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2000 Cherokee 4X2
Jeep 2000 Cherokee 4X2 Manuals
Manuals and User Guides for Jeep 2000 Cherokee 4X2. We have
1
Jeep 2000 Cherokee 4X2 manual available for free PDF download: Service Manual
Jeep 2000 Cherokee 4X2 Service Manual (2120 pages)
Brand:
Jeep
| Category:
Automobile
| Size: 43.09 MB
Table of Contents
Table of Contents
1
Introduction Table of Contents
2
Description and Operation
2
Vehicle Identification Number
2
Vehicle Identification Number Decoding Chart
2
Vehicle Safety Certification Label
3
International Symbols
3
Vehicle Identification Number
3
Fastener Identification
4
Fastener Usage
4
Threaded Hole Repair
4
Grade/Class Identification
4
Bolt Markings and Torque
5
Fastener Strength
6
How to Determing Bolt Strength
6
Metric System
7
Torque References
7
Conversion Formulas and Equivalent Values
7
Commo Metric Equivalents
7
Metric Conversion Chart
8
Torque Specifications
9
Specified Torque for Standard Bolts
9
E-Mark Label
11
Manufacturer Plate
11
Lubrication and Mainenance Table of Contents
12
Lubricants Table of Contents
12
Service Procedures
12
Parts and Lubricant Recommendations
12
Classification of Lubricants
12
API Quality Classification
13
Lubricants and Greases
13
Specifications
14
Power Steering
14
Maintenance Schedules Table of Contents
15
Unscheduled Inspection
15
Emission Control System Maintenance
15
Fluid Fill Locations and Lubrication Points
15
Jump Starting, Towing and Hoisting Table of Contents
20
Jump Starting Procedure
20
To Jump Start a Disabled Vehicle
20
Two-Wheel Drive Vehicle Towing
21
Towing-Rear End Lifted
21
Towing-Front End Lifted
21
Four-Wheel-Drive Vehicle Towing
21
Frame Rail
21
Towing-Rear/Front End Lifted
22
Emergency Tow Hooks
22
Hoisting Recommendations
22
Floor Jack
22
Frame Rail
22
Hoist
23
Frame Rail
23
Maintenance Schedule - Diesel Engine
25
At each Stop for Fuel or Scheduled Service Stop
25
Suspension Table of Contents
28
Alignment Table of Contents
28
Wheel Alignment Description and Operation
28
Wheel Alignment Measurements
29
Diagnosis and Testing
30
Suspension and Steering System
30
Pre-Alignment
31
Wheel Alignment
31
Caster
31
Toe Position (LHD)
31
Service Procedures
31
Toe Position
32
Alignment
33
Front Suspension Table of Contents
34
Front Suspension Description and Operation
34
Suspension Components
34
Coil Springs and Isolators Description and Operation
35
Lower Suspension Arms and Bushings Description and Operation
35
Upper Suspension Arms and Bushings Description and Operation
35
Frame Rail
35
Front Suspension Diagnosis and Testing
36
Front Suspension Removal and Installation
36
Stabilizer Bar Description and Operation
36
Track Bar Description and Operation
36
Frame Rail
36
Lower Suspension Arm Removal and Installation
37
Coil Springs/Jounce Bumper Installation
37
Steering Knuckle
37
Coil Spring and Shock Absorber
37
Upper Suspension Arm Removal and Installation
38
Front Axle Bushing Removal and Installation
38
Upper and Lower Suspension Arms
38
Bushing Removal
38
Frame Rail
38
Stabilizer Bar Removal and Installation
39
Track Bar Removal and Installation
39
Hub Bearing Removal
39
Bushing Installation
39
Frame Rail
39
Wheel Mounting Studs Removal and Installation
40
Hub Bearing Removal and Installation
40
Frame Rail
40
Front Suspension Specifications
41
Hub Bearing and Knuckle
41
Wheel Stud Removal
41
Special Tools
42
Front Suspension
42
Rear Suspension Table of Contents
43
Rear Suspension Description and Operation
43
Shock Absorbers Description and Operation
43
Jounce Bumpers Description and Operation
43
Frame Rail
43
Coil Spring and Isolators Operation
44
Rear Suspension Diagnosis and Testing
44
Rear Suspension Removal and Installation
44
Shock Absorber Removal and Installation
44
Leaf Spring Removal
45
Leaf Spring Installation
45
Leaf Spring and Shackle Bushing
45
Rear Suspension Specifications
46
Frame Rail
46
Differential and Driveline Table of Contents
48
Propeller Shafts Table of Contents
48
Propeller Shaft Description and Operation
48
Propeller Shaft Joints Description
49
Reference Marks on Yokes
49
Propeller Shaft Joint Angle Description and Operation
50
Propeller Shafts Diagnosis and Testing
51
Vibration
51
Driveline Vibration
51
Maximum Angles and Propeller Shaft Speed
51
Unbalance
52
Runout
52
Clamp Screw at Position 1
52
Two Clamp Screws at the same Position
52
Propeller Shafts Service Procedures
53
Driveline Angle Measurement Preparation
53
Propeller Shaft Angle Measurement
53
Runout Specifications
53
Universal Joint Angle Example
54
Front Prropeller Shaft Removal and Installation
55
Rear Propeller Shaft Removal
55
Front Propeller Shaft
55
Rear Propeller Shaft Installation
56
Single Cardan Universal Joint Disassembly
56
Dust Boot Clamp
56
Rear Propeller Shaft
56
Disassembly and Assembly
56
Single Cardan Universal Joint Assembly
57
Press out Bearing
57
Press out Remaining Bearing
57
Install Cross in Yoke
57
Double Cardan Joint Disassembly
58
Install Bearing on Trunnion
58
Remove Snap Rings
58
Double Cardan Joint Assembly
59
Remove Bearing from Yoke
59
Remove Centering Kit
59
Install Bearing Cap
59
Press in Bearing Cap
60
Install Link Yoke
60
Install Centering Kit
60
Propeller Shaft Cleaning and Inspection
61
Install Remaining Cross
61
Seat Snap Rings in Groove
61
Check Assembly
61
Propeller Shaft Adjustments
62
Propeller Shaft Specifications
62
Propeller Shaft Special Tools
62
Rear Axle Pinion Input Angle
62
Tube 181 and 186 FBI Axle Table of Contents
63
181 FBI Axle Description
63
181 FBI Axle Operation
64
186 FBI Axle Description and Operation
64
Lubricant Description
64
Standard Differential Description and Operation
65
Differential Operation—Straight Ahead Driving
65
Differential Operation—On Turns
65
Tube 181 and 186 FBI Axle Diagnosis and Testing
66
Tube 181 and 186 FBI Axle Diagnostic Chart
66
Tube 181 and 186 FBI Axle Service Procedures
68
Gear Noise Diagnosis and Testing
68
Bearing Noise Diagnosis and Testing
68
Low Speed Knock Diagnosis and Testing
68
Drive Axle Assembly Removal and Installation
69
Typical Housing Cover with Sealant
69
Tube Axle Assembly Removal and Installation
70
Axle Shaft - Cardan U-Joint Removal
70
Axle Shaft - Cardan U-Joint Installation
71
181 FBI Pinion Shaft Seal Removal and Installation
71
Pinion Yoke Removal
72
Pinion Seal Installation
72
Pinion Yoke Installation
72
Check Pinion Rotation Torque
72
186 FBI Pinion Shaft Seal Removal and Installation
73
Collapsible Spacer Removal W/Pinion Installed
74
Tightening Pinion Shaft Nut—Typical
74
Collapsible Spacer Removal W/Pinion Removed
75
Collapsible Spacer Installation
75
Remove Pinion Gear
75
Collapsible Preload Spacer
75
Tightening Pinion Nut
76
Check Pinion Gear Rotation Torque—Typical
76
Hub Bearing and Axle Shaft Removal
77
Hub, Knuckle and Axle Shaft
77
Hub Bearing Bolts
77
Hub Bearing and Axle Shaft Installation
78
Steering Knuckle and Ball Studs
78
Knuckle Removal
78
Hub Bearing and Axle Assembly
78
Upper Ball Stud Replacement
79
Lower Ball Stud Replacement
79
Knuckle Installation
79
Upper Ball Stud Remove/Install
79
Axle Bushing Replacement
80
Differential Removal
80
Lower Ball Stud Remove/Install
80
Bearing Cap Identification
80
Install Axle Housing Spreader
81
Install Dial Indicator
81
Spread Axle Housing
81
Differential Installation
82
Differential Case Removal
82
Differential Bearing Cap Reference Letters
82
Differential Side Bearings Removal and Installation
83
Axle Shaft Oil Seal Removal and Installation
83
181 FBI Pinion Removal
83
Axle Seal Installation
84
Front Bearing Cup Removal
84
Front Bearing Cup Installation
85
Rear Bearing Cup Removal
85
Rear Bearing Removal
85
Rear Pinion Bearing Cup Installation
85
Pinion Outer Bearing Cup Installation
86
Rear Pinion Bearing Installation
86
Pinion Preload Shims–Typical
87
186 FBI Pinion Removal
88
Check Pinion Gear Rotating Torque
88
Pinion Yoke Holder—Typical
88
Remove Pinion
89
Collapsible Spacer
89
186 FBI Pinion Installation
90
Inner Bearing Removal
90
Ring Gear Removal and Installation
92
Tightening Pinion Nut—Typical
92
Ring Gear Removal
92
Standard Differential Disassembly and Assembly
93
Ring Gear Bolt Installation
93
Mate Shaft Roll Pin Removal
93
Pinion Mate Gear Removal
93
Final Assembly
94
Cardan U-Joint Cleaning and Inspection
94
Axle Components Cleaning and Inspection
94
181 FBI Pinion Gear Depth Adjustments
95
Pinion Gear ID Numbers
95
Shim Locations
95
Pinion Depth Measurement and Adjustment
96
Pinion Gear Depth Variance
96
Pinion Gear Depth Gauge Tools—Typical
96
Pinion Height Block—Typical
96
186 FBI Pinion Gear Depth General Information
97
Gauge Tools in Housing—Typical
97
Pinion Gear Depth Measurement—Typical
97
181 FBI Differential Bearing Preload and Gear Backlash
99
Shim Selection
100
Axle Adjustment Shim Locations
100
Tighten Bolts Holding Bearing Caps
100
Seat Pinion Gear Side Differential Dummy Side Bearing
100
Seat Ring Gear Side Differential Dummy Side Bearing
101
Differential Side Play Measurement
101
Hold Differential Case and Zero Dial Indicator
101
Hold Differential Case and Read Dial Indicator
101
186 Fbi Differential Bearing Preload and Gear Backlash
103
Backlash Shim Adjustment
103
Gear Contact Pattern Analysis
106
Ring Gear Backlash Measurement
106
Gear Tooth Contact Patterns
107
Tube 181 and 186 FBI Axle Specifications
108
Tube 181 and 186 FBI Axle Special Tools
108
194 RBI Axle Table of Contents
112
194 RBI Axle Description
112
194 RBI Axle Operation
112
Standard Description and Operation
113
Trac-Lok Differential Description
113
194 RBI Axle Diagnosis and Testing
114
Track-Lok Operation
114
Trac-Lok Limited Slip Differential Operation
114
194 RBI Axle Diagnostic Chart
115
Vibration Diagnosis and Testing
117
Driveline Snap Diagnosis and Testing
117
Trac-Lok Differential Noise Diagnosis and Testing
117
Trac-Lok Test
118
Lubricant Change
118
Trac-Lok Test —Typical
118
Apply Sealant
118
Rear Axle Removal and Installation
119
Pinion Shaft Seal Removal
119
Pinion Shaft Seal Installation
120
Tightening Pinion Shaft Nut–Typical
121
Axle Shaft Removal
123
Tightening Pinion Nut–Typical
123
Check Pinion Gear Rotation Torque
123
Mate Shaft Lock Screw
123
Axle Installation
124
Axle Shaft Seal and Bearing Removal and Installation
124
Axle Shaft Seal Installation
125
Ring Gear Installation
128
Pinion Gear Removal
128
Install Differential Side Bearings
128
Pinion Gear Installation
130
Pinion Rear Bearing Cup Installation
130
Pinion Front Bearing Cup Installation
131
Shaft Rear Bearing Installation
131
194 RBI Axle Final Assembly
132
Standard Differential Disassembly
133
Pinion Mate Shaft Lock Screw
133
Trac-Lok Differential Disassembly
134
Trac–Lok Differential Components
134
Differential Case Holding Tool
134
Mate Shaft Removal
135
Step Plate Tool Installation
135
Threaded Adapter Installation
135
Tighten Belleville Spring Compressor Tool
136
Remove Pinion Gear Thrust Washer
136
Side Gear and Clutch Disc Removal
136
Trac-Lok Differential Assembly
137
Clutch Disc Pack
137
Clutch Discs and Lower Side Gear Installation
137
Upper Side Gear and Clutch Disc Pack Installation
137
Trac-Lok Cleaning and Inspection
138
Presoak Plates and Disc Cleaning and Inspection
138
Pinion Gear Depth Adjustments
138
Differential Bearing Preload and Gear Backlash Adjustments
141
Shim Selection Adjustments
141
Insert Starting Point Shims
141
Seat Pinion Gear Dummy Side Bearing
142
Seat Ring Gear Side Dummy Bearing
142
RBI Axle Specifications
146
194 RBI Axle Special Tools
146
8 1/4 Rear Axle Table of Contents
150
8 1/4 Axle Description and Operation
150
8 1/4 Axle
151
Differential Cover 8 1/4 Inch Axle
151
Trac-Lok Differential Description and Operation
152
8 1/4 Rear Axle Diagnosis and Testing
153
8 1/4 Rear Axle Diagnostic Chart
154
Trac-Lok Differential Noise Diagosis and Testing
156
Trac-Lok Test Diagnosis and Testing
157
Axle Shaft Removal and Installation
158
Axle Seal and Bearing Removal and Installation
159
Axle Shaft C–Lock
159
Axle Seal Removal
159
Axle Shaft Bearing Removal Tool
159
Pinion Seal Removal and Installation
160
Axle Shaft Seal and Bearing Installation
160
Yoke Removal
160
8 1/4 Axle Pinion Seal Installation
160
Mark for Installation Reference
162
Threaded Adjuster Tool
162
Bearing Caps & Bolts
162
Differential Bearing Removal
163
Pinion Gear Removal and Installation
164
Check Pinion Rotating Torque
167
8 1/4 Axle Cleaning and Inspection
172
8 1/4 Axle Pinion Gear Depth Adjustments
173
Differential Bearing Preload and Gear Backlash
174
Gear Contact Pattern Analysis Adjustments
176
Side Gear Clearance Adjustments
176
8 1/4 Rear Axle Specifications
178
8 1/4 Rear Axle Special Tools
178
Side Gear Clearance Measurement
178
Brakes Table of Contents
182
Base Brake System Table of Contents
182
Brake System Description
183
Service Warnings and Cautions Description
183
Braske Pedal Description and Operation
183
Brake Lamp Switch Description and Operation
183
Red Brake Warning Lamp Description and Operation
184
Power Brake Booster Description and Operation
184
Master Cylinder Description and Operation
184
Combination Valve Description and Operation
184
Front Disc Brakes Description and Operation
185
Power Brake Booster–Typical
185
Rear Drum Brake Description and Operation
186
Parking Brake Description and Operation
186
Brake Caliper Operation
186
Lining Wear Compensation by Piston Seal
186
Brake Components
187
Parking Brake Components
187
Brake Hoses and Lines Description
188
Base Brake System Diagnosis and Testing
188
Preliminary Brake Check
188
Road Testing
188
Pedal Pulsation Diagnosis and Testing
189
Brake Drug Diagnosis and Testing
189
Brake Fade Diagnosis and Testing
189
Brake Pull Diagnosis and Testing
189
Brake Noises
190
Brake Lamp Switch
190
Switch Circuit Identification
190
Switch Continuity Test
190
Master Cylinder/Power Booster Diagnosis and Testing
191
Power Booster Vacuum Test
191
Power Booster Check Valve Test
191
Typical Booster Vacuum Test Connections
191
Combination Valve Diagnosis and Testing
192
Pressure Differential Switch
192
Disc Brake Rotor
192
Rotor Minimum Thickness
192
Brake Line and Hoses Diagnosis and Testing
193
Brake Fluid Contamination Diagnosis and Testing
193
Brake Fluid Level
193
Master Cylinder Bleeding
193
Disc Rotor Machining
194
Base Brake Bleeding
194
Manual Bleeding
194
Pressure Bleeding
194
Brake Drum Machining
195
Brake Tube Flaring
195
Double Inverted Flaring
195
ISO Flaring
195
Brake Lamp Switch Removal and Installation
196
Brake Pedal Removal
196
Brake Pedal Installation
197
Combination Valve Removal and Installation
197
Master Cylinder Removal
197
Booster Push Rod
197
Master Cylinder Installation
198
Power Brake Booster Removal and Installation
198
Master Cylinder
198
Front Disc Brake Caliper Removal
199
Booster Mounting
199
Bottoming Caliper Piston with C-Clamp
199
Brake Hose and Bolt
199
Front Disc Brake Caliper Installation
200
Caliper Mounting Bolts
200
Caliper Removal
200
Caliper Lubrication Points
200
Front Disc Brake Shoes Removal and Installation
201
Mounting Bolt Dimensions
201
Outboard Brake Shoe Removal
201
Inboard Brake Shoe Removal
201
Disc Brake Rotor Removal and Installation
202
Drum Brake Shoes Removal and Installation
202
Wheel Cylinder Removal
202
Rotor and Hub
202
Rear Parking Brake Cables Removal and Installation
204
Parking Brake Lever
204
Parking Brake Cables
204
Cable Retainer
204
Parking Brake Lever Removal and Installation
205
Master Cylinder Reservoir Removal
205
Parking Brake Equalizer
205
Parking Brake Lever Assembly
205
Master Cylinder Reservoir Installation
206
Disc Brake Caliper Disassembly
206
Loosening Reservoir
206
Reservoir Removal
206
Disc Brake Caliper Assembly
207
Padding Caliper Interior
207
Caliper Piston Removal
207
Caliper Piston Dust Boot Removal
207
Piston Seal Removal
208
Mounting Bolt Bushing and Boot
208
Bushings and Boots Installation
208
Piston Seal Installation
208
Wheel Cylinder Disassembly and Assembly
209
Caliper Cleaning and Inspection
209
Piston Dust Boot Installation
209
Wheel Cylinder Components–Typical
209
Rear Drum Brake Cleaning and Inspection
210
Wheel Cylinder Cleaning and Inspection
210
Polishing Piston Bore
210
Shoe Contact Surfaces
210
Brake Lamp Switch Adjustment
211
Rear Drum Brake Adjustment
211
Adjustment with Brake Gauge
211
Adjustment with Adjusting Tool
211
Brakes Specifications
212
Parking Braking Cable Tensioner Adjustment
212
Brake Adjustment
212
Tensioner Rod Measurement
212
Brakes Special Tools
213
Antilock Brakes Table of Contents
214
Antilock Brake System Description and Operation
214
Controller Antilock Brakes Description and Operation
214
Hydraulic Control Unit Description and Operation
215
Wheel Speed Sensors and Tone Wheel Description and Operation
215
Pressure Decrease and Increase
215
Pressure Hold
215
G-Switch Description and Operation
216
ABS Warning Lamp Description and Operation
216
Front/Rear Sensor Air Gap
216
Pressure Differential Valve
216
Antilock Brakes Diagnosis and Testing
217
Bleeding ABS Brake System Service Procedures
217
Hydraulic Control Unit/Controller Antiblock Brakes Removal and Installation
217
Front Speed Sensor Removal and Installation
218
Rear Wheel Speed Sensor Removal
218
HCU/CAB Mounting
218
Front Wheel Speed Sensor
218
Rear Wheel Speed Sensor Installation
219
G-Switch Removal
219
Acceleration Switch and Rear Sensor Connections
219
Rear Wheel Speed Sensor
219
G-Switch Installation
220
Hydraulic Control Unit/Controller Antiblock Brakes Disassembly
220
New Rear Sensor
220
G-Switch Mounting
220
Hydraulic Control Unit/Controller Antiblock Brakes Assembly
221
Antilock Brakes Specifications
221
Brake Booster - RHD Diesel Removal
222
Brake Line Orientation
222
Differential Pressure Switch Electrical
222
Brake Booster - RHD Diesel Install
223
Master Cylinder - RHD Diesel Removal and Installation
224
Clutch Table of Contents
226
Clutch Description and Operation
226
Engine Powerflow
226
Flywheel Description and Operation
227
Clutch Disc Description and Operation
227
Clutch Pressure Plate Description
227
Clutch Operation
227
Clutch Pressure Plate Operation
228
Clutch Release Bearing Description and Operation
228
Clutch Disc-Typical
228
Clutch Pressure Plate-Typical
228
Hydraulic Clutch Linkage Description and Operation
229
Diagnosis and Testing Safety Precautions
229
Installation Methods and Parts Usage
229
Clutch Diagnostic Information
229
Clutch Components and Inspection
230
Clutch Contamination
231
Improper Clutch Release or Engagement
231
Clutch Misalignment
231
Clutch Housing Misalignment
231
Clutch Cover and Disc Runout
232
Clutch Diagnosis Chart
232
Clutch Component Lubrication
234
Recommended Lubricants
234
Clutch Linkage Fluid
234
Clutch Fluid Level
235
Flywheel
235
Clutch Master Cylinder Reservoir and Cap
235
Clutch Cover and Disc Removal and Installation
236
Clutch Disc and Pressure Plate Inspection
236
Release Bearing Removal and Installation
237
Pilot Bearing Removal and Installation
237
Typical Method of Aligning Clutch Disc
237
Release Bearing Attachment
237
Clutch Housing
238
Clutch Hydraulic Linkage Removal
238
Typical Method of Installing Pilot Bearing
238
Clutch Housing Attachment
238
Clutch Hydraulic Linkage Installation
239
Slave Cylinder
239
Left Hand Drive Clutch Master Cylinder
239
Right Hand Drive Clutch Master Cylinder
239
Clutch Specifications
240
Clutch Components
242
Clutch Hydraulic System
242
Clutch Cover (Pressure Plate) View
242
Clutch Components (VM Diesel)
243
Clutch Disc Position
243
Pilot Bearing Removal
244
Clutch Disc Alignment – Typical
244
Pilot Bearing Installation
245
Pilot Bearing Retainer Bolt Removal/Installation
245
Pilot Bearing Seated in Retainer
245
Flywheel Removal, Ispection and Installation
246
Checking Flywheel Runout
247
Flywheel Mounting (VM Diesel)
247
Cross Tightening Method
247
Flywheel Ring Gear Removal and Installation
248
Cooling System Table of Contents
250
Cooling System Description
250
Automatic Transmission Oil Cooler Description
251
Coolant Reserve/Overflow System Description
251
Coolant Circulation—2.5L/4.0L Engines
251
Auxiliary Transmission Oil Cooler
251
Coolant Reserve/Overflow System Operation
252
Cooling System Fans Description
252
Reserve/Overflow Tank—Except Right Hand Drive
252
Reserve/Overflow Tank—With Right Hand Drive
252
Block Heater Description and Operation
253
Block Heater Specifications
253
Thermostat Description
253
Engine Block Heater
253
Radiator Description
254
Radiator Pressure Cap Description and Operation
254
Cross Flow Radiator
254
Radiator Pressure Cap and Filler Neck— Typical
254
Water Pump Description
255
Hose Clamps Description and Operation
255
Reverse Rotating Water Pump—Typical
255
Spring Clamp Size Location
255
