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Stratus 2004
Chrysler Stratus 2004 Manuals
Manuals and User Guides for Chrysler Stratus 2004. We have
1
Chrysler Stratus 2004 manual available for free PDF download: Service Manual
Chrysler Stratus 2004 Service Manual (3505 pages)
Brand:
Chrysler
| Category:
Automobile
| Size: 70.16 MB
Table of Contents
Group Tab Locator
4
Introduction
6
Table of Contents
6
Body Code Plate
6
Fastener Identification
7
If Two Body Code Plates Are Required
7
Description
7
Bolt Markings and Torque
8
How to Determine Bolt Strength
9
Fastener Usage
10
International Symbols
10
Metric System
10
Description - Fastener Usage
10
Conversion Formulas and Equivalent Values
11
Common Metric Equivalents
11
Torque References
13
Vehicle Identification Number
14
Vin Code Breakdown
14
Vin Check Digit
15
Vehicle Safety Certification Label
15
E-Mark Label
15
Veci Label
16
Manufacturer Plate
16
Lubrication & Maintenance
18
Fluid Types
18
Description - Engine Oil and Lubricants
18
Api Service Grade Certified
19
Sae Viscosity
19
Energy Conserving Oil
19
Container Identification
19
Specialized Lubricants and Oils
20
Description - Engine Coolant
20
Description - Flexible Fuel Vehicles
20
Fuel Requirements
21
Engine Oil Selection for Operating on E-85
21
Engine Oil Selection for Operating on Gasoline
21
Cruising Range
21
Fluid Additives
22
Reformulated Gasoline
22
Gasoline/Oxygenate Blends
22
Mmt in Gasoline
22
Fluid Capacities
23
Materials Added to Fuel
23
Fuel System Cautions
23
Fluid Fill/Check Locations
23
Lubrication Points
23
Maintenance Schedules
24
At each Stop for Fuel
24
Once a Month
24
At each Oil Change
24
Schedule B - North America
25
Description - Export
30
Hoisting
34
Standard Procedure - Hoisting
34
Jump Starting
34
To Jump Start a Disabled Vehicle
35
Towing
35
Standard Procedure - Towing
35
Warnings and Precautions
35
Recommended Towing Equipment
36
Ground Clearance
36
Locked Vehicle Towing
36
Flat Towing with Tow Bar
36
Suspension
38
Front Suspension
39
Front Suspension Components
40
Operation - Front Suspension
41
Front Suspension Fastener Torque
41
Hub / Bearing
43
Diagnosis and Testing - Hub and Bearing
43
Remover, Tie Rod
43
Remover, Lower Ball Joint C-4150A
43
Speed Sensor Cable Routing Bracket
44
Hub and Bearing Attaching Bolts
44
Ball Joint Stud Removal from Steering Knuckle
44
Knuckle
45
Diagnosis and Testing - Steering Knuckle
45
Outer Tie Rod Attaching Nut
45
Lower Ball Joint Attachment to Steering Knuckle
46
Separating Ball Joint Stud from Steering
46
Separating Steering Knuckle from Driveshaft
46
Torquing Tie Rod Attaching Nut
47
Lower Ball Joint
48
Diagnosis and Testing - Lower Ball Joint
48
Lower Ball Joint Seal Boot
48
Removing Ball Joint Seal Retaining Ring
49
Grease Correctly Applied to Ball Joint Stud and Seal Boot
49
Correctly Installed Ball Joint Seal Retaining Ring Tool
50
Retaining Ring and Expandable Collar Installed on Tool
50
Installing Seal Boot Retaining Ring
50
Lower Control Arm
51
Diagnosis and Testing - Lower Control Arm
51
Retaining Ring Installed in Ball Joint Seal Boot
51
Properly Installed Ball Joint Seal Boot
51
Tie Rod End Attaching Nut
52
Separating Lower Ball Joint Stud from Steering Knuckle
52
Clevis to Lower Control Arm Attachment
53
Removing/Installing Nut from Stud of Stabilizer Link
53
Lower Control Arm Attachment to Front Suspension Crossmember
53
Disassembly - Rear Isolator Bushing
54
Attaching Front of Lower Control Arm to Suspension Crossmember
54
Removing Front Bushing from Lower Control Arm
54
Assembly - Front Isolator Bushing
55
Removing Lower Control Arm Rear Bushing
55
Assembly - Rear Isolator Bushing
55
Correctly Positioned Rear Isolator Bushing in Control Arm
56
Installing Rear Bushing in Lower Control Arm
56
Assembly - Clevis Bushing
56
Installing Clevis Bushing in Lower Control Arm
57
Torquing Tie Rod End Attaching Nut
57
Supporting Lower Control Arm with Jack Stand
57
Shock Assembly
58
Shock Assembly Components
58
Operation - Shock Assembly
59
Diagnosis and Testing - Shock Assembly
59
Removal - Shock Assembly
59
Wheel Speed Sensor Cable Routing Bracket
59
Clevis to Lower Control Arm Attaching Bolt
60
Shock Absorber Clevis Bracket Pinch Bolt
60
Shock Assembly Attachment to Shock Tower
60
Disassembly - Shock Assembly
61
Upper Hooks Positioned
61
Lower Hooks and Clamp
61
Retainer Nut Removal/Installation
62
Washer
62
Shock Absorber Rod Upper Isolator Bushing
62
Shock Absorber Rod Lower Isolator Bushing
62
Assembly - Shock Assembly
63
Shock Absorber Rod Bushing Identification
63
Jounce Bumper Installation
64
Shock Absorber Rod Collar Installation
64
Installation - Shock Assembly
65
Stabilizer Bar
65
Clevis Correctly Installed on Shock Absorber
65
Lower Control Arm Correctly Supported by Jack Stand
65
Diagnosis and Testing - Stabilizer Bar
66
Removal - Stabilizer Bar
66
Removal - Stabilizer Bar Bushing
66
Stabilizer Bar Attaching Link Nut Removal
66
Upper Control Arm
67
Upper Ball Joint
67
Installation - Stabilizer Bar
67
Installation - Stabilizer Bar Bushing
67
Removal - Upper Control Arm
68
Installation - Upper Control Arm
68
Inspection - Upper Control Arm
68
Rear Suspension
69
Description - Rear Suspension
69
Warnings and Cautions
69
Rear Suspension Fastener Torque
70
Rear Brake Support Plate Mounting Bolts
72
Hub/Bearing Assembly Retaining Nut
72
Correctly Stored Rear Brake Support Plate
72
Lateral Link Attachment to Rear Knuckle
73
Trailing Link Attachment to Rear Knuckle
73
Removing Ball Joint Stud from Knuckle
73
Shock Absorber Attachment to Knuckle
73
Trailing Link Bushing and Retainer Installation
74
Speed Sensor Head Attachment to Brake Support Plate
74
Lateral Link
75
Forward Lateral Link
75
Stabilizer Bar to Lateral Link Attachment
75
Lateral Link Attachment to Rear Suspension Crossmember
75
Rear Lateral Link
76
Rear Lateral Link Attachment to Knuckle
76
Retainer Nut Removal/Installation (Typical)
78
Shock Absorber Jounce Bumper and Collar
78
Lower Coil Spring Isolator
79
Jounce Bumper Installed
79
Installing Collar on Shock
79
Stabilizer Bar Bushing Inspection
81
Stabilizer Bar Attaching Link
81
Stabilizer Bar Attachment to Rear Suspension
81
Trailing Link
82
Diagnosis and Testing - Trailing Link
82
Trailing Link to Knuckle Attachment
82
Trailing Link Hanger Bracket Attachment to Vehicle
82
Separating Trailing Link from Hanger Bracket
83
Trailing Link Bushing Installation
83
Trailing Link Hanger Bracket Installation
83
Shock Absorber to Knuckle Attaching
84
Muffler Support Bracket
84
Exhaust Pipe Hanger at Rear Suspension Crossmember
85
Speed Sensor Cable Attachment to Control Arm
85
Ball Joint Stud Removal from Knuckle
85
Lowering and Supporting Rear Suspension Crossmember
86
Crossmember Attachment to Frame Rails
86
Upper Control Arm Attachment to Crossmember
86
Disassembly - Upper Ball Joint
87
Assembly - Upper Ball Joint
87
Removing Ball Joint from Upper Control Arm
87
Installing Ball Joint in Upper Control Arm
87
Locating Rear Suspension Crossmember in Vehicle
88
Wheel Alignment
89
Description - Wheel Alignment
89
Camber
89
Cross Camber
90
Caster
90
Toe
90
Cross Caster
90
Toe-Out on Turns
91
Steering Axis Inclination (S. A. I.)
91
Dynamic Toe Pattern
91
Included Angle (I. A.)
