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Dodge Caravan 2002
Chrysler Dodge Caravan 2002 Manuals
Manuals and User Guides for Chrysler Dodge Caravan 2002. We have
1
Chrysler Dodge Caravan 2002 manual available for free PDF download: Manual
Chrysler Dodge Caravan 2002 Manual (2399 pages)
Brand:
Chrysler
| Category:
Automobile
| Size: 84.63 MB
Table of Contents
Lubrication & Maintenance
14
Table of Contents
14
International Symbols
15
Description
15
Fluid Types Description Description - Engine Oil and Lubricants
15
Description - Engine Coolant
16
Oil
16
Description - Automatic Transmission Fluid
17
Description - Fuel Requirements
17
Description - Fuel Requirements - Diesel Engine
19
Lubrication & Maintenance
15
Hoisting
19
Description - Engine Oil - Diesel Engines
19
Lubrication & Maintenance
19
Fluid Fill/Check Locations Description
19
Lubrication Points Description
19
Maintenance Schedules Description
19
Standard Procedure - Hoisting
19
Jump Starting
20
Standard Procedure - Jump Starting
20
Towing
21
Standard Procedure - Towing
21
Suspension
24
Front Suspension
25
Description - Front Suspension
25
Operation - Front Suspension
25
Standard Procedure - Lubrication
25
Specifications
26
Front Suspension Fastener Torque
26
Special Tools
26
Front Suspension
27
Bushings
27
Hub / Bearing Description
27
Operation
27
Diagnosis and Testing - Hub and Bearing
28
Removal
28
Installation
29
Removal - Stabilizer Bar Cushion
27
Installation - Stabilizer Bar Cushion
27
Knuckle Description
29
Operation
29
Removal - Steering Knuckle
30
Inspection - Steering Knuckle
31
Installation - Steering Knuckle
32
Lower Ball Joint Description
33
Operation
33
Diagnosis and Testing - Lower Ball Joint
33
Lower Ball Joint Seal Boot
33
Description - Export
33
Removal
34
Removal - Ball Joint Seal Boot
34
Removal - Export
34
Lower Ball Joint Seal Boot
33
Front Suspension
34
Installation
34
Installation - Ball Joint Seal Boot
34
Installation - Export
35
Lower Control Arm Description
35
Operation
35
Removal - Lower Control Arm
35
Disassembly
36
(Rear Bushing - Standard)
36
Disassembly - Lower Control Arm
36
Disassembly - Lower Control Arm (Rear Bushing - Hydro)
36
Inspection - Lower Control Arm
37
Assembly
37
Assembly - Lower Control Arm (Rear Bushing - Standard)
37
Assembly - Lower Control Arm (Rear Bushing - Hydro)
38
Installation - Lower Control Arm
38
Stabilizer Bar
39
Stabilizer Bar Description
39
Operation
39
Removal
40
Inspection
40
Installation
41
Strut
42
Description - Strut Assembly
42
Operation - Strut Assembly
42
Diagnosis and Testing - Strut Assembly
43
Removal - Strut Assembly
43
Disassembly - Strut Assembly
45
Assembly - Strut Assembly
46
Installation - Strut Assembly
48
Rear Suspension
49
Operation - Rear Suspension
50
Special Tools
51
Rear Suspension
51
Specifications
51
Rear Suspension Fastener Torque
51
Bushings
52
Removal - Leaf Spring Front Bushing
52
Installation - Leaf Spring Front Bushing
52
Hub / Bearing Description
53
Operation
54
Diagnosis and Testing - Hub and Bearing
54
Removal
54
Installation
56
Jounce Bumper Description
59
Operation
59
Removal
59
Removal - Awd and Heavy Duty
59
Removal - Front-Wheel-Drive
59
Installation
59
Installation - Awd and Heavy Duty
59
Installation - Front-Wheel-Drive
59
Rear Suspension
60
Assembly - Shock Absorber (Upper Bushing)
61
Installation - Shock Absorber
61
Shock Absorber Description
60
Operation
60
Removal - Shock Absorber
60
Disassembly - Shock Absorber (Upper Bushing)
60
Spring - Awd Description
61
Operation
61
Removal - Awd
61
Installation - Awd
62
Spring - Fwd Description
63
Operation
63
Removal - Fwd
63
Installation - Fwd
64
Spring Mounts - Front Removal
65
Installation
66
Spring Mounts - Rear Removal
66
Installation
67
Stabilizer Bar Description
67
Operation
67
Removal
67
Installation - Awd
67
Removal - Awd
67
Removal - Fwd
67
Installation - Fwd
68
Track Bar Description
68
Operation
68
Removal
68
Installation
68
Differential & Driveline
80
Half Shaft - Front Description
81
Removal
81
Installation
83
Specifications - Half Shaft - Front
85
Half Shaft - Front
81
CV Boot - Inner
85
Removal
85
Half Shaft - Front
85
Description
85
Installation
85
CV Boot - Outer Removal
89
Installation
89
Outer CV Joint Bearing Shield Removal
92
Installation
92
Rear Driveline Module
103
Rear Driveline Module Description
104
Diagnosis and Testing Diagnosis and Testing - Rear Driveline Module Noise
104
Diagnosis and Testing - Rear Driveline Module Operation
106
Removal
106
Disassembly
107
Assembly
109
Installation
113
Specifications - Rear Driveline Module
114
Special Tools
114
Bi-Directional Overrunning Clutch Description
115
Operation
120
Differential Assembly Description