Viscous Fan Drive Description and Operation
256
Hose Clamp Tool
256
Typical Viscous Fan Drive
256
Electric Cooling Fan Description and Operation
257
Electric Cooling Fan
257
On-Board Diagnostics (OBD)
258
Cooling System Related Diagnostics
258
Accessory Drive Belt Diagnostic Visual Diagnosis
258
Accessory Drive Belt Diagnostic Noise Diagnosis
258
Accessory Drive Belt Diagnosis Chart
259
Preliminary Checks
260
Engine Cooling System Overheating
260
Cooling System Diagnostic Chart
261
Radiator Coolant Flow Check
266
Cooling System - Testing for Leaks
266
Ultraviolet Light Method
266
Leak Detection Using Black Light—Typical
266
Pressure Tester Method
267
Internal Leakage Inspection
267
Pressurizing System—Typical
267
Combustion Leakage Test
268
Viscous Fan Drive Leaks and Testing
268
Electric Cooling Fan and Relay Diagnosis
268
Radiator Cap-To-Filler Neck Seal - Pressure Relief Check
269
Radiator Cap - Pressure Testing
269
Radiator Pressure Cap
269
Pressure Testing Radiator Pressure Cap—Typical
269
Coolant - Low Level Aeration and Deaeration
270
Coolant - Routine Level Check
270
Coolant - Adding Additional
270
Coolant - Level Check
270
Refilling
271
Cooling System - Reverse Flushing
271
Chemical Cleaning
271
Reverse Flushing Radiator
271
Transmission Oil Coolers
272
Water-To-Oil Cooler
272
Air-To-Oil Cooler Removal and Installation
272
Coolant Reserve Tank Removal
272
Coolant Reserve Tank Installation
273
Water Pump Removal -2.5L Engine (LHD/RHD)
273
Water Pump Installation -2.5L Engine (LHD/RHD)
274
Fan Mounting Nuts
274
Power Steering Pump Attachment-2.5L
274
Water Pump Remove/Install—Typical
274
Water Pump Removal -4.0L Engine
275
Water Pump Installation -4.0L Engine
275
Water Pump Pulley Bolts
275
Power Steering Pump Attachment-4.0L
276
Thermostat Removal and Installation
277
Thermostat Recess
277
Radiator - 2.5L Removal and Installation
278
Radiator Petcock—Typical
278
Condenser-To-Radiator Mounting Brackets
279
Radiator Removal/Installation—2.5L Engines
279
Radiator -4.0L Removal
280
Radiator Alignment Dowels—Typical
280
Radiator -4.0L Installation
281
Radiator Removal/Installation—4.0L Engines
281
Electric Cooling Fan -2.5L Removal and Installation
282
Condenser to Radiator Mounting Brackets— 4.0L Engine
282
Electric Cooling Fan -4.0L Removal and Installation
283
Fan Shroud Removal/Installation
283
Fan Module Orientation and Mounting
283
Block Heater Removal and Installation
284
Auxiliary Cooling Fan—Remove/Install— Typical
284
Heater and Cord— 2.5L 4-Cylinder Engine
284
Heater and Cord—4.0L 6-Cylinder Engine
284
Belt Schematics
285
Belt Replacement or Adjustment - Left Hand Drive
285
Belt Replacement or Adjustment - Left Hand Drive Installation
285
Belt Replacement or Adjustment - Right Hand Drive
286
Belt Replacement or Adjustment - Right Hand Drive Installation
286
Models with 4.0L Engine—With A/C—Except RHD
286
Models with 4.0L Engine—With A/C—With RHD
286
Cooling System Fans Removal and Installation
287
Generator Belt Tension Adjust Bracket
287
Water Pump Mounted Cooling Fan
287
Viscous Fan Drive Removal/Installation
288
Radiator Pressure Cap Cleaning and Inspection
288
Radiator Cleaning and Inspection
288
Water Pump Cleaning and Inspection
288
Cooling System Hoses Inspection
289
Cooling System Specifications
289
Cooling System Special Tools
289
Coolant Routing
291
Engine Accessory Drive Belt Description
292
Coolant Tank Description
292
Coolant Description
292
Low Coolant Level Sensor Description and Operation
292
Thermostat Description and Operation
293
Pressure/Vent Cap Description and Operation
293
Water Pump— Typical
293
Low Coolant Level Sensor
293
Coolant Performance Description
294
Cooling System Hoses Descrription
294
Coolant Tank Pressure/Vent Cap
294
Clamp Number/Letter Location
295
Viscous Fan Drive
295
Belt Tension Description
296
Automatic Belt Tensioner Description
296
Noise
296
Leaks
296
Cooling System Diagnosis - Diesel Engine
297
Thermostat Diagnosis and Testing
303
Viscous Fan Drive Testing
303
Testing Cooling System for Leaks Ultraviolet Light Method
304
Typical Pressure Tester Adapters
304
Pressure/Vent Cap
305
Pressure Testing
305
Low Coolant Level - Aeration
305
Typical Cooling System Pressure Tester
305
Belt Diagnosis
306
Serpentine Belt Wear Patterns
306
Serpentine Drive Belt Diagnosis
307
Coolant Level Check
307
Draining Cooling System
308
Refilling Cooling System
308
Coolant Tank and Pressure/Vent Cap
308
Coolant Replacement
309
Radiator Removal and Installation
309
Fan Blade Installation
311
Thermostat Removal
311
Thermostat Installation
312
Drive Belt
312
Automatic Belt Tensioner
312
Water Pump Removal
312
Automatic Belt Tensioner Assembly
313
Thermal Viscous Fan Drive and Blade Assembly
314
Coolant Tube at Water Pump
314
Water Pump Installation
315
Water Pump Inspection
315
Radiator Cleaning
315
Fan Blade Inspection
315
Pressure/Vent Cap Inspection
316
Cooling System Cleaning/Reverse Flushing
316
Reverse Flushing Engine
316
Cooling System Torque Specifications
317
Battery Table of Contents
318
Battery Description
318
Low-Maintenance Battery - Typical
318
Battery Operation
319
Battery Size and Ratings
319
Battery Cables Description and Operation
320
Battery Cables
320
Battery Hold Downs Description and Operation
321
Battery Hold Downs
321
Battery Thermoguard Description and Operation
322
Battery Tray Desription and Operation
322
Battery Diagnosis
322
Abnormal Battery Discharging
325
Battery Testing
326
Built-In Test Indicator
326
Hydrometer Test
327
Built-In Test Indicator Sight Glass
327
Hydrometer - Typical
327
Open-Circuit Voltage Test
328
Testing Open-Circuit Voltage - Typical
328
Load Test
329
Volt-Ammeter-Load Tester - Typical
329
Volt-Ammeter-Load Tester Connections -Typical
329
Ignition-Off Draw Test
330
Remove Surface Charge from Battery - Typical
330
Load 50% CCA Rating - Note Voltage -Typical
330
Load Test Temperature
330
Battery Cables Diagnosis
331
Battery Cables Testing
332
Voltage Drop Test
332
Test Battery Negative Connection Resistance - Typical
332
Battery Charging
333
Test Battery Positive Connection Resistance -Typical
333
Test Battery Positive Cable Resistance - Typical
333
Test Ground Circuit Resistance - Typical
333
Charging a Completely Discharged Battery
334
Voltmeter Accurate to 1/10 Volt Connected - Typical
334
Charging Time Required
335
Battery Cables Removal
335
Charge Rate
335
Battery Charging Timetable
335
Battery Cables Installation
336
Battery Hold Downs Removal and Installation
337
Battery Hold Downs Remove/Install
337
Battery Removal and Installation
338
Remove Battery Cable Terminal Clamp - Typical
338
Battery Thermoguard Removal/Installation
339
Battery Tray Removal/Installation
339
Battery Cleaning
340
Clean Battery Cable Terminal Clamp - Typical
340
Clean Battery - Typical
340
Battery Inspection
341
Battery Specifications
341
Clean Battery Terminal Post - Typical
341
Removing Battery Cell Caps - Typical
341
Starting System Table of Contents
342
Starting System Description
342
Starting System Operation
343
Starter Motor Description
343
Starter Motor Operation
344
Starter Relay Description and Operation
344
Starting System Diagnosis
345
Starting System Testing
346
Cold Cranking Test
346
Feed Circuit Test
347
Volts-Amps Tester Connections - Typical
347
Test Battery Negative Connection Resistance- Typical
348
Test Battery Positive Cable Resistance -Typical
348
Starter Motor Noise - 2.5L Engine
349
Control Circuit Test
349
Test Starter Ground - Typical
349
Starter Motor Noise Diagnosis
350
Starter Motor
350
Starter Motor Shim
350
Starter Solenoid
351
Starter Relay
351
Relay Test
351
Continuity Test between Solenoid Terminal and Field Coil Terminal - Typical
351
Relay Circuit Test
352
Starter Motor Removal
352
Starter Motor Remove/Install - 2.5L Engine
353
Starter Connections Remove/Install - Typical
353
Starter Motor Remove/Install - 4.0L Engine
353
Starter Motor Installation
354
Starter Relay Removal and Installation
354
Starting System Cleaning and Inspection
355
Power Distribution Center
355
Starting Systems Specifications
356
Starting Systems Table of Contents
358
Starter - LHD (Diesel) Removal
358
LHD Engine Compartment — Diesel
358
Turbocharger Oil Return Hose — Position and Orientation
358
Starter - LHD (Diesel) Installation
359
Starter - RHD (Diesel) Removal and Installation
359
Turbocharger Oil Return Line
359
Starting System Torque Specifications
361
Charging System Table of Contents
362
Charging System Description and Operation
362
Generator Description and Operation
362
Battery Temperature Sensor Description and Operation
363
Electronic Voltage Regulator Description and Operation
363
Charging System Inspection
363
On-Board Diagnostic Test for Charging System
364
Generator Removal
364
Remove/Install Generator—2.5L Engine
364
Generator Installation
365
Remove/Install Generator—4.0L Engine—Lhd?Rhd
365
Generator Connectors—Typical Denso
365
Battery Temperature Sensor Removal and Installation
366
Charging System Specifications
366
Generator Removal and Installation
368
Generator Electrical
368
Ignition System Table of Contents
370
Ignition System Description and Operation
370
Distributor -2.5L Engine Description and Operation
371
Spark Plugs Description and Operation
371
Spark Plug Cables-2.5L Engine Descriptio and Operation
371
Ignition Coil - 2.5L Engine Description and Operation
372
Ignition Coil - 4.0L Engine Description and Operation
372
Ignition Coil Assembly—4.0L 6–Cylinder Engine
372
Coil Location—4.0L Engine
372
Crankshaft Position Sensor Description and Operation
373
Camshaft Position Sensor -2.5L Engine Description and Operation
373
Sensor Operation—2.5L 4-Cyl. Engine
373
Sensor Operation—4.0L 6-Cyl. Engine
373
Camshaft Position Sensor -4.0L Engine Description and Operation
374
Ignition Switch and Key Lock Cylinder Description
374
CMP and Oil Pump Drive Shaft—4.0L Engine
374
CMP Location—4.0L Engine
374
Ignition Switch and Key Lock Cylinder Operation
375
Distributor Cap -2.5L Engine
375
Distributor Rotor -2.5L Engine
375
Cap Inspection—External—Typical
375
Spark Plug Cables Testing
376
Spark Plug Cable Resistance
376
Cap Inspection—Internal—Typical
376
Rotor Inspection—Typical
376
Spark Plug Conditions
377
Normal Operating
377
Cold Fouling/Carbon Fouling
377
Wet Fouling or Gas Fouling
377
Scavenger Deposits
378
Chipped Electrode Insulator
378
Preignition Damage
378
Spark Plug Overheating
378
Mechanical Diagnosis
379
Spark Plug Cables Removal and Installation
379
Spark Plug Removal
379
Plug Cleaning
380
Plug Gap Adjustment
380
Spark Plug Gap
380
Plug Installation
380
Ignition Coil - 2.5L Engine Removal and Installation
381
Ignition Coil -4.0L Engine Removal
381
Ignition Coil -4.0L Engine Installation
382
Crankshaft Position (CKP) Sensor Removal
382
Ignition Coil Rail Location—4.0L 6–Cylinder Engine
382
Ignition Coil Electrical Connector—4.0L 6–Cylinder Engine
382
Crankshaft Position (CKP) Sensor Installation
383
Camshaft Position Sensor - 2.5L Engine Removal
383
Crankshaft Position Sensor—Two-Nut Mounting
383
Crankshaft Position Sensor—Two-Bolt Mounting
383
Camshaft Position Sensor - 2.5L Engine Installation
384
Camshaft Position Sensor - 4.0L Engine
384
Removal and Installation- Sensor Only
384
Removal - Oil Pump Drive and Sensor
384
Installation - Oil Pump Drive and Sensor
385
CMP Pulse Ring Alignment—4.0L Engine
385
Align Timing Marks—4.0L Engine
385
Distributor - 2.5L Engine
386
Plastic Alignment Pin—2.5L Engine
386
Distributor - 2.5L Engine Removal
387
Distributor—2.5L Engine—Typical
387
Align Timing Marks—2.5L Engine
387
Distributor - 2.5L Engine Installation
388
Slot at 10 O’clock Position—2.5L Engine
388
Pin Alignment Holes—2.5L Engine
388
Ignition Switch and Key Cylinder
389
Key Cylinder Removal
389
Distributor Pre-Position—2.5L Engine
389
Distributor Engaged Position—2.5L Engine
389
Ignition Switch Removal
390
Key Cylinder Release Tang
390
Key Cylinder and Cover Removal
390
Ignition Switch Lock Tab
390
Ignition Switch Installation
391
Key Cylinder Installation
391
Shifter/Ignition Interlock Removal/Installation
391
Ignition System Specifications
392
Ignition System Torque Specifications
393
Instrument Panel Systems Table of Contents
394
Instrument Panel System Description
394
Instrument Panel Description
394
Instrument Cluster Description
395
Gauge Operation
396
Indicator Lamp Operation
396
Cluster Illumination Lamp Operation
396
Instrument Panel Cigar Lighter Description
396
Instrument Panel Cigar Lighter Operation
397
Cigar Lighter Relay Description and Operation
397
Instrument Panel Power Outlet Description and Operation
397
Instrument Cluster Diagnosis and Testing
398
Preliminary Diagnosis
398
Actuator Test
398
Hard Wired Lamp Diagnosis
399
Anti-Lock Brake System Lamp
399
Low-Line Instrument Cluster Actuator Test
400
High-Line Instrument Cluster Actuator Test
401
Brake Warning Lamp
402
Four-Wheel Drive Indicator Lamp -Full Time
402
Four-Wheel Drive Indicator Lamp -Part Time
403
Headlamp High Beam Indicator Lamp
403
Low Washer Fluid Warning Lamp
403
Instrument Panel Cigar Lighter
404
Turn Signal Indicator Lamp
404
Cigar Lighter Relay
405
Instrument Panel Power Outlet
405
Steering Column Opening Cover Removal and Installation
406
Steering Column Opening Cover Remove/Install
406
Knee Blocker Removal and Installation
407
Instrument Panel Center Bezel Removal and Installation
407
Knee Blocker Mounting Screw Location
407
Instrument Panel Accessory Switch Bezel Removal and Installation
408
Cigar Lighter Relay Removal and Installation
409
Cluster Bezel Removal
409
Right Cowl Side Trim Remove/Install
409
Cluster Bezel Installation
410
Headlamp Switch Removal
410
Headlamp Switch Installation
411
Instrument Cluster Removal
411
Instrument Cluster Installation
412
Instrument Cluster Components
412
Cluster Bulb Removal
412
Odometer Reset Knob Boot
412
Cluster Hood and Mask Removal
413
Cluster Housing Rear Cover Removal
413
Cluster Bulb Installation
413
Instrument Panel Top Cover Removal and Installation
414
Cluster Lens Installation
414
Odommeter Reset Knob Boot Installation
414
Cluster Hood and Mask Installation
414
Glove Box Roll down
415
Glove Box Removal and Installation
415
Glove Box Stop Bumpers Remove/Install
415
Glove Box Components
416
Glove Box Hinge, Bin, Inner Door and Latch Removal
416
Glove Box Outer Door Removal
416
Glove Box Lock Cylinder Removal
416
Glove Box Outer Door Installation
417
Glove Box Lock Cylinder Installation
417
Glove Box Latch Striker Removal and Installation
417
Instrument Panel End Cap Removal/Installation
418
Instrument Panel Center Support Bracket Removal/Installation
419
Instrument Panel Assembly Removal
419
Instrument Panel Assembly Installation
421
Headlamp Leveling Switch Removal and Installation
422
Rear Fog Lamp Switch
422
Headlamp Leveling Switch Position and Orientation
422
Accessory Switch Bezel Remove/Install
423
Audio Systems Table of Contents
424
Audio System
424
Radio Description and Operation
424
Ignition-Off Draw Fuse Description and Operation
424
Speaker Description and Operation
425
Antenna Description and Operation
425
Radio Noise Suppression Description
425
Audio System Diagnosis and Testing
425
Radio Diagnosis and Testing
427
Speaker Diagnosis and Testing
427
Antenna Diagnosis and Testing
428
Radio Frequency Interference
429
Radio Installation and Removal
430
Amplifier Removal and Installation
430
Speaker Removal and Installation
431
Front Door Lower
431
Radio Connections - Typical
431
Amplifier Remove/Install
431
Front Door Upper
432
Front Door Trim Panel Remove/Install - Power Window
432
Front Door Lower Speaker Remove/Install
432
Front Door Flag Trim Panel Remove/Install
432
Rear Headliner Removal and Installation
433
Antenna Removal and Istallation
433
Rear Headliner Speaker Remove/Install
433
Antenna Cable Routing
433
Radio Noise Suppression Components
434
Engine-To-Body Ground Strap Removal
434
Antenna Mast Remove/Install - Typical
434
Antenna Cap Nut and Adapter Remove/Install - Typical
434
Engine-To-Body Ground Strap Installation
435
Audio Systems Special Tools
435
Horn Systems Table of Contents
436
Horn System Description and Operation
436
Horn Description
436
Remote Keyless Entry Receiver
436
Horn Operation
437
Horn Relay Description and Operation
437
Horn Switch Description
437
Driver Side Airbag Module Trim Cover and Horn Switch
437
Horn Switch Operation
438
Horn Relay Diagnosis and Testing
438
Relay Circuit Test Diagnosis and Testing
438
Horn Switch Diagnosis and Testing
439
Horn Diagnosis and Testing
439
Horn Relay Removal and Installation
439
Horn Removal
440
Right Cowl Side Inner Trim Remove/Install
440
Horn Installation
441
Speed Control System Table of Contents
442
Speed Control System Description and Operation
442
Speed Control Servo Description and Operation
443
Speed Control Solenoid Circuits Operation
443
Speed Control Switches Description and Operation
443
Servo Cable Description and Operation
444
Vacuum Reservoir Description and Operation
444
Vehicle Speed Sensor Description and Operation
445
Road Test Diagnosis and Testing
445
Vacuum Supply Test Diagnosis and Testing
445
Speed Control Servo Removal and Installation
446
Speed Control Switch
446
Speed Control Servo Location
446
Servo Cable Clip Remove/Install—Typical
446
Speed Control Switch Removal and Installation
447
Servo Cable Removal and Installation
447
Vacuum Reservoir Removal
447
Speed Control Servo Cable at Throttle Body
447
Vacuum Reservoir Installation
448
Speed Control System Specifications
448
Vacuum Reservoir Location
448
Vehicle Speed Control System Table of Contents
450
Diesel Engine Speed Control System Description and Operation
450
Turn Signal and Hazard Warning System Table of Contents
452
Turn Signal System Description and Operation
452
Hazard Warning System Description
452
Hazard Warning System Operation
453
Turn Signal Switch and Hazard Warning Switch Description and Operation
453
Turn Signal Cancelling Cam Description and Operation
454
Combination Flasher Description and Operation
454
Turn Signal and Hazard Warning Systems Diagnosis and Testing
455
Turn Signal Switch and Hazard Warning Switch Diagnosis and Testing
456
Combination Flasher Removal
456
Multi-Function Switch Continuity
456
Combination Flasher Installation
457
Turn Signal Switch and Hazard Warning Switch Removal
457
Turn Signal Switch and Hazard Warning Switch Installation
458
Water Shield Upper Screws Remove/Install
458
Water Shield Lower Screw Remove/Install
458
Wiper and Washer Systems Table of Contents
460
Windshield Wiper System
460
Windshield Washer System
460
Rear Wiper and Washer System
461
Wiper Arm and Blade Description and Operation
461
Wiper Linkage and Pivot Description and Operation
461
Wiper Motor Front Description and Operation
461
Wiper Motor Rear Description and Operation
462
Wiper Switch and Washer Switch Front Description and Operation
462
Wiper Switch and Washer Switch Rear Description and Operation
462
Washer Reservoir Description and Operation
462
Washer Pump Description and Operation
463
Washer Fluid Level Sensor Description and Operation
463
Washer Nozzle and Plumbing Description and Operation
463
Wiper System Diagnosis and Testing
463
Washer System Diagnosis and Testing
465
Wiper Switch and Washer Switch Diagnosis and Testing
466
Windshield Wiper Switch and Washer Switch Continuity
466
Rear Wiper Switch and Washer Switch Continuity
466
Wiper Blade Removal and Installation
467
Wiper Arm Removal and Installation
467
Wiper Linkage and Pivot
468
Wiper Motor Removal and Installation
468
Front Wiper Arm Installation
468
Rear Wiper Arm Remove/Install
468
Cowl Plenum Cover/Grille Panel Remove/Install
469
Wiper Linkage Module Remove/Install
469
Wiper Switch and Washer Switch Removal and Installation
470
Rear Wiper Motor Remove/Install
470
Steering Column Shrouds Remove/Install
470
Washer System Removal and Installation
472
Washer Reservoir
472
Washer Pump
472
Washer Reservoir Filler Neck Remove/Install
472
Washer Fluid Level Sensor Removal and Installation
473
Washer Nozzle Removal and Installation
473
Front Washer Nozzles Remove/Install
473
Rear Washer Nozzle Remove/Install
473
Check Valve
474
Rear Washer System Check Valve
474
Lamps Table of Contents
476
Lamp Systems Table of Contents
476
Headlamps Description and Operation
476
Headlamp Switch Description and Operation
476
Front Turn Signal/Parking Lamp Description and Operation
477
CHMSL Description and Operation
477
Daytime Running Lamps Description and Operation
477
Safety Precautions
477
Lamp Diagnosis Table of Contents
478
Diagnostic Procedures
478
Headlamp System Diagnosis
478
Fog Lamp Diagnosis and Testing
479
Headlamp Delay Module
480
Delay Function Inoperative
480
Headlamp Alignment Table of Contents