91
Thrust Angle
92
Diagnosis and Testing - Suspension and Steering
92
Standard Procedure - Pre-Wheel Alignment Inspection
94
Standard Procedure - Curb Height Measurement
94
Curb Height Specifications
95
Standard Procedure - Wheel Alignment
95
Rear Camber and Toe
95
Lateral Link Adjusting Screw Jam Nuts
95
Camber Adjustment Procedure
96
Rear Lateral Link Maximum Length Dimensions
96
Shock Assembly Mounting Bolts
96
Front Toe
97
Front Wheel Toe Adjustment
97
Differential & Driveline
100
Half Shaft
100
Halfshaft Diagnosis
100
Noise And/Or Vibration in Turns
101
Clunking Noise During Acceleration
101
Shudder or Vibration During Acceleration
101
Vibration at Highway Speeds
101
Properly Supported Brake Caliper—Typical
102
Removing Tie Rod End-To-Knuckle Nut
102
Brake Rotor Removal—Typical
102
Tie Rod End Removal from Steering Knuckle
102
Halfshaft Retaining Nut—Typical
103
Lower Ball Joint to Knuckle Attachment
103
Separating Ball Joint Stud from Steering Knuckle
103
Separating Halfshaft from Steering Knuckle
104
Separating Halfshaft from Hub/Bearing
104
Disengaging Inner Tripod Joint from Transaxle
104
Tripod Joint Removal from Transaxle
105
Outer C/V Joint Inspection
105
Steering Knuckle Installation on Outer C/V Joint
105
Lower Ball Joint to Steering Knuckle Attachment
106
Torquing Tie Rod End Nut
106
Installing Tie Rod End Nut
106
Installing Disc Brake Caliper and Rotor
106
Wheel Lug Torquing Sequence—Typical
107
Torquing Front Hub Nut—Typical
107
Halfshaft
108
CV Boot - Inner
108
Spider Assembly Removal from Tripod Joint Housing
108
Spider Assembly Retaining Snap Ring
109
Spider Assembly Removal from Interconnecting Shaft
109
Sealing Boot Installation on Interconnecting Shaft
109
Spider Assembly Installation on Interconnecting Shaft
110
Installing Spider Assembly on Interconnecting Shaft
110
Spider Assembly Retaining Snap Ring Installed
110
Installing Tripod Housing on Spider Assembly
110
Crimping Tool Installed on Sealing Boot Clamp
111
Sealing Boot Retaining Clamp Installed
111
Trim Stick Inserted for Venting Tripod Joint
111
Crimp Type Boot Clamp
112
Latching Type Boot Clamp
112
Clamping Tool Installed on Sealing Boot Clamp
112
Sealing Boot Clamp Properly Installed
113
Outer C/V Joint Removal from Interconnecting Shaft
113
Outer C/V Joint Seal Boot Clamps
113
Circlip Removal from Interconnecting Shaft
113
Outer C/V
114
Outer C/V Joint Correctly Installed on Interconnecting Shaft
114
Brakes
116
Brakes - Base
116
Standard Procedure - Base Brake Bleeding
118
Manual Bleeding
118
Pressure Bleeding
118
Proper Method for Purging Air from Brake System (Typical)
118
Brake Fastener Torque
119
Base Brake System
119
Brake Fluid Level Switch
120
Aspirator Valve
120
Retaining Tabs
120
Brake Lines
121
Description - Brake Tubes and Hoses
121
Operation - Brake Tubes and Hoses
121
Inspection - Brake Tubes and Hoses
121
Caliper Mounting
122
Stored Front Disc Brake Caliper
122
Removing Inboard Shoe
122
Cleaning - Disc Brake Shoes
123
Installation - Front Disc Brake Shoes
123
Inspection - Disc Brake Shoes
123
Inboard Shoe Orientation to Turning Rotor
123
Brake Pads/Shoes - Rear Disc
124
Removal - Rear Disc Brake Shoes
124
Caliper Guide Pin Bolts
124
Caliper Removal/Installation
124
Storing Caliper
125
Removing Outboard Brake Pad
125
Rear Brake Rotor
125
Removing Inboard Brake Pad
125
Installation - Rear Disc Brake Shoes
126
Brake Pads/Shoes - Rear Drum
127
Drum Brakes
127
Cable Removal from Lever
127
Hold-Down and Lower Return Springs
127
Bench Assembled Brake Shoes
128
Cable Installation to Lever
129
Brake Drum Measurement
129
Adjustment - Drum Brake Shoes
129
Brake Shoe Measurement
129
Disc Brake Caliper
130
Removal - Front Disc Brake Caliper
130
Caliper Guide Pin Bolt Caps
130
Front Disc Brakes
130
Disassembly - Caliper Guide Pin Bushings (Disc/Disc Brakes)
131
Disassembly - Caliper Piston and Seal
131
Removing Caliper/Piston Dust Boot
131
Removing Piston Seal
131
Cleaning - Caliper
132
Assembly - Caliper Guide Pin Bushings
132
Inspection - Caliper
132
Installing New Piston Seal
132
Installation - Front Disc Brake Caliper
133
Installing Piston into Caliper Bore
133
Installing Dust Boot
133
Disc Brake Caliper - Rear
134
Removal - Rear Disc Brake Caliper
134
Removing Caliper from Adapter
134
Assembly - Caliper Piston and Seal
136
Installation - Rear Disc Brake Caliper
137
Drum
138
Diagnosis and Testing - Brake Drum
138
Out-Of-Round
138
Runout
138
Drum Maximum Diameter Identification
139
Fabricated Tool
139
Fabricated Tool Inserted against Pawl
139
Diagnosis and Testing - Brake Fluid Contamination
140
Standard Procedure - Brake Fluid Level Checking
140
Brake Fluid
140
Junction Block
141
Junction Block Mounting
141
Brake Pedal Holding Tool Installed (Typical)
141
Master Cylinder
142
Junction Block Fitting Identification
142
Primary and Secondary Brake Tubes
142
Standard Procedure - Master Cylinder Bleeding
142
Power Brake Booster
143
Diagnosis and Testing - Power Brake Booster
143
Basic Test
143
Vacuum Leak Test
143
Correctly Isolated Remote Ground Cable
144
Input Rod Retaining Pin
144
Purge Solenoid
144
Power Brake Booster Mounting
144
Installation - Power Brake Booster
145
Proportioning Valve
145
Diagnosis and Testing - Proportioning Valve
145
Proportioning Valve Specifications
146
Rotor
147
Diagnosis and Testing - Brake Rotor
147
Braking Surface Inspection
147
Rotor Thickness Variation
147
Checking Rotor for Thickness
148
Marking Rotor and Wheel Stud
148
Checking Rotor Runout
148
Brake Rotor Limits
149
Checking Hub Runout
149
Index Rotor and Wheel Stud
149
Standard Procedure - Brake Rotor Machining
150
Specifications and Limits
150
On-Car Brake Lathe
150
Minimum Brake Rotor Thickness Markings
150
Removal - Front Rotor
151
Removal - Rear Rotor
151
Installation - Front Rotor
151
Installation - Rear Rotor
151
Support Plate
152
Flex Hose Mounting to Support Plate
152
Using Wrench to Release Cable
152
Wheel Cylinder
153
Wheel Cylinder Mounting
153
Parking Brake
154
Adjustment - Parking Brake
154
Bent Nail Park Brake Cable Tension Equalizer
154
Park Brake Lever Output Cable Adjustment Nut
154
Park Brake Cable Tension Equalizer
155
Cables - Parking Brake
155
Cable Retainer Installed on Tension Equalizer
155
Parking Brake Adjustment
155
Rear Park Brake Cables at Tension
156
Compressing Park Brake Cable Retaining Tabs
156
Cable Removal (Typical)
157
Park Brake Cable Removal/Installation at Floor Pan
157
Park Brake Cable Installed in Console Bracket
158
Output Cable to Equalizer Retaining Clip
158
Lever - Parking Brake
159
Park Brake Lever Output Cable Adjustment Nut (Typical)
159
Output Cable-To-Equalizer Retaining Clip
160
Park Brake Lever Bracket Mounting
160
Shoes - Parking Brake
161
Rear Park Brake Shoe Hold-Down Clip
162
Park Brake Shoe Adjuster
162
Brake Shoe Lower Return Spring
162
Brake Shoe and Upper Spring
163
Front Park Brake Shoe Hold down Clip
163
Brakes - Abs
164
Description - Antilock Brakes
164
Description - Abs Plus
164
Description - Electronic Variable Brake Proportioning
164
Description - Traction Control
165
Operation - Antilock Brakes
165
Tire Noise and Marks
165
Normal Braking
165
Operation - Abs Plus
166
Operation - Electronic Variable Brake Proportioning
166
Operation - Traction Control
166
Hydraulic Shuttle Valves
166
Diagnosis and Testing - Inspection and Road Test
167
Standard Procedure - Antilock Brake System Bleeding
168
Abs Fastener Torque
169
Tone Wheel Runout
169
Wheel Speed Sensor Air Gap
169
Front Wheel Speed Sensor
169
Speed Sensor Head Attachment to Steering Knuckle
170
Speed Sensor Head Removal from Steering Knuckle
170
Rear Wheel Speed Sensor
171
Correct Front Wheel Speed Sensor Cable Routing
171
Installing Speed Sensor Head in Steering Knuckle
171
Speed Sensor Harness Connector Location
171
Foam Sleeve Covered Sensor Harness Connector
172
Rear Speed Senor Cable Attachment to Body
172
Sensor Harness Connector
172
Rear Speed Sensor Head Attachment to Brake Support Plate
172
Installation - Jr27
173
Tone Wheel
173
Inspection - Tone Wheel
173
Installation - Jr41
173
Traction Control Switch
174
Steering Wheel and Shroud Mounting
174
Hcu
175
Normal Braking Hydraulic Circuit (W/O Traction Control)
176
Abs Hydraulic Circuit and Solenoid Valve Function
177
ABS Mode Hydraulic Circuit (W/O Traction Control)
177
ABS with Traction Control - Normal Braking Hydraulic Circuit
178
ABS with Traction Control - ABS Braking Hydraulic Circuit
179
Traction Control Hydraulic Circuit
180
Integrated Control Unit (ICU)
181
ICU Location
181
Icu Mounting Bolts
182
Brake Tube Fittings
182
(TYPICAL) CAB Attaching Bolts
182
(TYPICAL) Remove/Install CAB
183
Clutch
184
Modular Clutch Assembly
184
Mechanical
185
Clutch Coupling Powerflow - Typical
185
Clutch Cable Assembly
185
Clutch Release Bearing and Lever (Typical)
185
Release System - 2.7L/T850 Transaxle
186
Diagnosis and Testing - Clutch System
186
Clutch Hydraulic System—Typical
186
Clutch Release Bearing and Lever (2.7L/T850)
186
Service Diagnosis - Clutch Grab/Chatter
187
Service Diagnosis - Clutch Slips
187
Service Diagnosis - Improper Clutch Release
188
Service Diagnosis - Clutch Pedal Noise
188
Diagnosis and Testing - Clutch Chatter Complaints
189
Standard Procedure - Bleeding Clutch Hydraulic Circuit
189
Slave Cylinder Removal/Installation
189
Torque Specifications
190
Clutch Master Cylinder
191
Clutch Master Cylinder and Reservoir
191
Clutch Master Cylinder Removal/Installation
191
Clutch Pedal
192
Clutch Pedal Removal/Installation
192
Clutch Pedal Interlock Switch
193
Clutch Pedal Removal/Installation (2.7L Models)
193
Clutch Pedal Interlock
193
Service Diagnosis–Clutch Pedal Position Switch
194
Clutch Pedal Interlock Switch (2.0L Models)
194
Clutch Pedal Interlock Switch (2.7L Models)
