Jeep KJ Service Manual - 2002

ABS - DESCRIPTION, BRAKES . . . . . . . . . . . 5-32
ABS - OPERATION, BRAKES . . . . . . . . . . . . . 5-32
ABS - SPECIFICATIONS, BRAKES . . . . . . . . . 5-33
ABS BRAKE BLEEDING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
ABS INDICATOR - DESCRIPTION . . . . . . . . . 8J -11
ABS INDICATOR - OPERATION . . . . . . . . . . 8J -11
A/C APPLICATION TABLE,
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 24-9
A/C COMPRESSOR CLUTCH -
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 24-14
A/C COMPRESSOR CLUTCH -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-14
A/C COMPRESSOR CLUTCH - REMOVAL . . 24-13
A/C COMPRESSOR CLUTCH BREAK-IN -
STANDARD PROCEDURE. . . . . . . . . . . . . . . 24-12
A/C COMPRESSOR CLUTCH COIL -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 24-12
A/C COMPRESSOR CLUTCH RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-15
A/C COMPRESSOR CLUTCH RELAY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-16
A/C COMPRESSOR CLUTCH RELAY -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-15
A/C COMPRESSOR CLUTCH RELAY -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-16
A/C COMPRESSOR NOISE - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 24-42
A/C CONDENSER - DESCRIPTION . . . . . . . . 24-45
A/C CONDENSER - INSTALLATION . . . . . . . 24-46
A/C CONDENSER - OPERATION . . . . . . . . . . . 24-45
A/C CONDENSER - REMOVAL . . . . . . . . . . . 24-45
A/C DISCHARGE LINE - INSTALLATION . . . 24-47
A/C DISCHARGE LINE - REMOVAL . . . . . . . 24-46
A/C EVAPORATOR - DESCRIPTION . . . . . . . 24-49
A/C EVAPORATOR - INSTALLATION . . . . . . 24-49
A/C EVAPORATOR - OPERATION . . . . . . . . . 24-49
A/C EVAPORATOR - REMOVAL . . . . . . . . . . 24-49
A/C HEATER CONTROL - DESCRIPTION . . . 24-16
A/C HEATER CONTROL - INSTALLATION . . . 24-17
A/C HEATER CONTROL - REMOVAL . . . . . . 24-17
A/C HIGH PRESSURE SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-17
A/C HIGH PRESSURE SWITCH -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 24-18
A/C HIGH PRESSURE SWITCH -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-18
A/C HIGH PRESSURE SWITCH -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
A/C HIGH PRESSURE SWITCH -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
A/C LIQUID LINE - INSTALLATION . . . . . . . 24-47
A/C LIQUID LINE - REMOVAL . . . . . . . . . . . 24-47
A/C LOW PRESSURE SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-18
A/C LOW PRESSURE SWITCH -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 24-19
A/C LOW PRESSURE SWITCH -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-19
A/C LOW PRESSURE SWITCH -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
A/C LOW PRESSURE SWITCH -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
A/C ORIFICE TUBE - DESCRIPTION . . . . . . . 24-50
A/C ORIFICE TUBE - INSTALLATION . . . . . . 24-50
A/C ORIFICE TUBE - OPERATION . . . . . . . . 24-50
A/C ORIFICE TUBE - REMOVAL . . . . . . . . . . 24-50
A/C PERFORMANCE - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-2
A/C SUCTION LINE - INSTALLATION . . . . . . 24-49
A/C SUCTION LINE - REMOVAL . . . . . . . . . 24-48
ACCELERATOR PEDAL - INSTALLATION . . . 14-30
ACCELERATOR PEDAL - REMOVAL . . . . . . . 14-29
ACCESS PANEL - DESCRIPTION, LATCH . . 23-139
ACCESS PANEL - INSTALLATION, LATCH . 23-139
ACCESS PANEL - REMOVAL, LATCH . . . . . 23-139
ACCUMULATOR - DESCRIPTION . . . . . . . . . 24-51
ACCUMULATOR - INSTALLATION . . . . . . . . 24-51
ACCUMULATOR - OPERATION . . . . . . . . . . 24-51
ACCUMULATOR - REMOVAL . . . . . . . . . . . . 24-51
ACTUATION TEST MODE - DESCRIPTION,
CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
ACTUATOR - INSTALLATION, BLEND
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-20
ACTUATOR - INSTALLATION, FLOOR -
DEFROST DOOR . . . . . . . . . . . . . . . . . . . . . 24-25
ACTUATOR - INSTALLATION, PANEL
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
ACTUATOR - INSTALLATION,
RECIRCULATION DOOR . . . . . . . . . . . . . . . . 24-26
ACTUATOR - REMOVAL, BLEND DOOR . . . . 24-20
ACTUATOR - REMOVAL, FLOOR -
DEFROST DOOR . . . . . . . . . . . . . . . . . . . . . 24-24
ACTUATOR - REMOVAL, PANEL DOOR . . . . 24-24
ACTUATOR - REMOVAL, RECIRCULATION
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-26
ADAPTER - INSTALLATION, DISC BRAKE
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
ADAPTER - REMOVAL, DISC BRAKE
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
ADAPTER HOUSING SEAL -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-124
ADAPTER HOUSING SEAL - REMOVAL . . . 21-124
ADAPTOR - REMOVAL, DEFROST
DUCT/DEMISTER . . . . . . . . . . . . . . . . . . . . . 24-32
ADHESIVE LOCATIONS -
SPECIFICATIONS, WELD AND
STRUCTURAL . . . . . . . . . . . . . . . . . . . . . . . . 23-9