481
Headlamp Adjustment
481
Lamp Alignment Screen Preparation
481
Vehicle Preparation for Headlamp Alignment
481
Headlamp Alignment Screen—Typical
482
Headlamp Alignment Screen Target
482
Headlamp Beam Adjustment Screws
482
Fog Lamp Adjustment
483
Fog Lamp Alignment —Typical
483
Headlamp Alignment Special Tools
484
Lamp Bulb Service Table of Contents
485
Headlamp Bulb Removal and Installation
485
Fog Lamp Bulb Removal and Installation
485
Headlamp Bezel
485
Front Park/Turn Signal Lamp Bulb Removal and Installation
486
Side Marker Lamp Bulb Removal and Installation
486
Back-Up/Brake/Rear Turn Signal/Tail Lamp Bulb Removal and Installation
486
Park/Turn Signal Lamp Bulb
486
License Plate Lamp Bulb Removal and Installation
487
CHMSL Bulb Removal and Installation
487
Underhood Lamp Bulb Removal and Installation
487
Underhood Lamp Lens
487
Cargo Lamp Bulb Removal and Installation
488
Map Reading Lamp Bulb Removal and Installation
488
Visor Vanity Lamp Bulb Removal and Installation
488
Lamp Service Table of Contents
489
Headlamp Removal and Installation
489
Headlamp Connector
489
Headlamp
489
Fog Lamp Removal and Installation
490
Front Park/Turn Signal Lamp Removal and Installation
490
Side Marker Lamp Removal and Installation
490
Back-Up/Brake/Rear Turn Signal/Tail Lamp Removal and Installation
491
CHMSL Removal and Installation
491
License Plate Lamp Removal and Installation
491
Underhood Lamp Removal
491
Underhood Lamp Installation
492
Cargo Lamp Removal and Installation
492
Map/Reading Lamp
492
Cargo Lamp Lens
492
Visor Vanity Lamp Removal and Installation
493
Sentitel Headlamp Delay Module Removal and Installation
494
Daytime Running Lamp Module Removal and Installation
494
Bulb Application Table of Contents
495
Bulb Application Specifications
495
Headlamp Leveling Motor Description and Operation
496
Headlamp Leveling Motor Position and Orientation
496
Headlamp Leveling Motor Diagnosis
497
Headlamp and Foglamp Alignment Table of Contents
498
Headlamp Alignment Preparation
498
Headlamp/Fog Lamp Adjustment Using Alignment Screen
498
Alignment Screen Preparation
498
Fog Lamp Alignment
499
Headlamp Beam Adustment Screws
499
Fog Lamp Beam Adjustment Screws
500
Front Position Lamp Bulb Removal and Installation
501
Side Repeater Lamp Bulb Removal
501
Headlight Bezel Retaining Screws
501
Headlamp Retaining Screws
501
Side Repeater Lamp Bulb Installation
502
Rear Fog Lamp Bulb Removal and Installation
502
Rear Lamp Replacement
502
Headlamp Leveling Motor Removal
503
Headlamp Leveling Motor Installation
504
Side Repeater Lamp Removal and Installation
504
Front Fog Lamp Removal and Installation
504
Rear Turn Signal, Backup, Taillamp and Fog Lamp Removal and Installation
504
License Plate Lamp Installation
505
Passive Restraint Systems Table of Contents
508
Airbag System Description and Operation
508
Driver Side Airbag Module Description and Operation
509
Passenger Side Airbag Module Description and Operation
510
Airbag Control Module Description and Operation
510
Clockspring Description and Operation
511
Airbag System Diagnosis and Testing
511
16-Way Data Link Connector - Typical
511
Airbag System Service Procedures
512
Non-Deployed and Deployed Airbag System
512
Airbag System Storage
512
Airbag System Cleanup Procedure
512
Driver Side Airbag Module Removal
513
Wear Safety Glasses and Rubber Gloves
513
Vacuum Heater and A/C Outlets - Typical
513
Removal and Installation
513
Driver Side Airbag Module Installation
514
Driver Side Airbag Module Trim Cover Removal
514
Driver Side Airbag Module Trim Cover Installation
515
Horn Switch Feed Wire Remove/Install
515
Passenger Side Airbag Module Removal
516
Driver Side Airbag Trim Cover Locking Blocks Engaged
516
Passenger Side Airbag Module Installation
517
Passenger Side Airbag Module Connector
517
Passenger Side Airbag Door Removal and Installation
518
Airbag Control Module Removal and Installation
519
Clockspring Removal
520
Clockspring Installation
521
Upper Clockspring Latch Access Window
521
Clockspring Centering Adjustments
522
Passive Restraint Systems Special Tools
523
Electrically Heated Systems Table of Contents
524
Rear Window Defogger System Table of Contents
524
Rear Glass Heating Grid Description Ad Operation
525
Outside Mirror Heating Grid Description and Operation
525
Defogger Switch Description and Operation
525
Instrument Cluster Description and Operation
525
Defogger Relay Description and Operation
526
Defogger System Diagnosis and Testing
526
Rear Window Glass Grid Test
526
Rear Glass Heating Grid Diagnosis and Testing
527
Defogger Switch Diagnosis and Testing
527
Defogger Relay Diagnosis and Testing
527
Relay Test Diagnosis and Testing
527
Rear Glass Heating Grid Repair
529
Defogger Switch Removal and Installation
529
Defogger Relay
530
Heated Seat System Table of Contents
531
Heated Seat Switch Description and Operation
531
Seat Heat Interface Module Description and Operation
532
Heated Seat Relay Description and Operation
532
Heated Seat Element and Sensor Description and Operation
532
Heated Seat System Diagnosis and Testing
532
Heated Seat Switch Diagnosis and Testing
533
Backlighting Diagnosis and Testing
533
Telltales Diagnosis and Testing
533
Multiplexed Resistances Diagnosis and Testing
533
Heated Seat Element and Sensor Diagnosis and Testing
534
Seat Cushion Diagnosis and Testing
534
Seat Back Diagnosis and Testing
534
Heated Seat Sensor Diagnosis and Testing
534
Seat Heat Interface Module Diagnosis and Testing
535
Heated Seat Switch Removal and Installation
535
Seat Heat Interface Module Removal and Installation
535
Heated Seat Relay Removal and Installation
535
Rear Window Defogger System Table of Cotents
538
Rear Window Defogger System
538
Rear Glass Heating Grid Description and Operation
539
General Information
539
Outside Mirror Heating Grid
539
Defogger Switch
539
Instrument Cluster
539
Defogger Relay
540
Diagnosis and Testing Defogger System
540
Rear Glass Heating Grid
541
Defogger Switch
541
Defogger Relay
541
Instrument Cluster
542
Grid Line Repair - Typical
543
Service Procedures
543
Rear Glass Heating Grid Repair
543
Removal and Installation Defogger Switch
543
Defogger Relay Removal and Installation
544
Description and Operation
546
Seat Heat Interface Module
546
Heated Seat Relay
546
HEATED SEAT ELEMENT and SENSOR
546
Diagnosis and Testing
546
Heated Seat System
546
Backlighting Diagnosis and Testing
547
Seat Heat Interface Module Diagnostic Routines
547
Heated Seat Switch
547
Heated Seat Relay Diagnosis and Testing
548
HEATED SEAT ELEMENT and SENSOR
548
Seat Heat Interface Module
549
Removal and Installation Heated Seat Switch
549
Heated Seat Relay
549
Heated Seat Relay Remove/Install
550
Power Distribution Systems Table of Contents
552
Power Distribution System Description and Operation
552
Power Distribution Center Description and Operation
553
Ignition-Off Draw Fuse Description
553
Ignition-Off Draw Fuse Operation
554
Junction Block Description
554
Junction Block Location
554
Power Distribution Center Removal and Installation
555
Power Distribution Center Connections
555
Description and Operation
555
Ignition-Off Draw Fuse Removal
556
PDC Mounting Bracket Remove/Install
556
Ignition-Off Draw Fuse Installation
557
Junction Block Removal
557
Junction Block Installation
558
Power Distribution Center Disassembly and Assembly
558
PDC Housing Lower Cover Disassembly
558
PDC Relay Wedge Disassembly
558
PDC Relay Cassette Disassembly
559
Power Distribution Center Components
559
PDC Housing Lower Cover Remove/Install
559
PDC Relay Wedge Remove/Install
559
PDC Relay Cassette Assembly
560
PDC Relay Cassette Latches
560
PDC Relay Cassette Remove/Install
560
PDC Relay Wedge Assembly
561
PDC Housing Lower Cover Assembly
561
PDC Relay Cassette Terminal Remove/Install
561
Power Distribution Systems Special Tools
561
Power Lock Systems Table of Contents
562
Remote Keyless Entry System
562
Power Lock Switch Description and Operation
563
Door Module Description and Operation
563
Power Lock Motor Description and Operation
563
Remote Keyless Entry Transmitter Description and Operation
563
General Information
563
Power Lock System
563
Remote Keyless Entry Receiver
563
Power Lock System and Remote Keyless Entry System Diagnosis and Testing
564
Driver Door Module Diagnosis and Testing
564
Passenger Door Module Diagnosis and Testing
565
Power Lock Motor Diagnosis and Testing
565
DDM Power Lock Switch Continuity
565
Remote Keyless Entry Transmitter Diagnosis and Testing
566
Remote Keyless Entry Receiver Diagnosis and Testing
566
PDM Power Lock Switch Continuity
566
Power Lock Motor
566
Remote Keyless Entry Transmitter Battery Replacement
567
Remote Keyless Entry Receiver Programming
567
Service Procedures
567
Door Module Removal and Installation
568
Power Lock Motor Removal and Installation
568
Front Door Trim Panel Remove/Install
568
Liftgate Removal and Installation
569
Remote Keyless Entry Receiver Removal and Installation
569
Mini-Dome Mounted Type Removal and Installation
569
Overhead Mounted Type Removal and Installation
570
RKE Receiver Remove/Install
570
Vehicle Theft/Security Systems Table of Contents
572
Sentry Key Immobilizer System
572
Sentry Key Immobilizer Module Description and Operation
572
Sentry Key Immobilizer Transponder
573
Vehicle Identification Number
573
Sentry Key Immobilizer System Indicator Lamp Description and Operation
574
Sentry Key Immobilizer System Diagnosis and Testing
574
Sentry Key Immobilizer System Transponder Programming
575
Customer Learn
575
Sentry Key Immobilizer Module Removal and Installation
575
Sentry Key Immobilizer System Transponder Description and Operation
579
Power Seat Systems Table of Contents
584
Power Seat Switch Description and Operation
584
Power Seat Adjuster and Motors
584
Introduction
584
Circuit Breaker Description and Operation
585
Power Seat System Diagnosis and System
585
Circuit Breaker Diagnosis and Testing
585
Power Seat Adjuster and Motors Diagnosis and Testing
585
Power Seat Switch Removal/Installation
586
Power Seat Switch Continuity
586
Driver Seat Belt Switch Connector
587
Power Seat Remove/Install
587
Power Seat Adjuster and Motors Remove/Install
587
Power Window Systems Table of Contents
588
Power Window Switch Description and Operation
588
Power Window Motor Description and Operation
589
Power Window System Diagnosis and Testing
589
All/One Window Inoperative
589
Door Module
589
Circuit Breaker
589
Door Module Diagnosis and Testing
590
DDM Power Window Switch Continuity
590
Circuit Breaker
590
Power Window Switch Diagnosis and Testing
591
Power Window Motor Diagnosis and Testing
591
Rear Door Power Window Switch Continuity
591
Removal and Installation
591
Door Module
591
Power Window Switch Removal and Installation
592
Door Module Remove/Install
592
Rear Door Trim Panel Remove/Install
592
Power Window Motor Removal and Installation
593
Rear Door Power Window Switch Remove/Install
593
Power Mirror Systems Table of Contents
594
Power Mirror Description and Operation
594
Power Mirror Switch Description and Operation
594
Power Mirror System Diagnosis and Testing
595
Description and Operation
595
Power Mirror Switch Removal and Installation
596
Stand-Alone Power Mirror Switch Continuity
596
Driver Door Module Power Mirror Switch Continuity
596
Power Mirror System
596
Power Mirror Removal and Installation
597
Power Mirror Test
597
Stand-Alone Power Mirror Switch Remove/Install
597
Door Module
597
Window Regulator Crank Handle Remove -Typical
598
Front Door Trim Panel Remove/Install -Manual Window
598
Power Mirror Remove/Install
599
Chime/Buzzer Warning Systems Table of Contents
600
Introduction
600
Driver Door Jamb Switch Description and Operation
601
Driver Seat Belt Switch Description and Operation
601
Key-In Ignition Switch Description and Operationr Driver Door Jamb Switch Diagnosis and Testing
601
Headlamp Switch
601
Key-In Ignition Switch Diagnosis and Testing
602
Headlamp Switch Diagnosis and Testing
602
Instrument Cluster
602
Chime Warning System Switches Removal and Installation
603
Overhead Console Systems Table of Contents
604
Trip Computer Description and Operation
604
Compass Description and Operation
605
Thermometer Description and Operation
605
Reading and Courtesy Lamp Description and Operation
605
Overhead Console
605
Garage Door Opener Storage bin Description and Operation
606
Sunglasses Storage bin Description and Operation
606
Trip Computer, Compass and Thermometer Display Module Diagnosis and Testing
606
Self-Diagnostic Test
606
Thermometer Diagnosis and Testing
607
Sensor Test
607
Sensor Circuit Test
607
Compass Variation Adjustment Service Procedures
607
Compass Calibration
608
Variance Settings
608
Compass Demagnetizing
609
Overhead Console Removal and Installation
609
Roof Demagnetizing Pattern
609
Trip Computer, Compass and Thermometer Display Module Removal and Installation
610
Push Button Module Removal and Installation
610
Reading and Courtesy Lamp Bulb Removal and Installation
611
Garage Door Opener Storage bin Door Removal and Installation
611
Sunglasses Storage bin Removal and Installation
611
Ambient Temperature Sensor Removal and Installation
611
Compass Special Tools
612
Ambient Temperature Sensor Remove/Install
612
Wiring Diagrams Contents
614
General Information Index
616
Wiring Diagram Section
617
Circuit Information
619
Circuit Function
619
Wire Color Code Chart
619
Circuit Identification Code Chart
619
Section Identification
620
Symbols
620
Wiring Diagram Symbols
621
Terminology
622
Connector Information
622
Identification
622
Locations
622
Take Outs
623
Electrostatic Discharge Sensitive Devices
623
Troubleshooting Tools
623
Electrostatic Discharge Symbol
623
Intermittent and Poor Connections
624
Troubleshooting Tests
624
Testing for Voltagte Potential
624
Testing for Continuity
624
Testing for a Voltage Drop
625
Troubleshooting Wiring Problems
625
Wiring Repair
625
Terminal/Connector Repair-Molex Connectors
626
Terminal/Connector Repair-Thomas and Betts Connectors
626
Molex Connector Repair
626
Using Special Tool 6742
626
Terminal/Connector Repair-Augat Connectors
627
Connector Replacement
627
Single Lock Tab
627
Augat Connector Repair
627
Connector and Terminal Replacement
628
Terminal Removal
628
Terminal Removal Using Special Tool
628
Stagger Cutting Wires
628
Terminal Replacement
629
Diode Replacement
629
Connector Locking Wedge Tab
629
Wiring/Terminal Special Tool
630
Diode Identification
630
8W-02 Component Index
632
8W-10 Power Distribution
634
Gas
635
Diesel
640
8W-10 Power Distribution Except Built-Up-Export
661
8W-10 Power Distribution Built-Up-Export
662
8W-12 Junction Block Index
670
Front of Junction Block
671
8W-12 Junction Block LHD
677
8W-12 Junction Block RHD
678
8W-12 Junction Block Except Built-Up-Export
679
8W-12 Junction Block Built-Up-Export
680
8W-12 Junction Block Diesel
681
8W-12 Junction Block 2.5L
684
8W-12 Junction Block 4.0L
685
8W-12 Junction Block LHD Except Full Options
702
8W-12 Junction Block LHD Full Options
703
8W-12 Junction Block RHD Except Full Options
704
8W-12 Junction Block RHD Full Options
705
8W-15 Ground Distribution Index
708
8W-15 Ground Distribution Gas
709
8W-15 Ground Distribution Diesel
710
8W-15 Ground Distribution LHD 2.5L Gas
711
8W-15 Ground Distribution LHD 4.0L Except Built-Up-Export
712
8W-15 Ground Distribution RHD Gas
713
8W-15 Ground Distribution Except Built-Up-Export
714
8W-15 Ground Distribution Built-Up-Export LHD 4.0L A/T
715
8W-15 Ground Distribution Built-Up-Export LHD 4.0L M/T
716
8W-15 Ground Distribution Built-Up-Export Gas
717
8W-20 Charging System Index
730
8W-20 Charging System Gas
731
8W-20 Charging System Diesel
733
8W-21 Starting System Index
736
8W-21 Starting System 2.5L Gas A/T
737
8W-21 Starting System 4.0L Gas A/T
738
8W-21 Starting System 2.5L Gas M/T
739
8W-21 Starting System 4.0L Gas M/T
740
8W-21 Starting System Diesel
741
8W-30 Fuel/Ignition System Index
742
A/C Compressor Clutch Relay
742
8W-30 Fuel/Ignition System Gas
743
8W-30 Fuel/Ignition System LHD Gas
744
8W-30 Fuel/Ignition System RHD Gas
745
8W-30 Fuel/Ignition System 2.5L
749
8W-30 Fuel/Ignition System 4.0L
750
8W-30 Fuel/Ignition System 4.0L California/European III
752
8W-30 Fuel/Ignition System Gas Except Built-Up-Export
756
8W-30 Fuel/Ignition System LHD
761
8W-30 Fuel/Ignition System RHD
762
8W-30 Fuel/Ignition System Diesel
763
8W-31 Transmission Control System Index
776
8W-31 Transmission Control System 2.5L Gas A/T
777
8W-31 Transmission Control System 2.5L Gas
778
8W-31 Transmission Control System 4.0L
779
8W-33 Vehicle Speed Control Index
784
8W-33 Vehicle Speed Control Gas
785
8W-33 Vehicle Speed Control Diesel
786
8W-35 Anti-Lock Brakes Index
790
8W-35 Anti-Lock Brakes Gas
791
8W-35 Anti-Lock Brakes Diesel
792
8W-39 Vehicle Theft Security System Index
796
8W-39 Vehicle Theft Security System LHD
797
8W-39 Vehicle Theft Security System RHD
798
8W-40 Instrument Cluster Index
806
8W-40 Instrument Cluster
807
8W-40 Instrument Cluster Gas
809
8W-40 Instrument Cluster Diesel
810
8W-40 Instrument Cluster LHD Gas
811
8W-40 Instrument Cluster LHD Diesel
812
8W-40 Instrument Cluster RHD
813
8W-40 Instrument Cluster LHD
817
8W-41 Horn/Cigar Lighter/Power Outlet Index
824
8W-41 Horn/Cigar Lighter/Power Outlet LHD
825
8W-41 Horn/Cigar Lighter/Power Outlet RHD
826
8W-42 Air Conditioning-Heater Index
828
8W-42 Air Conditioning-Heater LHD Heater Only
829
8W-42 Air Conditioning-Heater RHD Heater Only
830
8W-42 Air Conditioning-Heater LHD
831
8W-42 Air Conditioning-Heater RHD
832
8W-42 Air Conditioning-Heater Diesel
835
8W-42 Air Conditioning-Heater Gas
836
8W-43 Airbag System Index
838
8W-43 Airbag System LHD
839
8W-43 Airbag System RHD
840
8W-44 Interior Lighting
842
A/C- Heater Control
842
8W-44 Interior Lighting LHD Except Built-Up-Export
843
8W-44 Interior Lighting LHD Built-Up-Export
844
8W-44 Interior Lighting RHD
845
8W-44 Interior Lighting Gas
847
8W-44 Interior Lighting Diesel
848
8W-44 Interior Lighting LHD
849
8W-47 Audio System Index
852
8W-47 Audio System LHD 6 Speaker System
853
8W-47 Audio System RHD 6 Speaker System
854
8W-47 Audio System Built-Up-Export
855
8W-47 Audio System LHD 4 Speaker System
860
8W-47 Audio System RHD 4 Speaker System
861
8W-47 Audio System 4 Speaker System
862
8W-48 Rear Window Defogger Index
864
8W-48 Rear Window Defogger LHD
865
8W-48 Rear Window Defogger RHD
866
8W-49 Overhead Console Index
868
8W-49 Overhead Console LHD
869
8W-49 Overhead Console RHD
870
8W-49 Overhead Console
873
8W-50 Front Lighting Index
874
8W-50 Front Lighting Except Built-Up-Export
875
8W-50 Front Lighting Built-Up-Export
876
8W-50 Front Lighting LHD Except Built-Up-Export
877
8W-50 Front Lighting RHD Except Built-Up-Export
878
8W-50 Front Lighting LHD Built-Up-Export
879
8W-50 Front Lighting RHD Built-Up-Export
880
8W-50 Front Lighting Gas Except DRL
887
8W-50 Front Lighting DRL
889
8W-50 Front Lighting Diesel
890
8W-51 Rear Lighting Index
894
8W-51 Rear Lighting Gas
899
8W-51 Rear Lighting Diesel
900
8W-51 Rear Lighting LHD Built-Up-Export
902
8W-51 Rear Lighting RHD Built-Up-Export
903
8W-52 Turn Signals Index
906
8W-52 Turn Signals Except Built-Up-Export
907
8W-52 Turn Signals Built-Up-Export Gas
908
8W-52 Turn Signals Diesel
909
8W-53 Wipers Index
914
8W-53 Wipers Gas
915
8W-53 Wipers Diesel
916
8W-53 Wipers LHD Gas
917
8W-53 Wipers LHD Diesel
918
8W-53 Wipers RHD Gas
919
8W-53 Wipers RHD Diesel
920
8W-54 Trailer Tow Index
922
8W-60 Power Windows Index
926
8W-60 Power Windows LHD
927
8W-60 Power Windows RHD
928
8W-61 Power Door Locks Index
932
8W-61 Power Door Locks LHD
933
8W-61 Power Door Locks RHD
934
8W-62 Power Mirrors Index
938
8W-62 Power Mirrors LHD Except Built-Up-Export Full Options
939
8W-62 Power Mirrors LHD Built-Up-Export Full Options
940
8W-62 Power Mirrors LHD Full Options
941
8W-62 Power Mirrors RHD Full Options
942
8W-62 Power Mirrors LHD Except Full Options
944
8W-62 Power Mirrors RHD Except Full Options
945
8W-63 Power Seat Index
946
Circuit Breaker 29
946
8W-63 Power Seat
947
Circuit Breaker 30
947
8W-63 Power Seat Heated Seats
949
8W-70 Splice Information Index
952
8W-70 Splice Information
953
8W-70 Splice Information Gas
954
Clockspring
954
8W-70 Splice Information Diesel
955
8W-80 Connector Pin-Outs Index
956
Clutch Interlock Switch
989
Clutch Interlock Switch Jumper
989
Combination Flasher
989
Controller Anti-Lock Brake
990
Daytime Running Lamp Module
992
Diode Module
992
Driver Door Jamb Switch
993
Driver Power Lock/Window Switch
994
Driver Power Mirror
994
Duty Cycle Evap/Purge Solenoid
995
Extended Idle Switch
999
Front Wiper Motor
999
Fuel Heater Relay
1000
Headlamp Delay Module
1003