194
Clutch Release Bearing and Lever
195
Clutch Release Bearing and Lever—Typical
195
Removal - T850 Equipped Models
196
Installation - T350 Equipped Models
196
Installation - T850 Equipped Models
196
Pivot Ball Removal/Installation
196
Pivot Ball Position
197
Release Bearing-To-Lever
197
Release Bearing and Lever
197
Clutch Release Cable
198
Clutch Cable at Transaxle
198
Clutch Cable at Pedal Assembly
198
Clutch Slave Cylinder
199
Slave Cylinder Location
199
Modular Clutch
200
Modular Clutch Removal/Installation
201
Cooling
202
Accessory Drive Belt Tension
202
Cooling System
204
Accessory Drive
205
Drive Belts
205
Accessory Drive Belt System - 2.7L
205
Accessory Drive Belt System - 2.0L/2.4L
205
Diagnosis and Testing - Accessory
206
Accessory Drive Belt Diagnosis
206
Belt Center Span Locations - 2.7L
206
2.7L Accessory Drive Belt Tension Chart
207
Air Conditioning Compressor/Generator Belt
207
Accessory Drive Belt Tensioner - 2.0L
207
Accessory Drive Belt Tensioner - 2.4L
207
Power Steering Pump Belt
208
Installation - 2.0L/2.4L
208
Drive Belt Wear Pattern
208
Air Conditioning Compressor/Generator Belt Tensioning
209
Power Steering Pump Belt Tensioning
210
Used Belt
210
Air Conditioning Compressor/Generator Belt Adjustment - 2.7L
210
Engine
211
Cooling Module
213
Cooling System Operation - 2.0L/2.4L
214
Cooling System Operation - 2.7L
215
Diagnosis and Testing - Cooling System Diagnosis
216
Diagnosis and Testing - Cooling System Flow Check
222
Alternative Method
222
Diagnosis and Testing - Cooling System Leak Testing
223
Diagnosis and Testing - Cooling System Aeration
223
Diagnosis and Testing - Cooling System Deaeration
224
Coolant Level Check - Routine
224
Fluid Level Check - 2.0/2.4L
224
Cooling System - Draining
225
Cooling System - Filling
225
Fluid Level Check - 2.7L
225
Filling - 2.0L/2.4L
225
Cooling System Filling - 2.0L/2.4L
226
Coolant
227
Cooling System Filling - 2.7L
227
Diagnosis and Testing - Coolant Concentration Testing
227
Coolant - Adding Additional
228
Standard Procedure - Coolant Service
228
Coolant Outlet Connector
228
Hose Clamp Pliers 8495
228
Coolant Recovery Container - 2.0L/2.4L
229
Coolant Outlet Connector - 2.7L
229
Coolant Pressure Container - 2.7L
230
Engine Block Heater
231
Engine Coolant Temperature Sensor
232
Engine Coolant Thermostat
233
Diagnosis and Testing - Engine Coolant Thermostat Testing
233
Coolant Outlet Connector - 2.0L/2.4L
234
Thermostat and Housing—2.7L Engine
234
Thermostat Indexing - 2.0L/2.4L
234
Hose Clamps
235
Low Profile Spring Clamp Size Location
235
Spring Clamp Size Location
235
Operation - Hose Clamps
235
Radiator
236
Hose Clamp Pliers
236
Cooling Module Mounting
236
A/C Condenser Mounting
236
Radiator Draincock
237
Pressure Cap
237
Draincock
237
Diagnosis and Testing - Pressure Cap Testing
238
Diagnosis and Testing - Cooling System Pressure Relief Testing
238
Cooling System Pressure Cap
238
Testing Cooling System Pressure Cap
238
Cooling System Pressure Cap to Filler Neck
239
Radiator Fan(S)
240
Diagnosis and Testing - Radiator Fan Control
240
Cooling System Pressure Cap - Typical
240
Fan Module
240
Radiator Fan Operation—2.0L Engine
241
Radiator Fan Operation—2.7L Engine
241
Radiator Fan Operation—2.4L Engine
241
Diagnosis and Testing - Electric Fan Motor Test
241
Thermostat Housing
242
Radiator Fan
242
Water Pump
243
Diagnosis and Testing - Water Pump
243
Water Pump - 2.0L/2.4L
243
Water Pump - 2.7L
244
Water Pump Weep Passages - 2.7L
245
Primary Water Pump Weep Passage - 2.7L
245
Secondary Water Pump Weep Passage - 2.7L
245
Water Pump Body
246
Water Pump Inlet Tube - Typical
246
Transmission
247
Transmission Cooler Hoses
247
Transmission Oil Cooler
247
Audio/Video
248
Audio System Diagnosis
249
Amplifier
251
Antenna Body & Cable
251
Diagnosis and Testing - Antenna Body and Cable
251
Antenna Tests - Typical
252
CD Changer
253
Power Antenna - Export
254
Remote Switches
254
Remote Radio Switches
254
Power Antenna - Typical
254
Diagnosis and Testing - Remote Switches
255
Remote Radio Switch Test
255
Remote Radio Switches - Typical
256
Radio
257
Antenna to Radio
257
Speaker
258
Standard - Jr41
258
Standard - Jr27
258
Diagnosis and Testing - Speaker
258
Front Door - Jr41
259
Instrument Panel
259
Instrument Panel Speaker
259
Rear Speaker - Jr41
259
Front Door Speaker – Jr41
260
Front Door Speaker – Jr27
260
Rear Speaker - Jr27
260
Chime/Buzzer
262
Door Ajar Chime
262
Enhanced Seat Belt Reminder
262
Exterior Lamps Left on
262
Single Warning Chime
263
Diagnosis and Testing - Chime Conditions
263
No Fasten Seat Belt Lamp When Ignition Switch Is Turned on
263
Electronic Control Modules
266
Standard Procedure - Pcm/Skim Programming
266
Programming the Pcm (Sbec)
267
Programming the Skim
267
Programming Ignition Keys to the Skim
267
Body Control Module
267
Controller Antilock Brake
269
Integrated Control Unit (Typical)
269
Cab Outputs
269
Cab Inputs
269
Heated Seat Module
270
Diagnosis and Testing - Heated Seat Module
270
Powertrain Control Module
271
Powertrain Control Module (PCM)
271
Ngc Controller
271
Transmission Control (2.4L Models Only)
273
CVI Calculation
273
Example of CVI Calculation
273
Shift Schedules
273
Operation - Sensor Return - Pcm Input
274
Operation - Data Bus Communication Receive - Pcm Input
274
Operation - Ignition Sense - Pcm Input
274
Pcm Replacement
274
Operation - Pcm Ground
275
Operation - 5 Volt Supply - Pcm Output
275
Bulb Check
275
Obtaining Dtc’s Using Drb Scan Tool
275
Standard Procedure - Quick Learn Procedure
276
Removal - Sbec Controller
276
Pcm Location
276
Pcm Mounting
276
Removal - Ngc Controller
277
Pcm Bracket
277
Negative Battery Cable
277
Battery Connection
277
Installation - Sbec Controller
278
Sentry Key Immobilizer Module
278
Pcm & Bracket
278
Installation - Ngc Controller
278
SKIM Remove/Install
279
Transmission Control Module
280
Clutch Volume Index (CVI)
280
Clutch Volumes
281
Standard Procedure - Pinion Factor Setting
282
Tcm/Bracket Assembly
283
TCM and Mounting Bracket
284
Engine Systems
286
Battery System
286
Diagnosis and Testing - Battery System
287
Micro 420 Battery Tester
287
Abnormal Battery Discharging
289
Battery System Diagnosis
289
Battery Specifications
290
Cleaning Battery
290
Battery Specifications & Ratings
291
Battery System Special Tools
291
JR Battery
291
Battery Testing
293
Battery Test Results
293
Charging a Completely Discharged Battery
294
Voltmeter
294
Charging Time Required
295
Standard Procedure - Open-Circuit Voltage Test
295
Charge Rate Table
295
Battery Charging Time Table
295
Standard Procedure - Ignition-Off Draw Test
296
Electronic Module Ignition-Off Draw (Iod) Table
296
Battery Holddown
297
Battery Location
297
Battery Cables
298
JR Battery Tray and Holddown Hardware
298
Diagnosis and Testing - Battery Cables
299
Voltage Drop Test
299
Test Battery Negative Connection Resistance
299
Battery Tray
300
Test Battery Positive Connection Resistance
300
Test Ground Circuit Resistance - Typical
300
Test Battery Positive Cable Resistance
300
JR Battery Tray
301
JR Battery Heater Blanket
302
Battery Heater Blanket
302
Charging
303
Description - Charging System
303
Operation - Charging System
303
Diagnosis and Testing - On-Board Diagnostic System
304
Diagnostic Trouble Codes
304
Erasing Diagnostic Trouble Codes
304
Generator
305
Removal - 4 Cylinder
305
Remove Battery Cable at Shock Tower
306
Wiring Connections
306
Generator and Map Sensor
306
Removal - 2.7L
307
Generator Battery Cable
307
Installation - 4 Cylinder
307
Voltage Regulator
308
Starting
309
Diagnosis and Testing - Control Circuit Test
309
Starter Solenoid
310
Starter Relay
310
Relay Test
310
Starter Relay Pinout
310
Relay Circuit Test
311
Safety Switches
311
Ignition Switch
311
Battery
311
Starting System Diagnosis
312
Diagnosis and Testing - Feed Circuit Resistance Test
313
Diagnosis and Testing - Feed Circuit Test
314
Starter Motor
314
Volt Ampere Tester
314
Starter - 4 Cylinder
315
Starter Removal - 4 Cylinder
315
O2 Sensor
315
Starter Motor Relay
316
Starter Motor Removal
316
Starter Solenoid
316
Heated Systems
318
Heated Glass System
318
Diagnosis and Testing - Heated Glass System
319
Rear Window Defogger Relay
319
Grid Line Test
319
Rear Window Defogger Switch
320
Diagnosis and Testing - Rear Window Defogger Relay
320
Diagnosis and Testing - Rear Window Defogger Switch
320
Testing with Scan Tool
320
Rear Window Defogger Grid Lines
321
Diagnosis and Testing – Rear Window Defogger Grid Lines
321
Standard Procedure - Rear Window Defogger Grid Line Repair
321
Heated Seat System
322
Diagnosis and Testing - Heated Seat System
323
Heated Seat Element
323
Diagnosis and Testing - Heated Seat Element
324
Seat Back
324
Seat Cushion
324
Seat Cushion Element Connector
324
Heated Seat Switch
325
Heating Element Installed
325
JR Heated Seat Switch
325
Checking Drivers Heated Seat Switch
326
Checking Passenger Heated Seat Switch
326
Horn
328
Horn System
328
Diagnosis and Testing - Horn System
328
Horn System Test
328
Diagnosis and Testing - Horn
330
Fuse Blown
330
Fuse Ok
330
Horn Relay
331
Horn Switch
331
Diagnosis and Testing - Horn Relay
331
Ignition Control
332
Description - Ignition System
332
Operation - Ignition System
332
Auto Shut down Relay
333
Spark Plug Cable Resistance
333
Camshaft Position Sensor
334
Cam Sensor/Egr Valve/Pcv Valve
334
Target Magnet Removal/Installation
334
Ignition Coil
335
Cam Sensor Location 2.7L
335
Target Magnet Installation
335
Ignition Coil 4 Cylinder
336
Ignition Coils, Coil Capacitor
336
Ignition Coil Connector
336
Ignition Coil Capacitor
337
Knock Sensor
337
Ignition Coil Removal
337
Spark Plug
338
Description - Standard 4 Cylinder
338
Knock Sensor - 4 Cylinder
338
Knock Sensor 2.7 L
338