120
Fluid - Differential Assembly
121
Standard Procedure - Differential
121
Assembly Fluid Drain and Fill
121
Fluid
122
Standard Procedure - Overrunning Clutch Housing Fluid Change
122
Viscous Coupler Description
123
Operation
123
Torque Arm Removal
125
Installation
125
Input Flange Seal Removal
125
Installation
126
Output Flange Seal Removal
127
Installation
128
Brakes
130
Brakes - Base
132
Description
132
Description - Base Brakes
132
Description - Base Brakes (Export)
132
Operation - Base Brakes
132
Warning
133
Caution
133
Diagnosis and Testing - Base Brake System
133
Standard Procedure - Base Brake Bleeding
136
Specifications
138
Brake Fastener Torque
138
Special Tools
138
Base Brake System
138
Brake Fluid Level Switch
139
Description
139
Operation
139
Removal
139
Installation
139
Adjustable Pedal Switch
140
Description
140
Diagnosis and Testing - Adjustable Pedal Switch
140
Removal
140
Installation
141
Pedal Position Sensor Description
141
Diagnosis and Testing - Pedal Position Sensor
142
Removal
142
Installation
142
Hydraulic/Mechanical
143
Description
143
Description - Disc Brakes (Front)
143
Description - Disc Brakes (Export)
144
Description - Disc Brakes (Rear)
144
Brakes - Base
145
Description - Drum Brakes (Rear)
145
Operation
145
Operation - Disc Brakes (Front)
145
Operation - Disc Brakes (Rear)
145
Diagnosis and Testing - Drum Brake Automatic Adjuster
145
Brake Pads/Shoes - Front
146
Removal
146
(Disc/Disc Brakes)
146
Removal - Front Disc Brake Shoes
146
Removal - Front Disc Brake Shoes (Disc/Drum Brakes)
147
Cleaning - Disc Brake Shoes
147
Inspection - Disc Brake Shoes
147
Installation Installation - Front Disc Brake
148
Installation - Front Disc Brake Shoes (Disc/Drum Brakes)
148
Brake Lines
146
Description - Brake Tubes and Hoses
146
Operation - Brake Tubes and Hoses
146
Inspection - Brake Tubes and Hoses
146
Brake Pads/Shoes - Rear Disc
148
Removal - Rear Disc Brake Shoes
148
Cleaning - Disc Brake Shoes
150
Inspection - Disc Brake Shoes
150
Installation - Rear Disc Brake Shoes
150
Brake Pads/Shoes - Rear Drum
151
Removal - Rear Drum Brake Shoes
151
Inspection - Rear Drum Brake Shoe Lining
154
Installation - Rear Drum Brake Shoes
154
Adjustments Adjustment - Rear Drum Brake Shoes
155
Disc Brake Caliper - Front
155
Removal
155
(Disc/Disc Brakes)
155
Removal - Front Disc Brake Caliper
155
Removal - Front Disc Brake Caliper (Disc/Drum Brakes)
155
Disassembly
156
Bushings (Disc/Disc Brakes)
156
Disassembly - Caliper Guide Pin
156
Disassembly - Caliper Piston and Seal
156
Cleaning - Caliper
157
Inspection - Caliper
157
Assembly
157
Assembly - Caliper Guide Pin Bushings (Disc/Disc Brakes)
157
Assembly - Caliper Piston and Seal
157
Caliper (Disc/Disc Brakes)
158
Installation
158
Installation - Front Disc Brake
158
Installation - Front Disc Brake Caliper (Disc/Drum Brakes)
159
Disc Brake Caliper - Rear
159
Removal - Rear Disc Brake Caliper
159
Disassembly - Caliper Piston and Seal
160
Cleaning - Caliper
161
Inspection - Caliper
161
Assembly - Caliper Piston and Seal
161
Installation - Rear Disc Brake Caliper
162
Disc Brake Caliper Guide Pins
163
Removal - Disc Brake Caliper Guide
163
Pins (Disc/Drum Brakes)
163
Installation - Disc Brake Caliper Guide Pins (Disc/Drum Brakes)
163
Disc Brake Caliper Adapter Removal - Front Disc Brake Caliper Adapter
163
Installation - Front Disc Brake Caliper Adapter
163
Fluid
164
Diagnosis and Testing - Brake Fluid Contamination
164
Standard Procedure - Brake Fluid Level Checking
164
Specifications Brake Fluid
164
Drum Removal
164
Installation
164
Junction Block
165
Description - Non-Abs Junction Block
165
Operation - Non-Abs Junction Block
165
Removal - Non-Abs Junction Block
165
Installation - Non-Abs Junction Block
165
Master Cylinder Description Description
166
Description - Rhd
167
Operation
167
Standard Procedure - Master Cylinder Bleeding
167
Removal Removal - Lhd
168
Removal - Rhd
169
Disassembly - Master Cylinder (Fluid Reservoir)
169
Assembly - Master Cylinder (Fluid Reservoir)
170
Installation Installation - Lhd
170
Installation - Rhd
171
Pedal - Adjustable Description
171
Operation
171
Diagnosis and Testing - Adjustable Pedal System
172
Removal
172
Installation
174
Pedal Torque Shaft - Rhd Removal
176
Installation
176
Power Brake Booster Description
177
Operation
178
Diagnosis and Testing - Power Brake Booster
178
Removal Removal - Lhd
179
Removal - Rhd
181
Installation
182
Installation - Lhd
182
Installation - Rhd
184
Proportioning Valve Description - Proportioning Valve (Height Sensing)
185
Operation - Proportioning Valve (Height Sensing)
186
Diagnosis and Testing - Proportioning Valve (Height Sensing)
186