Headlamp Leveling Switch
1004
Headlamp Switch
1004
Instrument Cluster
1007
Junction Block
1008
Left City Lamp
1012
Left Courtesy Lamp
1012
Left Front Park/Turn Signal Lamp
1013
Left Headlamp
1014
Left Heated Seat Switch
1015
Left Power Seat Switch
1016
Left Rear Door Jamb Switch
1016
Left Rear Door Lock Motor
1016
Left Tail/Stop Lamp
1018
Left Visor/Vanity Lamp
1019
License Lamp
1019
Message Center
1020
Overhead Module
1020
Passenger Door Lock Motor
1022
Power Mirror Switch
1023
Power Outlet
1025
Powertrain Control Module
1026
PRNDL Illumination
1032
Rear Fog Lamp Relay
1033
Rear Fog Lamp Switch
1033
Rear Window Defogger Switch
1033
Rear Wiper/Washer Switch
1034
Right Courtesy Lamp
1034
Right Front Park/Turn Signal Lamp
1035
Right Headlamp
1036
Right Headlamp Leveling Motor
1036
Right Heated Seat Switch
1037
Right Power Seat Switch
1038
Right Rear Door Jamb Switch
1038
Right Rear Door Lock Motor
1038
Right Visor/Vanity Lamp
1040
Shift Lock Solenoid
1041
Trailer Tow Connector
1042
Trailer Tow Left Turn Relay
1042
Trailer Tow Right Turn Relay
1042
8W-90 Connector Locations
1048
Connector/Ground Locations Description and Operation
1048
Transfer Case Switch Illumination
1057
Front End Lighting
1058
Left Engine Compartment 2.5L Engine LHD
1059
Left Engine Compartment 2.5L Engine RHD
1060
Right Engine Compartment 2.5L Engine RHD
1061
Engine Compartment Auxiliary Views 2.5L Engine LHD
1062
Engine Compartment Auxiliary Views 2.5L Engine RHD
1063
Engine Compartment Components LHD
1064
Engine Compartment Components RHD
1065
Left Engine Compartment 4.0L Engine LHD
1066
Left Engine Compartment 4.0L Engine RHD
1067
Right Engine Compartment 4.0L Engine LHD
1068
Right Engine Compartment 4.0L Engine RHD
1069
Engine Compartment Auxiliary Views 4.0L Engine LHD
1070
Engine Compartment Auxiliary Views 4.0L Engine RHD
1071
2.5L Engine
1072
4.0L Engine
1073
Transmission Connectors 2.5L Engine
1075
Transmission Connectors 4.0L Engine
1076
Instrument Panel LHD
1077
Instrument Panel RHD
1079
Under Dash Components
1081
Left Side Body LHD
1082
Left Side Body RHD
1083
Left Rear Body
1084
Right Side Body Junction Block
1085
Front and Rear Doors
1086
Liftgate
1087
Center Console LHD
1088
Headliner
1089
Steering Column
1090
Left Engine Compartment Diesel Engine LHD
1091
Left Engine Compartment Diesel Engine RHD
1092
Engine Compartment Auxiliary Views Diesel Engine
1093
Right Engine Compartment Diesel Engine LHD
1094
Right Engine Compartment Diesel Engine RHD
1095
Diesel Engine
1096
Engine and Battery Diesel Engine
1097
Transmission Diesel Engine
1098
8W-95 Splice Locations
1100
Splice Locations Description and Operation
1100
Left Engine Compartment Splices 4.0L Engine LHD
1105
Left Engine Compartment Splices 4.0L Engine RHD
1106
Right Engine Compartment Splices 4.0L Engine LHD
1107
Right Engine Compartment Splices 4.0L Engine RHD
1108
Left Engine Compartment Splices 2.5L Engine LHD
1109
Left Engine Compartment Splices 2.5L Engine RHD
1110
Right Engine Compartment Splices 2.5L Engine LHD
1111
Right Engine Compartment Splices 2.5L Engine RHD
1112
Front End Lighting Splices
1113
Engine Wiring Splices 4.0L Engine
1114
Engine Wiring Splices 2.5L Engine
1115
Instrument Panel Wiring Splices LHD
1116
Instrument Panel Wiring Splices RHD
1117
Instrument Panel to Body Harness Splices
1118
Left Side Body Harness Splices
1119
Right Side Body Harness Splices
1120
Trailer Tow Splices
1121
Power Seat Splices
1122
Right Front Door Splices
1122
Left Front Door Splices
1123
Liftgate Splices
1123
Headliner Splices
1124
Left Engine Compartment Splices Diesel LHD
1125
Left Engine Compartment Splices Diesel RHD
1126
Right Engine Compartment Splices Diesel LHD
1127
Right Engine Compartment Splices Diesel RHD
1128
Engine Table of Contents
1130
Engine Description
1131
Lubrication System Description and Operation
1131
Engine Firing Order
1131
Build Date Code Location
1131
Oil Lubrication System—2.5L Engine
1133
Сylinder Block Description
1134
Cylinder Head Description
1134
Crankshaft Description
1134
Cylinder Block—2.5L
1134
Piston and Connecting Rod Description
1135
Camshaft Description and Operation
1135
Rocker Arm Description and Operation
1135
Valves Description
1135
Valve Spring Description
1136
Cylinder Head Cover Description
1136
Hydraulic Tappet Description
1136
Valve Guide Description
1136
Oil Pan
1136
Valve Stem Seal Description
1137
Intake Manifold Description
1137
Exhaust Manifold Description
1137
Engine Diagnosis - Introduction
1137
Diagnosis and Testing
1137
Service Diagnosis - Performance
1138
Engine Performance Diagnosis Chart
1138
Service Diagnosis - Mechanical
1139
Intake Manifold Leakage Diagnosis
1142
Engine Cylinder Head Gasket Failure Diagnosis
1142
Cylinder-To-Cylinder Leakage Test
1142
Cylinder Combustion Pressure Leakage Test
1142
Cylinder Combustion Pressure Leakage Diagnosis Chart
1143
Engine Oil Leak Inspection
1143
Inspection for Rear Seal Area Leaks
1143
Air Leak Detection Test Method
1143
Engine Oil Pressure Diagnosis and Testing
1144
Valve Timing
1144
Valve Refacing
1144
Service Procedures
1144
Valve, Guide and Seal
1144
Valve Guides
1145
Valve Stem-To-Guide Clearance Measurement
1145
Valve Facing Margin
1145
Measurement of Valve Seat Runout
1145
Piston-Fitting
1146
Bore Gauge Method
1146
Valve Spring Tension Test
1146
Measurement of Lateral Movement of Valve Stem
1146
Piston Ring - Fitting
1147
Piston Size Chart
1147
Groove Height
1147
Moly Coated Piston
1147
Ring Side Clearance Chart
1148
Ring Gap Measurement Chart
1148
Top Compression Ring Identification
1149
Second Compression Ring Identification
1149
Compression Ring Chamfer Location
1149
Compression Ring Installation
1149
Connecting Rod Bearings - Fitting
1150
Connecting Rod Bearing Inspection
1150
Locking Tab Inspection
1150
Scoring Caused by Insufficient Lubrication or by Damaged Crankshaft Pin Journal
1150
Connecting Rod Bearing Fitting Chart
1151
Measuring Bearing Clearance with Plastigage
1151
Fitting Crankshaft Main Bearings Inspection
1152
Fitting Bearings (Crankshaft Installed)
1152
Bearing Insert Pair Chart
1152
Checking Connecting Rod Side Clearace— Typical
1152
Main Bearing Journal Diameter (Crankshaft Removed)
1153
Bearing-To-Journal Clearance (Crankshaft Installed)
1153
Form-In-Place Gaskets
1154
Mopar Silicone Rubber Adhesive Sealant
1154
Mopar Gasket Maker
1154
Surface Preparation
1154
Engine Performance
1155
Honig Cylinder Bores
1155
Cylinder Bore Crosshatch Pattern
1155
Service Engine Assembly (Short Block)
1156
Hydrostatic Lock
1156
Engine Oil Service
1156
API Service Grade Certified
1156
Repair Damaged or Worn Threads
1156
Lubricants
1156
Energy Conserving Oil
1157
Crankcase Oil Level Inspection
1157
Engine Oil Change
1157
Engine Oil Container Standard Notations
1157
Maintenance Schedules
1157
Engine Oil Filter Change
1158
Engine Mounts - Front Removal and Installation
1158
Oil Filter—2.5L Engine
1158
Oil Filter Sealing Surface—Typical
1158
Engine Mount- Rear Removal
1159
Manual Transmission
1159
Front Mounts
1159
Support Cushion Bracket—Left Side
1159
Engine Mount- Rear Installation
1160
Engine Removal
1160
Air Cleaner and Resonator Removal and Installation
1161
Upper Radiator Hose, Coolant Recovery Hose and Fan Shroud
1161
Engine Installation
1162
Intake Manifold Removal
1162
Air Cleaner, Resonator and Air Inlet Hose Removal and Installation
1162
Intake Manifold Installation
1163
Crankcase Ventilation (CCV) Hose—2.5L Engine
1163
Exhaust Manifold Removal and Installation
1164
Cylinder Head Cover Removal
1164
Cylinder Head Cover Installation
1165
Rocker Arms and Push Rods Removal and Installation
1165
Rocker Arm Assembly
1165
Valve Spring and Seal Removal and Installation
1166
Valve and Valve Components
1166
Cylinder Head Removal and Installation
1167
Engine Cylinder Head Assembly
1168
Fabricate Alignment Dowels
1168
Alignment Dowel Locations
1168
Cylinder Head Disassembly and Assembly
1169
Engine Cylinder Head Bolt Tightening Sequence
1169
Hydraulic Tappets Removal
1169
Hydraulic Tappets Installation
1170
Vibration Damper Removal and Installation
1170
Timing Case Cover Oil Seal Removal and Installation
1170
Hydraulic Valve Tappet Removal/Installation Tool
1170
Timing Case Cover Removal and Installation
1171
Timing Case Cover Oil Seal Installation
1171
Timing Case Cover Components
1171
Timing Case Cover Alignment and Seal Installation Tool 6139
1171
Timing Chain and Sprockets Removal and Installation
1172
Crankshaft—Camshaft Alignment
1172
Camshaft and Crankshaft Sprockets and Chain
1172
Camshaft Removal and Installation
1173
Loading Timing Chain Tensioner
1173
Verify Sprocket—Chain Installation
1173
Camshaft Pin Replacement Removal
1174
Timing Case Cover
1174
Camshaft Pin Replacement Installation
1175
Timing Chain Alignment
1175
Camshaft and Crankshaft Sprocket and Chain
1175
Camshaft Bearings
1176
Crankshaft Main Bearings Removal
1176
Verify Crankshaft—Camshaft Installation
1176
Crankshaft Main Bearings Installation
1177
Removing Main Bearing Caps and Lower Inserts
1177
Removing Upper Inserts
1177
Location of Mopar Gasket Maker
1177
Oil Pan Removal and Installation
1178
Crankshaft End Play Measurement
1178
Oil Pump
1179
Fabrication of Alignment Dowels
1179
Position of Dowels in Cylinder Block
1179
Location of Mopar Silicone Adhesive Sealant on Cylinder Block
1179
Oil Pump Removal and Installation
1180
Piston and Connecting Rod Removal
1180
Oil Pump Assembly
1180
Stamped Connecting Rods and Caps
1180
Piston and Connecting Rod Installation
1181
Rear Main Oil Seal Removal
1181
Removal of Connecting Rod and Piston Assembly
1181
Rod and Piston Assembly Installation
1181
Rear Main Oil Seal Installation
1182
Cylinder Block Disassembly and Assembly
1182
Rocker Arms and Push Rods Cleaning and Inspection
1182
Replacement of Rear Crankshaft Oil Seal
1182
Engine Cylinder Head Cleaning and Inspection
1183
Cylinder Block Cleaning and Inspection
1183
Oil Filter Adaptor Hole
1183
Front Oil Galley Hole
1183
Engine Specifications
1184
Specifications - Torque
1188
Torque Chart 2.5L Engine
1188
2.5L Engine Special Tools
1189
4.0L Engine Table of Contents
1190
Engine Description and Operation
1191
Lubrication System
1191
Oil Lubrication System—4.0L Engine
1193
Cylinder Block Description
1194
4.0L Cylinder Block with Main Bearing Caps and Cap Brace
1194
Cylinder Head 4.0L Engine
1194
Crankshaft with Select Fit Marking Location
1194
Camshaft Description
1195
Rocker Arm Description
1195
Rocker Arms 4.0L Engine
1195
Piston and Connecting Rod
1195
Valve Description
1196
Oil Pan Description
1196
Valve Spring
1196
Cylinder Head Cover
1196
Hydraulic Tappet
1196
Valve Guide
1196
Valve Stem Seal
1196
Intake Manifold
1196
Intake Manifold 4.0L Engine
1197
Exhaust Manifold
1197
Diagnosis and Testing
1197
Engine Diagnosis-Introduction
1197
Service Diagnosis- Performance
1198
Service Diagnosis- Mechanical
1199
E
1199
Ngine Mechanical Diagnosis Chart
1199
Intake Manifold Leakage Diagnosis
1201
Сylinder Compression Pressure Test
1202
Cylinder-To-Water Jacket Leakage Test
1202
Cylinder Combustion Pressure Leakage Test
1202
Engine Cylinder Head Gasket Failure Diagnosis
1202
Engine Oil Leak Inspection
1203
Valve Service
1204
Engine Oil Pressure
1204
Service Procedures
1204
Valve Timing
1204
Valve Seat Refacing
1205
Valve Stem Oil Seal Replacement
1205
Measurement of Valve Guide Bore Diameter
1205
Piston Fitting
1206
Bore Gage Method
1206
Bore Gauge
1207
Piston Dimensions
1207
Ring Side Clearance Measurement
1208
Gap Measurement
1208
Fitting Connecting Rod Bearings Inspection
1209
Ring Gap Orientation
1209
Bearing-To-Journal Clearance
1210
Side Clearance Measurement
1211
Checking Connecting Rod Side Clearance— Typical
1212
Main Bearing Wear Patterns
1212
Fitting Crankshaft Main Bearings
1212
Bearing Insert Pairs Chart
1213
Crankshaft Journal Size Paint I. D. Location
1213
Main Bearing Journal Diameter
1214
Main Bearing Fitting Chart
1214
Gasket Application
1215
Form-In-Place Gaskets
1215
Honing Cylinder Bores
1216
Engine Performance
1216
Repair Damaged or Worn Threads
1217
Engine Oil Specification
1217
Service Engine Assembly (Short Block)
1217
Hydrostatic Lock
1217
Engine Oil Service
1217
Sae Viscosity
1218
Filter Specification
1218
Engine Oil Dipstick—4.0L Engine
1218
Oil Filter Removal and Installation
1219
Used Engine Oil Disposal
1219
Oil Filter—4.0L Engine
1219
Engine Mounts-Front
1219
Engine Mount - Rear Removal and Installation
1220
Support Cushion Bracket
1220
Engine Assembly Removal
1221
Upper Radiator Hose, Coolant Recovery Hose, Fan Shroud and Heater Hoses
1222
Heater Hoses (RH Drive Vehicle)
1222
Engine Assembly Installation
1223
Intake and Exhaust Manifold Removal and Installation
1224
Intake and Exhaust Manifolds—4.0L
1224
Cylinder Head Cover Removal and Installation
1225
Cylinder Head Cover Gasket Locator Pins
1225
Exhaust Manifold-4.0L Engine
1225
Rocker Arms and Push Rods
1225
Valve Springs and Oil Seals Removal
1226
Valve Springs and Oil Seals Installation
1227
Cylinder Head
1227
Cylinder Head Bolts
1228
Valves and Valve Springs Removal and Installation
1229
Hydraulic Tappets Removal and Installation
1229
Hydraulic Valve Tappet Removal— Installation Tool
1229
Vibration Damper Removal Tool 7697
1230
Timing Case Cover
1230
Timing Chain and Sprockets Removal
1231
Camshaft Sprocket and Thrust Plate
1231
Timing Chain and Sprockets Installation
1232
Camshaft Removal and Instalation
1232
Camshaft Bearing Removal and Installation
1233
Crankshaft / Camshaft Sprocket Timing Mark Alignment
1233
Crankshaft / Camshaft Chain Drive Installation—Typical
1234
Main Bearing Caps and Brace.
1234
Crankshaft Main Bearings
1234
Location of Sealer
1235
Oil Pan
1236
Pistins Ans Connecting Rods Removal
1237
Oil Pan Sealer Location
1237
Position of 5/16 Inch Oil Pan Bolts
1237
Pistons and Connecting Rods
1237
Pistins Ans Connecting Rods Installation
1238
Main Bearings Caps and Brace
1238
Crankshaft Oil Seals - Rear Removal and Installation
1239
Oil Pump Removal
1240
Oil Pump Installation
1241
Timing Case Cover Oil Seal
1241
Disassembly and Assembly
1241
Cylinder Block
1241
Cylinder Head Cleaning and Inspection
1242
Cylinder Head Cover Cleaning and Inspection
1242
Hydraulic Tappets Cleaning and Inspection
1242
Rocker Arms and Push Rods
1242
Leak-Down Tester
1243
Cylinder Bore Measurement
1243
Cylinder Block
1243
4.0L Engine Specifications
1244
Torque Specifications
1247
Special Tools 4.0L Engine
1248
Engine Identification
1250
Engine Code Location
1250
Service Diagnosis - Diesel - Performance
1251
Diagnosis and Testing
1251
Service Diagnosis - Diesel - Mechanical
1258
Tappet Noise
1260
Valve Service
1260
Valve Disassembly
1260
Valve Cleaning
1260
Service Procedures
1260
Valve Inspection
1261
Valve Stand down
1261
Valve Specification
1261
Engine Mounts - LHD Diesel Removal and Installation
1262
Valve Guide Height
1262
Engine Compartment View — Diesel
1262
Installation - Right Side
1263
Removal - Left Side
1263
Left Engine Mount Sill Plate Nuts
1263
A/C Compressor Position & Orientation
1263
Installation - Left Side
1264
Engine Mounts - RHD Diesel
1264
Left Engine Mount Retaining Bolts
1264
Right Engine Mount Sill Plate Nuts
1265
A/C Compressor Position and Orientation
1266
2.5L Diesel Engine Removal
1267
Engine Ground Wire Location
1268
Exhaust System Inlet Pipe Connection
1268
Clutch Slave Cylinder
1268
Transfer Case Shift Linkage — 4X4
1268
2.5L Diesel Engine Installation
1269
Cylinder Head Cover
1271
Hydraulic Tappets
1272
Oil Level High and Low
1272
Tappet and Rocker Arm Assembly
1272
Valve Springs Removal
1273
Rocker Arm Retaining Nut
1273
Rocker Arms and Push Rods
1273
Valve Springs Installation
1274
Engine Cylinder Head Removal
1274
Turbocharger
1274
Cylinder Head Gaskets
1275
Oil Feed Line Retainer
1275
Rocker Arm Oil Feed Lines
1275
Fuel Injector Tool VM.1012B
1275
Fuel Injector
1276
Rocker Arm Retaining Nuts
1276
Steel Type Cylinder Head Gasket—Identification
1276
Measuring Piston Protrusion
1276
Engine Cylinder Head Installation
1277
Piston Protrusion Chart
1277
Timing Gear Cover Oil Seal Removal and Installation
1279
Timing Gear Cover Removal and Installation
1279
Timing Gear Cover Oil Seal
1279
Front Cover Sealer Location
1279
Vibration Damper
1279
Thrust Plate Inspection
1280
Camshaft Assembly
1280
Timing Marks
1280
Camshaft Bearings Removal and Installation
1281
Camshaft Thrust Plate
1281
Internal Vacuum Pump Removal
1282
Oil Pan
1282
Oil Pump
1282
Internal Vacuum Pump Installation
1283
Oil Pump Pressure Relief Valve Removal
1283
Vacuum Pump Parts
1283
Oil Pump Pressure Relief Valve Installation
1284
Oil Filter Adapter and Engine Oil Cooler Removal and Installation
1284
Pistons and Connecting Rod Assembly Removal
1284
Vacuum Pump Mounting Hole
1284
Piston Pin - Removal
1285
Piston Ring - Removal
1285
Piston Ring Fitting
1285
Piston Rings - Installation
1285
Pistons and Connecting Rod Assembly Installation
1286
Piston Pin Installation
1286
Ring Gap Measurement
1286
Piston Ring to Groove Clearance
1286
Cylinder Wall Liner Assembly Removal and Installation
1287
Liner Inspection
1288
Liner Installation
1288
Crankshaft and Bearing Assembly
1289
Crankshaft Main Bearings
1289
Crankshaft and Bearing Installation
1290
Crankshaft Special Tool VM.1004
1290
Crankshaft Support Locator Bolts
1290
Crankshaft and Carrier Bearing Assembly
1290
Main Bearing Support Alignment
1291
Measuring Crankshaft End Play
1291
Hydraulic Tappets Disassemble and Assemble
1292
Oil Pump Bore Depth
1292
Checking Cylinder Head Flatness
1292
Disassembly and Assembly
1292
Cleaning and Inspection
1292
Rocker Arms and Push Rods
1292
Rocker Arm and Push Rods Inspection
1293
Pistons and Connecting Rod Assembly
1293
Inspection - Pistons
1293
Inspection - Connecting Rod
1293
Inspection - Crankshaft Journals
1294
Cylinder Wall Liner Assembly Inspection
1294
Connecting Rod Identification
1294
Piston and Connecting Rod Assembly
1294
Oil Pump Cleaning and Inspection
1295
Oil Pump Inner and Outer Rotors
1295
Checking Rotor Clearance
1295
Specifications
1295
Engine Specifications
1295
Torque Specifications
1297
Engine Special Tools
1298
Exhaust System Contents
1302
Exhaust System Description
1302
Exhaust Pipe—2.5L Early Build
1302
Exhaust Pipe—2.5L Late Build
1302
Exhaust Pipe—4.0L Early Build
1303
Exhaust Pipe—4.0L Late Build
1303
Exhaust System—Typical 2.5L and 4.0L Early Build
1303
Description and Operation
1303
Exhaust System—Typical 2.5L and 4.0L Late Build
1304
Catalytic Converters Description
1305
Muffler Description
1305
4.0L Catalytic Converter and O2 Sensor Configuration—California and Federal Emissions
1305
Exhaust System
1305
Tailpipe Description and Operation
1306
Exhaust System Diagnosis Chart
1306
Diagnosis and Testing
1306
Exhaust Pipe - Early Build Removal and Installation
1307
Exhaust Pipe - Late Build Removal and Installation
1308
Catalytic Converter - Early Build
1308
Nut
1308
Transmission Support
1308
Mini Catalytic Converter
1308
Exhaust Manifold
1308
Catalytic Converter - Early Build Removal and Installation
1309
Catalytic Converter - Late Build Removal and Installation
1309
Catalytic Converter to Muffler and Exhaust Pipe Connection—Early Build
1309
Muffler and Tailpipe - Early Build Removal
1310
Front Exhaust Tailpipe Hanger
1310
Muffler and Tailpipe - Early Build Installation
1311
Muffler and Tailpipe - Late Build
1311
Muffler and Tailpipe - Late Build Removal and Installation
1312
Heat Shields Removal and Installation
1313
Exhaust System Specifications
1313
Torque Specifications
1313
Exhaust System and Turbocharger Table of Contents
1314
Exhaust System Description and Operation
1314
Exhaust Heat Shields Description and Operation
1314
Exhaust Pipe Removal
1314
Exhaust Pipe Installation
1315
Muffler and Exhaust Tailpipe Removal and Installation
1315
Exhaust Manifold and Turbocharger (LHD) Removal
1315
Exhaust down Pipe to Exhaust Pipe
1315
Engine Compartment
1316
Exhaust Downpipe Heatshield
1316
Exhaust Manifold and Turbocharger (LHD) Cleaning and Installation
1317
Turbocharger Oil Return Hose
1317
Turbocharger / Exhaust Manifold Assembly
1317
Exhaust Manifold and Turbocharger (RHD) Removal
1318
Exhaust Manifold and Turbocharger (RHD) Cleaning and Installation
1320
2.5L Turbo Diesel — Heatshields
1320
RHD Turbo Position & Orientation
1320
Intake Manifold Removal, Cleaning and Installation
1323
Exhaust System and Turbocharger Specifications
1323
Exhaust Pipe
1323
Frame and Bumpers Table of Contents
1324
Frame Description
1324
Bumpers Description and Operation
1324
Frame Rail
1324
Bumpers Table of Contents
1325
Front Bumper End Cap Removal and Installation
1325
Front Bumper Removal and Installation
1326
Front Tow Hook Removal and Installation
1326
Vacuum Reservoir