ADJ USTER - DIAGNOSIS AND TESTING,
HYDRAULIC LASH. . . . . . . . . . . . . . . . . 9-19,9-30
ADJ USTER - INSTALLATION, SEAT BELT
TURNING LOOP . . . . . . . . . . . . . . . . . . . . . 8O-38
ADJ USTER - REMOVAL, SEAT BELT
TURNING LOOP . . . . . . . . . . . . . . . . . . . . . 8O-37
ADJ USTMENT - STANDARD
PROCEDURE, CAMBER AND CASTER . . . . . . . 2-5
ADJ USTMENT - STANDARD
PROCEDURE, CAMBER, CASTER AND
TOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
ADJ USTMENT - STANDARD
PROCEDURE, COMPASS VARIATION . . . . . . 8M-3
ADJ USTMENT - STANDARD
PROCEDURE, TOE . . . . . . . . . . . . . . . . . . . . . . 2-5
ADJ USTMENT, ADJ USTMENTS . . . 23-119,23-124,
23-131
ADJ USTMENT, ADJ USTMENTS . . . . . . . . . . . 3-55
ADJ USTMENT, ADJ USTMENTS -
SUNROOF GLASS PANEL . . . . . . . . . . . . . 23-178
ADJ USTMENT, FRONT FOG LAMP UNIT . . . 8L-25
ADJ USTMENT, HEADLAMP UNIT . . . . . . . . . 8L-42
ADJ USTMENT, LOCK OUT . . . . . . . . . . . . . . . 5-30
ADJ USTMENT, REAR DRUM BRAKE . . . . . . . 5-12
ADJ USTMENTS - ADJ USTMENT . . 23-119,23-124,
23-131
ADJ USTMENTS - ADJ USTMENT . . . . . . . . . . 3-55
ADJ USTMENTS - SUNROOF GLASS
PANEL ADJ USTMENT . . . . . . . . . . . . . . . . 23-178
ADJ USTMENTS, FRONT AXLE - 186FIA . . . . 3-25
ADJ USTMENTS, GEARSHIFT CABLE . . . . . 21-130
ADJ USTMENTS, PARK-INTERLOCK
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-154
ADJ USTMENTS, REAR AXLE - 8 1/4 . . . . . . . 3-92
AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT - STANDARD
PROCEDURE, SERVICE . . . . . . . . . . . . . . . . . 8O-6
AIR CHECKING TRANSMISSION CLUTCH
OPERATION - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-80
AIR CONDITIONER - DESCRIPTION,
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1
AIR CONDITIONER - OPERATION,
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-2
AIR CONTROL MOTOR - DESCRIPTION,
IDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
AIR CONTROL MOTOR - INSTALLATION,
IDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-36
AIR CONTROL MOTOR - OPERATION,
IDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
AIR CONTROL MOTOR - REMOVAL, IDLE . . 14-36
AIR TEMPERATURE SENSOR -
DESCRIPTION, INTAKE . . . . . . . . . . . . . . . . 14-36
AIR TEMPERATURE SENSOR -
INSTALLATION, INTAKE . . . . . . . . . . . . . . . . 14-38
AIR TEMPERATURE SENSOR -
OPERATION, INTAKE . . . . . . . . . . . . . . . . . . 14-36
AIR TEMPERATURE SENSOR -
REMOVAL, INTAKE . . . . . . . . . . . . . . . . . . . 14-37
AIRBAG - DESCRIPTION, DRIVER . . . . . . . . 8O-17
AIRBAG - DESCRIPTION, PASSENGER . . . . 8O-27
AIRBAG - DESCRIPTION, SIDE CURTAIN . . 8O-38
AIRBAG - INSTALLATION, DRIVER . . . . . . . 8O-20
AIRBAG - INSTALLATION, PASSENGER . . . 8O-29
AIRBAG - INSTALLATION, SIDE CURTAIN . . 8O-41
AIRBAG - OPERATION, DRIVER . . . . . . . . . 8O-18
AIRBAG - OPERATION, PASSENGER . . . . . . 8O-27
AIRBAG - OPERATION, SIDE CURTAIN . . . . 8O-39
AIRBAG - REMOVAL, DRIVER . . . . . . . . . . . 8O-19
AIRBAG - REMOVAL, PASSENGER . . . . . . . 8O-28
AIRBAG - REMOVAL, SIDE CURTAIN . . . . . 8O-40
AIRBAG CONTROL MODULE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8O-9
AIRBAG CONTROL MODULE -
DESCRIPTION, SIDE IMPACT . . . . . . . . . . . 8O-43
AIRBAG CONTROL MODULE -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-12
AIRBAG CONTROL MODULE -
INSTALLATION, SIDE IMPACT. . . . . . . . . . . 8O-45
AIRBAG CONTROL MODULE -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8O-10
AIRBAG CONTROL MODULE -
OPERATION, SIDE IMPACT . . . . . . . . . . . . . 8O-43
AIRBAG CONTROL MODULE - REMOVAL . . 8O-11
AIRBAG CONTROL MODULE - REMOVAL,
SIDE IMPACT . . . . . . . . . . . . . . . . . . . . . . . 8O-44
AIRBAG DOOR - INSTALLATION,
PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8O-30
AIRBAG DOOR - REMOVAL, PASSENGER . . 8O-29
AIRBAG INDICATOR - DESCRIPTION . . . . . . 8J -12
AIRBAG INDICATOR - OPERATION . . . . . . . 8J -12
AIRBAG MOUNTING BRACKET -
INSTALLATION, PASSENGER . . . . . . . . . . . 8O-31
AIRBAG MOUNTING BRACKET -
REMOVAL, PASSENGER . . . . . . . . . . . . . . . 8O-31
AJ AR INDICATOR - DESCRIPTION, DOOR . . 8J -17
AJ AR INDICATOR - DESCRIPTION, GATE . . 8J -20
AJ AR INDICATOR - DESCRIPTION,
GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -21
AJ AR INDICATOR - OPERATION, DOOR . . . 8J -17
AJ AR INDICATOR - OPERATION, GATE . . . . 8J -20
AJ AR INDICATOR - OPERATION, GLASS . . . 8J -21
AJ AR SWITCH - DESCRIPTION, DOOR . . . . 8L-77
AJ AR SWITCH - DESCRIPTION, FLIP-UP
GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-77
AJ AR SWITCH - DESCRIPTION, HOOD . . . . 8Q-11
AJ AR SWITCH - DESCRIPTION,
TAILGATE. . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-82
AJ AR SWITCH - DIAGNOSIS AND
TESTING, HOOD . . . . . . . . . . . . . . . . . . . . . 8Q-12