Description - Platinum Plugs
339
Spark Plug Cable
339
Platinum Pads
339
Setting Spark Plug Electrode Gap
339
Instrument Cluster
340
Diagnosis and Testing - Instrument Cluster
340
Instrument Cluster Mask/Lens
341
Vacuum Fluorescent Display
342
Lamps
344
Lamps/Lighting - Exterior
344
Lamp Systems
345
Daytime Running Lamp (Canada Only)
345
Diagnosis and Testing - Lamps/Lighting
346
Headlamp Diagnosis
347
Fog Lamp Diagnosis
348
Exterior Lamps
349
Brake Lamp Switch
349
Bulb Application Table
349
Bulb Application Table - Export
349
Switch Test - Released
350
Switch Test - Depressed Position
350
Switch and Bracket
350
Adjustments
351
Adjustment - Brake Lamp Switch
351
Center High Mounted Stop Lamp
351
Center High Mounted Stop Lamp Unit
351
Center High Mounted Stop Lamp Unit - Jr27 Only
352
Combination Flasher
352
Combination Flasher Location
352
Combination Flasher Diagnosis
353
Fog Lamp
354
Fog Lamp Unit
355
Standard Procedure - Fog Lamp Unit Alignment
355
Standard Procedure - Fog Lamp Unit Alignment - Export
355
Fog Lamp Unit Adjuster
355
Fog Lamp Alignment - Export
356
Hazard Warning Switch
357
Front Position Lamp Location
357
Front Position Lamp
357
Headlamp
358
Headlamp - Export
358
Headlamp Leveling Motor Diagnosis
359
Headlamp Leveling Switch
359
Headlamp Leveling Motor
359
Headlamp Unit
360
Headlamp Alignment Preparation
360
Alignment Screen Preparation
360
Headlamp Adjustment
360
Headlamp Unit - Export
361
Headlamp Alignment Screen
361
Headlamp Alignment
362
Headlamp Alignment Screen - Export
362
License Plate Lamp
363
Headlamp Alignment Screws
363
License Plate Lamp Bulb
363
License Plate Lamp Unit
364
Multi-Function Switch
364
License Plate Lamp Unit - Jr27 Only
364
Combo Flasher Connector (A)
365
Multi-Function Switch Continuity/Resistance
366
Rear Fog Lamp - Export
367
Park/Turn Signal Lamp
367
Multi-Function Switch Mounting
367
Park and Turn Signal Lamp Bulb
367
Rear Fog Lamp Unit - Export
368
Side Repeater Lamp Unit - Export
368
Access to Side Repeater Lamp
368
Side Repeater Lamp
368
Tail Lamp
369
Tail Lamp Unit
369
Trunk Lamp Unit
369
Lamps/Lighting - Interior
370
Interior Lamps
370
Cluster Illumination and Warning Lamps
371
Cluster Illumination Lamps
371
Dome Lamp
372
Console Courtesy Lamp
372
Dome Lamp Bulb
372
Door Courtesy Lamp
373
Reading Lamp
373
Illuminated Entry
373
Transmission Range Indicator Illumination
374
Vanity Lamp
374
Message Systems
376
Compass/Mini-Trip Computer
376
Compass Mini-Trip Computer Messages
377
Compass Calibration
377
Variance Setting Procedure
377
Compass/Mini-Trip Computer Retaining Screws
378
Variance Settings
378
Universal Transmitter
379
Diagnosis and Testing - Universal Transmitter
379
Radio Frequency Detector
379
Power Systems
380
Power Locks
380
Power Door Locks
380
Automatic Door Locks
380
Table of Contents
380
Central Locking
381
Child Protection Lock
381
Horn Chirp Toggle
381
Power Locks
381
Operation
381
Door Lock Inhibit
382
Remote Keyless Entry
382
Diagnosis and Testing - Remote Keyless Entry
382
Door Cylinder Lock Switch Removal
382
Door Lock Motor Diagnosis and Testing - Door Lock Motor
383
Door Lock / Unlock Switch Diagnosis and Testing - Door Lock
383
Installation
383
Removal
383
Keyless Entry Transmitter Diagnosis and Testing - Keyless Entry Module
384
Standard Procedure - Rke Transmitter Programming
384
Decklid Release Solenoid Diagnosis and Testing - Decklid Release Solenoid
384
Removal
384
Installation
384
Decklid Release Switch Removal
384
Transmitter
385
Remote Keyless Entry Module
385
Specifications
385
Removal
385
Installation
385
Power Mirrors
386
Automatic Day/Night Mirror
386
Outside Rear View Mirror
386
Diagnosis and Testing - Power Mirrors
386
Power Mirrors Description
387
Automatic Day / Night Mirror Description
387
Diagnosis and Testing - Automatic Day/Night Inside Mirror
387
Operation
387
Power Mirror Switch Diagnosis and Testing - Power Mirror Switch
388
Sideview Mirror
388
Removal
388
Installation
388
Power Seat System
389
Driver Power Seat - Convertible
389
Driver Seat Switch
390
Circuit Breaker Test
390
Voltage Test
390
Diagnosis and Testing - Driver Seat Switch
391
Hard-Top Power Seat Switch Continuity Test
391
Rear View of Hard-Top Power Seat Switch
391
Convertible Power Seat Switch Continuity Test
392
Rear View of Convertible Power Seat Switch
392
Power Seat Track
393
Power Seat Switch and Seat Side Shield
393
Switch Harness Connector Circuit Test
394
Seat Switch Electrical Connector - Hardtop
394
Power Windows
396
Circuit Test
396
Window Drop Relay Test - Jr27 Only
397
Window Drop Relay
397
Window Motor
397
Diagnosis and Testing - Window Motor
397
Window Switch
398
Diagnosis and Testing - Window Switch
398
Master Window Switch Test
398
Passenger Window Switch
398
Passenger Window Switch Test
399
Restraints
400
Diagnosis and Testing - Airbag System
401
Restraints Warning Warnings
401
Standard Procedure Standard Procedure - Handling Airbags
402
Standard Procedure - Service after an Airbag Deployment
402
Curtain Airbag
402
Seat Belt Tensioners
402
Child Restraint Anchor Description
403
Child Tether Cup Removal
403
Operation
403
Installation
403
Child Tether Cup Cover Removal
404
Clock Spring Description
404
Standard Procedure - Clock Spring Centering
404
Installation
404
Operation
404
Installation
405
Curtain Airbag Description
405
Operation
405
Removal
405
Driver Airbag Description
406
Operation
406
Removal
406
Installation
406
Driver Airbag Trim Cover Removal
406
Front Seat Belt & Retractor - Jr27 Only Removal
407
Installation
407
Occupant Restraint Controller Description
408
Lower Seat Belt Anchor and Recliner Cable
408
Installation
408
Operation
408
Passenger Airbag Description
409
Rear Seat Belt Buckle - Jr27 Only Removal
409
Installation
409
Operation
409
Rear Seat Belt & Retractor - Jr27 Only Removal
410
Satellite Acceleration Sensor Description
410
Installation
410
Operation
410
Seat Belt Control Timer Module - Jr27 - Export Description
411
Diagnosis and Testing - Seat Belt Control Timer Module
411
Installation
411
Operation
411
Diagnostic Mode
412
Sctm Conditions
412
Both Seat Belts Locked All the Time
412
Detectable Faults
412
Seat Belt Height Adjuster Removal
413
Installation
413
Seat Belt - Rear Inboard Removal
414
Seat Belt - Rear Outboard Removal
414
Seat Belt & Retractor - Front Outboard Removal
414
Installation
414
Seat Belt & Retractor - Rear Center Removal
415
Seat Belt Tensioner Description
415
Installation
415
Operation
416
Speed Control
418
Interactive Speed Control
418
Climbing a Grade
418
Speed Control Switch
418
Downshift Delay
419
Grade Hunting
419
Automatic Speed Control Overspeed Reduction
419
Description
419
Operation
419
Specifications - Torque
420
Servo Description
420
Operation
420
Speed Control Cable and Bracket
421
Removal
421
Installation
421
Switch Removal
421
Switch Removal
422
Installation
422
Vacuum Reservoir Description
422
Operation
422
Installation
423
Vehicle Theft Security
424
Vehicle Theft Security System
424
Sentry Key Immobilizer System
424
Arming the Vtss
425
Triggering the Vtss
425
Diagnosis and Testing - Vehicle Theft Security System
426
Transponder Key
426
Transponder Key - Typical
426
Standard Procedure - Transponder Programming
427
“Customer Learn” Mode
427
Using a Drb III Scan Tool
427
Vtss/Skis Indicator Lamp
428
Wipers/Washers
430
Wiper System
430
Multi-Function Switch with Integral Wiper/Washer Switch
430
Wipers/Washers Description
431
Operation
431
Diagnosis and Testing - Windshield Washers
432
Washer Nozzle Removal
432
Installation
432
Washer Reservoir Removal
432
Washer Reservoir Pump Removal
433
Wiper Arms Removal
433
Adjustments - Wiper Arms
433
Installation
433
Wiper Blades Removal
434
Wiper Linkage Removal
434
Wiper Motor Removal
434
Cleaning
434
Installation
434
Wiper Motor Crank Alignment
435
Installation
435
Wiper Motor Assembly Removal
436
Installation
436
Wiring
438
8W-01 Wiring Diagram Information
440
Wiring Diagram Information
440
Description - How to Use Wiring Diagrams
440
Wiring Diagram Information
441
Terminology
444
Description - Circuit Information
444
Wire Color Code Chart
444
Wire Code Identification
444
Description - Circuit Functions
445
Description - Section Identification and Information
445
Circuit Identification Code Chart
445
Wiring Section Chart
445
Description - Connector, Ground and Splice Information
446
Warnings - General
446
Diagnosis and Testing - Wiring Harness
446
Intermittent and Poor Connections
447
Probing Tool
447
Troubleshooting Wiring Problems
447
Electrostatic Discharge Symbol
447
Standard Procedure
447
Voltage Potential
448
Standard Procedure - Testing for Ashort to Ground
448
Voltage Drop
449
Special Tools
449
Wiring/Terminal
449
Testing for Voltage Drop
449
Standard Procedure - Testing for Ashort to Ground on Fuses Powering Several Loads
449
Connector Removal
450
Connector Installation
450
Removal of Dress Cover
450
Examples of Connector Secondary Terminal Locks
451
Terminal Removal
452
Diode Identification
453
Diode Removal
453
Installation
453
Terminal Removal
453
Standard Procedure - Wire Splicing
454
Splice Band
454
Crimping Tool
454
8W-02 Component Index
456
8W-10 Power Distribution
458
Fuses
460
8W-12 Junction Block
486
8W-15 Ground Distribution
514
8W-20 Charging System
542
8W-21 Starting System
546
8W-30 Fuel/Ignition System
550
8W-31 Transmission Control System
582
8W-33 Vehicle Speed Control
598
8W-35 Antilock Brakes
604
8W-39 Vehicle Theft Security System
610
8W-40 Instrument Cluster
618
8W-41 Horn/Cigar Lighter/Power Outlet
626
8W-43 Occupant Restraint System
642
8W-44 Interior Lighting
654
8W-48 Rear Window Defogger
692
8W-50 Front Lighting
696
8W-62 Power Mirrors
746
8W-63 Power Seat
752
8W-64 Power Sunroof
758
8W-66 Power Top
760