1326
Rear Bumper End Cap Removal and Installation
1327
Rear Bumper Removal and Installation
1327
Rear Tow Hook Removal and Installation
1328
Frame Rail
1328
Frame Table of Contents
1329
Front Skid Plate Removal and Installation
1329
Transfer Case Skid Plate Removal and Installation
1329
Nut
1329
Fuel Tank Skid Plate Removal and Installation
1330
Trailer Hitch Removal and Installation
1330
Frame and Bumpers Specifications
1330
Trailer Hitch Harness Connector
1330
Frame Dimensions
1331
Emergency Tow Eyes Description and Operation
1334
Front and Rear Emergency Tow Eyes
1334
Frame Rail
1334
Fuel System Table of Contents
1336
Fuel Delivery System Table of Contents
1336
PCM Vin Reprogramming Operation
1336
Fuel Delivery System Description
1336
Fuel Delivery System Operation
1337
Fuel Pump Module Description and Operation
1337
Fuel Tank/Fuel Pump Module (Top View)
1337
Fuel Pump Module Components
1337
Fuel Pump Description and Operation
1338
Fuel Gauge Sending Unit Description and Operation
1338
Fuel Filter/Fuel Pressure Regulator Description and Operation
1338
Fuel Tank Description and Operation
1339
Fuel Injectors Description and Operation
1339
Fuel Injector—Typical
1339
Fuel Injector Rail/Fuel Damper - 2.5L Engine Description and Operation
1340
Fuel Rail/Fuel Damper -4.0L Engine Description and Operation
1340
Fuel Tank Filler Tube Cap Description and Operation
1341
Fuel Tubes/Lines/Hoses and Clamps Description
1341
Quick-Connect Fittings Descriptions
1341
Fuel Pump Pressure Test Diagnosis and Testing
1341
Fuel Pump Capacity Test
1342
Fuel Pressure Leak down Test
1342
Fuel Pressure Test Gauge (Typical Gauge Installation at Test Port)
1342
Fuel Pump Amperage Test
1343
Connecting Adapter Tool—Typical
1343
Low Current Shunt Adapter
1344
Fuel Gauge Sending Unit
1345
Fuel Injector Test
1345
Quick-Connect Fittings
1345
Service Procedures
1345
Fuel System Pressure Release
1345
Procedure
1345
Disconnecting
1346
Single-Tab Type Fitting
1346
Disconnecting Single-Tab Type Fitting
1346
Removing Pull Tab
1347
Typical Two-Tab Type Quick-Connect Fitting
1347
Plastic Retainer Ring Type Fitting
1347
Latch Clip—Type 1
1347
Connecting
1348
Fuel Filter/Fuel Pressure Regulator Removal
1348
Fuel Line Disconnection Using Special Tool
1348
Removal and Installation
1348
Fuel Filter/Fuel Pressure Regulator Installation
1349
Fuel Pump Module Removal
1349
Fuel Filter/Fuel Pressure Regulator
1349
Fuel Filter/Fuel Pressure Regulator Gasket
1349
Fuel Pump Module Installation
1350
Fuel Pump Inlet Filter Removal and Installation
1350
Top View of Fuel Tank and Fuel Pump Module
1350
Locknut Removal/Installation—Typical
1350
Fuel Gauge Sending Unit Removal and Installation
1351
Fuel Injector Rail/Fuel Damper - 2.5L Engine Removal
1351
Fuel Injector Rail/Fuel Damper - 2.5L Engine Installation
1352
Fuel Injector Rail/Fuel Damper - 4.0L Engine Removal
1352
Fuel Rail Mounting—2.5L Engine
1352
Fuel Injector Rail/Fuel Damper - 4.0L Engine Installation
1353
Fuel Injjectors Removal and Installation
1354
Fuel Tank
1354
Fuel Tank Removal
1354
Fuel Injector Mounting
1354
Fuel Hose Shield
1355
Fuel Fill and Vent Hoses
1355
Fuel Tank Connections at Front of Fuel Tank
1355
Fuel Tank Mounting Straps/Nuts
1355
Fuel Tank Installation
1356
Fuel Tank Filler Tube Cap Removal/Installation
1356
Accelerator Pedal Removal
1356
Fuel Fill/Vent Hose Index Marks
1356
Accelerator Pedal Installation
1357
Throttle Cable Removal and Installation
1357
Accelerator Pedal Mounting—Typical
1357
Throttle Cable at Throttle Body
1357
Fuel System Specifications
1358
Fuel Requirements
1358
Reformulated Gasoline
1358
Gasoline/Oxygenate Blends
1358
Fuel Tank Capacity
1358
Fuel System Pressure
1358
Fuel System Cautions
1359
Fuel System Torque Chart
1359
Fuel Injection System Table of Contents
1360
Powertrain Control Module (PCM) Description and Operation
1360
Modes of Operation
1361
PCM Location
1361
Description and Operation
1361
Ignition Switch (Key-On) Mode
1362
Engine Start-Up Mode
1362
Engine Warm- up Mode
1362
Idle Mode
1363
Cruise Mode
1363
Acceleration Mode
1363
Deceleratio Mode
1363
Automatic Shutdown (ASD) Relay Sense - PCM Input Description and Operation
1364
Brake Switch - PCM Input Operation
1364
Five Volt Sensor Supplies - Primary and Secondary Description and Operation
1364
Wide Open Throttle Mode
1364
Battery Voltage-Pcm Input
1364
Engine Coolant Temperature Sensor - PCM Input Description and Operation
1365
Extended Idle Switch - PCM Input Description and Operation
1365
Oxygen Sensor - PCM Input Description and Operation
1365
Fuel Level Sensor-Pcm Input
1365
Ignition Circuit Sense - Input Description and Operation
1366
Ignition Circuit Sense-Pcm Input
1366
Intake Manifold Air Temperature Sensor - PCM Input Description and Operation
1367
Manifold Absolute Pressure (MAP) Sensor - PCM Input Description and Operation
1367
Oil Pressure Sensor - PCM Input Desription and Operation
1368
Power Grounds Operation and Description
1368
Power Steering Pressure Switch - PCM Input Description and Operation
1368
Sensor Return - PCM Iput Operation
1369
Throttle Position Sensor (TPS) - PCM Input Description and Operation
1369
Vehicle Speed and Distance Sensor - PCM Input Description and Operation
1369
Auto Shutdown (ASD) Relay - PCM Output Description and Operation
1369
CCD Bus Circuits - PCM Outputs Operation
1370
Data Link Connector - PCM Input and Output Description and Operation
1370
Fuel Injectors - PCM Output Description and Operation
1370
Idle Air Control (IAC) Motor-PCM Output Description and Operation
1370
Fuel Pump Relay-Pcm Output
1370
Radiator Fan Relay - PCM Output Description and Operation
1371
Throttle Body Description and Operation
1371
Visual Inspection
1372
Powertrain Control Module (PCM)
1372
Power Distribution Center (PDC)
1372
Ignition Coil—2.5L Engine
1372
Diagnosis and Testing
1372
Ignition Coil—4.0L Engine
1373
Intake Manifold Air Temp. Sensor Location— 2.5L Engine
1373
Sensor Locations—4.0L Engine
1374
Rubber L-Shaped Fitting—Map Sensor-To-Throttle Body
1374
Engine Coolant Temperature Sensor— Typical
1374
Front Oxygen Sensor—4.0L—Federal Emissions
1374
Oxygen Sensors—4.0L—California Emissions
1375
Front Oxygen Sensor—2.5L—Federal Emissions
1375
Rear Oxygen Sensor—2.5L/4.0L—Federal Emissions
1375
ASD and Fuel Pump Relays Diagnosis and Testing
1376
Vehicle Speed Sensor—Typical— 4WD Shown
1376
Power Steering Pressure Switch—2.5L Engine
1376
ASD and Fuel Pump Relays Operation
1377
Throttle Body Minimum Air Flow Check Procedure
1377
ASD and Fuel Pump Relay Terminals—
1377
6714 Fixed Orifice Tool
1377
Automatic Shutdown (ASD) Relay Removal and Installation
1378
Install Orifice Tool 2.5L 4–Cylinder Engine
1378
Install Orifice Tool 4.0L 6–Cylinder Engine
1378
Fuel Pump Relay Removal and Installation
1379
Throttle Body Removal and Installation
1379
Throttle Body and Sensor Locations—4.0L Engine
1379
Throttle Position Sensor (TPS) Removal and Installation
1380
Idle Air Control (IAC) Motor Removal and Installation
1380
Throttle Body and Sensor Locations—2.5L Engine
1380
TPS Mounting Screws
1380
Manifold Absolute Pressure (MAP) Sensor Removal and Installation
1381
Powertrain Control Module (PCM) Removal and Installation
1381
Mounting Bolts (Screws)—Iac Motor
1381
MAP Sensor Mounting
1381
Power Steering Pressure Switch - 2.5L Engine Removal and Installation
1382
Oxygen Sensor Removal
1382
PCM Mounting
1382
Oxygen Sensor Installation
1383
Front Oxygen Sensor—4.0L—Federal/California Emissions
1383
Front Oxygen Sensor—2.5L—Federal/California Emissions
1383
Air Cleaner Element (Filter) Removal and Installation
1384
Engine Coolant Temperature Sensor Removal
1384
Air Cleaner Housing and Element (Filter)
1384
Clamp Removal and Installation
1384
Engine Coolant Temperature Sensor Installation
1385
Intake Manifold Air Temperature Sensor Removal and Installation
1385
IAT Sensor Location
1385
Vehicle Speed Sensor Removal and Installation
1386
Fuel Systems Specifications
1386
Torque Chart
1386
Fuel Systems Special Tools
1387
Fuel System - 2.5L Diesel Engine Table of Contents
1388
Fuel Delivery System - 2.5L Diesel Engine Table of Contents
1388
Fuel System Pressure Warning Description
1389
Fuel Tank Description
1389
Fuel Tank Module Description
1389
Fuel Gauge Sending Unit Description
1389
Engine
1389
Description and Operation
1389
Fuel Filter/Water Separator
1389
Fuel Shutdown Solenoid Description
1390
Fuel Injection Pump Description
1390
Fuel Filter/Water Separator Location
1390
Fuel Injectors Description
1391
Fuel Tubes/Lines/Hoses and Clamps - Low-Pressure Type Description
1391
Fuel Injectors and Drain Tubes
1391
Fuel Injector Sensor
1391
Quick-Connect Fittings - Low Pressure Type Description
1392
High-Pressure Fuel Lines Description
1392
Plastic Retainer Ring-Type Fitting
1392
Fuel Drain Tubes Description
1393
Fuel Heater Description
1393
Fuel Heater Relay Description
1393
Fuel Heater Temperature Sensor and Element Location
1393
Diagnosis and Testing
1393
General Information
1393
Visual Inspection
1393
PCM Location—Typical
1394
ECM Location—Lhd
1394
Glow Plug Connector
1394
Glow Plug Relay Location
1395
Fuel Shutdown Solenoid Location
1395
Vehicle Speed Sensor—4 Wheel Drive
1395
Air in Fuel System
1396
Fuel Heater Relay Test
1396
Engine Coolant Temperature Sensor Location
1396
Vaccum Pump at Front of Engine
1396
Fuel Injector/Needle Movement Sensor Test
1397
Fuel Injection Pump Test
1397
Typical Inspection of Fuel Injector
1397
Engine
1397
Fuel Supply Restrictions
1398
Low/High-Pressure Linesne Leak Test
1398
Fuel Shutdown Solenoid Test
1398
High-Pressure Fuel Line Leak Test
1398
Air Bleed Procedures
1399
Air Bleeding at Fuel Filter
1399
Typical Fuel Pressure Test at Injection Pump
1399
Overflow Valve
1399
Service Procedures
1399
Fuel Injection Pump Timing
1400
Accelerator Pedal Removal and Installation
1400
High-Pressure Fuel Line Bleeding
1400
Accelerator Pedal Mounting-Typical
1400
Fuel Drain Tubes
1401
Fuel Filter/Water Separator
1401
Draining Wter from Filter Bowl
1401
Fuel Filter Removal/Installation
1401
Fuel Heater Relay
1402
Fuel Level Sensor Removal
1402
Fuel Injection Pump Removal
1402
Fuel Injection Pump
1403
Access Plug at Rear of Pump
1403
Installing Dial Indicator and Special Adapter Tools
1403
Installation/Adjusting Pump Timing
1404
Removing Pump Drive Gear Nut
1404
Pump Gear Tools
1404
Installing Pump Drive Gear Removal Tools
1404
Injection Pump Mounting Nuts
1405
Fuel Injectors Removal
1406
Fuel Injectors Installation
1407
Wiring Harness through Socket
1407
Fuel Tank Connections at Front of Tank
1407
Fuel Reservoir Module Removal and Installation
1408
Module Connector Retainer and Lock
1408
Fuel Reservoir Module Lock Nut Removal
1408
Frame Rail
1408
High-Pressure Lines Removal and Installation
1409
Fuel System - 2.5L Diesel Engine Specifications
1409
Fuel Tank Capacity
1409
Fuel Injector Firing Sequence
1409
Fuel Injection System Description
1410
Powertrain Control Module (PCM) Description
1411
PCM Location—Lhd
1411
Description and Operation
1411
Boost Pressure Sensor Description
1412
Vehicle Theft Alarm Description
1412
Battery Voltage - PCM Input Description
1412
Boost Pressure Sensor Location
1412
Ignition Circuit Sense - ECM/PCM Input Description
1413
Ignition Circuit Sense - PCM Input
1413
Power Ground
1413
Sensor Return-Ecm/Pcm Input (Analog Ground)
1413
Needle Movement or Intrumented First Injector-Ecm Input
1413
Fuel Injector Sensor-Ground
1413
Engine Coolant Temperature Sensor-Ecm/Pcm Input
1413
Engine Speed Sensor-Ecm Input
1413
Air Conditioning (A/C) Controls - ECM Inputs Description
1414
Engine Speed Sensor Location
1414
Speed Sensor Operation
1414
Brake Switch - ECM Input Description
1415
Data Link Connector - PCM and ECM Input and Output
1415
Vehicle Speed Sensor - ECM Input
1415
Speed Control - ECM Input Description
1415
ASD Relay - ECM Input Description
1416
Five Volt Power - ECM/PCM Output Description
1416
Engine Coolant Gauge - PCM Output Description
1416
Glow Plug Lamp - PCM Output
1416
Engine Oil Pressure Gauge-Pcm Output
1416
Speed Control-Pcm Outputs
1416
Description and Operation
1416
Air Conditioning Relay-Ecm Output
1416
Timing Solenoid-Ecm Output
1416
Glow Plug Relay - ECM Output Description
1417
Glow Plugs Description
1417
Glow Plug Control
1417
Tachometer-Pcm Output
1417
Electric Vacuum Modulator (EVM)- ECM Output Description
1418
Diesel Diagnostics
1418
ASD Relay Test
1418
Engine Coolant Temperature Sensor Test
1418
Diagnosis and Testing
1418
Engine Speed Sensor Test
1418
Glow Plug Test
1418
Typical Glow Plug Tester
1419
Glow Plug Relay Test
1420
Wiring Connection at Glow Plug
1420
Relays - Operation/Testing
1421
Boost / Pressure Sensor
1421
Diagnostic Trouble Codes
1422
ASD Relay
1422
A/C Clutch Relay
1422
Engine Speed Sensor Removal and Installation
1422
Vehicle Speed Sensor Test
1422
Engine Coolant Temperature Sensor
1422
Glow Plugs
1422
Glow Plugs Installation
1423
Glow Plug Relay Removal and Installation
1423
Glow Plug Electrical Connector
1423
Powertrain Control Module (Pcm)
1423
Sensor Removal/Installation—Typical
1424
Vehicle Speed Sensor
1424
Specifications
1425
Glow Plug Current Draw
1425
Torque Chart-2.5L Diesel
1425
Steering Table of Contents
1426
Power Steering Table of Contents
1426
Steering System Description and Operation
1426
Power Steering Gear and Pump - 4.0L
1426
Power Steering System Diagnosis Charts
1427
Steering Noise
1427
Binding and Sticking
1428
Insufficient Assist or Poor Return to Center
1428
Loose Steering and Vehicle Leads/Drifts
1429
Power Steering Pump Table of Contents
1430
Power Steering Pump Description and Operation
1430
Power Steering Pressure Line Description and Operation
1430
Pump with Integral Reservoir
1430
Power Steering Return Line Description and Operation
1431
Power Flow Diagnosis and Pressure Diagnosis and Testing
1431
Flow and Pressure Test
1431
Pump Specifications
1431
Pump Leakage Diagnosis
1432
Power Steering Pump - Initial Operation
1432
Pump Steering Pump Removal and Installation
1432
Pump Reservoir - 2.5L Removal and Installation
1432
Service Procedures
1432
Pump Pulley Disassembly and Assembly
1433
Pump Reservoir Disassembly and Assembly
1433
Pump Mounting LHD
1433
Pump Mounting 4.0L RHD
1434
Pulley Removal
1434
Pulley Installation
1434
Steering Special Tools
1435
Specifications Torque Chart
1435
Power Steering Pump
1435
Power Steering Gear Table of Contents
1436
Power Steering Gear Description and Operation
1436
Power Steering Gear Leakage
1436
Steering Gear Removal
1437
Housing End Plug Disassembly and Assembly
1437
Pitman Shaft/Seals/Bearing Disassembly
1437
Steering Gear Mounting (LHD)
1437
Frame Rail
1437
Pitman Shaft/Seals/Bearing Assembly
1438
End Plug Components
1438
Installing the Retaining Ring
1438
Side Cover and Pitman Shaft
1438
Spool Valve Disassembly
1439
Pitman Shaft Seals and Bearing
1439
Needle Bearing Removal
1439
Lock Nut and Adjuster Nut
1439
Spool Valve Assembly
1440
Thrust Support Assembly
1440
Valve Assembly with Stub Shaft
1440
Stub Shaft
1440
Rack Piston and Worm Shaft Disassembly
1441
Valve Seals
1441
Stub Shaft Installation
1441
Stub Shaft Cap O-Ring
1441
Rack Piston and Worm Shaft Assembly
1442
Rack Piston End Plug
1442
Rack Piston with Arbor
1442
Rack Piston
1442
Worm Shaft
1443
Installing Balls in Rack Piston
1443
Balls in the Return Guide
1443
Worm Thrust Bearing Preload Adjustment
1444
Adjuster Lock Nut
1444
Alignment Marking on Housing
1444
Adjustments Steering Gear
1444
Over-Center Adjustment
1445
Aligning to the Second Mark
1445
Steering Gear Centered
1445
Checking Over-Center Rotation Torque
1445
Power Steering Gear Specifications
1446
Power Steering Gear Special Tools
1446
Torque Chart
1446
Steering Linkage Table of Contents
1447
Steering Linkage Description
1447
Steering Linkage—Lhd
1447
Steering Linkage
1448
Tie Rod Removal and Installation
1448
Steering Linkage—Rhd
1448
Pitman Arm Removal and Installation
1449
Drag Link Removal and Installation
1449
Ball Stud Puller
1449
Tie Rod/Drag Link Clamps
1449
Steering Damper Removal and Installation
1450
Steering Linkage Specifications
1450
Steering Linkage Special Tools
1450
Steering Column Table of Contents
1451
Steering Column Description
1451
Steering Colum Service Precautions
1451
Steering Column Removal
1451
Steering Column Installation
1452
Steering Wheel
1452
Key Cylinder Release Access Hole
1452
Column Shrouds
1452
Steering Column Harness
1453
Non-Tilt Column
1453
Power Steering System - 2.5L VM Diesel Table of Contents
1454
Power Steering Pump
1454
Power Steering Pump - 2.5L VM Diesel Table of Contents
1455
Power Steering Pump - LHD Removal
1455
Engine Mount Sill Plate Nuts
1455
Power Steering Pump - LHD Installation
1456
Removing the Power Steering Pump Pulley
1456
Engine Mount Retaining Bolts
1456
Power Steering Pump - RHD Removal
1458
Installing Pump Pulley
1458
Power Steering Pump - RHD Installation
1459
Removing Pump Pulley
1459
Steering Gear - RHD Removal
1460
Power Steering Fluid Pressure and Return Line Location – RHD
1460
Steering Gear - RHD Installation
1461
Steering Gear
1461
Steering Gear Retaining Bolts
1461
Frame Rail
1461
Transmission and Transfer Case Table of Contents
1462
AX5 Manual Transmission Table of Contents
1462
AX5 Manual Transmission Description and Operation
1462
Transmission Identification
1462
AX5 Manual Transmission
1463
Description and Operation
1463
Lubricant
1463
Low Lubricant Level
1464
Hard Shifting
1464
Transmission Noise
1464
Transmission Removal
1464
Diagnosis and Testing
1464
Removal and Installation
1464
Slave Cylinder—Typical
1465
Marking Propeller Shaft and Axle Yokes
1465
Crankshaft Position Sensor —2.5 and 4.0L Engine
1465
Transmission Installation
1466
Front Bearing Retainer Seal Removal and Installation
1467
Align Propeller Shaft and Rear Axle Yokes Alignment Marks
1467
Install Front Bearing Retainer Seal
1467
Recommendations
1467
Extension Housing Seal Removal and Installation
1468
Adapter Housing Seal Removal and Installation
1468
Remove Extension Housing Seal
1468
Install Extension Housing Seal
1468
Adapter/Extension Housing and Front Bearing Retainer Disassembly
1469
Install Adapter Housing Seal
1469
Remove Shift Tower
1469
Remove Shift Tower Gasket
1469
Disassembly and Assembly
1469
Remove Detent Ball Plug
1470
Remove Detent Spring
1470
Remove Detent Ball
1470
Shift Arm Retainer Bolt Removal
1471
Shift Arm Restrictor Pins
1471
Removing Shift Lever Shaft Plug
1471
Remove Shifter Shaft
1471
Loosen Adapter/Extension Housing
1472
Remove Adapter/Extension Housing–Typical
1472
Speedometer Drive Gear Assembly
1472
Remove Front Bearing Retainer
1472
Adapter/Extension Housing and Front Bearing Retainer Assembly
1473
Remove Input Shaft Bearing Snap-Ring
1473
Separate Intermediate Plate and Transmission Case
1473
Remove Intermediate Plate from Transmission Case
1473
Install Transmission Gear Case to the Intermediate Plate
1474
Install Front Bearing Snap-Rings
1474
Install Front Bearing Retainer
1474
Install Adapter/Extension Housing–Typical
1475
Position Shift Arm in Adapter or Extension Housing
1475
Install Shifter Arm Shaft
1475
Install Shift Arm Retainer Bolt
1476
Shifter Arm Shaft Plug Installation
1476
Install Shifter Restrictor Pins
1476
Install Detent Ball
1476
Install Detent Spring
1477
Install Detent Ball Plug
1477
Install Shift Tower
1477
Install Backup Lamp Switch
1477
Shift Mechanism and Geartrain Disassembly
1478
Positioning Intermediate Plate in Vise
1478
Remove Fifth Gear Snap-Ring
1478
Remove Shift Fork Retainer Bolt
1478
Remove Fifth Gear Blocker Ring
1479
Remove Fifth Gear Synchro Ring
1479
Remove Fifth Gear and Synchro Assembly
1479
Remove Fifth Gear Thrust Ring
1479
Remove Fifth Gear Thrust Ring Lock Ball
1480
Remove Reverse Idler Shaft
1480
Remove Output Shaft Rear Bearing Retainer
1480
Remove Shift Fork to Shift Rail Bolts
1480
Remove Reverse Shift Arm Bracket Bolts
1481
Remove Output Shaft Rear Bearing Snap-Ring
1481
Remove Countershaft and Countershaft Rear Bearing
1481
Remove Mainshaft
1481
Remove 3–4 Shift Fork
1482
Remove 1–2 Shift Fork
1482
Remove Lock Ball and Spring
1482
Remove Fifth Gear Shift Rail
1483
Remove Fifth Gear Check Ball
1483
Remove Reverse Shift Head and Rail Assembly
1483
Remove Reverse Shift Rail
1483
Remove Interlock Pin from Reverse Shift Rail
1484
Remove Reverse Check Ball
1484
Remove 1–2 Shift Rail Interlock Pin
1484
Remove 1–2 Check Ball
1484
Shift Mechanism and Geartrain Assembly
1485
Shift Rail Components
1485
Install 1–2 Check Ball
1485
Install 1–2 Shift Rail Interlock Pin
1486
Install Reverse Check Ball
1486
Install Reverse Interlock Pin
1486
Install Reverse Arm Bracket to Fork
1486
Install Reverse Shift Rail
1487
Install Reverse Snap-Ring