AJ AR SWITCH - INSTALLATION, HOOD . . . 8Q-12
AJ AR SWITCH - OPERATION, DOOR . . . . . . 8L-77
AJ AR SWITCH - OPERATION, FLIP-UP
GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-77
AJ AR SWITCH - OPERATION, HOOD . . . . . 8Q-12
AJ AR SWITCH - OPERATION, TAILGATE . . . 8L-82
AJ AR SWITCH - REMOVAL, HOOD . . . . . . . 8Q-12
AJ AR SWITCH BRACKET -
INSTALLATION, HOOD. . . . . . . . . . . . . . . . . 8Q-13
AJ AR SWITCH BRACKET - REMOVAL,
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
AJ AR SWITCH STRIKER -
INSTALLATION, HOOD. . . . . . . . . . . . . . . . . 8Q-14
AJ AR SWITCH STRIKER - REMOVAL,
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
ALIGNMENT - DESCRIPTION, WHEEL . . . . . . . 2-3
ALIGNMENT - OPERATION, WHEEL . . . . . . . . 2-3
ALIGNMENT, SPECIFICATIONS . . . . . . . . . . . . 2-6
ALUMINUM THREAD REPAIR -
STANDARD PROCEDURE. . . . . . . . . . . . . . . 21-81
AMBIENT TEMP SENSOR - DESCRIPTION . . 8M-9
AMBIENT TEMP SENSOR - OPERATION . . . 8M-9
AMBIENT TEMPERATURE SENSOR -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8M-9
AMBIENT TEMPERATURE SENSOR
CIRCUIT - DIAGNOSIS AND TESTING . . . . . 8M-9
AMPERAGE TEST - DIAGNOSIS AND
TESTING, FUEL PUMP . . . . . . . . . . . . . . . . . 14-16
AMPLIFIER CHOKE AND RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8A-3
AMPLIFIER CHOKE AND RELAY -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8A-4
AMPLIFIER CHOKE AND RELAY -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8A-4
AMPLIFIER CHOKE AND RELAY -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-3
AMPLIFIER CHOKE AND RELAY -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-4
ANCHOR - DESCRIPTION, CHILD TETHER . 8O-13
ANCHOR - OPERATION, CHILD TETHER . . . 8O-13
ANGLE - STANDARD PROCEDURES,
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . 3-3
ANTENNA BODY & CABLE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8A-4
ANTENNA BODY & CABLE -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8A-6
KJ INDEX 1
Description Group-Page Description Group-Page Description Group-Page
ANTENNA BODY & CABLE - OPERATION . . . 8A-5
ANTENNA BODY & CABLE - REMOVAL . . . . . 8A-6
ANTENNA BODY AND CABLE -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8A-5
ANTENNA CABLE - INSTALLATION,
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 8A-8
ANTENNA CABLE - REMOVAL,
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 8A-7
ANTILOCK BRAKE - INSTALLATION,
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . 8E-10
ANTILOCK BRAKE - REMOVAL,
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . 8E-10
ANTILOCK BRAKING SYSTEM -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 5-33
A-PILLAR SEAL - INSTALLATION . . . . . . . 23-185
A-PILLAR SEAL - REMOVAL . . . . . . . . . . . 23-185
A-PILLAR TRIM AND GRAB HANDLE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-156
A-PILLAR TRIM AND GRAB HANDLE -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-156
A-PILLAR WEATHERSTRIP/RETAINER -
INSTALLATION, WINDSHIELD . . . . . . . . . . 23-187
A-PILLAR WEATHERSTRIP/RETAINER -
REMOVAL, WINDSHIELD. . . . . . . . . . . . . . 23-186
APPLICATION TABLE, SPECIFICATIONS -
A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-9
AREA LEAKS - DIAGNOSIS AND
TESTING, REAR SEAL . . . . . . . . . . . . . . . . . . 9-61
ARM - DESCRIPTION, FRONT WIPER . . . . . 8R-12
ARM - DESCRIPTION, LOWER CONTROL . . . 2-21
ARM - DESCRIPTION, REAR WIPER . . . . . . 8R-37
ARM - DESCRIPTION, ROCKER . . . . . . 9-29,9-37
ARM - INSTALLATION, FRONT WIPER . . . . 8R-13
ARM - INSTALLATION, LOWER CONTROL . . 2-10,
2-21
ARM - INSTALLATION, REAR WIPER . . . . . 8R-38
ARM - INSTALLATION, ROCKER . . . . . . . . . . 9-37
ARM - INSTALLATION, UPPER CONTROL . . . 2-21
ARM - OPERATION, FRONT WIPER . . . . . . 8R-12
ARM - OPERATION, LOWER CONTROL . . . . . 2-21
ARM - OPERATION, REAR WIPER . . . . . . . 8R-38
ARM - REMOVAL, FRONT WIPER . . . . . . . . 8R-12
ARM - REMOVAL, LOWER CONTROL . . 2-10,2-21
ARM - REMOVAL, REAR WIPER . . . . . . . . . 8R-38
ARM - REMOVAL, ROCKER . . . . . . . . . . . . . . 9-37
ARM - REMOVAL, UPPER CONTROL . . . . . . 2-20
ARM, BUSHINGS, AND BALL J OINT -
DESCRIPTION, UPPER SUSPENSION . . . . . . 2-20
ARM, BUSHINGS, AND BALL J OINT -
OPERATION, UPPER SUSPENSION . . . . . . . . 2-20
ARM PARK RAMP - INSTALLATION,
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-43
ARM PARK RAMP - REMOVAL, WIPER . . . 8R-43
ASD AND FUEL PUMP RELAYS -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 8I-4
ASD SENSE - PCM INPUT - OPERATION . . . . 8I-4
ASH RECEIVER LAMP BULB -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-71
ASH RECEIVER LAMP BULB - REMOVAL . . 8L-71
ASH RECEIVER LAMP UNIT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-72
ASH RECEIVER LAMP UNIT - REMOVAL . . 8L-72