8W-70 Splice Information
764
8W-80 Connector Pin-Outs
772
A/C Compressor Clutch - Black 2 Way
776
A/C Evaporator Temperature Sensor - Black 2 Way
776
A/C Pressure Transducer - Gray 4 Way
776
A/C-Heater Control C1 (Mtc) - Natural 8 Way
776
A/C-Heater Control C2 (Mtc) - Black 10 Way
777
Airbag Control Module (Orc) (Base) - Yellow 23 Way
777
Airbag Control Module C1 (Orc) (Premium) - Yellow 32 Way
778
Airbag Control Module C2 (Orc) (Premium) - Yellow 32 Way
779
Ambient Temp Sensor - Black 2 Way
779
Auto Headlamp Relay (Premium) - Natural 5 Way
780
Automatic Day/Night Mirror - Black 7 Way
780
Automatic Temperature Control Head - Black 12 Way
780
Autostick Switch - Natural 4 Way
781
Back-Up Lamp Switch (2.0L Mtx) - Gray 2 Way
781
Back-Up Lamp Switch (2.7L Mtx) - Black 2 Way
781
Blend Door Actuator - Natural 5 Way
781
Blower Motor - Black 2 Way
782
Blower Motor Power Module C1 (Atc) - Black 4 Way
782
Blower Motor Power Module C2 (Atc) - Black 2 Way
782
Blower Motor Resistor Block (Mtc) - Black 10 Way
782
Body Control Module C1 - 16 Way
783
Body Control Module C2 - 26 Way
783
Body Control Module C3 - Gray 16 Way
784
Body Control Module C4 - 26 Way
784
Brake Fluid Level Switch - Black 2 Way
785
Brake Lamp Switch - Gray 6 Way
785
Brake Transmission Shift Interlock Solenoid - White 2 Way
785
C100 - (Instrument Panel Side)
785
C100 - Lt. Green (Headlamp and Dash)
786
C101 - (Instrument Panel Side)
786
C104 (Eatx) - (Headlamp and Dash Side)
787
C105 (Eatx) - (Headlamp and Dash Side)
787
C111 - Black (Engine Harness Side)
788
C111 - Black (Headlamp and Dash Side)
789
C113 (2.7L) - (Engine Harness Side)
789
C121 - Natural (Headlamp and Dash Side)
790
C121 - Natural (Unibody Side)
790
C168 (2.7L) - Black (Engine Harness Side)
791
C169 (2.7L Mtx) - Black (Headlamp and Dash Side)
792
C169 (2.7L Mtx) - Black (Mtx Harness Side)
792
C200 (Atc) - (Hvac Side)
792
C200 (Atc) - White (Instrument Panel Side)
793
C200 (Mtc) - Natural (Hvac Side)
793
C200 (Mtc) - Natural (Instrument Panel Side)
793
C225 - Black (Jumper Side)
794
C225 - Black (Unibody Side)
794
C300 (Jr27/Jr41 Export) - Black (Unibody Side)
794
C300 (Jr41 Except Export) - (Unibody Side)
794
C300 - Black (Left Rear Lamp Side)
795
C301 - Black (Right Rear Lamp Side)
795
C302 - (Instrument Panel Side)
796
C302 - Black (Unibody Side)
796
C303 - Lt. Gray (Instrument Panel Side)
796
C303 - Lt. Gray (Unibody Side)
797
C304 (Jr41) - Yellow (Instrument Panel Side)
797
C304 (Jr41) - Yellow (Unibody Side)
797
C305 (Jr41) - Black (Chmsl Side)
798
C305 (Jr41) - Black (Unibody Side)
798
C306 - (Instrument Panel Side)
798
C306 - Black (Unibody Side)
798
C307 (Except Jr41 Export) - Natural (Dome Lamp Side)
799
C307 (Except Jr41 Export) - Natural (Unibody Side)
799
C307 (Jr41 Export) - Natural (Dome Lamp Side)
799
C308 (Jr41) - Blue (Rear Door Side)
799
C308 (Jr41) - Blue (Unibody Side)
800
C309 (Jr27 Power Seat) - Gray (Power Seat Jumper Side)
800
C309 (Jr27 Power Seat) - Gray (Unibody Side)
800
C309 (Jr41 Power Seat) - Black (Power Seat Jumper Side)
800
C310 - Brown (Instrument Panel Side)
801
C310 - Brown (Left Front Door Side)
801
C311 - Blue (Instrument Panel Side)
802
C311 - Blue (Left Front Door Side)
802
C315 - Brown (Instrument Panel Side)
803
C315 - Brown (Right Front Door Side)
804
C316 - Blue (Instrument Panel Side)
804
C316 - Blue (Right Front Door Side)
805
C318 (Jr41) - Blue (Right Rear Door Side)
805
C318 (Jr41) - Blue (Unibody Side)
805
C320 (Jr27) - Black (Rear Side)
806
C320 (Jr27) - Black (Unibody Side)
806
C321 - Black (Fuel Pump Side)
806
C321 - Black (Unibody Side)
807
C323 - Black (Jumper Side)
807
C323 - Black (Switch Side)
808
C324 - Black (Jumper Side)
808
C324 - Black (Seat Side)
808
C325 - Black (Jumper Side)
808
C325 - Black (Seat Side)
809
Camshaft Position Sensor - Black 3 Way
809
CD Changer - Black 8 Way
809
Center High Mounted Stop Lamp (Jr27) - Red 3 Way
809
Center High Mounted Stop Lamp (Jr41) - Black 2 Way
810
Clockspring C1 - 5 Way
810
Clockspring C2 - Yellow 2 Way
810
Clockspring C3 - 4 Way
810
Coil on Plug No. 1 (2.7L) - Black 2 Way
811
Coil on Plug No. 2 (2.7L) - Black 2 Way
811
Coil on Plug No. 3 (2.7L) - Black 2 Way
811
Coil on Plug No. 4 (2.7L) - Black 2 Way
811
Coil on Plug No. 6 (2.7L) - Black 2 Way
812
Compass/Mini-Trip Computer - Black 6 Way
812
Controller Antilock Brake - 24 Way
812
Crankshaft Position Sensor - Black 3 Way
813
Data Link Connector - Black 16 Way
813
Decklid Cylinder Lock Switch (Vtss) - 2 Way
813
Decklid Release Solenoid/Ajar Switch (Jr27/Jr41 Export) - 3 Way
814
Decklid Release Solenoid/Ajar Switch (Jr41 Except Export) - 3 Way
814
Decklid Release Switch - Black 2 Way
814
Dome Lamp (Jr41) - Black 3 Way
814
Driver Airbag Squib 2 - Black 2 Way
815
Driver Cylinder Lock Switch (Vtss) - Gray 2 Way
815
Driver Door Lock Switch - Natural 4 Way
815
Driver Heated Seat Module - Black 6 Way
816
Driver Power Window Motor (Jr27) - Black 2 Way
816
Driver Power Window Motor (Jr41) - 2 Way
816
Driver Seat Belt Solenoid (Jr27 Export) - Natural 2 Way
816
Driver Seat Belt Switch (Jr41 Except Export) - Gray 2 Way
817
Driver Seat Belt Tensioner (Jr27) - Yellow 4 Way
817
Driver Seat Belt Tensioner (Jr41) - Yellow 2 Way
817
Engine Coolant Temp Sensor - Black 2 Way
817
Evap/Purge Solenoid - 2 Way
818
Fog Lamp Relay (Premium) - Natural 5 Way
818
Front Vertical Motor (Jr27) - Black 2 Way
818
Front Vertical Motor (Jr41) - Black 2 Way
818
Front Wiper Motor - 4 Way
819
Fuel Injector No. 1 - Black 2 Way
819
Fuel Injector No. 3 - Black 2 Way
819
Fuel Injector No. 4 - Black 2 Way
819
Fuel Injector No. 5 (2.7L) - Black 2 Way
820
Fuel Injector No. 6 (2.7L) - Black 2 Way
820
Fuel Pump Module - 4 Way
820
Generator - Black 2 Way
820
Headlamp Washer Pump Motor (Jr41 Export) - 2 Way
821
Heated Seat Switch - White 7 Way
821
Horizontal Motor (Jr27) - Black 2 Way
821
Horizontal Motor (Jr41) - Black 2 Way
821
Idle Air Control Motor (2.0L/2.4L) - Black 2 Way
822
Idle Air Control Motor (2.7L) - Black 4 Way
822
Ignition Coil Pack (2.0L/2.4L) - Black 3 Way
822
Ignition Switch C1 - Black 2 Way
822
Ignition Switch C2 - Black 10 Way
823
Ignition Switch C3 - Green 2 Way
823
Inlet Air Temp Sensor - Black 2 Way
823
Input Speed Sensor - Gray 2 Way
823
Instrument Cluster - 26 Way
824
Junction Block Body Control Module Jb - 12 Way
824
Junction Block C1 - Brown 12 Way
825
Junction Block C2 - 10 Way
825
Junction Block C3 - White 4 Way
825
Junction Block C4 - Blue 10 Way
825
Junction Block C5 - Gray 16 Way
826
Junction Block C6 - White 6 Way
826
Junction Block C7 - Natural 12 Way
826
Junction Block C8 - Black 8 Way
827
Junction Block C9 - White 12 Way
827
Junction Block C10 - Natural 6 Way
827
Junction Block C11 (Export) - Black 8 Way
828
Knock Sensor (2.0L/2.4L) - Black 2 Way
828
Knock Sensor (2.7L) - Gray 2 Way
828
Leak Detection Pump (2.7L) - Black 4 Way
828
Left Back-Up Lamp - Black 2 Way
829
Left Curtain Airbag Squib (Jr41) - Yellow 2 Way
829
Left Fog Lamp (Jr27) - Gray 2 Way
829
Left Fog Lamp (Jr41) - Black 2 Way
829
Left Front Instrument Panel Speaker (Jr27 Base) - Black 3 Way
830
Left Front Instrument Panel Speaker (Jr27 Premium) - Black 2 Way
830
Left Front Instrument Panel Speaker (Jr41 Premium) - 3 Way
830
Left Front Wheel Speed Sensor - Black 2 Way
830
Left Lavalier Module (Export) - 6 Way
831
Left License Lamp (Jr27) - Natural 2 Way
831
Left License Lamp (Jr41 Export) - Natural 2 Way
831
Left Park/Turn Signal Lamp - Black 3 Way
831
Left Rear Door Lock Motor/Ajar Switch (Jr41) - Black 4 Way
832
Left Rear Fog Lamp (Jr27 Export) - Gray 2 Way
832
Left Rear Fog Lamp (Jr41 Export) - Gray 3 Way
832
Left Rear Power Window Motor - 2 Way
832
Left Rear Power Window Switch (Jr41) - Blue 6 Way
833
Left Rear Speaker - 3 Way
833
Left Rear Wheel Speed Sensor - Black 2 Way
833
Left Remote Radio Switch (2.7L) - 2 Way
833
Left Side Impact Sensor 1 - Gray 2 Way
834
Left Speed Control Switch - Black 2 Way
834
Left Tail/Side Marker Lamp - 2 Way
834
Left Tail/Stop Lamp - Gray 3 Way
834
Left Tail/Turn Signal Lamp (Jr41 Dodge) - Gray 3 Way
835
Left Turn Lamp (Chrysler/Except Jr41 Dodge) - tan 2 Way
835
Left Visor/Vanity Lamps - Black 2 Way
835
License Lamp (Jr41 Except Export) - Natural 2 Way
835
Manifold Absolute Pressure Sensor (2.7L) - Black 3 Way
836
Master Power Window Switch - Blue 12 Way
836
Mode Door Actuator - Black 5 Way
837
Multi-Function Switch C1 - Natural 10 Way
837
Multi-Function Switch C2 - Blue 12 Way
837
Natural Vacuum Leak Detection Assembly (2.4L Except Export)
838
Oil Pressure Switch - 2 Way
838
Output Speed Sensor - Gray 2 Way
838
Overhead Map/Courtesy Lamps (Jr41) - Black 3 Way
838
Oxygen Sensor 1/1 Upstream (2.0L/2.4L) - Black 4 Way
839
Oxygen Sensor 1/2 Downstream (2.0L/2.4L) - Black 4 Way
839
Oxygen Sensor 1/2 Right Bank down (2.7L) - Black 4 Way
839
Oxygen Sensor 2/1 Left Bank up (2.7L) - Black 4 Way
839
Oxygen Sensor 2/2 Left Bank down (2.7L) - Black 4 Way
840
Park Lamp Relay (Premium) - Natural 5 Way
840
Passenger Airbag - Yellow 4 Way
840
Passenger Door Lock Motor/Ajar Switch - Black 4 Way
840
Passenger Door Lock Switch - Natural 4 Way
841
Passenger Heated Seat Module - Black 6 Way
841
Passenger Power Window Motor (Jr27) - Black 2 Way
841
Passenger Power Window Motor (Jr41) - 2 Way
841
Passenger Power Window Switch - Blue 6 Way
842
Passenger Seat Belt Solenoid (Jr27) - Black 2 Way
842
Passenger Seat Belt Tensioner (Jr27) - Yellow 4 Way
842
Passenger Seat Belt Tensioner (Jr41) - Yellow 2 Way
842
Pcv Heater (2.7L) - Black 2 Way
843
Power Amplifier C1 (Jr27 Premium) - White 12 Way
843
Power Amplifier C1 (Jr41 Premium) - White 22 Way
843
Power Amplifier C2 (Jr27 Premium) - White 18 Way
844
Power Amplifier C2 (Jr41 Premium) - White 12 Way
844
Power Antenna (Export) - Brown 2 Way
844