1487
Install Fifth Gear Check Ball
1487
Install Fifth Gear Shift Rail
1487
Install 1–2 Shift Fork
1488
Install 3–4 Shift Fork
1488
Install Shift Fork Bolts
1488
Reverse Shift Arm Position
1489
Install Compression Spring and Pin
1489
Install Reverse Idler Shaft
1489
Align Idler Shaft Pin
1489
Depress Pin in Reverse Idler Gear Shaft
1490
Install Fifth Gear Thrust Ring Lock Ball
1490
Install Fifth Gear Thrust Ring
1490
Install Fifth Gear Retainer Bolt
1490
Countershaft Disassembly and Assembly
1491
Input Shaft Disassembly and Assembly
1491
Countershaft Front Bearing Snap-Ring
1491
Separate Input and Output Shafts
1491
Output Shaft Disassembly
1492
Select Input Shaft Bearing Snap-Ring
1492
Install Output Shaft Pilot Bearing Rollers
1492
Check Output Shaft Gear Thrust Clearance
1492
Remove Fifth Gear, First Gear Bearing, and Race
1493
Remove First Gear Bearing Inner Race Lock Ball
1493
Transmission Assembly Information
1494
Remove Second Gear, Reverse Gear, and 1–2 Synchronizer
1494
Remove 3–4 Synchronizer Snap Ring
1494
Remove 3–4 Synchronizer and Third Gear
1494
Geartrain Components
1495
Synchronizer Identification
1495
Select 3–4 Synchronizer Snap-Ring
1495
Check Third Gear Clearance
1496
Install First Gear Bearing Inner Race Lock Ball
1496
First Gear Components
1496
Check First–Second Gear Thrust Clearance
1496
Semi-Synchronized Reverse Idler Gear Disassembly
1497
Select/Install Fifth Gear Snap Ring
1497
Remove Reverse Idler Gear Snap-Ring
1497
Remove Reverse Idler Gear Plate Washer
1497
Semi-Synchronized Reverse Idler Gear Assembly
1498
AX5 Manual Transmission Components Cleaning and Inspection
1498
Gear Case, Adapter/Extension Housing, Intermediate Plate Cleaning and Inspection
1498
Output Shaft Cleaning and Inspection
1498
Countershaft Cleaning and Inspection
1499
Gear and Synchronizer Cleaning and Inspection
1499
Check Shaft and Bearing Race Flange Thickness
1499
Check Output Shaft Runout
1499
AX5 Manual Transmission Specifications
1500
Check Gear–To–Shaft Oil Clearance
1500
Check Synchronizer Ring Wear
1500
Check Fork–To–Hub Clearance
1500
Torque
1500
AX5 Manual Transmission Special Tools
1501
NV3550 Manual Transmission Table of Contents
1503
NV3550 Manual Transmission Description and Operation
1503
NV3550 Manual Transmission Identification
1503
Gear Ratios
1503
Drain and Fill Plug Locations
1504
NV3550 Shift Mechanism
1504
NV3550 Identification
1504
General Information
1504
Nv3550 Manual Transmission
1504
Lubricant
1504
Low Lubricant Level Diagnosis and Testing
1505
Hard Shifting
1505
Transmission Noise
1505
Removal and Installation
1505
Transmission
1505
Shift Tower Removal and Installation
1508
Yoke Seal - 2WD Removal and Installation
1508
Removing Transmission Housing Yoke Seal
1508
Nv3550 Manual Transmission
1508
Rear Housing Yoke Bushing Removal and Installation
1509
Transmission Disassembly
1509
Front Housing
1509
Installing Transmission Housing Yoke Seal
1509
Disassembly and Assembly
1509
Shift Tower Removal
1510
Shift Shaft Lock Bolt Removal
1510
Detent Plunger and Spring Removal
1510
Input Shaft Bearing Retainer Bolt Removal— Typical
1510
Loosening Bearing Retainer Sealer Bead—Typical
1511
Input Shaft Bearing Retainer Removal— Typical
1511
Input Shaft Snap Ring Removal—Typical
1511
Housing and Bearing Retainer Bolt Locations
1511
Shift Shaft, Shift Forks and Reverse Idler Segment
1512
Front Housing Removal
1512
Input Shaft Bearing and Countershaft Front Bearing Race Location
1512
Geartrain and Shift Component Identification
1512
Removing the Shift Socket Roll Pin
1513
Removing Shift Shaft Lever and Bushing Roll Pin
1513
Shift Shaft Removal
1513
Shift Socket and Roll Pin
1513
Removing 3-4 Shift Fork
1514
Reverse Idler Shaft/Support Bolts
1514
Installing Assembly Fixture on Geartrain
1514
Geartrain and Housing Mounted on Fixture Tool
1514
Rear Housing Removal - 2WD
1515
Rear Adapter Housing Removal - 4WD
1515
Removing/Installing Output Shaft Bearing Retainer Bolts—2Wd
1515
Unseating Rear Housing from Output Shaft Bearing—2Wd
1515
Rear Housing Removal—2Wd
1516
Remove Countershaft Rear Bearing
1516
Location of Dimples in Seal Face—4Wd
1516
Rear Seal Removal—4Wd
1516
Geartrain Disassembly from Fixture
1517
Rear Bearing Snap Ring Removal—4Wd
1517
Rear Adapter Housing Removal
1517
Rear Adapter Housing Components
1517
Output Shaft
1518
Third Gear Needle Bearing Removal
1518
Thrust Washer Retaining Ring Removal
1518
Two-Piece Thrust Washer Removal
1518
Second Gear Synchro Ring and Cones Removal
1519
Hub and Sleeve Removal—1-2 Synchro
1519
First Gear Needle Bearing Removal
1519
Output Shaft Bearing Snap Ring Removal
1519
Fifth Gear Needle Bearing Removal
1520
Fifth-Reverse Synchro Hub Snap Ring Removal
1520
Fifth-Reverse Synchro Hub and Sleeve Removal
1520
Reverse Gear and Needle Bearing Removal
1520
Transmission Assembly
1521
Reverse Idler Disassembly
1521
Synchronizer
1521
Reverse Idler Components
1521
Assembled View of Synchro Components
1522
Reverse Gear Bearing Installation
1522
Reverse Gear Installation
1522
Reverse Gear Synchro Ring Installation
1522
Fifth-Reverse Synchro Assembly Installation
1523
Installing Fifth-Reverse Synchro Hub Snap Ring
1523
Installing Fifth Gear Synchro Ring
1523
Installing Fifth Gear Bearing
1524
Fifth Gear Installation
1524
First Gear Bearing Installation
1524
First Gear Installation
1524
First Gear Synchro Ring Installation
1525
Starting 1-2 Synchro on Shaft
1525
Pressing 1-2 Synchro Assembly Onto Output Shaft
1525
Installing 1-2 Synchro Hub Snap Ring
1526
Second Gear Synchro Ring Installation
1526
Second Gear Bearing Installation
1526
Second Gear Installation
1526
Installing Two-Piece Thrust Washer
1527
Starting Retaining Ring over Two-Piece Thrust Washer
1527
Seating Thrust Washer Retaining Ring
1527
Third Gear Bearing Installation
1528
Installing Third Gear
1528
Third Speed Synchro Ring Installation
1528
Starting 3-4 Synchro Hub on Output Shaft
1528
Reverse Idler Assembly
1529
Pressing 3-4 Synchro Assembly on Output Shaft
1529
Installing 3-4 Synchro Hub Snap Ring
1529
Installing Output Shaft Bearing Snap Ring
1529
Correct Synchro Sleeve Position
1530
Idler Gear and Bearing Installation
1530
Idler Gear Rear Thrust Washer Installation
1530
Shift Shaft and Detent Plunger Bushing/Bearings
1531
Geartrain Assembly
1531
Idler Gear and Shaft Assembly
1531
Preparing Assembly Fixture for Geartrain Build-Up
1532
Installing Pilot Bearing in Input Shaft
1532
Installing Fourth Gear Synchro Ring on Input Shaft
1532
Idler Pedestal Basic Height Adjustment
1532
Output Shaft and Geartrain Installed in Input Shaft
1533
Countershaft Installed on Fixture Tool
1533
Reverse Idler Assembly Positioned on Assembly Fixture Pedestal
1534
Positioning Output Shaft Bearing Retainer for Rear Housing Installation
1534
Assembling 1-2 and Fifth-Reverse Shift Forks
1534
Rear Housing -2WD
1535
Shift Forks Installed in Synchro Sleeves
1535
Preparing Rear Housing Dowels for Installation
1535
Lubricating Countershaft Rear Bearing
1535
Countershaft Rear Bearing Seated in Seated in Race
1536
Rear Housing Installation—2Wd
1536
Applying Sealer to Retainer and Housing Bolts
1536
Removing Pilot Stud Tool and Installing Retainer Bolts—2Wd
1536
Adapter Housing - 4WD
1537
Shift Shaft, Shaft Lever and Bushing and Shift Socket
1537
Preparing Adapter Housing for Installation—4Wd
1537
Installing Rear Bearing Snap Ring—4Wd
1537
Installing 3-4 Shift Fork
1538
Shift Shaft Installation
1538
Assembling Shift Shaft Lever and Bushing
1538
Installing Shift Shaft Lever and Bushing
1538
Inserting Shaft into Lever Opening in Housing
1539
Shift Socket Installation
1539
Roll Pin Identification—Shaft Lever and Shift Socket
1539
Starting Roll Pin in Shift Shaft Lever
1539
Front Housing and Input Shaft Bearing Retainer
1540
Correct Seating of Shift Shaft Lever Roll Pin
1540
Starting Roll Pin in Shift Socket
1540
Seating Shift Socket Roll Pin
1540
Lubricating/Positioning Countershaft Front Bearing
1541
Applying Sealer to Front/Rear Housings
1541
Installing Housing Attaching Bolts
1541
Installing Shift Shaft Bushing Lock Bolt
1542
Installing Shift Shaft Detent Plunger, Spring, and Plug
1542
Installing Backup Light Switch
1542
Installing Input Shaft Snap Ring—Typical
1542
Shift Tower and Lever Assembly
1543
Installing Oil Seal in Front Bearing Retainer
1543
Applying Sealer to Bearing Retainer and Housing—Typical
1543
Installing Input Shaft Bearing Retainer— Typical
1543
Transmission Components Cleaning and Inspection
1544
Shift Lever Assembly
1544
Shift Shaft and Forks
1544
Front/Rear Housings and Bearing Retainers
1544
Countershaft Bearings and Races
1545
Shift Forks and Shaft
1545
NV3550 Manual Transmission Specifications
1546
NV3550 Manual Transmission Special Tools
1546
Shift Socket
1546
Output Shaft and Geartrain
1546
Torque
1546
Automatic Transmission - 30RH Table of Contents
1549
30RH Automatic Transmission Description
1550
Description and Operation
1550
30RH Automatic Transmission
1551
30RH Automatic Transmission Operation
1552
Transmission Gear Ratios
1552
Transmission Part Number and Serial Number Location
1552
Park Powerflow
1553
Neutral Powerflow
1553
Reverse Powerflow
1554
First Gear Powerflow
1555
Second Gear Powerflow
1556
Fluid
1557
Fluid Description
1557
Direct Drive Powerflow
1557
Fluid Operation
1558
Torque Converter Description
1558
Fluid Additives
1558
Torque Converter Assembly
1558
Impeller
1559
Turbine
1559
Stator
1560
Stator Components
1560
Torque Converter Operation
1561
Torque Converter Clutch (TCC)
1561
Stator Location
1561
Oil Pump Description
1562
Torque Converter Fluid Operation
1562
Stator Operation
1562
Oil Pump Operation
1563
Valve Body Description and Operation
1563
Regulator Valve
1564
Valve Body Assembly
1564
Regulator Valve in Park Position
1565
Regulator Valve in Neutral Position
1566
Regulator Valve in Drive Position
1567
Regulator Valve in Reverse Position
1567
Kickdown Valve
1568
Kickdown Limit Valve
1568
Kickdown Limit Valve-Low Speeds
1569
Kickdown Limit Valve-High Speeds
1569
1–2 Shift Valve
1570
1–2 Shift Valve-Before Shift
1570
1–2 Shift Control Valve
1571
1–2 Shift Valve-After Shift
1571
Shuttle Valve
1572
2–3 Shift Valve
1572
Throttle Valve
1573
2–3 Shift Valve-Before Shift
1573
2–3 Shift Valve-After Shift
1574
Switch Valve
1575
Converter Clutch Control Valve
1575
Fail-Safe Valve
1575
Switch Valve-Torque Converter Unlocked
1576
Switch Valve-Torque Converter Locked
1577
Accumulator Description and Operation
1578
Manual Valve
1578
Accumulator
1578
Pistons Description and Operation
1579
Pressure
1579
Pressure on a Confined Fluid
1579
Accumulator in Neutral and Drive Positions
1579
Force Multiplication
1580
Piston Travel
1580
Front Clutch Description and Operation
1581
Rear Clutch Description and Operation
1582
Overrunning Clutch Description and Operation
1583
Planetary Gearset Description and Operation
1583
Bands Description and Operation
1584
Servos Description and Operation
1584
Kickdown Front Band
1584
Low/Reverse Rear Band
1584
Governor Description and Operation
1585
Gearshift Mechanism Description and Operation
1585
Low/Reverse Rear Servo
1585
Front Servo
1585
Converter Drainback Valve Description and Operation
1586
Brake Transmission Shift Interlock Mechanism Description and Operation
1586
Governor
1586
Automatic Transmission Diagnosis
1587
Effects on Incorrect Fluid Level
1587
Causes of Burnt Fluid
1587
Governor—No Output Shaft Rotation
1587
Diagnosis and Testing
1587
Fluid Contamination
1588
Ignition Interlock Cable Routing
1588
Ignition Key Cylinder Actuation
1588
Park/Neutral Position Switch
1589
Vehicle Is Drivable/Disabled
1589
Switch Test
1589
Gearshift Cable
1589
Preliminary Diagnosis
1589
Throttle Valve Cable
1590
Analyzing Road Test
1590
Hydraulic Pressure Test
1590
Clutch and Band Application
1590
Road Testing
1590
Pressure Test Procedure
1591
Pressure Test Port Locations
1591
Pressure Test Ports at Side of Case
1591
Pressure Test Ports at Rear of Case—2Wd
1591
Air Testing Transmission Clutch and Band Operation
1592
Pressure Test Analysis
1592
Converter Housing Fluid Leak Diagnosis
1593
Torque Converter Leak Points
1593
Front and Rear Clutch Air Test
1593
Front and Rear Servo Apply Air Test
1593
Converter Housing Area Leak Connection
1594
Diagnosis Chart
1594
Converter Leak Points—Typical
1594
Fluid Level Check
1602
Fluid Level Check Procedure
1602
Fluid and Filter Replacement
1602
Dipstick Fluid Level Marks—Typical
1602
Service Procedures
1602
Transmission Fill Procedure
1603
Converter Drainback Check Valve Service
1603
Oil Pump Volume Check
1603
Transmission Filter–Typical
1603
Flushing Coolers and Tubes
1604
Cooler Flush Using Tool 6906A
1604
Aluminium Thread Repair
1605
Crankshaft Position Sensor—2.5L Engine
1605
Removal and Installation
1605
Transmission
1605
Aluminium Thread Installation
1606
Typical Method of Checking Converter Seating
1606
Torque Converter Removal and Installation
1607
Transmission Attachment
1607
Yoke Seal Replacement Removal and Installation
1608
Extension Housing Bushing Removal and Installation
1608
Adapter Housing Removal
1608
Checking Torque Converter Seating
1608
Adapter Housing Installation
1609
Speedometer Adapter Removal and Installation
1609
Bushing Removal—Typical
1609
Extension Housing Seal Installation
1609
Park/Neutral Position Switch Removal
1610
Speedometer Pinion Adapter Components
1610
Index Numbers on Speedometer Pinion Adapter
1610
Park/Neutral Position Switch Installation
1611
Gearshift Cable Removal and Installation
1611
Brake Transmission Shift Interlock Removal
1611
Brake/Park Interlock Cable
1611
Brake Transmission Shift Interlock Installation
1612
Valve Body Removal
1612
Cable and Shifter
1612
Valve Body Installation
1613
Solenoid Wire Connector
1613
Accumulator Piston and Springs
1613
Valve Body
1613
Output Shaft Rear Bearing Removal and Installation
1614
Governor and Park Gear Removal
1614
Output Shaft Rear Bearing—Typical
1614
Governor Valve
1614
Governor and Park Gear Installation
1615
Park Lock Removal and Installation
1615
Governor and Park Gear Disassembly
1615
Governor Body
1615
Disassembly and Assembly
1615
Governor and Park Gear Assembly
1616
Park Lock
1616
Governor Filter
1616
Snap Ring, Washer, and Outer Weight
1616
Valve Body Disassembly
1617
Intermediate and Inner Governor Weights
1617
Adjusting Screw Bracket, Springs, Valve Removal
1618
Securing Detent Ball and Spring with Retainer Tool
1618
Manual and Throttle Levers
1618
Park Rod
1619
Converter Clutch Solenoid
1619
Clutch Module and Connecting Tube
1619
Converter Clutch and Fail Safe Valves
1619
Transfer and Separator Plates
1620
Rear Servo and Rear Clutch Check Balls
1620
Shuttle Valve End Plate
1620
Shuttle Valve E-Clip and Secondary Spring
1620
Control Valves, Shift Valves, and Governor Plugs
1621
Correct Position of Valve Body Check Balls
1623
Converter Clutch Valve Module
1623
Valve Body Transfer Plate Screws
1624
Transmission
1624
Manual Valve and Throttle Lever Alignment
1625
Adjusting Screw Bracket, Springs, and Valves
1625
Repair Stand
1626
Accumulator Piston and Spring
1626
Front Band Adjusting Screw Lock Nut
1626
Oil Pump/Reaction Shaft Support
1626
Front Band Strut
1627
Front/Rear Clutch Assemblies
1627
Separating Front Clutch from Rear Clutch
1627
Output Shaft Thrust Plate and Washer
1627
Front Band
1628
Planetary Geartrain
1628
Rear Band Adjuster Location
1628
Low-Reverse Drum Snap Ring
1628
Rear Support
1629
Overrunning Clutch Cam Bolt Locations
1629
Rear Band and Link
1629
Front Band Reaction Pin Access Plug
1629
Front Band Reaction Pin
1630
Front Band Lever
1630
Rear Band Servo Lever Pin
1630
Compressing Front Servo
1630
Compressing Rear Servo Spring
1631
Clutch Cam Alignment
1631
Output Shaft and Planetary Geartrain
1632
Input Shaft Seal Ring Location
1632
Front and Rear Clutches
1632
Output Shaft Thrust Plate
1633
Assembling Front and Rear Clutch Units
1633
Output Shaft Thrust Washer
1633
Aligning Rear Clutch Disc Lugs
1633
Installing Front/Rear Clutch
1634
Front Band Linkage Installation
1634
Reaction Shaft Support Seal Rings
1634
Front Clutch Thrust Washer Installation
1635
Installing Pilot Studs and Oil Pump Gasket
1635
Installing Oil Pump and Reaction Shaft Support
1635
Overrunning Clutch/Low-Reverse Drum Disassembly and Assembly
1636
Checking Input Shaft End Play
1636
Removing Overrunning Clutch from Low-Reverse Drum
1636
Overrunning Clutch Rollers, Springs, Retainer
1636
Front Servo Piston Disassembly and Assembly
1637
Temporary Assembly of Clutch and Drum to Check Operation
1637
Assembled Overrunning Clutch
1637
Rear Servo Piston Disassembly and Assembly
1638
Oil Pump and Reaction Shaft Support Disassembly
1638
Rear Servo Components
1638
Removing Pump Seal Ring
1638
Oil Pump Bushing Replacement
1639
Reaction Shaft Support Bushing Removal
1639
Pump Gear Removal
1639
Support Hub Thrust Washer
1639
Oil Pump and Reaction Shaft Support Assembly
1640
Replacing Reaction Shaft Support Bushing
1640
Supporting Pump and Installing Outer Gear
1640
Pump Inner Gear Installation
1640
Front Clutch Disassembly and Assembly
1641
Hub Seal Ring Position
1641
Assembling Reaction Shaft Support and Pump Housing
1641
Pump Oil Seal Installation
1641
Rear Clutch Disassembly
1642
Front Clutch Components
1642
Compressing Front Clutch Piston Spring
1643
Front Clutch Piston Installation
1643
Clutch Piston Spring Installation
1643
Correct Spring Retainer Installed Position
1643
Rear Clutch Assembly
1644
Rear Clutch Components
1644
Removing/Installing Input Shaft Snap-Ring
1645
Rear Clutch Retainer and Input Shaft Seal Ring Installation
1645
Input Shaft Seal Ring Identification
1645
Pressing Input Shaft into Rear Clutch Retainer
1645
Planetary Geartrain/Output Shaft Disassembly
1646
Piston Spring/Wave Spring Position
1646
Checking Rear Clutch Pack Clearance
1646
Installing Rear Clutch Thrust Washer
1646
Planetary Geartrain/Output Shaft Assembly
1647
Front Annulus and Planetary Assembly Removal
1647
Front Planetary Snap Ring Removal
1647
Front Planetary and Annulus Gear Disassembly
1647
Assembling Rear Annulus and Planetary Gear
1648
Installing Rear Annulus and Planetary on Output Shaft
1648
Installing Rear Planetary Front Thrust Washer
1648
Installing Spacer on Sun Gear
1648
Installing Driving Shell Front Thrust Plate on Sun Gear
1649
Installing Driving Shell Rear Thrust Plate
1649
Supporting Sun Gear on Wood Block
1649
Installing Sun Gear Lock Ring
1649
Installing Assembled Sun Gear and Driving Shell on Output Shaft
1650
Installing Rear Thrust Washer on Front Planetary Gear
1650
Installing Front Planetary and Annulus Gears
1650
Positioning Thrust Plate on Front Annulus Support
1650
Installing Front Annulus Thrust Washer
1651
Installing Front Annulus Snap Ring
1651
Installing Planetary Selective Snap Ring
1651
Checking Planetary Geartrain End Play
1651
Governor and Park Gear Cleaning and Inspection
1652
Extension Housing and Park Lock Cleaning and Inspection
1652
Valve Body Cleaning and Inspection
1652
Governor Weights
1652
Governor Components
1653
Park Sprag, Shaft and Spring
1654
Park Sprag Reaction Plug and Spring Location
1654
Correct Position of Sprag and Spring
1654
Transmission Cleaning and Inspection
1655
Valve Body Components
1655
Overrunning Clutch/Low-Reverse Drum/Override Piston Retainer Cleaning and Inspection
1656
Front and Rear Servo Cleaning and Inspection
1656
Oil Pump and Reaction Shaft Support Cleanig and Inspection
1656
Front and Rear Clutch Cleaning and Inspection
1657
Front Clutch Piston Retainer Check Ball Location
1657
Planetary Geartrain/Output Shaft Cleaning and Inspection
1658
Gearshift Cable Adjustments
1658
Gearshift Adjustment Procedure
1658
Retainer Bushing Location/Inspection
1658
Brake Transmission Shift Interlock Cable Adjustment
1659
Transmission Throttle Valve Cable Adjustment
1659
Checking Throttle Valve Cable Adjustment
1659
Shift Cable Attachment at Transmission–Typical
1659
Front Band Adjustment
1660
Throttle Valve Cable Adjustment Procedure
1660
Throttle Cable Attachment at Engine
1660
Throttle Cable Attachment at Transmission
1660
Rear Band Adjustment
1661
Valve Body Adjustments
1661
Control Pressure Adjustments
1661
Line Pressure Adjustment
1661
Throttle Pressure Adjustment
1662
Schematics and Diagrams
1662
Hydraulic Schematics
1662
Schematics and Diagrams
1663
Hydraulic Schematics
1663
Hydraulic Flow in Park/Neutral
1663
Hydraulic Flow in D-First Gear
1664
Hydraulic Flow in D-Second Gear
1665
Hydraulic Flow in D-Third Gear
1666
Hydraulic Flow in D-Third Gear (Converter Clutch Applied)
1667
Hydraulic Flow at Part Throttle 3-2 Kickdown
1668
Hydraulic Flow at Full Throttle 3-2 Kickdown
1669
Hydraulic Flow in Manual Second
1670
Hydraulic Flow in Manual Low
1671