ASSEMBLY - ASSEMBLY, INPUT CLUTCH . 21-138
ASSEMBLY - DESCRIPTION, INPUT
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-133
ASSEMBLY - DESCRIPTION,
TRANSMISSION SOLENOID/TRS . . . . . . . . 21-169
ASSEMBLY - DISASSEMBLY, INPUT
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-135
ASSEMBLY - INSTALLATION . . . . . . . . . 8W-97-11
ASSEMBLY - INSTALLATION, GUIDE . . . . . 23-179
ASSEMBLY - INSTALLATION,
INSTRUMENT PANEL. . . . . . . . . . . . . . . . . 23-151
ASSEMBLY - INSTALLATION, MODULE . . . 23-181
ASSEMBLY - INSTALLATION,
TRANSMISSION SOLENOID/TRS . . . . . . . . 21-170
ASSEMBLY - OPERATION, INPUT
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-135
ASSEMBLY - OPERATION,
TRANSMISSION SOLENOID/TRS . . . . . . . . 21-169
ASSEMBLY - POWER DISTRIBUTION
CENTER ASSEMBLY . . . . . . . . . . . . . . . 8W-97-10
ASSEMBLY - REMOVAL, GUIDE . . . . . . . . 23-179
ASSEMBLY - REMOVAL, INSTRUMENT
PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-149
ASSEMBLY - REMOVAL, MODULE . . . . . . 23-181
ASSEMBLY - REMOVAL, TRANSMISSION
SOLENOID/TRS . . . . . . . . . . . . . . . . . . . . . 21-170
ASSEMBLY, 4C RETAINER/BULKHEAD . . . . 21-123
ASSEMBLY, ASSEMBLY - POWER
DISTRIBUTION CENTER . . . . . . . . . . . . 8W-97-10
ASSEMBLY, DIAGNOSIS AND TESTING . . . . 21-90
ASSEMBLY, DIFFERENTIAL . . . . . . . . . 3-105,3-41
ASSEMBLY, DIFFERENTIAL - TRAC-LOK . . . 3-109,
3-77
ASSEMBLY, DISC BRAKE CALIPERS . . . . . . . 5-16
ASSEMBLY, HVAC HOUSING . . . . . . . . . . . . 24-34
ASSEMBLY, INPUT CLUTCH ASSEMBLY . . 21-138
ASSEMBLY, INSTRUMENT CLUSTER . . . . . . 8J -10
ASSEMBLY, LOW/REVERSE CLUTCH . . . . . 21-146
ASSEMBLY, MANUAL - NV1500 . . . . . . . . . 21-13
ASSEMBLY, MANUAL - NV3550 . . . . . . . . . 21-48
ASSEMBLY, OIL PUMP . . . . . . . . . . . . . . . . . 9-67
ASSEMBLY, OIL PUMP . . . . . . . . . . . . . . . 21-151
ASSEMBLY, PLANETARY GEARTRAIN . . . . 21-160
ASSEMBLY, SINGLE CARDAN
UNIVERSAL J OINTS . . . . . . . . . . . . . . . . . . . . 3-9
ASSEMBLY, TRANSFER CASE - NV231 . . . 21-194
ASSEMBLY, TRANSFER CASE - NV242 . . . 21-230
ASSEMBLY, VALVE BODY . . . . . . . . . . . . . 21-176
ASSEMBLY, WHEEL CYLINDERS . . . . . . . . . . 5-29
ASSEMBLY WINDOW DEFOGGER
FUNCTION - DIAGNOSIS AND TESTING,
REAR HVAC CONTROL . . . . . . . . . . . . . . . . . 8G-9
ASSIST HANDLE - INSTALLATION . . . . . . . 23-157
ASSIST HANDLE - REMOVAL . . . . . . . . . . . . 23-157
AUDIO - DESCRIPTION . . . . . . . . . . . . . . . . . 8A-1
AUDIO - DIAGNOSIS AND TESTING . . . . . . . 8A-2
AUDIO - OPERATION . . . . . . . . . . . . . . . . . . . 8A-1
AUTOMATIC TRANSMISSION - 45RFE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 21-76
AUTOMATIC TRANSMISSION - 45RFE -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 21-77
AUTOMATIC TRANSMISSION -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 21-77
AUTOMATIC TRANSMISSION FLUID -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
AUTOMATIC TRANSMISSION FLUID -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
AXLE - 186FIA - ADJ USTMENTS, FRONT . . . 3-25
AXLE - 186FIA - DESCRIPTION, FRONT . . . . 3-19
AXLE - 186FIA - INSTALLATION, FRONT . . . . 3-24
AXLE - 186FIA - OPERATION, FRONT . . . . . . 3-19
AXLE - 186FIA - REMOVAL, FRONT . . . . . . . 3-24
AXLE - 198RBI - DESCRIPTION, REAR . . . . . 3-49
AXLE - 198RBI - INSTALLATION, REAR . . . . 3-54
AXLE - 198RBI - OPERATION, REAR . . . . . . . 3-49
AXLE - 198RBI - REMOVAL, REAR . . . . . . . . 3-54
AXLE - 8 1/4 - ADJ USTMENTS, REAR . . . . . 3-92
AXLE - 8 1/4 - DESCRIPTION, REAR . . . . . . 3-86
AXLE - 8 1/4 - INSTALLATION, REAR . . . . . . 3-91
AXLE - 8 1/4 - OPERATION, REAR . . . . . . . . 3-86
AXLE - 8 1/4 - REMOVAL, REAR . . . . . . . . . . 3-91
AXLE - DESCRIPTION . . . . . . . . . . . . . . . . . . . 0-2
AXLE - DIAGNOSIS AND TESTING . . . . 3-20,3-51,
3-88
AXLE - INSTALLATION, 198 RBI . . . . . . . . . . 5-28
AXLE - INSTALLATION, 8 1/4 . . . . . . . . . . . . 5-28
AXLE - REMOVAL, 198 RBI . . . . . . . . . . . . . . 5-27
AXLE - REMOVAL, 8 1/4 . . . . . . . . . . . . . . . . 5-27
AXLE - SPECIFICATIONS, FRONT . . . . . . . . . 3-33
AXLE - SPECIFICATIONS, REAR . . . . . . . . . . 3-62
AXLE BEARINGS - INSTALLATION . . . . 3-102,3-38
AXLE BEARINGS - REMOVAL . . . . . . . 3-102,3-38
AXLE BEARING/SEAL - INSTALLATION . . . . . 3-67
AXLE BEARING/SEAL - REMOVAL . . . . . . . . . 3-66
AXLE SHAFT SEALS - INSTALLATION . 3-102,3-38
AXLE SHAFT SEALS - REMOVAL . . . . 3-101,3-37
AXLE SHAFTS - INSTALLATION . . 3-101,3-37,3-65
AXLE SHAFTS - REMOVAL . . . . . 3-101,3-37,3-65
AXLE, SPECIAL TOOLS - 8 1/4 . . . . . . . . . . . 3-98
AXLE, SPECIAL TOOLS - FRONT . . . . . . . . . . 3-34
AXLE, SPECIAL TOOLS - REAR . . . . . . . . . . . 3-63
AXLE, SPECIFICATIONS - REAR . . . . . . . . . . 3-98
BACK - FRONT - INSTALLATION, SEAT . . . 23-166