Removal - Proportioning Valve (Height Sensing)
187
Installation - Proportioning Valve (Height Sensing)
188
Rotor
188
Diagnosis and Testing - Brake Rotor
188
Standard Procedure - Brake Rotor Machining
190
Removal - Front Brake Rotor
191
Installation - Front Brake Rotor
191
Specifications Brake Rotor
192
Brake Rotor - Export
192
Support Plate - Drum Brake Removal
193
Installation
193
Wheel Cylinders Removal
194
Inspection
194
Installation
194
Parking Brake Description Description
194
Description - Export
195
Operation
195
Standard Procedure Standard Procedure - Parking Brake Automatic Adjuster Tension Release
195
Standard Procedure - Parking Brake Automatic Adjuster Tension Reset
196
Cables - Parking Brake Removal Removal - Parking Brake Cable (Front)
196
Removal - Parking Brake Cable (Intermediate)
197
Removal - Parking Brake Cable (Right Rear)
198
Removal - Parking Brake Cable (Left Rear)
199
Installation - Parking Brake Cable
200
Installation - Parking Brake Cable (Intermediate)
200
Adjustment - Parking Brake Cables
201
Installation - Parking Brake Cable (Left Rear)
201
Installation - Parking Brake Cable (Right Rear)
201
Lever - Parking Brake Removal
201
Installation
202
Cables - Parking Brake (Export)
201
Removal - Front Cable
201
Installation - Front Cable
201
Lever - Parking Brake (Export)
203
Removal - Parking Brake Lever and Front Cable
203
Installation - Parking Brake Lever and Front Cable
204
Shoes - Parking Brake Removal
204
Installation
210
Adjustments
212
Adjustment - Parking Brake Shoes
212
Brakes - Abs
214
Brakes - Abs
215
Description - Electronic Variable
215
Description - Traction Control System
215
Operation
215
Operation - Antilock Brake System
215
Operation - Electronic Variable Brake Proportioning
216
Operation - Traction Control System
216
Caution
217
Cautions
217
Standard Procedure - Antilock Brake System Bleeding
217
Specifications
218
Abs Fastener Torque
218
Tone Wheel Runout
218
Wheel Speed Sensor Air Gap
218
Front Wheel Speed Sensor Removal
218
Installation
218
Rear Wheel Speed Sensor - Awd Removal
219
Brakes - Abs
219
Installation
219
Rear Wheel Speed Sensor - Fwd Removal
220
Installation
220
Tone Wheel
221
Inspection - Tone Wheel
221
Traction Control Switch Diagnosis and Testing - Traction Control Switch
221
Hydraulic/Mechanical
222
Operation - Hydraulic Circuits and Valves
222
Hcu (Hydraulic Control Unit) Description
228
Operation
228
Icu (Integrated Control Unit) Description
229
Operation
229
Removal Removal - Lhd
229
Removal - Rhd
230
Disassembly - Icu
232
Assembly - Icu
232
Installation Installation - Lhd
233
Installation - Rhd
234
Clutch
236
Clutch
238
Diagnosis and Testing
238
Diagnosis and Testing - Drive Plate
240
Misalignment
240
Diagnosis and Testing - Clutch Chatter Complaints
241
Diagnosis and Testing - Clutch Cover and Disc Runout
241
Special Tools - T850 Transaxle
241
Clutch Release Lever and Bearing
241
Removal
243
Master Cylinder - Rhd Removal
243
Clutch
243
Installation
243
Master Cylinder - Lhd Removal
244
Installation
245
Modular Clutch Assy - 2.4L Gas Removal
246
Installation
246
Slave Cylinder Removal
246
Clutch Disc and Pressure Plate - 2.5L Td Removal
247
Installation
247
Flywheel Removal
248
Installation
248
Cooling
250
Cooling
251
Diagnosis and Testing Diagnosis and Testing - Cooling System Leak Test
251
Diagnosis and Testing - Cooling System Flow Check
252
Diagnosis and Testing - Cooling System Aeration
253
Diagnosis and Testing - Cooling System Deaeration
253
Description
253
Standard Procedure - Adding Additional Coolant
253
Standard Procedure - Cooling System Filling
253
Standard Procedure Standard Procedure - Cooling System Draining
253
Standard Procedure - Coolant Level Check
254
Accessory Drive Belt Tension
255
Specifications Cooling System Capacity
255
Torque
255
Cooling System
256
Accessory Drive
257
Drive Belts Description
258
Operation
258
Diagnosis and Testing - Accessory Drive Belt
258
Removal
259
Cleaning
260
Inspection
260
Installation
260
Adjustments
261
Drive Belts - 3.3/3.8L Removal
261
Cleaning
262
Inspection
262
Installation
262
Belt Tensioner - 3.3/3.8L
258
Belt Tensioner - 2.4L
258
Rs Engine
263
Diagnosis and Testing - Engine Cooling System
264
Coolant
268
Cleaning
268
Diagnosis and Testing - Coolant Concentration Testing
268
Inspection
268
Standard Procedure - Coolant Service
269
Coolant Recovery Container Description
269
Operation
269
Diagnosis and Testing - Coolant Recovery System
269
Removal
270
Installation
270
Engine Block Heater Description
270
Operation
270
Diagnosis and Testing - Engine Block Heater Testing
270
Engine Coolant Temperature Sensor - 3.3/3.8L Description
271
Installation
271
