARGE LINE.....................................................................................................................1889 REMOVAL........................................................................................................................1889 INSTALLATION...................................................................................................................1889 EVAPORATOR PROBE...................................................................................................................1890 REMOVAL........................................................................................................................1890 INSTALLATION...................................................................................................................1891 EXPANSION VALVE....................................................................................................................1891 REMOVAL........................................................................................................................1891 INSTALLATION...................................................................................................................1891 FILTER- DRIER ASSEMBLY.............................................................................................................1892 REMOVAL........................................................................................................................1892 INSTALLATION...................................................................................................................1892 HEATER A/ C UNIT HOUSING...........................................................................................................1892 REMOVAL........................................................................................................................1892 INSTALLATION...................................................................................................................1892 HEATER CORE........................................................................................................................1892 REMOVAL........................................................................................................................1892 INSTALLATION...................................................................................................................1894 HEATER HOSES.......................................................................................................................1894 REMOVAL........................................................................................................................1894 INSTALLATION...................................................................................................................1894 LIQUID LINE........................................................................................................................1894 REMOVAL........................................................................................................................1894 INSTALLATION...................................................................................................................1894 MODE DOOR ACTUATOR.................................................................................................................1895 REMOVAL........................................................................................................................1895 INSTALLATION...................................................................................................................1895 SIDE WINDOW DEMISTER DUCTS.........................................................................................................1895 LEFT SIDE......................................................................................................................1895 RIGHT SIDE.....................................................................................................................1895 SUCTION LINE.......................................................................................................................1895 REMOVAL........................................................................................................................1895 INSTALLATION...................................................................................................................1896 RECIRC DOOR ACTUATOR...............................................................................................................1896 REMOVAL........................................................................................................................1896 INSTALLATION...................................................................................................................1896 DISASSEMBLY AND ASSEMBLY...............................................................................................................1896 HEATER A/ C UNIT RECONDITION.......................................................................................................1896 DISASSEMBLY— EVAPORATOR HOUSING................................................................................................1896 ASSEMBLY— EVAPORATOR HOUSING...................................................................................................1898 DISASSEMBLY— DISTRIBUTION HOUSING..............................................................................................1898 ASSEMBLY— DISTRIBUTION HOUSING.................................................................................................1902 EMISSION CONTROL SYSTEMS...................................................................................................................1905 GENERAL INFORMATION....................................................................................................................1905 SYSTEM DESCRIPTION.................................................................................................................1905 DESCRIPTION AND OPERATION..............................................................................................................1905 MALFUNCTION INDICATOR LAMP (MIL)...................................................................................................1905 STATE DISPLAY TEST MODE............................................................................................................1906 STATE DISPLAY INPUTS AND OUTPUTS...............................................................................................1906 STATE DISPLAY SENSORS..........................................................................................................1906 CIRCUIT ACTUATION TEST MODE........................................................................................................1907 DIAGNOSTIC TROUBLE CODES...........................................................................................................1907 BULB CHECK.....................................................................................................................1907 OBTAINING DTC’S USING DRB SCAN TOOL............................................................................................1907 DIAGNOSTIC TROUBLE CODE DESCRIPTIONS...........................................................................................1908 MONITORED SYSTEMS..................................................................................................................1912 HEX 66, and 7A—OXYGEN SENSOR (O2S) MONITOR.....................................................................................1912 HEX 67, 69, 7C, and 7D—OXYGEN SENSOR HEATER MONITOR............................................................................1912 HEX 2E—EGR MONITOR.............................................................................................................1912 HEX 6A,6B, 6C, 6D, 6E, AE, and AF—MISFIRE MONITOR..............................................................................1913 HEX 76, 77, 78, and 79—FUEL SYSTEM MONITOR.....................................................................................1913 HEX 70, and B4 CATALYST MONITOR ...............................................................................................1913 HEX A0, A1, B7, and B8 LEAK DETECTION PUMP MONITOR.............................................................................1913 TRIP DEFINITION....................................................................................................................1914 COMPONENT MONITORS.................................................................................................................1914 NON-MONITORED CIRCUITS.............................................................................................................1915 FUEL PRESSURE .................................................................................................................1915 SECONDARY IGNITION CIRCUIT.....................................................................................................1915 CYLINDER COMPRESSION...........................................................................................................1915 EXHAUST SYSTEM.................................................................................................................1915 FUEL INJECTOR MECHANICAL MALFUNCTIONS..........................................................................................1915 EXCESSIVE OIL CONSUMPTION......................................................................................................1915 THROTTLE BODY AIR FLOW.........................................................................................................1915 VACUUM ASSIST..................................................................................................................1915 PCM SYSTEM GROUND..............................................................................................................1915 PCM CONNECTOR ENGAGEMENT.......................................................................................................1915 HIGH AND LOW LIMITS................................................................................................................1915 LOAD VALUE.........................................................................................................................1916 DESCRIPTION AND OPERATION..............................................................................................................1917 EVAPORATION CONTROL SYSTEM.........................................................................................................1917 ROLLOVER VALVE.....................................................................................................................1917 EVAPORATIVE (EVAP) CANISTER........................................................................................................1917 PROPORTIONAL PURGE SOLENOID........................................................................................................1917 