BACK - FRONT - REMOVAL, SEAT . . . . . . . 23-166
BACK - REAR - INSTALLATION, SEAT . . . . 23-168
BACK - REAR - REMOVAL, SEAT . . . . . . . 23-168
BACK COVER - FRONT - INSTALLATION,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
BACK COVER - FRONT - REMOVAL, SEAT . 23-166
BACK COVER - REAR - INSTALLATION,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-169
BACK COVER - REAR - REMOVAL, SEAT . 23-169
BACK CUSHION - FRONT -
INSTALLATION, SEAT. . . . . . . . . . . . . . . . . 23-167
BACK CUSHION - FRONT - REMOVAL,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
BACK CUSHION - REAR - INSTALLATION,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
BACK CUSHION - REAR - REMOVAL,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
BACK FRAME - REAR - INSTALLATION,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-171
BACK FRAME - REAR - REMOVAL, SEAT . 23-171
BACK LATCH / LOCK - INSTALLATION,
FOLDING REAR SEAT . . . . . . . . . . . . . . . . 23-170
BACK LATCH / LOCK - REMOVAL,
FOLDING REAR SEAT . . . . . . . . . . . . . . . . 23-170
BACK LATCH STRIKER - INSTALLATION,
REAR SEAT . . . . . . . . . . . . . . . . . . . . . . . . 23-171
BACK LATCH STRIKER - REMOVAL,
REAR SEAT . . . . . . . . . . . . . . . . . . . . . . . . 23-170
BACK RECLINER - FRONT -
INSTALLATION, SEAT. . . . . . . . . . . . . . . . . 23-166
BACK RECLINER - FRONT - REMOVAL,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-166
BACKUP LAMP SWITCH - DESCRIPTION . . 8L-15
BACKUP LAMP SWITCH - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8L-15
BACKUP LAMP SWITCH - OPERATION . . . . 8L-15
BAFFLE SEAL - INSTALLATION,
COWL/PLENUM WINDOW . . . . . . . . . . . . . 23-187
BAFFLE SEAL - REMOVAL, COWL/
PLENUM WINDOW . . . . . . . . . . . . . . . . . . 23-187
BALANCE SHAFT - INSTALLATION . . . . . . . . 9-74
BALANCE SHAFT - REMOVAL . . . . . . . . . . . . 9-74
BALANCING - STANDARD PROCEDURE,
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-4
BALL J OINT - DESCRIPTION, UPPER
SUSPENSION ARM, BUSHINGS . . . . . . . . . . 2-20
BALL J OINT - DIAGNOSIS AND TESTING,
LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
BALL J OINT - INSTALLATION, UPPER . . . . . 2-20
BALL J OINT - OPERATION, UPPER
SUSPENSION ARM, BUSHINGS . . . . . . . . . . 2-20
BALL J OINT - REMOVAL, UPPER . . . . . . . . . 2-20
BAR - INSTALLATION, STABILIZER . . . . 2-14,2-19
BAR - REMOVAL, STABILIZER . . . . . . . 2-14,2-19
BAR BUSHINGS - INSTALLATION,
STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
BAR BUSHINGS - REMOVAL, STABILIZER . . . 2-9
BARRELS - INSTALLATION, PANEL
OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-29
BARRELS - REMOVAL, PANEL OUTLET . . . 24-29
BASE - DESCRIPTION, BRAKES . . . . . . . . . . . 5-2
BASE - WARNING, BRAKES . . . . . . . . . . . . . . 5-2
BASE BRAKE SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
BASE BRAKES, SPECIAL TOOLS . . . . . . . . . . . 5-7
BASE COAT/CLEAR COAT FINISH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 23-162
BATTERIES - STANDARD PROCEDURE,
RKE TRANSMITTER . . . . . . . . . . . . . . . . . . . 8N-8
BATTERY - DESCRIPTION . . . . . . . . . . . . . . . 8F-7
BATTERY - DIAGNOSIS AND TESTING . . . . . 8F-8
BATTERY CABLES - DESCRIPTION . . . . . . . 8F-18
BATTERY CABLES - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-19
BATTERY CABLES - OPERATION . . . . . . . . . 8F-18
BATTERY CHARGING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8F-8
BATTERY HOLDDOWN - DESCRIPTION . . . . 8F-17
BATTERY HOLDDOWN - INSTALLATION . . . 8F-17
BATTERY HOLDDOWN - OPERATION . . . . . 8F-17
BATTERY HOLDDOWN - REMOVAL . . . . . . . 8F-17
BATTERY SYSTEM - CLEANING . . . . . . . . . . . 8F-5
BATTERY SYSTEM - DESCRIPTION . . . . . . . . 8F-1
BATTERY SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-2
BATTERY SYSTEM - INSPECTION . . . . . . . . . 8F-6
BATTERY SYSTEM - OPERATION . . . . . . . . . 8F-2
BATTERY SYSTEM - SPECIAL TOOLS . . . . . . 8F-7
BATTERY SYSTEM - SPECIFICATIONS . . . . . . 8F-6
BATTERY TEMPERATURE SENSOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8F-24
BATTERY TEMPERATURE SENSOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8F-24
BATTERY TEMPERATURE SENSOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8F-24
BATTERY TEMPERATURE SENSOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-24
BATTERY TRAY - DESCRIPTION . . . . . . . . . 8F-21
BATTERY TRAY - INSTALLATION . . . . . . . . . 8F-21
2 INDEX KJ
Description Group-Page Description Group-Page Description Group-Page
BATTERY TRAY - OPERATION . . . . . . . . . . . 8F-21
BATTERY TRAY - REMOVAL . . . . . . . . . . . . 8F-21
BEAM INDICATOR - DESCRIPTION, HIGH . . 8J -22
BEAM INDICATOR - OPERATION, HIGH . . . . 8J -22
BEAM RELAY - DESCRIPTION,
HEADLAMP HIGH . . . . . . . . . . . . . . . . . . . . 8L-33
BEAM RELAY - DESCRIPTION,