Installation
272
Engine Coolant Thermostat Description
272
Operation
272
Diagnosis and Testing - Engine Coolant Thermostat
272
Engine Coolant Thermostat - 2.4L Removal
272
Installation
273
Engine Coolant Thermostat - 3.3/3.8L Removal
273
Radiator
274
Description
274
Operation
274
Removal
276
Installation
276
Radiator Draincock Removal
276
Radiator Pressure Cap Description
276
Operation
276
Diagnosis and Testing Diagnosis and Testing - Cooling System Pressure Cap Testing
277
Diagnosis and Testing - Radiator Cap to Filler Neck Seal
277
Cleaning
278
Inspection
278
Radiator Fan Description
278
Operation
278
Diagnosis and Testing - Radiator Fan Motor
279
Removal
279
Installation
280
Radiator Fan Relay Description
280
Operation
280
Removal
280
Installation
281
Water Pump - 2.4L Description
281
Operation
281
Removal
281
Cleaning
281
Inspection
281
Water Pump - 3.3/3.8L Description
283
Operation
283
Removal
283
Cleaning
284
Inspection
284
Installation
284
Water Pump Inlet Tube - 2.4L Description
285
Removal
285
Installation
285
Water Pump Inlet Tube - 3.3/3.8L Removal
285
Transmission
287
Coolers and Tubes
287
Cleaning
288
Inspection
288
Installation
288
Cooling 2.5L Turbo Diesel
292
System
292
Diagnosis and Testing - Cooling System Leak Test
295
Diagnosis and Testing - Cooling System Flow Check
296
Diagnosis and Testing - Cooling System Aeration
296
Cooling 2.5L Turbo Diesel
296
Cleaning
296
Inspection
296
Specifications Specifications - Torque
297
Specifications - Cooling System Capacity
297
Transmission Oil Cooler Lines
288
Removal
288
Accessory Drive
298
Belt Tensioner
299
Removal
299
Installation
299
Idler Pulley Removal
299
Operation
299
Operation-Accessory Drive Belt
299
Diagnosis and Testing - Accessory Drive Belt
300
Removal
300
Removal-Accessory Drive Belt
300
Installation
302
Installation-Accessory Drive Belt
302
Installation-Power Steering Belt
302
Drive Belts
299
Description
299
Description - Accessory Drive Belt
299
Description - Power Steering Belt
299
Rg Engine
303
Coolant Description
304
Diagnosis and Testing - Coolant Concentration Testing
304
Standard Procedure Standard Procedure - Coolant Service
305
Standard Procedure - Adding Additional Coolant
305
Standard Procedure - Coolant Level Check
305
Standard Procedure - Cooling System Filling
305
Standard Procedure - Cooling System Draining
306
Coolant Recovery Press Container Description
306
Operation
306
Removal
307
Installation
307
Engine Coolant Temp Sensor Description
308
Operation
308
Removal
308
Installation
308
Engine Coolant Thermostat Description
309
Operation
309
Removal
309
Installation
309
Radiator Description
310
Operation
310
Removal
310
Installation
311
Radiator Draincock Removal
311
Water Pump Description
312
Operation
312
Removal
312
Removal - Water Pump
312
Removal - Water Pump Housing
312
Cleaning
312
Installation
312
Installation - Water Pump
312
Installation - Water Pump Housing
313
Radiator Pressure Cap Description
314
Operation
314
Diagnosis and Testing Diagnosis and Testing - Cooling System Pressure Cap
314
Diagnosis and Testing - Pressure Relief Test
315
Cleaning
315
Inspection
315
Radiator Fan Description
315
Operation
316
Diagnosis and Testing - Radiator Fan Motor
316
Removal
317
Installation
317
Hose Clamps
317
Description - Hose Clamps
317
Operation - Hose Clamps
317
Radiator Fan Relay Description
318
Operation
318
Coolant System Hoses
318
Removal
318
Removal - Lower Radiator Hose
318
Removal - Upper Radiator Hose
318
Removal - Coolant Bypass Hose
319
Installation
319
Installation - Coolant Bypass Hose
319
Installation - Lower Radiator Hose
319
Installation - Upper Radiator Hose
319
Audio
320
Antenna Body and Cable Description
323
Diagnosis and Testing - Antenna Body and Cable
323
Removal
323
Installation
324
Audio
323
Description
323
Operation
323
Antenna Module - Export Description
325
Operation
325
Diagnosis and Testing - Antenna Module - Export
325
Removal
326
Installation
326
CD Changer Description
326
Operation
326
Quarter Glass Integral Antenna - Export Description
327
Operation
327
Diagnosis and Testing - Quarter Glass Integral Antenna - Export
327
Instrument Panel Antenna Cable Removal
327
Installation
327
Radio
328
Diagnosis and Testing - Radio
328
Removal
328
Installation
329
Radio Noise Suppression Components Description
329
Operation
330
Remote Switches Description
330
Diagnosis and Testing - Remote Switches
330
Removal
331
Installation
331
Speaker
331
Diagnosis and Testing - Speaker
331
Removal
332
Chime/Buzzer
334
Chime/Buzzer
335
Diagnosis and Testing - Dome Lamp on Chime
335
Diagnosis and Testing - Engine
335
Diagnosis and Testing - Exterior Lamps on Chime
335