PRESSURE-VACUUM FILLER CAP.........................................................................................................1918 LEAK DETECTION PUMP................................................................................................................1918 POSITIVE CRANKCASE VENTILATION (PCV) SYSTEMS.......................................................................................1919 PCV VALVE......................................................................................................................1919 CRANKCASE VENT FILTER..............................................................................................................1920 VEHICLE EMISSION CONTROL INFORMATION LABEL.........................................................................................1920 DIAGNOSIS AND TESTING..................................................................................................................1920 LEAK DETECTION PUMP................................................................................................................1920 PCV VALVE TEST.....................................................................................................................1920 ROLLOVER VALVES....................................................................................................................1921 REMOVAL AND INSTALLATION...............................................................................................................1920 LEAK DETECTION PUMP REPLACEMENT....................................................................................................1920 REMOVAL........................................................................................................................1920 INSTALLATION...................................................................................................................1921 DESCRIPTION AND OPERATION..............................................................................................................1922 GENERAL INFORMATION................................................................................................................1922 DIAGNOSIS AND TESTING..................................................................................................................1923 EGR SYSTEM ON-BOARD DIAGNOSTICS....................................................................................................1923 EGR SYSTEM TEST....................................................................................................................1923 EGR GAS FLOW TEST..................................................................................................................1924 EGR VALVE LEAKAGE TEST.............................................................................................................1924 EGR VALVE CONTROL (TRANSDUCER) TEST................................................................................................1925 TESTING ELECTRICAL SOLENOID PORTION OF VALVE...................................................................................1925 TESTING VACUUM TRANSDUCER PORTION OF VALVE.....................................................................................1925 REMOVAL AND INSTALLATION...............................................................................................................1925 EGR VALVE SERVICE—3.0L ENGINES.....................................................................................................1925 REMOVAL........................................................................................................................1925 INSTALLATION...................................................................................................................1925 EGR VALVE SERVICE—3.3/3.8L ENGINES.................................................................................................1926 REMOVAL........................................................................................................................1926 INSTALLATION ..................................................................................................................1926 EGR TUBE SERVICE—3.0L ENGINES......................................................................................................1926 REMOVAL........................................................................................................................1926 INSTALLATION...................................................................................................................1926 EGR TUBE SERVICE—3.3/3.8L ENGINES..................................................................................................1926 REMOVAL........................................................................................................................1926 INSTALLATION...................................................................................................................1927 SPECIAL TOOLS..........................................................................................................................1927 EMISSION CONTROL SYSTEM............................................................................................................1927 EMISSION CONTROL SYSTEM 1 .................................................................................................................1929 GENERAL INFORMATION....................................................................................................................1929 SYSTEM DESCRIPTION 2.5L DIESEL ENGINE.............................................................................................1929 MONITORED CIRCUITS.............................................................................................................1929 NON– MONITORED CIRCUITS........................................................................................................1929 HIGH AND LOW LIMITS............................................................................................................1930 DESCRIPTION AND OPERATION..............................................................................................................1930 DIAGNOSTIC TROUBLE CODES...........................................................................................................1930 ACCESSING DIAGNOSTIC TROUBLE CODES.............................................................................................1930 ERASING TROUBLE CODES..........................................................................................................1930 DESCRIPTION AND OPERATION..............................................................................................................1933 VACUUM HOSE ROUTING SCHEMATIC......................................................................................................1933 EXHAUST GAS RECIRCULATION (EGR) SYSTEM.............................................................................................1933 GENERAL INFORMATION............................................................................................................1933 EGR SYSTEM OPERATION...........................................................................................................1933 DIAGNOSIS AND TESTING..................................................................................................................1934 EGR GAS FLOW TEST..................................................................................................................1934 ELECTRIC VACUUM MODULATOR (EVM) TEST...............................................................................................1935 VACUUM TEST....................................................................................................................1935 REMOVAL AND INSTALLATION...............................................................................................................1935 EGR VALVE..........................................................................................................................1935 REMOVAL........................................................................................................................1935 INSTALLATION...................................................................................................................1935 EGR TUBE...........................................................................................................................1935 REMOVAL........................................................................................................................1935 INSTALLATION...................................................................................................................1935 ELECTRIC VACUUM MODULATOR (EVM)....................................................................................................1935 REMOVAL........................................................................................................................1936 INSTALLATION...................................................................................................................1936 SPECIFICATIONS.........................................................................................................................1936 TORQUE CHART— 2.5L DIESEL..........................................................................................................1936 GENERAL INFORMATION....................................................................................................................1937 GENERAL INFORMATION................................................................................................................1937 POSITIVE CRANKCASE VENTILATION SYSTEM (PCV) SYSTEM— 2.0L ENGINE....................................................................1937 REMOVAL AND INSTALLATION...............................................................................................................1937 EGR VALVE..........................................................................................................................1937 REMOVAL........................................................................................................................1937 INSTALLATION...................................................................................................................1938 EGR TUBE...........................................................................................................................1938 REMOVAL........................................................................................................................1938 INSTALLATION...................................................................................................................1938 TORQUE.............................................................................................................................1938
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