HEADLAMP LOW. . . . . . . . . . . . . . . . . . . . . 8L-39
BEAM RELAY - DIAGNOSIS AND
TESTING, HEADLAMP HIGH . . . . . . . . . . . . 8L-34
BEAM RELAY - DIAGNOSIS AND
TESTING, HEADLAMP LOW. . . . . . . . . . . . . 8L-40
BEAM RELAY - INSTALLATION,
HEADLAMP HIGH . . . . . . . . . . . . . . . . . . . . 8L-35
BEAM RELAY - INSTALLATION,
HEADLAMP LOW. . . . . . . . . . . . . . . . . . . . . 8L-41
BEAM RELAY - OPERATION, HEADLAMP
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-33
BEAM RELAY - OPERATION, HEADLAMP
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-39
BEAM RELAY - REMOVAL, HEADLAMP
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-34
BEAM RELAY - REMOVAL, HEADLAMP
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-40
BEARING - FITTING - STANDARD
PROCEDURE, CONNECTING ROD . . . . . . . . . 9-40
BEARING - INSTALLATION, CLUTCH
RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
BEARING - INSTALLATION, HUB . . . . . . . . . . . 2-9
BEARING - INSTALLATION, PILOT . . . . . . . . . 6-8
BEARING - REMOVAL, CLUTCH RELEASE . . . 6-6
BEARING - REMOVAL, HUB . . . . . . . . . . . . . . 2-9
BEARING - REMOVAL, PILOT . . . . . . . . . . . . . 6-8
BEARING, FITTING - CONNECTING ROD . . . . 9-49
BEARING, FITTING - MAIN . . . . . . . . . . . . . . 9-45
BEARINGS - INSTALLATION, AXLE . . . 3-102,3-38
BEARINGS - INSTALLATION,
DIFFERENTIAL CASE . . . . . . . . . . 3-110,3-44,3-79
BEARINGS - REMOVAL, AXLE . . . . . . . 3-102,3-38
BEARINGS - REMOVAL, DIFFERENTIAL
CASE . . . . . . . . . . . . . . . . . . . . . . 3-110,3-43,3-79
BEARING/SEAL - INSTALLATION, AXLE . . . . 3-67
BEARING/SEAL - REMOVAL, AXLE . . . . . . . . 3-66
BELT / CHAIN COVER(S) -
INSTALLATION, TIMING. . . . . . . . . . . . . . . . . 9-76
BELT / CHAIN COVER(S) - REMOVAL,
TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-74
BELT - DIAGNOSIS AND TESTING,
SERPENTINE DRIVE . . . . . . . . . . . . . . . . . . . 7-15
BELT & RETRACTOR - INSTALLATION,
FRONT SEAT . . . . . . . . . . . . . . . . . . . . . . . . 8O-24
BELT & RETRACTOR - INSTALLATION,
REAR CENTER SEAT . . . . . . . . . . . . . . . . . . 8O-33
BELT & RETRACTOR - INSTALLATION,
REAR OUTBOARD SEAT . . . . . . . . . . . . . . . 8O-34
BELT & RETRACTOR - REMOVAL, FRONT
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-23
BELT & RETRACTOR - REMOVAL, REAR
CENTER SEAT . . . . . . . . . . . . . . . . . . . . . . . 8O-32
BELT & RETRACTOR - REMOVAL, REAR
OUTBOARD SEAT . . . . . . . . . . . . . . . . . . . . 8O-33
BELT BUCKLE - INSTALLATION, FRONT
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-26
BELT BUCKLE - INSTALLATION, REAR
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-35
BELT BUCKLE - REMOVAL, FRONT SEAT . . 8O-25
BELT BUCKLE - REMOVAL, REAR SEAT . . . 8O-34
BELT MOLDING - INSTALLATION, FRONT
DOOR OUTER . . . . . . . . . . . . . . . . . . . . . . 23-186
BELT MOLDING - INSTALLATION, REAR
DOOR OUTER . . . . . . . . . . . . . . . . . . . . . . 23-186
BELT MOLDING - REMOVAL, FRONT
DOOR OUTER . . . . . . . . . . . . . . . . . . . . . . 23-186
BELT MOLDING - REMOVAL, REAR
DOOR OUTER . . . . . . . . . . . . . . . . . . . . . . 23-186
BELT SWITCH - DESCRIPTION, SEAT . . . . . 8O-35
BELT SWITCH - OPERATION, SEAT . . . . . . . 8O-36
BELT TENSIONER - DESCRIPTION, SEAT . . 8O-36
BELT TENSIONER - OPERATION, SEAT . . . . 8O-36
BELT TURNING LOOP ADJ USTER -
INSTALLATION, SEAT . . . . . . . . . . . . . . . . . 8O-38
BELT TURNING LOOP ADJ USTER -
REMOVAL, SEAT . . . . . . . . . . . . . . . . . . . . . 8O-37
BELTLINE WEATHERSTRIP -
INSTALLATION, SWING GATE . . . . . . . . . . 23-186
BELTLINE WEATHERSTRIP - REMOVAL,
SWING GATE . . . . . . . . . . . . . . . . . . . . . . . 23-186
BEZEL - INSTALLATION, CLUSTER . . . . . . 23-147
BEZEL - INSTALLATION, INSTRUMENT
PANEL CENTER . . . . . . . . . . . . . . . . . . . . . 23-154
BEZEL - INSTALLATION, INSTRUMENT
PANEL PASSENGER SIDE . . . . . . . . . . . . . 23-154
BEZEL - INSTALLATION, SHIFT . . . . . . . . . 23-158
BEZEL - REMOVAL, CLUSTER . . . . . . . . . . 23-147
BEZEL - REMOVAL, INSTRUMENT PANEL
CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-154
BEZEL - REMOVAL, INSTRUMENT PANEL
PASSENGER SIDE . . . . . . . . . . . . . . . . . . . 23-154
BEZEL - REMOVAL, SHIFT . . . . . . . . . . . . . 23-158
BEZELS - INSTALLATION, INSTRUMENT
PANEL DRIVER SIDE . . . . . . . . . . . . . . . . . 23-154
BEZELS - REMOVAL, INSTRUMENT
PANEL DRIVER SIDE . . . . . . . . . . . . . . . . . 23-153
BLADE - DESCRIPTION, FRONT WIPER . . . 8R-13
BLADE - DESCRIPTION, REAR WIPER . . . . 8R-39
BLADE - INSTALLATION, FRONT WIPER . . . 8R-14
BLADE - INSTALLATION, REAR WIPER . . . . 8R-40
BLADE - OPERATION, FRONT WIPER . . . . . 8R-14
BLADE - OPERATION, REAR WIPER . . . . . . 8R-39
BLADE - REMOVAL, FRONT WIPER . . . . . . 8R-14
BLADE - REMOVAL, REAR WIPER . . . . . . . 8R-40