Power Mirror Switch - Black 10 Way
845
Power Outlet (Jr27/Jr41 Export) - Black 3 Way
845
Power Seat Switch (Jr27) - 12 Way
845
Power Seat Switch (Jr41) - Blue 10 Way
846
Power Steering Pressure Switch (2.0L) - Black 2 Way
846
Power Top Pump Motor (Jr27) - Red 2 Way
846
Power Top Switch (Jr27) - 3 Way
846
Power Top Up/Down Relays (Jr27) - 6 Way
847
Powertrain Control Module C1 (Ngc) - 38 Way
847
Powertrain Control Module C1 (Sbec) - Gray 40 Way
848
Powertrain Control Module C2 (Ngc) - 38 Way
849
Powertrain Control Module C2 (Sbec) - Gray 40 Way
850
Powertrain Control Module C3 (Ngc) - 38 Way
851
Powertrain Control Module C4 (Ngc) - 38 Way
852
Radiator Fan - 4 Way
853
Radio C1 - White 22 Way
853
Radio C2 - Black 10 Way
853
Rear Floor Courtesy Lamp - White 2 Way
854
Rear Vertical Motor (Jr27) - Black 2 Way
854
Rear Vertical Motor (Jr41) - Black 2 Way
854
Recirculation Door Actuator - 2 Way
854
Right Back-Up Lamp - Gray 2 Way
855
Right Curtain Airbag Squib (Jr41) - Yellow 2 Way
855
Right Fog Lamp (Jr27) - Gray 2 Way
855
Right Fog Lamp (Jr41) - Black 2 Way
855
Right Front Instrument Panel Speaker (Jr27 Base) - Black 3 Way
856
Right Front Instrument Panel Speaker (Jr27 Premium) - Black 2 Way
856
Right Front Instrument Panel Speaker (Jr41 Premium) - 3 Way
856
Right Front Wheel Speed Sensor - Black 2 Way
856
Right Headlamp (Except Export) - Black 3 Way
857
Right Lavalier Module (Export) - 6 Way
857
Right License Lamp (Jr41 Export) - Natural 2 Way
857
Right Park/Turn Signal Lamp - Black 3 Way
857
Right Power Mirror - Natural 6 Way
858
Right Rear Door Lock Motor/Ajar Switch (Jr41) - Black 4 Way
858
Right Rear Fog Lamp (Jr27 Export) - Gray 2 Way
858
Right Rear Fog Lamp (Jr41 Export) - Gray 3 Way
858
Right Rear Power Window Motor - 2 Way
859
Right Rear Power Window Switch (Jr41) - Blue 6 Way
859
Right Rear Speaker - 3 Way
859
Right Rear Wheel Speed Sensor - Black 2 Way
859
Right Remote Radio Switch (2.7L) - 2 Way
860
Right Side Impact Sensor 1 - Gray 2 Way
860
Right Speed Control Switch - Black 2 Way
860
Right Tail/Side Marker Lamp - 2 Way
860
Right Tail/Stop Lamp - Gray 3 Way
861
Right Tail/Turn Signal Lamp (Jr41 Dodge) - Gray 3 Way
861
Right Turn Lamp (Chrysler/Except Jr41 Dodge) - tan 2 Way
861
Right Visor/Vanity Lamps - Black 2 Way
861
Sentry Key Immobilizer Module - Black 6 Way
862
Sun Sensor (Atc) - Black 4 Way
862
Sunroof Control Module (Jr41) - White 6 Way
862
Sunroof Switch (Jr41) - Natural 4 Way
862
Throttle Position Sensor (2.0L/2.4L) - Natural 3 Way
863
Throttle Position Sensor (2.7L) - Black 3 Way
863
Traction Control Switch - 2 Way
863
Transmission Control Module (2.7L) - Black 60 Way
864
Transmission Range Indicator Illumination (Prndl) - Brown 2 Way
865
Transmission Range Sensor - Dk. Gray 10 Way
865
Transmission Solenoid/ Pressure Switch Assembly - Black 8 Way
865
Trunk Lamp - White 2 Way
866
Vehicle Speed Sensor (2.0L Mtx) - Black 3 Way
866
Window Drop Relay Assembly (Jr27) - 12 Way
866
Vehicle Speed Control Servo - 4 Way
866
8W-91 Connector/Ground/Splice Location
868
Right Headlamp Connectors
880
Right Front Lighting Connectors
880
Right Side Engine Compartment Connectors
881
Left Front Engine Compartment Connectors
881
Left Rear Engine Compartment Connectors
883
Left Fog Lamp
883
Power Distribution Center
884
Battery Cable Connectors
884
Generator and A/C Connectors
891
Inlet Air Temperature Sensor 2.7L
892
Rear Engine Conn 2.0L/2.4L
892
Oxygen Sensors 2.0L/2.4L
893
Oxygen Sensors 2.7L
893
8W-97 Power Distribution
922
Center Console Power Outlet
922
Power Outlet
922
Iod Fuse
923
Cigar Lighter / Power Outlet Base Removal
923
Tool for Cigar Lighter / Power Outlet Removal
923
Junction Block Location
924
Junction Block/Bcm
925
Power Distribution Center
925
Power Outlet
926
Engine 2.0L Dohc
928
Engine Identification
931
Diagnosis and Testing - Engine Diagnosis - Performance
932
Inspection for Rear Seal Area Leaks
937
Standard Procedure - Repair of Damaged or Worn Threads
937
Standard Procedure - Hydrostatic Locked Engine
937
Standard Procedure - Form-In-Place Gaskets and Sealers
938
Sealer Application
938
Standard Procedure - Engine Gasket Surface Preparation
939
Standard Procedure - Measuring Bearing Clearance Using Plastigage
939
Proper Tool Usage for Surface Preparation
939
Plastigage Placed in Lower Shell—Typical
939
Standard Procedure - Engine Core and Oil Gallery Plugs
940
Core Hole Plug Removal
940
Removal - Engine Assembly
940
Positioning Engine Cradle Support Post Mounts
942
Installation - Engine Assembly
943
Air Cleaner Element
951
Air Cleaner Housing
951
Cylinder Head
951
Cylinder-To-Cylinder Leakage Test
952
Removal - Cylinder Head
952
Cylinder-To-Water Jacket Leakage Test
952
Visual Test Method
952
Checking Wear on Valve Guide—Typical
953
Valve Guide Height
953
Installation - Cylinder Head
954
Checking Bolts for Stretching (Necking)
954
Cylinder Head Gasket Positioning
954
Cylinder Head Tightening Sequence
954
Camshaft Oil Seal(S)
955
Camshaft Sprocket - Removal/Installation
955
Camshaft Oil Seal - Removal with C-4679A
955
Camshaft Seal - Installation
955
Camshaft(S)
956
Cylinder Head and Camshafts
956
Camshaft End Play - Typical
956
Camshaft Bearing Cap Identification
957
Camshaft Bearing Cap - Removal
957
Checking Camshaft(S) for Wear
957
Camshaft Bearing Cap Tightening Sequence
957
Cylinder Head Cover
958
Cylinder Head Cover Bolt Seals
958
Cylinder Head Cover Gasket and Spark Plug Well Seals
958
Spark Plug Well Seals
958
Hydraulic Lash Adjusters
959
Hydraulic Lash Adjuster Noise Diagnosis
959
Sealer Locations
959
Cylinder Head Cover Tightening Sequence
959
Intake/Exhaust Valves & Seats
960
Rocker Arms
960
Hydraulic Lifter
960
Valve Springs and Seals
961
Rocker Arm - Removal/Installation
961
Rocker Arm
961
Valve Spring - Removal/Installation
961
Installation - Cylinder Head on
962
Installation - Cylinder Head off
962
Valve Stem Seal/Valve Spring Seat
962
Valve Stem Oil Seal Tool
962
Engine Block
963
Cylinder Block and Bedplate
963
Cylinder Bore Cross-Hatch Pattern
963
Crankshaft
964
Cylinder Bore
964
Removal - Crankshaft
964
Checking Crankshaft End Play
964
Identify Connecting Rod to Cylinder
965
Engine Block and Components
965
Crankshaft Main Bearing Location
966
Bedplate Bolts
966
Crankshaft Journal Measurements
966
Main Bearing Identification
966
Installing Main Bearing Upper Shell
967
Bedplate Sealing
967
Main Bearing Caps/Bedplate Torque Sequence
967
Crankshaft Oil Seal - Front
968
Crankshaft Sprocket—Removal
968
Crankshaft Key
969
Front Crankshaft Oil Seal—Removal
969
Front Crankshaft Oil Seal - Installation
969
Crankshaft Sprocket - Installation
969
Crankshaft Oil Seal - Rear
970
Rear Crankshaft Oil Seal—Removal
970
Crankshaft Rear Seal and Special Tool 6926-1
970
Piston & Connecting Rod
971
Standard Procedure - Piston to Cylinder Bore Fitting
971
Crankshaft Seal Special Tool 6926-2
971
Crankshaft Rear Oil Seal - Installation
971
Piston Measurement Location
972
Cylinder Bore Measurement
972
Piston Markings
972
Connecting Rod Guides—Typical
973
Installing Piston
973
Connecting Rod Bearings
974
Piston Rings
974
Connecting Rod - Fitting
974
Standard Procedure - Piston Ring - Fitting
974
Piston Rings—Removing and Installing
975
Installing Side Rail
975
Piston Ring Installation
975
Piston Ring End Gap Position
975
Structural Collar
976
Vibration Damper
976
Structural Collar - Removal/Installation
976
Vibration Damper - Removal
976
Engine Mounting
977
Engine Support Adjustment
977
Vibration Damper - Installation
977
Left Mount
978
Right Mount
978
Left Side Mount - Typical
978
Engine Mounting—Right Side
978
Front Mount
979
Rear Mount
979
Front Engine Mount
979
Engine Mounting—Rear
979
Lubrication
980
Engine Lubrication Components
980
Oil
981
Engine Oil Level Check
981
Engine Lubrication System
981
Oil Level
982
Oil Filter
983
Oil Filter Adapter
983
Oil Pan
983
Engine Oil Filter Adapter to Engine Block
983
Oil Pressure Sensor/Switch
984
Oil Pump
984
Oil Pan Sealing
984
Engine Oil Pressure Switch
984
Oil Pressure Relief Valve
985
Oil Pump and Tube
985
Measuring Outer Rotor Thickness
986
Measuring Inner Rotor Thickness
986
Checking Oil Pump Cover Flatness
986
Measuring Outer Rotor Clearance in Housing
987
Measuring Clearance between Rotors
987
Measuring Clearance over Rotors
987
Oil Pump Sealing
988
Crankshaft Sprocket—Installation
988
Front Crankshaft Seal—Installation
988
Intake Manifold
989
Fuel Rail Support Bracket
989
Exhaust Manifold
990
Exhaust Manifold Heat Shield Bolts
990
Intake Manifold Tightening Sequence
990
Valve Timing
991
Timing Belt Cover(S)
991
Exhaust Manifold Tightening Sequence
991
Camshaft Timing Check
991
Rear Cover
992
Front Cover
992
Front Timing Belt Cover
992
Timing Belt and Sprockets
993
Removal - Timing Belt
993
Timing Belt System - 2.0L DOHC
993
Removal - Camshaft Sprocket(S)
994
Removal - Crankshaft Sprocket
994
Camshaft Timing Marks
994
Timing Belt Removal
994
Crankshaft Sprocket - Removal
995
Crankshaft Sprocket Timing
995
Installation - Camshaft Sprockets
995
Timing Belt Tension Adjustment
996
Timing Belt Tensioner & Pulley
997
Timing Belt Tension Verification
997
Timing Belt Tensioner Assembly
997
Engine 2.4L Dohc
998
Engine 2.7L Dohc
1070
Crankshaft Main Bearings
1117
Timing Chain Cover
1146
Timing Chain Cover Sealing
1146
Timing Chain and Sprockets
1147
Removal - Timing Chain
1147
Timing Mark Alignment
1147
Primary Timing Chain Tensioner
1147
Timing Drive System - Primary
1148
Rear Bumper Reinforcement
1170
Installation - Jr-41
1170
Installation - Jr-27
1170
Removal - Jr-27
1171
Fuel System
1182
Fuel Delivery
1182
Fuel Delivery
1183
Fuel Rail
1189
Fuel Tank
1191
Fuel Injection
1196
Accelerator Pedal
1202
Crankshaft Position Sensor
1203
Fuel Injector
1206
Fuel Pump Relay
1208