Diagnosis and Testing - Key-In Ignition Chime
335
Temperature Critical Chime
335
Diagnosis and Testing - Low Oil
336
Diagnosis and Testing - Seat Belt Chime
336
Diagnosis and Testing - Seat Belt Lamp
336
Diagnosis and Testing - Tire Pressure Monitor
336
Diagnosis and Testing - Turn Signal on Chime
336
Pressure Chime
336
Diagnosis and Testing - Warning Lamp Announcement Chime
337
Electronic Control Modules
338
Electronic Control Modules Standard Procedure - Pcm/Skim Programming
339
Body Control Module Description
340
Operation
340
Removal
342
Installation
342
Adjustable Pedal Module
340
Diagnosis and Testing - Adjustable
340
Pedal Module
340
Removal
340
Installation
340
Electronic Control Modules
340
Controller Antilock Brake Description
342
Removal
343
Installation
343
Front Control Module
345
Diagnosis and Testing - Front Control Module
345
Removal
345
Installation
345
Data Link Connector
346
Heated Seat Module Description
346
Operation
346
Diagnosis and Testing - Heated Seat Module
346
Removal
347
Installation
347
Power Liftgate Module Description
347
Operation
347
Installation
348
Powertrain Control Module Description Description
348
Diagnostic Trouble Code
350
Operation - Sensor Return - Pcm Input
362
Operation - Sci Receive - Pcm Input
362
Operation - Ignition Sense - Pcm Input
362
Operation - Pcm Ground
362
Operation
362
Operation - 5 Volt Supply - Pcm Output
362
Operation - 8-Volt Supply - Pcm Output
362
Standard Procedure - Obtaining Diagnostic Trouble Codes
362
Removal
363
Installation
363
Sentry Key Immobilizer Module Description
363
Operation
364
Removal
364
Installation
364
Transmission Control Module Description
365
Operation
365
Standard Procedure Standard Procedure - Pinion Factor Setting
368
Standard Procedure - Quick Learn Procedure
368
Removal
368
Installation
369
Sliding Door Control Module Description
370
Operation
371
Removal
371
Installation
371
Memory Seat/Mirror Module Description
370
Operation
370
Diagnosis and Testing - Memory Seat/Mirror Module
370
Removal
370
Installation
370
Engine Systems
376
Battery System
377
System
379
Cleaning
380
Inspection
380
Specifications
381
Special Tools
382
Battery System Special Tools
382
Description
382
Operation
384
Standard Procedure Standard Procedure - Spiral Plate Battery Charging
385
Standard Procedure - Conventional Battery Charging
386
Standard Procedure - Ignition-Off Draw Test
388
Standard Procedure - Open-Circuit Voltage Test
388
Standard Procedure - Checking Battery Electrolyte Level
389
Battery System
389
Removal - Battery
389
Installation
390
Battery Holddown Description
390
Operation
390
Removal
390
Installation
391
Battery Cables Description
391
Operation
391
Diagnosis and Testing - Battery Cable
391
Removal
393
Installation
393
Battery Tray Description
393
Operation
394
Removal
394
Installation
394
Thermowrap
394
Description
394
Operation
395
Removal
395
Installation
395
Charging
396
Charging
397
Diagnosis and Testing - On-Board
397
Diagnostic System
397
Specifications
398
Generator
398
Torque
398
Special Tools
398
Battery Temperature Sensor
399
Description
399
Operation
399
Removal
399
Generator Description
399
Removal Removal - 2.4L
399
Removal - 3.3/3.8L
399
Installation Installation - 2.4L
400
Installation - 3.3/3.8L
400
Generator Decoupler Pulley Description
400
Operation
401
Diagnosis and Testing - Generator Decoupler Pulley
401
Removal
401
Installation
401
Voltage Regulator Description
402
Operation
402
Starting
403
Circuit Test
406
Starting
408
Diagnosis and Testing - Feed Circuit
408
Resistance Test
408
Diagnosis and Testing - Feed Circuit Test
408
Starter
409
Torques
409
Removal
410
Removal - 2.4L
410
Removal - 3.3/3.8L
411
Starter Motor
410
Installation
411
Installation - 2.4L
411
Installation - 3.3/3.8L
411
Engine Systems
412
Battery System
413
Battery System
414
Inspection
417
Specifications
417
Battery System Special Tools
418
Battery Description
418
Operation
420
Diagnosis and Testing - Battery
420
Standard Procedure Standard Procedure - Spiral Plate Battery Charging
421
Standard Procedure - Conventional Battery Charging
422
Standard Procedure - Ignition-Off Draw Test
424
Standard Procedure - Open-Circuit Voltage Test
424
Standard Procedure - Checking Battery Electrolyte Level
425
Battery System
425
Battery Holddown Description
426
Operation
426
Removal
427
Installation
427
Battery System
426
Removal - Battery
426
Installation
426
Battery Cables Description
427
Operation
427
Diagnosis and Testing - Battery Cable
427
Removal
429
Installation
429
Battery Tray Description
429
Operation
430
Removal
430
Installation
430
Thermowrap
430
Description
430
Charging
431
Diagnosis and Testing - On-Board Diagnostic System