Hydraulic Flow in Reverse
1672
30H Automatic Transmission Specifications
1673
30Rh Automatic Transmission
1673
30H Automatic Torque
1674
30H Automatic Special Tools
1674
30Rh Transmissions
1674
AW-4 Automatic Transmission Table of Contents
1678
AW-4 Automatic Transmission Desription and Operation
1679
Electronic Controls
1679
Geartrain Operation and Application Charts
1679
Description and Operation
1679
Component Function Chart
1680
Component Application Chart
1680
First/Second/Third/Reverse Gear Components
1681
Fourth Gear Override Components
1681
Fluid
1681
Torque Converter
1683
Oil Pump Description and Operation
1688
Transmission Valve Body Components Description
1689
Transmission Valve Body Solenoids
1689
Two–Section Transmission Valve Body
1689
Upper Body Components
1689
Transmission Valve Body Components Operation
1690
Lower Body Components
1690
Primary Regulator Valve
1691
Throttle Valve and Downshift Plug
1691
Cut-Back Valve
1691
Secondary Regulator Valve
1691
Converter Clutch Relay Valve
1692
2-3 Shift Valve
1692
Second Coast Modulator Valve
1694
Low Coast Modulator Valve
1694
Pistons Description
1695
Accumulator Control Valve
1695
Accumulators
1695
Pistons Operation
1696
Pistons Pressure
1696
Force and Pressure Relationship
1696
Transmission Ranges and Shift Lever Positions
1697
Transmission Control Module (TCM) Description and Operation
1698
Hydraulic System Description
1698
Transmission Cooler Description
1698
Sensor
1698
Cooler Service
1699
Auxiliary Cooler Mounting (Left Hand Drive)
1699
Brake Transmission Shift Interlock Mechanism
1699
General Diagnosis Information
1700
Effects of Incorrect Fluid Level
1700
Diagnosis and Testing
1700
Preliminary Diagnosis Check Procedure
1701
Causes of Burnt Fluid
1701
Fluid Contamination
1701
Preliminary Inspection and Adjustment
1702
Manual Shifting Test
1702
Hydraulic Pressure Test
1702
Time Lag Test
1703
Test Procedure
1703
Pressure Test Gauge Connection
1703
Pressure Test Analysis
1703
Time Lag Test Analysis
1704
Service Diagnosis Table
1704
Transmission Solenoid Testing
1706
Switch Testing
1706
Testing Transmission Valve Body Solenoid
1706
Park/Neutral Position Switch
1706
Speed Sensor Testing
1707
Flow Testing Transmission Main Cooler
1707
Gearshift Cable
1707
Throttle Valve Cable
1707
Torque Converter Stator Clutch Inspection
1708
Checking Fluid Level
1708
Checking Operation of Torque Converter Stator One–Way Clutch
1708
Service Procedures
1708
Checking Fluid Condition
1709
Refilling after Overhaul or Fluid/ Filter Change
1709
Transmission Control Module (Tcm) Service
1709
Oil Pump Volume Check
1709
Flushing Coolers and Tubes
1709
Aluminum Thread Repair
1710
Transmission and Torque Converter Removal
1711
Transmission Fill Tube (Two–Piece)
1711
Crankshaft Position Sensor
1711
Removal and Installation
1711
Transmission and Torque Converter Installation
1712
Transmission Mounting
1712
Speed Sensor Removal
1713
Torque Converter
1713
Adapter Housing Seal
1713
Speed Sensor Installation
1714
Adapter Housing Seals
1714
Transmission Speed Sensor Removal/Installation
1714
Speedometer Adapter
1714
Speed Sensor Rotor-Speedometer Drive Gear Removal
1715
Speed Sensor Rotor-Speedometer Drive Gear Installation
1716
Removing/Installation Speedometer Drive Gear
1716
Removing Speed Sensor Rotor
1716
Park/Neutral Position Switch Removal/Installation
1716
Gerashift Cable Removal and Installation
1717
Park/Neutral Position Switch Adjustment
1717
Brake Transmission Shift Interlock
1717
Transmission Valve Body Solenoids Removal and Installation
1719
Oil Screen Removal/Installation
1719
Solenoid Wire Connectors
1719
Transmission Valve Body Removal and Installation
1720
Removing Transmission Valve Body Oil Tubes
1720
Removing/Installing Throttle Cable
1720
Transmission Control Module
1721
Transmission Valve Body Bolt Locations
1721
Accumulator Springs
1721
Removing/Installing Check Ball and Spring
1721
Solenoid Harness Adapter Seal Removal
1722
Installing Transmission Valve Body Oil Tubes
1722
TCM Location (Left/Right Hand Drive)
1722
Harness Adapter Removal/Installation
1722
Solenoid Harness Adapter Seal Installation
1723
Manual Valve Shaft Seal Removal
1723
Removing/Installing Park Rod Bracket
1723
Removing/Installing Park Rod
1723
Manual Valve Shaft Seal Installation
1724
Cutting Spacer Sleeve
1724
Installing Spacer Sleeve on Sector
1724
Accumulator Pistons and Springs Removal and Installation
1725
Installing Park Rod Bracket
1725
Small Cushion Spring Retention
1725
Second Coast Brake Servo Removal
1726
Accumulator Pistons, Springs and Spacers
1726
Removing/Installing Servo Piston Cover Snap Ring
1726
Removing Servo Cover and Piston
1726
Second Coast Brake Servo Installation
1727
Park Rod and Pawl Removal
1727
Second Coast Brake Servo Components
1727
Park Rod and Pawl Installation
1728
Transmission Throttle Cable Removal
1728
Transmission Throttle Cable Attachment
1728
Removing/Installing Park Pawl, Pin and Spring
1728
Transmission Throttle Cable Installation
1729
Oil Pump Seal Removal and Installation
1729
Typical Harness and Cable Clamp Attachment
1730
Converter Housing Removal
1730
Removing Oil Screen
1730
Disassembly and Assembly
1730
Transmission
1730
Valve Body Oil Tube Removal
1731
Solenoid Wire Location
1731
Removing Bracket and Harness
1731
Valve Body Bolt Locations
1731
Disconnecting Throttle Cable
1732
Removing Accumulator Springs, Spacers and Check Ball
1732
Accumulator Piston Removal
1732
Oil Pump Race Removal
1733
Removing Overdrive Planetary and Clutch Assembly
1733
Fourth Gear Planetary Race Removal
1733
Removing Bearing, Race and Planetary Ring Gear
1734
Removing Overdrive Brake Pack Snap Ring
1734
Overdrive Support Bearing/Race Removal
1734
Overdrive Support Snap Ring Removal/Installation
1735
Overdrive Support Bolt Removal
1735
Removing Overdrive Support
1735
Remove Overdrive Support Race
1735
Second Coast Brake Piston Components
1736
Removing Direct and
1736
Bearing and Race Removal from Clutch Hub
1736
Second Coast Brake Band Removal
1736
Front Planetary Ring Gear Removal
1737
Removing Ring Gear Bearing and Rear Race
1737
Removing Planetary Snap Ring and Gear
1737
Removing Sun Gear, Input Drum and One–Way Clutch
1738
Checking Second Brake Clutch Pack Clearance
1738
Removing Second Brake Clutch Pack Snap Ring
1738
Removing/Measuring Second Brake Clutch Disc Thickness
1738
Removing Park Rod and Bracket
1739
Removing Park Pawl, Pin and Spring
1739
Checking First–Reverse Brake Clutch Pack Clearance
1739
Removing Second Brake Piston Sleeve
1740
Removing Rear Planetary, Second Brake Drum and Output Shaft
1740
Removing/Installing Bearing and Race Assembly
1740
Checking Rear Bushing Inside Diameter
1740
Checking First–Reverse Brake Piston Operation
1741
Removing/Installing Piston Snap Ring
1741
Removing/Installing Reaction Sleeve
1741
Removing/Installing First–Reverse Brake No.1 Piston
1741
Thrust Bearing Chart
1742
Installing Thrust Bearing and No. 10 Race
1743
Aligning Second Brake Drum and Clutch Pack Teeth
1743
Output Shaft/Rear Planetary Assembly and Installation
1743
Planetary Snap Ring Installation
1743
Checking First–Reverse Brake Pack Clearance
1744
Second Brake Piston Sleeve Installation
1744
Park Lock Pin, Spring and Pawl Installation
1744
Park Lock Rod Installation
1744
Park Rod Bracket Installation
1745
Checking Park Pawl Engagement
1745
Installing No. 1 One–Way Clutch
1745
Second Brake Pack Installation
1745
Checking Second Brake Pack Clearance
1746
Installing Sun Gear and Input Drum
1746
Installing Front Planetary Gear
1746
Supporting Output Shaft
1746
Installing Front Planetary Snap Ring
1747
Installing Second Coast Brake Band
1747
Installing Second Coast Brake Band Retaining Pin
1747
Installing Forward–Direct Clutch Thrust Bearing and Race
1748
Installing Planetary Ring Gear Race
1748
Aligning Forward–Direct Clutch Splines
1748
Installing Front Planetary Ring Gear
1748
Installing Ring Gear Bearing and Race
1749
Installing Front Planetary and Forward–Direct Clutch Assembly
1749
Checking Input Drum–To–Direct Clutch Drum Clearance
1749
Assembling Second Coast Brake Piston
1749
Installing Second Coast Brake Piston Snap Ring
1750
Marking Brake Piston Rod
1750
Checking Second Coast Brake Piston Stroke
1750
Installing Overdrive Support Thrust Race and Washer
1751
Installing Overdrive Support
1751
Installing Overdrive Support Snap Ring
1751
Installing Overdrive Support Bolts
1751
Checking Output Shaft End Play
1752
Installing Overdrive Brake Clutch Pack
1752
Installing Overdrive Brake Snap Ring
1752
Installing Overdrive Support Thrust Bearing and Races
1753
Installing Overdrive Planetary Ring Gear
1753
Installing Ring Gear Thrust Bearing and Race
1753
Installing Planetary Thrust Race
1753
Installing Overdrive Planetary and Clutch Assembly
1754
Installing Input Shaft Thrust Bearing and Race Assembly
1754
Installing Oil Pump Thrust Race
1754
Installing Transmission Throttle Cable
1754
Clutch and Brake Feed Hole Locations
1755
Accumulator Piston and Spring Installation
1755
Installing Check Ball Body and Spring
1755
Aligning Manual Valve, Shift Sector and Detent Spring
1756
Connecting Transmission Throttle Cable
1756
Connecting Valve Body Solenoid Wires
1756
Installing Valve Body Oil Tubes
1756
Installing Transmission Speed Sensor Rotor and Key
1757
Installing Spacer and Speedometer Drive Gear
1757
Applying Sealer to Case Rear Flange
1757
Installing Transmission Speed Sensor
1757
Installing Converter Housing
1758
Park/Neutral Position Switch Installation/Adjustment
1758
Installing Cable/Harness Clamps
1758
Oil Pump Disassembly
1759
Checking Converter Installation
1759
Oil Pump Components
1759
Checking Pump/Stator Shaft Bushings
1760
Checking Pump Gear Clearances
1760
Installing Pump Seal
1761
Checking Pump Gear Rotation
1761
Overdrive Planetary Gear and Clutch Disassembly
1762
Overdrive Planetary Gear and Clutch Components
1762
Checking One–Way Clutch
1763
Removing Overdrive Clutch from Gear
1763
Assembling Converter, Pump and Clutch for Test
1763
Removing Clutch Drum Bearing and Race
1764
Removing Clutch Pack Snap Ring
1764
Removing Clutch Piston Snap Ring
1764
Removing Overdrive Clutch Piston
1764
Checking Piston Return Spring Length
1765
Testing Clutch Piston Check Ball
1765
Checking Clutch Drum Bushings
1765
Removing Ring Gear Bearing and Race
1765
Removing Ring Gear Hub
1766
Remove Planetary Gear Race
1766
Removing Snap Ring and Retaining Plate
1766
Removing One–Way Clutch
1767
Removing Planetary Thrust Washer
1767
Checking Planetary Bushing
1767
Overdrive Planetary Gear and Clutch Assembly
1768
Install Planetary Thrust Washer
1768
Assembling One–Way Clutch and Race
1768
Install Ring Gear Bearing and Race
1768
Installing Piston Return Springs
1769
Installing Clutch Piston Snap Ring
1769
Installing Overdrive Clutch Discs and Plates
1769
Installing Retainer and Snap Ring
1769
Overdrive Support Disassembly
1770
Installing Clutch Drum Bearing and Race Assembly
1770
Checking Brake Piston Movement
1770
Removing Support Thrust Bearing and Races
1770
Overdrive Support Assembly
1771
Removing Clutch Drum Thrust Washer and Race
1771
Overdrive Support Components
1772
Removing Support Seal Rings
1772
Direct Clutch Disassembly
1773
Installing Support Seal Rings
1773
Installing Support Thrust Bearing and Races
1773
Separate Direct Clutch from Forward Clutch
1773
Mount Direct Clutch on Overdrive Support
1774
Checking Direct Clutch Piston Stroke Length
1774
Removing Piston Return Spring
1775
Removing Direct Clutch Piston
1775
Testing Piston Check Ball Seating
1775
Direct Clutch Assembly
1776
Direct Clutch Components
1776
Installing Direct Clutch Discs and Plates
1777
Install Clutch Pack Retainer
1777
Adjusting Clutch Pack Snap Ring Position
1777
Checking Direct Clutch Assembled Height
1777
Forward Clutch Disassembly
1778
Forward Clutch Components
1778
Positioning Drum and Support on Wood Blocks
1779
Removing Retainer and Clutch Pack
1779
Removing Cushion Plate
1779
Removing Forward Clutch Piston
1780
Removing/Installing Clutch Drum O–Ring
1780
Removing Clutch Drum Seal Rings
1780
Removing Clutch Drum Thrust Bearing Assembly
1780
Forward Clutch Assembly
1781
Measuring Clutch Disc Thickness
1781
Checking Return Spring Length
1781
Testing Piston Check Ball
1781
Installing Thrust Bearing and Race
1782
Installing Clutch Drum Shaft Seal Rings
1782
Installing Forward Clutch Discs and Plates
1782
Front Planetary Gear Disassembly
1783
Checking Forward Clutch Assembled Height
1783
Front Planetary Gear Components
1783
Front Planetary Gear Assembly
1784
Front Planetary Rear Bearing and Race Installation
1784
Front Planetary Thrust Race Installation
1784
Front Planetary Front Bearing and Races Installation
1784
Sun Gear and One–Way Clutch Disassembly
1785
Sun Gear and One–Way Clutch Components
1785
Checking One–Way Clutch Operation
1785
Removing/Installing Brake Hub and Clutch Assembly
1785
Sun Gear and No. 1 One-Way Clutch
1785
Removing/Installing Thrust Washer
1786
Removing/Installing Sun Gear Seal Rings
1786
Removing/Installing Sun Gear
1786
Removing/Installing Second Snap Ring
1786
Sun Gear and One–Way Clutch Assembly
1787
Checking Sun Gear Bushings
1787
Installing Clutch and Hub Assembly on Sun Gear
1787
Second Brake Components
1787
Second Brake Disassembly
1788
Removing/Installing Second Brake Assembly
1788
Removing/Installing Second Brake Drum Thrust Washer
1788
Removing/Installing Second Brake Piston Snap Ring
1788
Second Brake Assembly
1789
Removing/Installing Piston and Sleeve
1789
Measuring Second Brake Piston Return Springs
1789
Checking Second Brake Piston Operation
1789
Planetary, Brake Pack, Output Shaft
1790
Rear Planetary, Brake Pack, Output Shaft Components
1790
Planetary, Brake Pack, Output Shaft Disassembly
1791
Removing/Installing Output Shaft
1791
Removing/Installing Shaft Seal Ring
1791
Removing/Installing First–Reverse Brake Pack
1791
Checking No. 2 One–Way Clutch Operation
1792
Removing/Installing Clutch Inner Race
1792
Removing/Installing One–Way Clutch
1792
Planetary, Brake Pack, Output Shaft Assembly
1793
Removing/Installing Rear Planetary Thrust Washers
1793
Removing/Installing Ring Gear Thrust Bearing and Races
1793
Removing/Installing Ring Gear Hub
1793
Transmission Valve Body
1794
Installing No. 2 One–Way Clutch
1794
Transmission Parts Cleaning and Inspection
1797
Gearshift Cable
1797
Brake Transmission Shift Interlock Cable Adjustment
1797
Park Lock Cable Attachment
1798
Throttle Cable Components
1798
Transmission Throttle Valve Cable Adjustment
1798
AW-4 Automatic Transmission Specifications
1799
AW-4 Clutch Disc and Plate Thickness
1799
AW-4 Bushing and Piston Clearance
1800
AW-4 Retainer and Piston Specifications
1801
AW-4 Valve Body Ball Dimensions
1802
AW-4 Valve Valve and Spring Identification
1803
AW-4 Torque Specifications
1804
AW-4 Special Tools
1805
NV231 Transfer Case Table of Contents
1807
NV231 Transfer Case Description and Operation
1807
Operating Ranges
1807
Shift Mechanism
1807
Lubricant and Fill Level Description
1808
NV231 Diagnosis Chart
1808
Fill/Drain Plug Locations
1808
Nv231 Transfer Case
1808
Diagnosis and Testing
1808
Transfer Case Removal and Installation
1809
Transfer Case Mounting
1809
Shift Lever Removal and Installation
1810
Shift Linkage
1810
Speedometer Removal, Installation and Indexing
1811
Front Output Shaft Seal Removal
1811
Speedometer Components
1811
Nv231 Transfer Case
1811
Front Output Shaft Seal Installation
1812
NV231 Transfer Case Disassembly
1812
Location of Index Numbers on Speedometer Adapter
1812
Remove Front Output Shaft Seal
1812
Rear Slinger Removal
1813
Rear Retainer Seal
1813
Output Shaft Rear Bearing Retaining Ring
1813
Rear Retainer Removal
1813
Yoke and Range Lever Removal
1814
Pick-Up Tube O-Ring Location
1814
Yoke Nut Removal
1814
Front Output Shaft and Drive Chain Removal
1815
Rear Case Alignment Bolt Locations
1815
Loosening Rear Case
1815
Oil Pickup Tube Removal
1815
Shift Forks and Manshaft Removal
1816
Remove Front Output Shaft and Chain
1816
Detent Plug, Spring and Plunger Removal
1816
Mode Fork and Sleeve Removal
1816
Mainshaft Disassembly
1817
Shift Sector Removal
1817
Sector Bushing and O-Ring Removal
1817
Mode Hub Retaining Ring Removal
1817
Input Gear and Low Range Gear Removal
1818
Drive Sprocket Removal
1818
Front Bearing Retainer Bolts
1818
Front Bearing Retainer Removal
1818
Input and Low Range Gear Disassembly
1819
Input Gear and Planetary Carrier Removal
1819
Input Gear Snap-Ring Removal
1819
Input Gear Retainer Removal
1819
NV231 Transfer Case Assembly
1820
Input Gear Removal
1820
Rear Tabbed Thrust Washer Removal
1820
Front Output Seal Removal
1820
Front Output Shaft Bearing Removal and Installation
1821
Installing Output Shaft Front Bearing Retaining Ring
1821
Front Output Seal Installation
1821
Output Shaft Rear Bearing Installation Depth
1822
Input Shaft Bearing Removal
1822
Seating Input Shaft Bearing
1823
Remove Input Gear Pilot Bearing
1823
Install Input Gear Pilot Bearing
1823
Input and Low Range Gear Assembly and Installation
1824
Oil Pump Seal Installation
1824
Installing Rear Bearing in Retainer
1824
Input/Low Range Gear Components
1824
Mainshaft Assembly
1825
Shift Forks and Mainnshaft Installation
1825
Input/Low Range Gear Installation
1825
Install Snap-Ring
1825
Front Output Shaft and Drive Chain Installation
1826
Shift Sector Installation
1826
Range Lever Installation
1826
Install Range Fork and Hub Assembly
1826
Oil Pump and Rear Case Assembly/Installation
1827
Mode Fork and Sleeve Installation
1827
Shift Detent Components
1827
Installing Drive Chain and Front Output Shaft
1827
Yoke and Range Lever Installation
1828
Rear Retainer Installation
1828
Installing Case Magnet
1828
Pickup Tube O-Ring Position
1828
Output Shaft Yoke Installation
1829
Yoke Seal Washer Installation
1829
Output Shaft Seal and Protector
1829
Rear Seal Installation
1829
NV231 Transfer Case Cleaning and Inspection
1830
Mainshaft/Sprocket/Hub Inspection
1830
Input Gear and Planetary Carrier
1830
Slinger Boot Installation
1830
Shift Forks/Hubs/Sleeves
1831
Rear Retainer/Bearing/Seal/Slinger/Boot
1831
Input Gear and Carrier Components
1831
Shift Forks
1831
Rear Output Shaft/Yoke/Drive Chain
1832
Low Range Annulus Gear
1832
Front-Rear Cases and Front Retainer
1832
Rear Retainer Components
1832
Oil Pump/Oil Pickup
1833
Shift Linkage Adjustment
1833
Seal Contact Surface of Yoke Slinger
1833
NV231 Transfer Case Specifications
1834
NV231 Special Tools
1834
Torque
1834
NV242 Transfer Case Table of Contents
1836
NV242 Transfer Case Description
1836
NV242 Transfer Case Identification
1836
Fill/Drain Plug and I. D. Tag Locations
1836
NV242 Diagnosis Chart
1837
Description and Operation
1837
Nv242 Transfer Case
1837
Lubricant and Fill Level
1837
Diagnosis and Testing
1837
Shift Lever Removal
1838
Shift Lever Installation
1839
Speedometer Removal
1839
Speedometer Installation and Indexing
1840
Front Output Shaft Seal
1840
Nv242 Transfer Case
1840
Front Output Sahft Seal Installation
1841
NV242 Transfer Case Disassembly
1841
Output Boot—Typical
1841
Rear Seal Removal
1842
Rear Bearing I. D. Retaining Ring Removal
1842
Pickup Tube O-Ring Location
1842
Spline and Dowel Bolt Locations
1843
Loosening/Removing Rear Case
1843
Oil Pickup Screen, Hose and Tube Removal
1843
Shift Forks and Mainshaft Removal and Disassembly
1844
Range Lever Removal
1844
Drive Sprocket Snap-Ring Removal
1844
Drive Sprocket and Chain Removal
1844
Removing Front Output Shaft
1845
Detent Component Removal
1845
Shift Rail Removal
1845
Mode Fork and Mainshaft Removal
1845
Intermediate Clutch Shaft Snap-Ring Removal
1846
Clutch Shaft Thrust Ring Removal
1846
Intermediate Clutch Shaft Removal
1847
Differential Snap-Ring Removal
1847
Disengaging Low Range Fork
1847
Input Gear/Low Range Assembly Removal and Disassembly
1848
Low Range Fork and Hub Removal
1848
Shift Sector Position
1848
Input and Low Range Gear Assembly Removal
1849
Low Range Gear Snap-Ring Removal/Installation
1849
Low Range Gear Disassembly
1849
Differential Disassembly
1850
Inspecting Low Range Annulus Gear
1850
Separating Differential Case Halves
1850
Planet Gears and Thrust Washer Removal
1850
Bearing and Seal Installation
1851
Mainshaft and Sprocket Gear Removal
1851
Front Output Shaft Front Bearing Snap-Ring Removal
1851
Front Output Shaft Front Bearing Installation
1851
Install Front Output Shaft Seal
1852
Input Gear Bearing Removal
1852
Seating Input Gear Bearing
1852
Front Bearing Retainer Seal Installation
1853
Remove Front Output Shaft Rear Bearing
1853
Install Front Output Shaft Rear Bearing
1853
Differential Assembly
1854
Input Gear/Low Range Assembly
1854
Pickup Tube O-Ring Installation
1854