Throttle Body
1215
Throttle Position Sensor
1219
Steering
1222
Diagnosis and Testing - Power Steering Flow and Pressure Test
1223
Power Steering Analyzer with Hoses Installed
1223
Power Steering Analyzer Adapters 6893
1223
Diagnosis and Testing - Steering System Diagnosis Charts
1224
Power Steering Noise
1224
Power Steering Fluid
1229
Power Steering Fastener Torque
1229
Column
1231
Steering Column and Intermediate Shaft
1231
Removal - Steering Column
1232
Speed Control Switches
1233
Airbag Attaching Bolts
1233
Airbag Electrical Connections
1234
Remote Audio Switches Connector
1234
Puller Installed on Steering Wheel
1234
Wiring Harness Connection to Clock Spring
1235
Intermediate Shaft
1238
Column Fastener Torque
1238
Diagnosis and Testing - Steering Column Intermediate Shaft
1238
Intermediate Shaft Attachment
1239
Removing Roll Pin from Flex Joint (Typical)
1239
Tool Set-Up for Installing Roll Pin (Typical)
1239
Steering Wheel
1240
Gear
1242
Power Steering Gear
1242
Power Steering Pressure Switch
1248
Transaxle
1262
T350 Manual Transaxle
1262
Transaxle Identification
1263
Metal I.D. Tag
1263
Bar Code Label
1263
Gear Ratios
1264
Lubricant/Additives
1264
Sealants
1264
Hard Shifting
1264
Low Lubricant Level
1265
Clutch Problems
1265
Case Bolts
1265
Transaxle Case Halves
1266
Separate Case Halves
1266
Bellhousing Case Half Removal
1266
Differential Assembly Removal
1266
Reverse Idler Shaft
1267
Reverse Idler Gear and Spacer
1267
Reverse Idler Shaft Removal
1267
Screws Retaining Reverse Fork Bracket
1267
Remove Reverse Fork Bracket
1268
Selector Shaft
1268
Remove Selector Shaft Spacer
1268
Transaxle Cover Removal
1268
End Cover
1269
Bench Fixture
1269
Snap Rings Retaining Bearings
1269
Bearing Fixture
1269
Pressing Gears out of Case
1270
Oil Feed Trough
1270
Reverse Brake Friction Cone
1270
Transaxle Case Removal
1270
Shift Blocker Removal
1271
–2 Shift Fork Removal
1271
Gear Train Removal
1271
Shift Rail Installation
1272
Shift Blocker Installation
1272
Reverse Brake Blocking Ring Installation
1272
Reverse Brake Friction Cone Installation
1273
Gear Case Half
1273
Friction Cone Lugs
1273
Installing Input and Output Bearings
1273
Transaxle End Cover
1274
Output Shaft
1299
Vehicle Speed Sensor
1302
T850 Manual Transaxle
1303
41Te Automatic Transaxle
1370
Output Gear Bearing Shim Chart
1402
Transfer Shaft Bearing Shim Chart
1408
Install Transfer Shaft Gear
1409
Install Rear Cover
1409
Install Rear Cover Bolts
1409
Install Low/Reverse Clutch Pack
1410
Install Low/Reverse Reaction Plate Snap Ring
1410
Install One Disc
1410
Install Low/Reverse Reaction Plate
1410
Low/Reverse Reaction Plate Chart
1411
Tapered Snap Ring Instructions
1411
Snap Ring Installed
1411
Check Low/Reverse Clutch Clearance
1411
Proper Orientation of 2/4 Clutch Retainer and Spring
1412
/4 Clutch Retainer
1412
Install 2/4 Clutch Retainer Snap Ring
1412
Check 2/4 Clutch Clearance
1412
Number 7 Bearing
1413
Install Rear Sun Gear and #7 Needle Bearing
1413
Install Front Carrier and Rear Annulus Assembly
1413
Install Front Sun Gear Assembly
1413
Select Thinnest No. 4 Thrust Plate
1414
View through Input Speed Sensor Hole
1414
Remove Oil Pump O-Ring
1414
Measure Input Shaft End Play Using End Play Set 8266
1414
No. 4 Thrust Plate Chart
1415
Install Input Clutch Assembly
1415
Install Caged Needle Bearing
1415
Install Cooler Bypass Valve
1415
Install Oil Pump Gasket
1416
Install Oil Pump
1416
Install Pump-To-Case Bolts
1416
Install Low/Reverse Accumulator
1416
Install Low/Reverse Accumulator Plug
1417
Install Low/Reverse Accumulator Snap Ring
1417
Accumulator (Underdrive)
1417
Accumulator (Overdrive)
1417
Install Underdrive and Overdrive Accumulators
1418
Install Valve Body
1418
Install Valve Body-To-Case Bolts
1418
Install Oil Filter
1418
Install Oil Pan
1419
Solenoid/Pressure Switch Assembly and Gasket
1419
Attaching Bolts
1419
41Te Transaxle Hydraulic Schematics
1420
Specifications - 41Te Transaxle
1432
Accumulator
1440
Underdrive and Overdrive Accumulators
1440
Low/Reverse Accumulator Assembly
1440
2/4 Accumulator Assembly
1440
Autostick Switch
1441
Automatic Overrides
1441
Automatic Shifts will Occur under the Following Conditions
1441
Manual Shifts Are Not Permitted under the Following Conditions
1441
Driving Clutches
1442
Final Drive
1442
Underdrive Clutch
1442
Overdrive Clutch
1442
Differential Cover Bolts
1443
Remove Differential Cover
1443
Differential Retainer Bolts
1443
Remove Bearing Retainer
1443
Checking Side Gear End Play
1444
Position Button and Collets Onto Differential and Bearing
1444
Position Tool 5048 over Button and Collets at Differential Bearing
1444
Differential Service Tools
1445
Remove Differential Bearing Cone
1445
Remove Bearing Cup
1445
Position Bearing Cup Remover Tool in Retainer
1445
Position Bearing Cone Onto Differential
1446
Differential Bearing Retainer
1446
Differential Bearing Preload Measurement and Adjustment
1447
Install Differential Cover
1447
Tool L-4436 and Torque Wrench
1447
Differential Bearing Shim Chart
1448
Fluid
1449
Fluid Level and Condition Check
1449
Fluid Level Check
1449
Preload Adjustment W/O Shim
1449
Fluid Level Check Using Drb
1450
Fluid Condition
1450
Transmission Fluid Temperature Chart
1450
Standard Procedure - Fluid and Filter Service
1451
Fluid/Filter Service (Recommended)
1451
Dipstick Tube Fluid Suction Method
1451
Fluid Level Indicator
1451
Gearshift Cable
1452
Gearshift Cable at Transaxle
1452
Gearshift Knob
1452
Gearshift Bezel
1452
Center Console Assembly
1453
Shift Cable Adjust Lever Nut—Typical
1453
Gearshift Cable at Floor Shifter
1453
Gearshift Cable Routing
1453
Gearshift Linkage Adjustment
1454
Shift Cable Adjust Lever Nut
1454
Gearshift Mechanism
1455
Gearshift Cable at Floor Shifter—Typical
1456
Release Cable from Bracket at Retainer Lock
1456
Interlock Cable at Floor Shifter Assembly
1456
Autostick Connector
1457
Shifter Assembly
1457
Input Clutch Assembly
1458
Holding Clutches
1458
2/4 Clutch
1458
Low/Reverse Clutch
1458
Reverse Clutch Snap Ring
1459
Pry Reverse Clutch Reaction Plate
1459
Reverse Clutch Reaction Plate
1459
Reverse Clutch Pack
1459
Od/Reverse Pressure Plate Snap Ring
1460
Od/Reverse Pressure Plate
1460
Waved Snap Ring
1460
Remove OD Clutch Pack
1460
#3&4 Thrust Washers
1461
Underdrive Shaft Assembly
1461
No. 2 Needle Bearing
1461
OD/UD Reaction Plate Tapered Snap Ring
1461
OD/UD Reaction Plate
1462
Remove One UD Clutch Disc
1462
UD Clutch Flat Snap Ring
1462
Underdrive Clutch Pack
1462
UD Spring Retainer Snap Ring
1463
UD Return Spring and Retainer
1463
Underdrive Clutch Piston
1463
Input Hub Tapered Snap Ring
1463
Tap on Input Hub
1464
Input Hub Removed
1464
Pull Retainer from Piston
1464
Remove Snap Ring
1464
Snap Ring and Return Spring
1465
Remove Input Shaft Snap Ring
1465
Remove Input Shaft
1465
Install Input Shaft
1465
Install Input Shaft Snap Ring
1466
Return Spring and Snap Ring
1466
Install Snap Ring
1466
Install Od/Reverse Piston
1466
Install Input Shaft Hub Assembly
1467
Install Input Hub Tapered Snap Ring
1467
Seal Compressor Special Tool 5067
1467
Install UD Spring Retainer and Snap Ring
1468
Install Last UD Clutch Disc
1469
Tapered Snap Ring
1469
Seating Tapered Snap Ring
1469
Input Clutch Assembly on Pressure Fixture Tool 8391
1470
Set up Dial Indicator to Measure UD Clutch Clearance
1470
Press down on UD Clutch Pack and Zero Dial Indicator
1470
Install OD Clutch Pack
1471
Install Waved Snap Ring
1471
Install Flat Snap Ring
1471
Measure OD Clutch Pack Clearance
1472
Install Reverse Clutch Pack
1472
Install Reaction Plate
1472
Install Reverse Clutch Snap Ring
1473
Pry up Reaction Plate to Seat against Snap Ring
1473
Measure Reverse Clutch Pack Clearance
1473
Press down on Reverse Clutch and Zero Indicator
1473
Install No. 2 Needle Bearing
1474
Install Underdrive Shaft Assembly
1474
Install No. 3 Thrust Washer
1474
Reverse Clutch Snap Ring Thickness
1474
Install No. 3 Thrust Plate
1475
Install Overdrive Shaft Assembly
1475
Oil Pump Assembly
1475
Transaxle Oil Cooler Fittings
1476
Reaction Shaft Support
1476
Measure Outer Gear to Pocket
1477
Planetary Geartrain
1477
Seal - Oil Pump
1478
Shift Interlock Cable
1478
Remove Oil Pump Seal
1478
Ignition Key/Switch Positions
1478
Convertible Top
1540
Diagnosis and Testing - Hydraulic Systems
1540
Hydraulic System Tests
1540
Adjustment - Convertible Top
1541
Adjustment - Hydraulic Motor/Pump Bleeding Procedures
1541
Adjustment Locations
1541
Adjustment - Top Frame Cam
1542
To Adjust Cam Setting
1542
Adjustment - Balance Link
1543
Adjustments - Dowel Pin
1543
Roof Latch and Guide Dowel Pin
1543
Balance Link Adjustment
1543
Specifications - Convertible Top Torque
1544
Folding Top Cover
1544
Top Headlining
1545
Hydraulic Cylinder
1546
Hydraulic Lines
1546
Hydraulic Motor/Pump Assembly
1547
Convertible Top Rear Window
1547
Hydraulic Pump Assembly
1547
Sail Panel Reference Marks
1548
Sail Springs
1548
Rear Window Rear Stop Screw
1548
Convertible Top Storage
1549
Rear Window Locking Strip
1549
Center Convertible Top Storage
1549
Decklid/Hatch/Liftgate/Tailgate
1550
Decklid Hinge and Gas Support Cylinder
1550
Gas Prop
1551
Decklid Latch
1551
Gas Prop-Rod Lock Cap
1551
Decklid Latch Striker
1552
Decklid Lock Cylinder
1552
Emergency Release Cable
1553
Decklid Latch Cover
1553
Door - Front
1554
Check Strap
1555
Door
1555
Front Door Check Strap
1555
Front Door Hinges
1555
Door Glass
1556
Front Door Glass
1556
Inner Belt Stabilizer
1556
Regulator Lift Channel
1557
Rear Guide Bolts
1557
Up-Stop Access Hole
1557
Up-Stop Adjustments
1558
Jack Screw Access Hole
1558
Reflector Plate
1558
Front Adjuster
1558
Glass – Front/Rear Adjustment
1559
Forward up Stop Adjustment
1559
Rear up Stop Adjustment
1559
Mirror Flag
1559