432
Special Tools
433
Specifications
433
Generator
433
Torque
433
Generator Description
434
Removal - 2.4L
434
Battery Temperature Sensor
434
Description
434
Operation
434
Removal
434
Charging
434
Removal - 2.5L
435
Removal - 3.3/3.8L
436
Removal - 3.5L
437
Installation
438
Installation - 2.4L
438
Installation - 2.5L
439
Installation - 3.3/3.8L
439
Installation - 3.5L
439
Generator Decoupler Pulley
439
Description
441
Operation
441
Installation
441
Voltage Regulator Description
441
Starting
442
Starting
445
Diagnosis and Testing - Control
445
Circuit Test
445
Diagnosis and Testing - Feed Circuit
447
Resistance Test
447
Diagnosis and Testing - Feed Circuit Test
447
Starting
447
Starter Motor Removal Removal - 2.4L
449
Removal - 3.3/3.8L
450
Removal - 3.5L
450
Removal - 2.5L
451
Installation
452
Installation - 2.4L
452
Installation - 2.5L
452
Installation - 3.3/3.8L
452
Installation - 3.5L
452
Heated Systems
454
Heated Glass
455
Defogger Relay Description
455
Operation
455
Rear Window Defogger Grid Standard Procedure - Grid Line Repair Rear
455
Rear Window Defogger Switch Description
455
Windshield Grid
456
Diagnosis and Testing - System Test
456
Standard Procedure - Grid Line and Terminal Repair
456
Heated Mirrors
458
Heated Mirrors Description
458
Operation
459
Heated Mirrors
459
Heated Mirror Grid
459
Standard Procedure - Heated Mirror
459
Mirror Switch
459
Description
459
Relay Description
459
Diagnosis and Testing - Heated Seat
461
Heated Seat System
461
Operation
461
System
461
Diagnosis and Testing - Driver Heated Seat Switch
462
Driver Heated Seat Switch
462
Operation
462
Installation
463
Removal
463
Diagnosis and Testing - Heated Seat Elements
464
Heated Seat Element Description
464
Heated Seat System
464
Operation
464
Diagnosis and Testing - Heated Seat Sensor
465
Heated Seat Sensor Description
465
Installation
465
Operation
465
Removal
465
Diagnosis and Testing - Passenger Heated Seat Switch
466
Operation
466
Passenger Heated Seat Switch Description
466
Removal
467
Installation
468
Ignition Control
476
Specifications
477
Spark Plug
477
Spark Plug Cable Resistance
477
Torque
477
Firing Order
478
Camshaft Position Sensor Description
478
Operation
479
Removal Removal - 2.4L
479
Removal - 3.3/3.8L
479
Installation Installation - 2.4L
481
Installation - 3.3/3.8L
481
Auto Shut down Relay
478
Description
478
Operation
478
Ignition Coil Description
481
Operation
481
Removal Removal - 2.4L
482
Ignition Control
482
Removal - 3.3/3.8L
482
Installation Installation - 2.4L
482
Installation - 3.3/3.8L
483
Knock Sensor Description
483
Operation
483
Removal Removal - 2.4L
483
Installation - 3.8L
483
Installation Installation - 2.4L
483
Removal - 3.8L
483
Spark Plug
484
Description
484
Description - Platinum Plugs
484
Description - Standard 4 Cylinder
484
Removal
484
Installation
485
Spark Plug Cable Description
485
Removal
485
Ignition Control
486
Camshaft Position Sensor Description
487
Removal
487
Installation
487
Glow Plug
487
Description
487
Operation
487
Table of Contents
502
Operation
504
Warning
504
Description
505
Operation
505
Specifications
505
Switch
505
Removal
506
Center High Mounted Stop Lamp Unit
507
Installation
507
Center High Mounted Stop Lamp
507
Removal
507
Fog Lamp
508
Diagnosis and Testing - Fog Lamp
508
Removal
510
Installation
510
Fog Lamp - Export Removal
510
Fog Lamp Unit Standard Procedure Standard Procedure - Fog Lamp Unit Alignment
511
Standard Procedure - Fog Lamp Unit Alignment - Export
511
Removal
512
Installation
512
Lamps/Lighting - Interior
512
Front Position Lamp - Export Removal
512
Headlamp
513
Diagnosis and Testing - Headlamp
513
Removal
515
Installation
515
Lamps/Lighting - Exterior
513
Headlamp - Export Removal
515
Headlamp Leveling Motor - Export
516
Leveling Motor - Export
516
Removal
516
Installation
516
Headlamp Switch Diagnosis and Testing Diagnosis and Testing - Headlamp Switch
517
Diagnosis and Testing - Headlamp Switch - Export
518
Headlamp Leveling Switch - Export Description
517
Diagnosis and Testing - Headlamp Leveling Switch - Export
517
Headlamp Unit Standard Procedure Standard Procedure - Headlamp Unit Alignment
518
Standard Procedure - Headlamp Unit Alignment - Export
520
Removal
520
Installation
521
Multi-Function Switch
522
Description - Turn Signal System
522
Operation - Turn Signal System
522
Diagnosis and Testing - Multi-Function Switch
523
Removal
523
Installation
523
License Lamp Removal
522
Installation
522
Park/Turn Signal Lamp Removal
523
Park/Turn Signal Lamp - Export Removal
523
Installation
524
Lamps/Lighting - Exterior Description
524
Tail Lamp - Export Removal
524
Installation
525
Rear Fog Lamp - Export Description