Installing Differential Sprocket Gear
1854
Installing Mainshaft and Planet Gears
1855
Differential Case Assembly
1855
Low Range and Input Gear Assembly
1855
Install Low Range Gear Snap Ring
1855
Input Gear Snap Ring Installation
1856
Installing Front Bearing Retainer
1856
Sector O-Ring and Bushing Installation
1856
Assembling Low Range Fork and Hub
1856
Positioning Low Range Fork
1857
Installing Mainshaft Bearing Rollers and Spacers
1857
Installing Differential Snap-Ring
1858
Installing Intermediate Clutch Shaft
1858
Installing Clutch Shaft Thrust Washer
1858
Installing Clutch Shaft Snap-Ring
1858
Mode Fork Assembly Inspection
1859
Installing Mode Fork and Sleeve
1859
Assembled Mainshaft and Mode Fork Installation
1860
Shift Rail Installation
1860
Installing Low Range Fork Lockpin
1860
Detent Pin, Spring and Plug Installation
1860
Oil Pump and Rear Case Installation
1861
Drive Chain and Sprocket Installation
1861
Drive Sprocket Snap-Ring Installation
1861
Oil Screen and Pickup Tube Installation
1861
Front Yoke and Switch Installation
1862
Rear Bearing Retaining Ring Installation
1862
NV242 Transfer Case Cleaning and Inspection
1863
Oil Pump/Oil Pickup Cleaning and Inspection
1866
NV242 Transfer Case Specifications
1866
Shift Linkage Adjustment
1866
NV242 Transfer Case Special Tools
1867
Transmission - 2.5L Turbo Diesel Engine Removal
1870
Drain Plug and Backup Light Switch Location
1870
Marking Propeller Shaft and Axle Yoke
1870
Transmission - 2.5L Turbo Diesel Engine Installation
1871
Vehicle Speed Sensor
1871
Engine Speed Sensor
1871
Transmission to Engine Mounting
1872
Transmission and Transfer Case Specifications
1873
Clutch Housing to Transmission
1873
Fill Plug Location
1873
Specifications Torque
1874
Tires and Wheels Table of Contents
1876
Tires Table of Contents
1876
Tires Desription
1876
Tire Identification
1876
Radial-Ply Tires Description
1877
Spare Tire- Temporary Description
1877
Tire Inflation Pressures
1877
Under/Over Inflation Wear
1877
Description and Operation
1877
Tire Pressure for High Speed Description
1878
Replacement Tires Description
1878
Pressure Gauges Diagnosis and Testing
1878
Tread Wear Indicators
1878
Description and Operation
1878
Wheels
1878
Tire Wear Patterns
1878
Tire Noise or Vibration
1878
Rotation
1879
Match Mounting
1879
Tire Wear Patterns
1879
Tire Rotation Pattern
1879
Service Procedures
1879
Repairing Leaks
1880
Dial Indicator
1880
First Measurement on Tire
1880
Remount Tire 180 Degrees
1880
Cleaning Tires
1881
Tires Specifications
1881
Remount Tire 90 Degrees in Direction of Arrow
1881
Tire Repair Area
1881
Cleaning and Inspection
1881
Tire Size
1881
Wheels Table of Contents
1882
Wheel Description
1882
Wheel Inspection
1882
Tire and Wheel Runout
1882
Vehicle Safety Certification Label
1882
Relocate Wheel on Hub
1883
Relocate Tire on Wheel
1883
Wheel Installation
1883
Radial Runout
1883
Wheel Replacement
1884
Tire and Wheel Balance
1884
Lateral Runout
1884
Lug Nut Tightening Pattern
1884
Static Unbalance and Balance
1885
Dynamic Unbalance and Balance
1885
Tires and Wheels Specifications
1886
Body Table of Contents
1888
Body Components
1888
Paint Description and Operation
1888
Stationary Glass Description and Operation
1888
Exterior Components Operation
1889
Safety Precautions Table of Contents
1890
Safety Precautions and Warnings Description
1890
Paint Table of Contents
1891
Paint Code
1891
Base Coat/Clear Coat Finish Description
1891
Finesse Sanding, Buffing and Polishing Description
1891
Vehicle Safety Certification Label
1891
Paint Specifications
1892
Vehicle Safety Certification Label
1892
Stationary Glass Table of Contents
1893
Windshield Safety Precautions Description and Operation
1893
Windshield Removal
1893
Windshield Installation - Short Method
1894
Cutting Urethane Around Windshield—Typical
1894
Windshield Installation - Extended Method
1895
Work Surface Set up
1895
Masking Tape Location for Blackout Primer
1895
Blackout Primer Application
1895
Rear Door Stationary Window Glass Removal
1896
Applicator Nozzle Preparation
1896
Rear Door Stationary Window Glass Installation
1897
Rear Quarter Window Glass Removal and Installation
1897
Division Bar/Stationary Glass
1897
Quarter Window Reveal Molding, Glass and Seal
1897
Liftgate Glass Removal and Installation
1898
Quarter Window with Vent
1898
Quarter Window Glass and Seal Installation
1898
Seats Table of Contents
1900
Head Restraint Sleeve Removal
1900
Head Restraint Sleeve Extractor
1900
Head Restraint Sleeve Installation
1901
Head Restraint Cover Removal and Installation
1901
Head Restraint Sleeve Extractor Installation
1901
Head Restraint Sleeve Extractor Positioning
1901
Bucket Seat Removal and Installation
1902
Bucket Seat Track Removal and Installation
1902
Bucket Seat Platform
1902
Head Restraint Cover
1902
Bucket Seatback Cover Removal and Installation
1903
Bucket Seatback Removal
1903
Seatback Cover
1903
Hog Ring
1903
Bucket Seatback Installation
1904
Bucket Seat Cushion Cover Removal and Installation
1904
Bucket Seat Recliner Removal and Installation
1904
Rear Seat Cushion Removal
1904
Rear Seat Cushion Installation
1905
Rear Seatback Removal and Installation
1905
Bucket Seat Recliner
1905
Seat Cushion Release Strap
1905
Rear Seat Cushion Cover Removal and Installation
1906
Rear Seatback Latch Striker and Bumper Removal and Installation
1906
Seat Cushion Cover Retaining Clip Removal
1906
Seatback Latch Striker Bracket
1906
Rear Seatback Cover Removal and Installation
1907
Seats Special Tools
1907
Body Component Service Table of Contents
1908
Water Leaks
1909
Visual Inspection before Water Leak Tests
1909
Water Leak Tests
1909
Water Leak Detection
1909
Wind Noise
1910
Visual Inspection before Tests
1910
Body Lubrication
1910
Bright Light Leak Test Method
1910
Grille Removal and Installation
1911
Grille Opening Panel Removal and Installation
1911
Hood Removal and Installation
1911
Hood Components
1912
Hood Hinge Removal and Installation
1913
Hood Latch Removal and Installation
1913
Hood Latch Striker Removal and Installation
1913
Hood Hinge and Seal
1913
Hood Release Cable Removal and Installation
1914
Hood Safety Latch Removal and Installation
1914
Safety Latch Striker Removal and Installation
1914
Hood Silencer Pad Removal
1914
Hood Silencer Pad Installation
1915
Cowl Weatherstrip Removal and Installation
1915
Cowl Grille Removal and Installation
1915
Hood Safety Latch Striker
1915
Body Decals
1916
Body Decals Removal and Installation
1916
Cowl Grille, Screen and Washer Nozzles
1916
Cowl Grille Screw Tightening Sequence
1916
Exterior Nameplates Removal and Installation
1917
Decal Alignment Reference Mark
1917
Side View Mirror Removal and Installation
1918
Front Fender Flare Removal and Installation
1918
Exterior Nameplates
1918
Front Wheelhouse Liner Removal and Installation
1919
Right/Left Front Fender Removal and Installation
1919
Front Door Trim Panel Removal and Installation
1920
Right Front Fender
1920
Inner Support Bracket
1920
Front Door Waterdam Removal and Installation
1921
Window Crank—Typical
1921
Front Door Trim Panel-Manual Window
1921
Front Door Trim Panel-Power Window
1921
Front Door Removal and Installation
1922
Front Door Hinge Removal and Installation
1922
Front Door Restraint Removal and Installation
1922
Front Door Outside Handle Removal
1922
Front Door Outside Handle Installation
1923
Front Door Lock Cylinder Removal and Installation
1923
Door Restraint (Check)
1923
Front Door Outside Handle
1923
Lock Cylinders Removal and Installation
1924
Front Door Latch Removal and Installation
1924
Front Door Latch Striker Removal and Installation
1924
Front Door Inside Handle Actuator Removal and Installation
1924
Front Door Inner Belt Weatherstrip Installation
1925
Front Door Outer Belt Weatherstrip Removal and Installation
1925
Front Door Glass Run Channel Weatherstrip Removal and Installation
1925
Front Door Opening Weatherstrip Removal
1925
Front Door Opening Weatherstrip Installation
1926
Front Door Opening Secondary Weatherstrip Removal and Installation
1926
Front Door Glass Exterior Molding Removal and Installation
1926
Front Door Window Regulator Removal
1926
Power Window Regulator
1927
Manual Window Regulator
1927
Front Door Regulator
1927
Front Door Spacer Block—Two-Door Vehicles Removal and Installation
1928
Front Door Glass Removal and Installation
1928
Rear Door Trim Panel Removal and Installation
1929
Rear Door Waterdam Removal and Installation
1929
Rear Door Removal and Installation
1930
Rear Door Restraint Removal and Installation
1930
Rear Door Hinge Removal
1930
Latch Rods
1930
Rear Door Hinge Installation
1931
Rear Door Outside Handle Removal and Installation
1931
Rear Door Latch Removal and Installation
1931
Latch Rod
1931
Rear Door Latch Striker Removal and Installation
1932
Rear Door Inside Handle Actuator Removal and Installation
1932
Rear Door Inner Belt Weatherstrip Removal and Installation
1932
Rear Door Outer Belt Weatherstrip Removal
1932
Rear Door Outer Belt Weatherstrip Installation
1933
Rear Door Glass Run Channel Weatherstrip Removal and Installation
1933
Rear Door Glass Run Channel Removal and Installation
1933
Rear Door Weatherstrip Removal
1933
Rear Door Glass Exterior Molding
1933
Rear Door Weatherstrip Installation
1934
Rear Door Window Regulator Removal and Installation
1934
Rear Door Window Glass Removal
1934
Door Opening Weatherstrip
1934
Rear Door Window Glass Installation
1935
Body Side Molding Removal and Installation
1935
Regulator to Glass Screw Removal/Installation
1935
Rear Door Window
1935
Rear Fender Flare Removal and Installation
1936
Quarter Window Applique Removal and Installation
1936
Drip Rail Molding Removal
1936
Drip Rail Molding Installation
1937
Luggage Rack Removal and Installation
1937
Air Exhaust Grille Removal and Installation
1937
A-Pillar Trim Removal and Installation
1938
Lower A-Pillar Cowl Trim Removal
1938
Trim Panels—2-Door Vehicles
1938
Lower A-Pillar Cowl Trim Installation
1939
Front Inner Scuff Plate Removal Ad Installation
1939
Door Sill Scuff Plate Removal and Installation
1939
Assist Handle Removal and Installation
1939
B-Pillar Trim
1939
B-Pillar Trim Installation
1940
C-Pillar Trim Removal and Installation
1940
B-Pillar Trim—4-Door Vehicles
1940
Quarter Panel Trim Extension Removal and Installation
1941
Quarter Panel Trim and Wheelhouse Cover Removal and Installation
1941
Spare Tire
1941
Liftgate Pillar Trim Removal and Installation
1942
Liftgate Opening Upper Trim Removal and Installation
1942
Liftgate Scuff Plate Removal and Installation
1942
Front Shoulder Belt/Buckle
1942
Front Shoulder Belt/Buckle Removal and Installation
1943
Anchor Bolt
1943
Front Shoulder Belt—2-Door Vehicles
1943
Rear Shoulder/Lap Belts/Buckle Removal and Installation
1944
Full Floor Console Removal
1944
Front Shoulder Belt—4-Door Vehicles
1944
Full Floor Console Installation
1945
Front Carpet/Mat Removal and Installation
1945
Rear Carpet/Mat Removal and Installation
1945
Rearview Mirror Removal and Installation
1946
Rearview Mirror Support Bracket Installation
1946
Wheelhouse Insulation
1946
Sunvisor Removal and Installation
1947
Sunvisor W/Vanity Lamp
1947
Headliner Trim Moldings
1947
Headliner Removal and Installation
1948
Liftgate Trim Panel Removal
1948
Upper Trim Molding—4-Door
1948
Headliner Retainer Clip and Retainer Rail
1948
Liftgate Trim Panel Installation
1949
Liftgate Hinge Removal
1949
Liftgate Hinge Installation
1950
Liftgate Support Rod Ball Stud Removal and Installation
1950
Liftgate Outside Handle Removal
1950
Liftgate Outside Handle Installation
1951
Liftgate Lock Cylinder
1951
Liftgate Latch Removal and Installation
1951
Liftgate Latch Striker Removal and Installation
1951
Liftgate Weatherstrip Installation and Removal
1952
Up and down - Minor Adjustment
1953
Alignment Major - Adjustment
1953
Door Latch Adjustment
1953
Hood Bumper
1953
Liftgate Adjustments
1954
Rear Seatback Adjustments
1954
Body Compoents Specifications
1954
Weld Locations
1955
Upper Cowl
1955
Cowl
1957
A-Pillar
1958
B-Pillar
1962
D-Pillar
1963
Fuel Filler Opening
1964
Cargo Area Floor Pan
1965
Roof and D-Pillar
1966
Liftgate Opening
1967
Roof
1968
Frame Rail
1970
Frame Rail
1971
Frame Rail
1972
Frame Rail
1973
Reinforcement
1974
Front Inner Fender
1975
Front Inner Fender and Radiator Closure Panel
1976
Front Fender
1978
Body Side
1979
Rear Wheelhouse
1980
Rear Inner Wheelhouse
1981
Underbody
1988
Body Sealing Locations
1999
Application Methods
1999
Cowl and Dash Panel
2000
Dash Panel and Floor Pan
2001
Floor Pan
2002
Front Inner Wheelhouse
2004
Roof Panel
2008
Fuel Filler Housing
2009
Structural Adhesive Locations
2011
Left Quarter Panel
2011
Roof Bows
2013
Body Gap and Flush Measurements
2014
Body Opening Dimensions
2015
Windshield Opening
2015
Front Door Opening 2-Door
2016
Front Door Opening 4-Door
2017
Rear Door Opening
2018
Quarter Window Opening 2-Door
2019
Quarter Window Opening 4-Door
2020
Body Components Torque Specifications
2022
Body Components Special Tools
2022
Heating and Air Conditioning Table of Contents
2024
Blower Motor Description and Operation
2025
Blower Motor Relay Description and Operation
2025
Accumulator - Typical
2025
Blower Motor Resistor Description and Operation
2026
Blower Motor Switch Description and Operation
2026
Compressor Description and Operation
2026
Compressor Clutch Description and Operation
2026
Compressor Clutch Relay Description and Operation
2027
Condenser Description and Operation
2027
Dual Function High Pressure Switch (4.0L) Description and Operation
2027
Evaporator Coil Description
2027
Evaporator Coil Operation
2028
Fixed Orifice Tube Description and Operation
2028
Heater and Air Conditioner Description
2028
Common Blend-Air Heater-Air Conditioner System - Typical
2028
Heater and Air Conditioner Operation
2029
Heater and Air Conditioner Control Description and Operation
2029
Heater Core Description and Operation
2029
High Pressure Cut-Off Switch Description and Operation
2029
High Pressure Relief Valve Description and Operation
2030
Low Pressure Cycling Clutch Switch Description and Operation
2030
Refrigerant Description and Operation
2030
Refrigerant Lines Description
2030
Refrigerant Lines Operation
2031
Refrigerant Line Couplers Description and Operation
2031
Refrigerant Oil Description and Operation
2031
Spring-Lock Coupler - Typical
2031
Refrigerant System Service Port Description and Operation
2032
Vacuum Check Valve Description and Operation
2032
A/C Performance
2032
Low Pressure Cycling Clutch Switch - Typical
2033
Performance Temperature and Pressure
2033
Blower Motor
2035
Blower Motor Relay
2036
Blower Motor Resistor
2037
Blower Motor Switch
2037
Compressor
2037
Compressor Clutch Coil
2038
Compressor Clutch Relay Test
2038
Dual Function High Pressure Switch/High Pressure Cut-Off Switch
2039
Heater Performance
2039
Maximum Heater Output
2039
Temperature Control
2040
Low Pressure Cycling Clutch Switch
2040
Refrigerant System Leaks
2040
System Empty
2040
System Low
2041
Vacuum System
2041
Vacuum Check Valve
2041
Heater - A/C Controls
2041
Locating Vacuum Leaks
2042
Refrigerant Oil Level Service Procedures
2042
Vacuum Circuit Test
2042
Vacuum Circuits - Heater Only
2043
Vacuum Circuits - Heater-A/C
2044
Refrigerant Recovery
2045
Refrigerant System Evacuate
2045
Refrigerant System Charge
2045
Refrigerant System Service Equipment
2045
Manifold Gauge Set Connections
2046
Cooling System Requirements
2047
Refrigerant Hoses/Lines/Tubes Precautions
2047
Accumulator Removal and Installation
2048
Blend-Air Door Motor Removal and Installation
2049
Blower Motor Removal and Installation
2049
Blower Motor Relay Remove/Install
2050
Compressor Removal and Installation
2051
Compressor Clutch Removal and Inspection
2052
Clutch Nut Remove
2052
Clutch Plate Remove
2052
External Snap Ring Remove
2052
Compressor Clutch Installation
2053
Shaft Protector and Puller
2053
Install Puller Plate
2053
Clutch Coil Lead Wire Harness
2053
Clutch Break-In
2054
Compressor Clutch Relay
2054
Clutch Pulley Install
2054
Clutch Plate Driver
2054
Condenser Removal and Installation
2055
Dual Function High Pressure Switch/High Pressure Cut-Off Switch Removal and Installation
2056
Ducts and Outlets
2056
Panel Outlet Ducts
2056
Panel Outlet Barrels
2056
Demister Hoses
2057
Demister Ducts
2057
Console Rear Duct
2057
Floor Duct and Adapter
2057
Evaporator Coil
2058
Fixed Orifice Tube
2058
Heater - A/C Control Removal
2058
Heater - A/C Control Installation
2059
Heater-A/C Housing Removall
2059
Heater-A/C Control Connections
2059
Heater-A/C Housing Disassembly
2060
Heater-A/C Unit Connector
2060
Heater-A/C Housing Assembly
2061
Heater-A/C Housing Installation
2061
Heater -A/C Housing Door
2062
Blend-Air Door
2062
Panel/Demist Door and Lever
2062
Mode Door Lever Remove/Install - Typical
2062
Defrost Door and Lever
2063
Floor Door and Lever
2063
Recirculation Air Door
2063
Heater Core
2064
Liquid Line Removal and Installation
2064
Low Pressure Cycling Clutch Switch Removal and Installation
2065
Kick Cover Removal
2065
Kick Cover Installation
2066
Mode Door Vacuum Actuator
2066
Defrost Door Actuator
2066
Floor Door Actuator
2066
Panel/Demist Door Actuator
2067
Recirculation Air Door Actuator
2067
Vacuum Actuator Remove/Install - Typical
2067
Refrigerant Line Coupler Removal and Installation
2068
Suction and Discharge Line
2068
Refrigerant Line Spring-Lock Coupler Disconnect
2068
Suction and Discharge Line Removal and Installation
2069
Heating and Air Conditioning Specifications
2070
Vacuum Supply
2070
Compressor - 2.5L VM Diesel Description and Operation
2074
Compressor Clutch - 2.5L VM Diesel Description and Operation
2074
Left-Hand Drive Removal and Installation
2075
Right-Hand Drive 2.5L Engine Removal and Installation
2076
Right-Hand Drive 4.0L Engine
2077
Compressor - 2.5L VM Diesel Removal
2077
Compressor Clutch - 2.5L VM Diesel Removal
2079
Compressor Clutch - 2.5L VM Diesel Inspection
2080
Clutch Field Coil Snap Ring Remove
2080
Check Clutch Air Gap
2081
Emission Control System Table of Contents
2082
On-Board Diagnostics Table of Contents
2082
Emission Control Operation
2082
Malfunction Indicator Lamp (MIL) Description and Operation
2083
Stay Display Test Mode Operation
2083
Circuit Actuation Test Mode Operation
2083
Diagnostic Trouble Codes Operation
2083
Diagnostic Trouble Code Descriptions
2084
Task Manager Description and Operation
2097
Test Sequence
2097
MIL Illumination
2097
Diagnostic Trouble Codes (Dtcs)
2097
DTC Self Erasure
2098
Trip Indicator
2098
Freeze Frame Data Storage
2099
Similar Conditions Window
2099
Monitored Systems Operation
2100
Oxygen Sensor (O2S) Monitor
2100
Oxygen Sensor Heater Monitor
2100
Leak Detection Pump Monitor
2100
Misfire Monitor
2101
Fuel System Monitor
2101
Catalysr Monitor
2101
Trip Definition Operation
2102
Component Monitors Operation
2102
Non-Monitored Circuits Operation
2103
High and Low Limits Operation
2103
Load Value Operation
2103
Evaporative Emission Controls Table of Contents
2104
Evaporative Control System Operation
2104
Rollover Valve Description and Operation
2104
Rollover Valve Location
2104
EVAP Canister Description and Operation
2105
Duty Cycle EVAP Canister Purge Solenoid Operation
2105
Leak Detection Pump Operation
2105
EVAP Canister Location
2105
Crankcase Ventilation System Description and Operation
2106
Evaporative System Monitor Schematic—Typical
2106
Vehicle Emission Control Information Label Description and Operation
2107
Vacuum Schematics
2107
CCV System—2.5/4.0L Engine—Typical
2107
VECI Label Location—Typical
2107
Leak Detection Pump
2108
Crankcase Ventilation System Testing/Cleaning
2108
EVAP Canister Removal and Installation
2108
Duty Cycle EVAP Canister Purge Solenoid Removal and Installation
2108
Leak Detection Pump Removal and Installation
2109
Evaporative Emission Controls Sspecifications
2109
On-Board Diagnostics - 2.5L Diesel Engine Table of Contents
2110
Emission Control System - 2.5L Diesel Engine Description
2110
ECM Monitored/Non-Monitored Systems
2110
High and Low Limits
2111
Diagnostic Troublw Codes Description
2111
Accessing Diagnostic Trouble Codes
2111
Erasing Trouble Codes
2111
MSA Controller DRBIII Codes
2112
PCM DRBIII Codes
2114
Exhaust Emission Controls - 2.5L Diesel Engine Table of Contents
2115
Vacuum Hose Routing Schematic Description
2115
Exhaust Gas Recirculation System Description and Operation
2115
Typical Hose Routing
2115
EGR Solenoid Test
2116
Vacuum Test
2116
EGR Valve Removal and Installation
2116
EGR Tube Removal and Installation
2116
Electric Vacuum Modulator (EVM) Removal and Installation
2117
Emission Control System Specifications
2117
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