Front Door Glass Adjustment Specifications
1560
Front/Rear Glass Position
1560
Door Glass Alignment Verification
1561
Exterior Handle
1561
Door Glass Inner Belt Stabilizer
1561
Outside Door Handle - Jr27 Only
1561
Hinge
1562
Latch
1562
Front Door Latch
1562
Latch and Lock Rod Clips
1563
Lock and Latch Rods at Door Latch
1563
Door Latch
1563
Door Latch Adjustment
1563
Latch Striker
1564
Lock Button Bell Crank
1564
Door Latch Striker
1564
Lock Button Bell Crank – Typical
1564
Lock Cylinder
1565
Door Lock Cylinder
1565
Side View Mirror Flag/Door Glass Channel
1565
Trim Panel
1566
Mirror Bezel and Door Trim Access Cover
1566
Lower Door Trim Panel Removal
1566
Rear Vertical Guide Bar
1567
Glass to Lift Plate Attaching Screws
1567
Window Regulator
1568
Front Door Regulator
1568
Applique
1569
Front Door Applique
1569
Installation - Jr-27 Only
1569
Door Pin Assembly
1570
Door Pin Receiver
1570
Door Pin Receiver Adjustment
1570
Watershield
1571
Door Watershield
1571
Doors - Rear
1572
Rear Door Applique
1572
Rear Check Strap
1573
Rear Door Check Strap
1573
Rear Door/Hinges
1573
Rear Door Glass
1574
Rear Door Outside Handle
1574
Exterior
1579
Accessory Drive Belt Splash Shield
1579
Battery Splash Shield
1580
Body Side Moldings
1580
Cowl Cover
1580
Exterior Name Plates
1581
Front Fender
1581
Installation - Foam Tape
1581
Removal - Foam Tape
1581
Fuel Fill Door
1582
Left Fender
1582
Grille
1583
Front Grille - Jr-27
1583
Front Grille - Jr-41
1583
Left Front Wheelhouse Splash Shield
1584
Radiator Support Crossmember
1584
Fender Trim – Typical
1584
Wheelhouse Splash Shield
1584
Rear Wheelhouse Splash Shield
1585
Right Front Wheelhouse Splash Shield
1585
Splash Shield
1585
Side View Mirror
1586
Side View Mirror Glass
1586
Side View Mirror Cover
1586
Spoiler
1587
Spoiler Attaching Nuts
1587
Spoiler - Jr-41
1587
Tape Stripe
1588
Removal - Adhesives
1588
Installation - Adhesives
1588
Hood
1589
Adjuster Bumper
1589
Hood Adjuster Bumper
1589
Hood Overslam Bumper
1589
Hood Latch Release Cable
1591
Latch Release Cable
1591
Hood Release Cable Routing
1591
Hood Release Cable Handle
1591
Prop Rod
1592
Hood Prop Rod
1592
CD Changer Trim Bezel
1593
Glove Box
1593
Glove Box Latch
1594
Instrument Panel Assembly
1594
Hvac Housing Retaining Nuts
1594
Rear Heat Duct
1594
To Separate the Instrument Panel and Hvac Unit Housings
1595
To Connect the Instrument Panel and Hvac Unit Housings
1595
Instrument Panel Removal
1596
Instrument Panel Center Bezel
1597
Instrument Panel Cluster Bezel
1597
Instrument Panel End Cover
1598
Instrument Panel Inboard Bezel
1599
Instrument Panel Outboard Bezel
1599
Instrument Panel Top Cover
1600
Left Lower Instrument Panel Trim
1600
Left Lower Instrument Silencer Panel
1601
Right Lower Silencer Panel
1601
Right Instrument Panel Trim Bezel
1602
Right Lower Instrument Panel Trim
1602
Dash Panel
1603
Kick Shield
1603
Interior
1605
A-Pillar Trim
1606
Interior Trim Panels
1606
Carpets and Floor Mats
1607
B-Pillar Lower Trim
1607
Floor Carpet
1607
Floor Carpet Jr-27
1608
Center Header Trim Panel
1609
Door Sill Trim Panel
1609
Cowl Trim Panel
1609
Floor Console
1610
Transmission Range Indicator Bezel
1610
Forward Instrument Panel Console
1611
Headliner
1611
Headlining Wiring
1612
Header Trim Panel - Right or Left
1613
Header Trim Panel (Right Side)
1613
Lower Quarter Trim
1614
Quarter Trim Panel
1614
Speaker Grille
1614
Rear Shelf Trim Panel
1615
Rear Shelf Center Plug
1615
Rear Shelf Trim
1615
Rear View Mirror
1616
Inside Rear View Mirror
1616
Sun Visor
1616
Shift Boot
1617
Shift Knob – Automatic Trans
1617
Shift Boot – Typical
1617
Sun Visor
1617
Sun Visor Support
1618
Upper B-Pillar Trim
1618
Upper Quarter Trim
1618
Upper Deck Molding
1618
Windshield Header Damper
1619
Upper Quarter Trim W/O Curtain Air Bag
1619
Paint
1620
Exterior Colors
1620
Interior Colors
1620
Basecoat/Clearcoat Finish
1621
Paint Code
1621
Painted Surface Touch-Up
1621
Finesse Sanding/Buffing and Polishing
1621
Adjustable Quarter Glass Jr-27
1622
Quarter Window Module
1622
Quarter Glass
1622
Quarter Glass Adjustment
1623
Bottom of Glass – Inboard/Outboard Adjustments
1623
Top of Glass – Inboard/Outboard Adjustments
1623
Quarter Glass Adjustment Specifications
1624
Forward Jack Screw Adjustment
1624
In/Out allen Adjustment
1624
Quarter Glass Alignment Verification
1625
Seats
1626
Headrest
1627
Front Seat
1627
Head Restraint Removal
1627
Front Seat Exploded View
1628
Front Seat Removal
1629
Seat Track Position
1630
Rear Seat
1638
Rear Seat Cushion
1639
Wind Deflector
1659
Weatherstrip/Seals
1661
A-Pillar Weatherstrip Retainer and Molding
1662
Decklid Opening Weatherstrip
1662
Door Inner Belt Weatherstrip
1663
Drip Rail Weatherstrip
1663
Door Opening Trim Welt
1663
Front & Rear Door Opening Weatherstrip
1664
Front Door Glass Run Weatherstrip
1664
Door Glass Run Weatherstrip
1664
Front Door Outer Belt Molding
1665
Front Door Inner Belt Weatherstrip
1665
Front Door Outer Belt Molding Removal
1665
Header / A-Pillar Weatherstrip
1666
Butyl Patch and L – FOAM
1666
L Shape Foam Location
1666
Body Structure
1672
Opening Dimensions
1675
Specifications - Body Opening
1675
Controls
1819
A/C Compressor Clutch
1820
Clutch Plate
1820
External Snap Ring
1820
Shaft Protector and Puller
1821
Clutch Coil Lead Wire Harness
1821
Puller Plate
1821
Clutch Field Coil Snap Ring
1821
Clutch Pulley Install
1822
Clutch Plate Driver
1822
Check Clutch Air Gap
1822
A/C Compressor Clutch Coil
1823
A/C Compressor Clutch Relay
1823
Diagnosis and Testing - Compressor Clutch Coil
1823
Diagnosis and Testing - A/C Compressor Clutch Relay
1823
A/C Heater Control
1824
Instrument Panel Center Trim Bezel Remove/Install
1824
A/C Heater Control - Mtc
1825
A/C Heater Control Remove/Install
1825
Control Harness
1825
Control Mounting Screws
1825
A/C Pressure Transducer
1826
Evaporator Temperature Sensor
1826
Control Bezel
1826
Evaporator Temperature Sensor Set Point
1827
Evaporator Probe
1827
In-Car Temperature Sensor
1828
In-Car Sensor Aspirator Motor Operation
1828
Atc In-Car Temperature Sensor
1828
Diagnosis and Testing - Sun Sensor
1829
Sun Sensor
1829
Atc Sun Sensor
1829
Ambient Temp Sensor
1830
Blend Door Actuator
1831
Mode Door Actuator
1831
Blend Actuator Spline
1831
Recirculation Door Actuator
1832
Mode Actuator Spline
1832
Blower Motor Resistor
1833
Recirculation Actuator
1833
Recirculation Door Gear
1833
Resistor Block
1834
Thermal Limiter Switch
1834
Power Module
1835
Distribution
1836
Blower Motor
1836
Hvac Housing
1836
Instrument Panel A/C Outlets
1847
Plumbing
1848
A/C Compressor
1848
A/C Condenser
1849
A/C Expansion Valve
1850
Air Conditioning Lines
1850
A/C Evaporator
1851
Evaporator Housing Seals
1851
Evaporator Coil
1851
Recirculation Motor
1852
Hvac Harness
1852
Hvac Housing - New H-Valve Connector
1853
Evaporator Coil (New) H-Valve
1853
Discharge Line
1854
Suction Line
1855
Receiver Drier and Lines
1855
Receiver Drier with Lines
1855
Receiver / Drier
1856
Service Port Valve Core
1857
Heater Core
1857
Emissions Control
1862
Description - Trip Definition
1862
Description - Monitored Component
1862
Comprehensive Components
1863
Oxygen Sensor (O2S) Monitor
1863
Evaporative Emissions
1872
Operation - Evaporation Control System
1872
Orvr System Schematic 2.7 Atx
1873
Evap/Purge Solenoid
1876
Fuel Filler Cap
1876
Natural Vac Leak Detection Assy
1876
Nvld Assembly
1876
Leak Detection Pump
1877
Locking Tab
1877
Assembly Removed
1877
Fuel Tank and Evap System
1877
Orvr
1878
Ldp Location
1878
Pcv Valve
1880
Component Locations
2499
Charts and Graphs
2535
Airbag System
2551
Audio System
2556
Wiper System
2567
Calibration Mismatch
2578
Cluster Message Mismatch
2580
Driver Seat Belt Tensioner Circuit Open
2593
Driver Seat Belt Tensioner Circuit Short
2596
Driver Seat Belt Tensioner Short to Battery
2599
Driver Seat Belt Tensioner Short to Ground
2602
Driver Squib 1 Circuit Open
2605
Driver Squib 1 Circuit Short
2608
Driver Squib 1 Short to Battery
2611
Driver Squib 1 Short to Ground
2614
Driver Squib 2 Circuit Open
2617
Driver Squib 2 Circuit Short
2620
Driver Squib 2 Short to Battery
2623
Driver Squib 2 Short to Ground
2626
Left Side Impact Sensor 1 Internal 1
2629
Loss of Ignition Run Only
2635
No Cluster Message
2639
No Left Side Impact Sensor 1 Communication
2641
No Right Side Impact Sensor 1 Communication
2649
Passenger Seat Belt Tensioner Circuit Open
2665
Passenger Seat Belt Tensioner Circuit Short
2668
Passenger Seat Belt Tensioner Short to Battery
2671
Passenger Seat Belt Tensioner Short to Ground
2674
Passenger Squib 1 Circuit Open
2676
Passenger Squib 1 Circuit Short
2679
Passenger Squib 1 Short to Battery
2682
Passenger Squib 1 Short to Ground
2685
Passenger Squib 2 Circuit Open
2688
Passenger Squib 2 Circuit Short
2691
Passenger Squib 2 Short to Battery
2694
Passenger Squib 2 Short to Ground
2697
Vehicle Body Style Mismatch
2705
Airbag Indicator on Without Active Trouble Codes
2707
Cassette Player Inop
2713
CD Play Failure
2717
CD Read Failure
2718
CD Temperature High
2719
Low Voltage Level
2720
No Antenna Connection
2721
Vehicle Speed Warning Chime Problem
2735
Pcm Messages Not Received
2742
No Response from Instrument Cluster
2755
No Response from Radio
2767
Door Ajar
2790
Driver Door Ajar Circuit Open
2792
Driver Door Ajar Circuit Shorted to Ground
2793
Left Rear Door Ajar Circuit Open
2794
Passenger Door Ajar Circuit Shorted to Ground
2797
Right Rear Door Ajar Circuit Open
2798
Electrically Heated Systems
2800
Exterior Lighting
2807
Brake Warning Indicator Always on
2913
Brake Warning Indicator Inoperative
2914
Rke Fob Battery Low
2955
Door Lock Inhibit Inoperative
2971
Alarm Trips on Its Own
2990
System Initialization
3455
Diagnostic Mode
3455
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