524
Repeater Lamp - Export Removal
524
Tail Lamp Removal
524
Tail Lamp Unit Removal
525
Lamps/Lighting - Interior
526
Dome Lamp
527
Lamps/Lighting - Interior
527
Center Console Lamp Switch Removal
527
Installation
527
Cluster Illumination Lamps Removal
527
Courtesy Lamp Removal
527
Dome Lamp Removal
527
Glove Box Lamp Switch Removal
527
Installation
528
Liftgate Lamp Removal
528
Reading Lamp Removal
528
Installation
529
Vanity Lamp Removal
529
Message Systems
530
Overhead Console
531
Operation
531
Diagnosis and Testing - Overhead
531
Console
531
Standard Procedure
532
Courtesy Lamp Replacement
532
Standard Procedure - Compass Calibration
532
Standard Procedure - Reading
532
Standard Procedure - Compass Demagnetizing
533
Standard Procedure - Compass Variation Adjustment
533
Removal - Overhead Console
534
Installation
534
Electronic Vehicle Info Center Description
535
Operation
535
Diagnosis and Testing - Electronic Vehicle Information Center
535
Standard Procedure - Electronic Vehicle Information Center Programming
536
Removal
537
Installation
537
Universal Transmitter Description
538
Operation
539
Diagnosis and Testing - Universal Transmitter
539
Compass/Mini-Trip Computer Description
538
Operation
538
Diagnosis and Testing - Compass Mini-Trip Computer
538
Removal
538
Installation
538
Ambient Temp Sensor Description
539
Diagnosis and Testing Diagnosis and Testing - Ambient Temperature Sensor
540
Diagnosis and Testing - Ambient Temperature Sensor Circuit
540
Removal
540
Installation
540
Power Systems
542
Power Liftgate System
543
Operation
544
Diagnosis and Testing - Power Liftgate System
545
Standard Procedure Standard Procedure - Liftgate Adjustment
549
Standard Procedure - Power Liftgate Learn Cycle
550
Pinch Sensor Description
550
Operation
550
Removal
550
Installation
550
Full Open Switch Description
551
Operation
551
Removal
551
Installation
551
Liftgate Motor Description
551
Operation
552
Removal
552
Installation
552
Engage Actuator Description
552
Removal
553
Installation
553
Power Liftgate System
553
Transverse Bracket
554
Description
555
Operation
555
Removal
555
Installation
555
Lift Gear & Link Rod
555
Description
556
Operation
556
Removal
556
Installation
556
Latch Actuator
556
Operation
557
Removal
557
Installation
557
Exterior Handle Switch
558
Operation
558
Removal
558
Installation
558
Chime/Thermistor Description
558
Power Sliding Door System
559
Diagnosis and Testing - Power Sliding
562
Standard Procedure - Power Door
568
Standard Procedure - Sliding Door
568
Power Sliding Door System
562
Latch
569
Description
569
Operation
569
Removal
569
Installation
570
Operation
570
Removal
570
Installation
571
Sliding Door Motor
570
Full Open Switch
571
Description
572
Power Sliding Door System
572
Lower Drive Unit Description
572
Removal
573
Installation
573
Left B-Pillar Switch
572
Operation
572
Removal
572
Installation
572
Right B-Pillar Switch Description
572
Lower Drive Unit Track & Rack Description
574
Operation
574
Removal
574
Installation
574
Wiring Harness
575
Description
575
Operation
575
Removal
575
Installation
576
Flex Drive
576
Description
576
Operation
577
Removal
577
Installation
577
Sliding Door Module
578
Description
578
Operation
578
Removal
579
Installation
579
Power Locks
580
Power Locks
581
Operation
581
Door Cylinder Lock Switch
582
Operation
582
Diagnosis and Testing - Door Cylinder Lock Switch
582
Removal
583
Installation
583
Door Lock Motor Diagnosis and Testing - Door Lock Motor
583
Door Lock Switch Diagnosis and Testing - Door Lock Switch
583
Removal
584
Installation
584
Keyless Entry Transmitter Standard Procedure Standard Procedure - Horn Chirp Preference
584
Standard Procedure - Battery Replacement
584
Specifications
584
Battery
584
Range
584
Remote Keyless Entry Module Description
585
Operation
585
Diagnosis and Testing - Remote Keyless Entry Module
585
Standard Procedure - Programming Rke Module
585
Removal
585
Installation
586
Sliding Door Lock Motor Removal
586
Power Mirrors
587
Automatic Day / Night Mirror
589
Diagnosis and Testing - Automatic Day
589
Power Mirrors
589
Power Foldaway Mirror Switch - Export Description
590
Remote Switch
590
Sideview Mirror Removal
590
Switch
590
Removal
590
Installation
590
Power Seat System
592
Power Seat System
593
Description - Memory System
593
Operation - Power Seat System
594
Operation - Memory System
594
Diagnosis and Testing Diagnosis and Testing - Power Seat System
594
Diagnosis and Testing - Memory System
595
Driver Seat Switch Description
595
Diagnosis and Testing - Driver Seat
596
Switch
596
Installation
597
Memory Set Switch Description
597
Operation
597
Diagnosis and Testing - Memory Switch
598
Removal
598
Installation
598
Passenger Seat Switch Description
598
Operation
598
Installation
600
Memory Mirror/Seat Module Description
600
Operation
600
Diagnosis and Testing - Memory Mirror/Seat Module
600
Removal
600
Driver Power Seat Track Description
601
Operation
601
Diagnosis and Testing - Driver Power Seat Track
601
Removal
602
Installation
602
Passenger Power Seat Track Description
602
Operation
603
Diagnosis and Testing - Power Seat Track
603
Removal
603
Restraints
610
Restraints
611
Restraints Description
611
Operation
611
Warning
611
Diagnosis and Testing - Airbag System
611
Driver Airbag Description
612
Standard Procedure - Clean up
613
Removal
613
Installation
613
Clock Spring Description
612
Operation
612
Standard Procedure - Clock Spring Centering
612
Removal
612
Installation
612
Driver Airbag Trim Cover Removal
613
Installation
614
Occupant Restraint Controller Description
614
Operation
614
Removal
614
Passenger Airbag Description
615
Operation
615
Standard Procedure - Clean up
615
Removal
615
Installation
615
Seat Belt Outboard Front Removal
616
Installation
616
Seat Airbag Description
616
Operation
616
Seat Belt First Row Anchor Bracket - Lwb Removal
617
Installation
617
Seat Belt Left First Row Outboard - Swb Three Door Removal
617
Seat Belt First Row Outboard - Swb Four Door Removal
618
Installation
618
Seat Belt First Row Outboard - Lwb Four Door Removal
619
Installation
619
Seat Belt Second Right Row Outboard - Lwb Removal
619
Seat Belt Second Right Row Outboard - Lbw with Rear Hvac Removal
620
Installation
620
Seat Belt Second Row Outboard - Swb Removal
621
Installation
621
Seat Belt Buckle First Row Quad Bucket Removal
622
Seat Belt Buckle - Front Inboard Removal
622
Installation
622
Seat Belt Tensioner Description
623
Operation
623
Seat Belt Buckle Second Row - Three Passenger Bench Removal
623
Seat Belt Buckle First Row - Two Passenger Bench Removal
623
Installation
623
Shoulder Belt Height Adjuster Removal
624
Installation
624
Shoulder Belt Height Adjuster Knob Removal
624
Side Impact Airbag Control Module Description
625
Operation
625
Removal
625
Installation
625
Speed Control
626
Speed Control
627
Operation
627
Diagnosis and Testing - Road Test
628
Specifications - Torque
628
Cable Description
629
Operation
629
Removal
629
Installation
629
Description
629
Speed Control
629
Installation
630
Switch Description
630
Operation
630
Removal
630
Installation
631
Vacuum Reservoir Description
631
Operation
631
Removal
631
Wipers/Washers
638
Wipers/Washers
639
Operation
639
Diagnosis and Testing
639
Diagnosis and Testing - Front Wiper
639
Diagnosis and Testing - Front Wiper/Washer Switch
639
System
639
Diagnosis and Testing - Failed Park Switch
640
Diagnosis and Testing - Rear Wiper System
642
Diagnosis and Testing - Washer System
642
Front Wiper Arms Standard Procedure - Front Wiper Arm Alignment
646
Removal
647
Installation
647
Front Washer Pump Motor Removal
646
Installation
646
Front Wiper Motor Removal
647
Headlamp Washers - Export Description
648
Operation
648
Diagnosis and Testing - Headlamp Washers - Export
648
Removal
650
Installation
650
Headlamp Washer Pump Motor - Export Removal
650
Installation
651
Wipers/Washers
650
Headlamp Washer Hose - Export Removal
650
Rear Washer Pump Motor Removal
651
Installation
652
Rear Wiper Arm Removal
652
Rear Wiper/Washer Switch Description
653
Operation
653
Rear Wiper Motor Removal
653
Installation
653
Washer Fluid Level Switch Removal
653
Installation
654
Washer Hoses Removal
654
Wiper Blades Removal
655
Cleaning
656
Installation
656
Washer Reservoir Removal
655
Installation
655
Wiper Linkage Removal
656
Wiper Module Removal
656
Installation
657
Wiring Diagram
660
Wiring Diagram Information
660
Diagrams
660
Description - Circuit Information
664
Description - Circuit Functions
665
Description - Section Identification and Information
665
Description - Connector, Ground and Splice Information
666
Diagnosis and Testing - Wiring Harness
666
Standard Procedure Standard Procedure - Electrostatic Discharge (Esd) Sensitive Devices
667
Standard Procedure - Testing for Ashort to Ground
668
Standard Procedure - Testing for Continuity
668
Standard Procedure - Testing of Voltage Potential
668
Special Tools
669
Standard Procedure - Testing for Ashort to Ground on Fuses Powering Several Loads
669
Standard Procedure - Testing for Avoltage Drop
669
Wiring/Terminal
669
Warning Warnings - General
666
Connector Removal
670
Installation
670
Diode Removal
673
Installation
673
Terminal Removal
673
Terminal
674
Wire
674
Standard Procedure - Wire Splicing
674
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