BLEEDING - STANDARD PROCEDURE,
ABS BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
BLEEDING - STANDARD PROCEDURE,
MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
BLEEDING - STANDARD PROCEDURE,
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . 5-24
BLEEDING - STANDARD PROCEDURE,
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
BLEND DOOR - INSTALLATION . . . . . . . . . . 24-35
BLEND DOOR - REMOVAL . . . . . . . . . . . . . 24-35
BLEND DOOR ACTUATOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-20
BLEND DOOR ACTUATOR - REMOVAL . . . . 24-20
BLOCK - CLEANING, ENGINE . . . . . . . . . . . . 9-39
BLOCK - DESCRIPTION, ENGINE . . . . . . . . . . 9-39
BLOCK - DESCRIPTION, J UNCTION . . . . 8W-97-4
BLOCK - DESCRIPTION, J UNCTION . . . . . . . 5-20
BLOCK - DIAGNOSIS AND TESTING,
J UNCTION. . . . . . . . . . . . . . . . . . . . . . . . 8W-97-4
BLOCK - INSPECTION, ENGINE . . . . . . . . . . . 9-40
BLOCK - INSTALLATION, J UNCTION . . . . . . . 5-20
BLOCK - OPERATION, J UNCTION . . . . . . 8W-97-4
BLOCK - OPERATION, J UNCTION . . . . . . . . . 5-20
BLOCK - REMOVAL, J UNCTION . . . . . . . . . . . 5-20
BLOCKER - INSTALLATION, KNEE . . . . . . . 23-155
BLOCKER - REMOVAL, KNEE . . . . . . . . . . 23-155
BLOWER MOTOR - DESCRIPTION . . . . . . . 24-30
BLOWER MOTOR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-30
BLOWER MOTOR - INSTALLATION . . . . . . . 24-31
BLOWER MOTOR - OPERATION . . . . . . . . . 24-30
BLOWER MOTOR - REMOVAL . . . . . . . . . . . 24-30
BLOWER MOTOR RELAY - DESCRIPTION . . 24-20
BLOWER MOTOR RELAY - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 24-21
BLOWER MOTOR RELAY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-22
BLOWER MOTOR RELAY - OPERATION . . . 24-20
BLOWER MOTOR RELAY - REMOVAL . . . . . 24-21
BLOWER MOTOR RESISTOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-22
BLOWER MOTOR RESISTOR -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 24-22
BLOWER MOTOR RESISTOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-22
BLOWER MOTOR RESISTOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
BLOWER MOTOR RESISTOR - REMOVAL . . 24-22
BLOWER MOTOR SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-23
BLOWER MOTOR SWITCH - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 24-23
BLOWER MOTOR SWITCH -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-23
BLOWER MOTOR SWITCH - OPERATION . . 24-23
BLOWER MOTOR SWITCH - REMOVAL . . . 24-23
BODY - ASSEMBLY, VALVE . . . . . . . . . . . . 21-176
BODY & CABLE - DESCRIPTION,
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-4
BODY & CABLE - INSTALLATION,
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-6
BODY & CABLE - OPERATION, ANTENNA . . . 8A-5
BODY & CABLE - REMOVAL, ANTENNA . . . . 8A-6
BODY - CLEANING, VALVE . . . . . . . . . . . . 21-175
BODY - DESCRIPTION, THROTTLE . . . . . . . 14-43
BODY - DESCRIPTION, VALVE . . . . . . . . . . 21-171
BODY - DISASSEMBLY, VALVE . . . . . . . . . 21-173
BODY - INSPECTION, VALVE . . . . . . . . . . . 21-175
BODY - INSTALLATION, THROTTLE . . . . . . . 14-44
BODY - INSTALLATION, VALVE . . . . . . . . . 21-177
BODY - OPERATION, THROTTLE . . . . . . . . . 14-43
BODY - OPERATION, VALVE . . . . . . . . . . . 21-171
BODY - REMOVAL, THROTTLE . . . . . . . . . . 14-43
BODY - REMOVAL, VALVE . . . . . . . . . . . . . 21-172
BODY AND CABLE - DIAGNOSIS AND
TESTING, ANTENNA . . . . . . . . . . . . . . . . . . . 8A-5
BODY CONTROL MODULE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8E-2
BODY CONTROL MODULE - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8E-7
BODY CONTROL MODULE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 8E-7
BODY CONTROL MODULE - OPERATION . . . 8E-5
BODY CONTROL MODULE - REMOVAL . . . . . 8E-7
BODY LUBRICATION - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 23-3
BODY SIDE MOLDINGS - INSTALLATION . 23-140
BODY SIDE MOLDINGS - REMOVAL . . . . . 23-140
BODY, SPECIAL TOOLS . . . . . . . . . . . . . . . . . 23-5
BOOSTER - DESCRIPTION, POWER
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
BOOSTER - DIAGNOSIS AND TESTING,
MASTER CYLINDER/POWER . . . . . . . . . 5-21,5-24
BOOSTER - INSTALLATION, POWER
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
BOOSTER - OPERATION, POWER BRAKE . . . 5-21
BOOSTER - REMOVAL, POWER BRAKE . . . . 5-22
BOOT - INSTALLATION, 4WD FLOOR
SHIFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-156
BOOT - REMOVAL, 4WD FLOOR SHIFT . . . 23-156
BORE HONING - STANDARD
PROCEDURE, CYLINDER . . . . . . . . . . . . . . . . 9-39
BOX - INSTALLATION, GLOVE . . . . . . . . . . 23-148
BOX - REMOVAL, GLOVE . . . . . . . . . . . . . 23-148
BOX LATCH - INSTALLATION, GLOVE . . . . 23-148
BOX LATCH - REMOVAL, GLOVE . . . . . . . . 23-148
BOX LATCH STRIKER - INSTALLATION,
GLOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-149
BOX LATCH STRIKER - REMOVAL,
GLOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-148
B-PILLAR LOWER TRIM - INSTALLATION . 23-157
B-PILLAR LOWER TRIM - REMOVAL . . . . 23-157
B-PILLAR UPPER TRIM - INSTALLATION . 23-158
B-PILLAR UPPER TRIM - REMOVAL . . . . . 23-157
BRACKET - INSTALLATION, CLEVIS . . . . . . . 2-13
BRACKET - INSTALLATION, HOOD AJ AR
SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
BRACKET - INSTALLATION, PASSENGER
AIRBAG MOUNTING . . . . . . . . . . . . . . . . . . 8O-31
BRACKET - INSTALLATION, REARVIEW
MIRROR SUPPORT . . . . . . . . . . . . . . . . . . 23-161
BRACKET - REMOVAL, CLEVIS . . . . . . . . . . . 2-13
BRACKET - REMOVAL, HOOD AJ AR
SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
BRACKET - REMOVAL, PASSENGER
AIRBAG MOUNTING . . . . . . . . . . . . . . . . . . 8O-31
BRAKE - ADJ USTMENT, REAR DRUM . . . . . . 5-12
BRAKE - DESCRIPTION, PARKING . . . . . . . . 5-29
BRAKE - DESCRIPTION, REAR DRUM . . . . . 5-10
BRAKE - INSTALLATION, CONTROLLER
ANTILOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-10
BRAKE - OPERATION, PARKING . . . . . . . . . . 5-29
BRAKE - OPERATION, REAR DRUM . . . . . . . 5-11
BRAKE - REMOVAL, CONTROLLER
ANTILOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-10
BRAKE BLEEDING - STANDARD
PROCEDURE, ABS . . . . . . . . . . . . . . . . . . . . . 5-33
BRAKE BOOSTER - DESCRIPTION,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
BRAKE BOOSTER - INSTALLATION,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
BRAKE BOOSTER - OPERATION, POWER . . . 5-21
BRAKE BOOSTER - REMOVAL, POWER . . . . 5-22
BRAKE CALIPER ADAPTER -
INSTALLATION, DISC. . . . . . . . . . . . . . . . . . . 5-18
BRAKE CALIPER ADAPTER - REMOVAL,
DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
BRAKE CALIPERS - ASSEMBLY, DISC . . . . . . 5-16
BRAKE CALIPERS - CLEANING, DISC . . . . . . 5-16
BRAKE CALIPERS - DESCRIPTION, DISC . . . 5-13
BRAKE CALIPERS - DISASSEMBLY, DISC . . . 5-14
BRAKE CALIPERS - INSPECTION, DISC . . . . 5-16
BRAKE CALIPERS - INSTALLATION, DISC . . . 5-17
KJ INDEX 3
Description Group-Page Description Group-Page Description Group-Page
BRAKE CALIPERS - OPERATION, DISC . . . . . 5-14
BRAKE CALIPERS - REMOVAL, DISC . . . . . . 5-14
BRAKE COMPONENTS, SPECIFICATIONS . . . . 5-6
BRAKE DRUM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
BRAKE DRUM MACHINING - STANDARD
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 5-27
BRAKE FLUID CONTAMINATION -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 5-26
BRAKE FLUID, SPECIFICATIONS . . . . . . . . . . 5-27
BRAKE HOSE - INSTALLATION, FRONT . . . . . 5-10
BRAKE HOSE - INSTALLATION, REAR . . . . . . 5-10
BRAKE HOSE - REMOVAL, REAR . . . . . . . . . . 5-9
BRAKE INDICATOR - DESCRIPTION,
BRAKE/PARK . . . . . . . . . . . . . . . . . . . . . . . . 8J -13
BRAKE INDICATOR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -14
BRAKE INDICATOR - OPERATION,
BRAKE/PARK . . . . . . . . . . . . . . . . . . . . . . . . 8J -13
BRAKE LAMP SWITCH - DESCRIPTION . . . 8L-16
BRAKE LAMP SWITCH - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8L-17
BRAKE LAMP SWITCH - INSTALLATION . . . 8L-18
BRAKE LAMP SWITCH - OPERATION . . . . . 8L-16
BRAKE LAMP SWITCH - REMOVAL . . . . . . 8L-17
BRAKE LINE AND HOSES - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
BRAKE LINES - DESCRIPTION . . . . . . . . . . . . 5-8
BRAKE PADS - INSTALLATION, FRONT . . . . . 5-11
BRAKE PADS - REMOVAL, FRONT . . . . . . . . 5-11
BRAKE ROTOR - DIAGNOSIS AND
TESTING, DISC . . . . . . . . . . . . . . . . . . . . . . . 5-18
BRAKE ROTOR - STANDARD
PROCEDURE, DISC . . . . . . . . . . . . . . . . . . . . 5-19
BRAKE SHOES - INSTALLATION, DRUM . . . . 5-11
BRAKE SHOES - REMOVAL, DRUM . . . . . . . 5-11
BRAKE SYSTEM - DIAGNOSIS AND
TESTING, BASE . . . . . . . . . . . . . . . . . . . . . . . . 5-3
BRAKE TRANSMISSION SHIFT
INTERLOCK SYSTEM - DESCRIPTION. . . . 21-124
BRAKE TRANSMISSION SHIFT
INTERLOCK SYSTEM - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 21-125
BRAKE TRANSMISSION SHIFT
INTERLOCK SYSTEM - OPERATION . . . . . 21-125
BRAKE/PARK BRAKE INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -13
BRAKE/PARK BRAKE INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -13
BRAKES - ABS - DESCRIPTION . . . . . . . . . . . 5-32
BRAKES - ABS - OPERATION . . . . . . . . . . . . 5-32
BRAKES - ABS - SPECIFICATIONS . . . . . . . . 5-33
BRAKES - BASE - DESCRIPTION . . . . . . . . . . . 5-2
BRAKES - BASE - WARNING . . . . . . . . . . . . . . 5-2
BRAKES, SPECIAL TOOLS - BASE . . . . . . . . . 5-7
BRAKING SYSTEM - DIAGNOSIS AND
TESTING, ANTILOCK . . . . . . . . . . . . . . . . . . . 5-33
BREAK-IN - STANDARD PROCEDURE,
A/C COMPRESSOR CLUTCH . . . . . . . . . . . . 24-12
BUCKLE - INSTALLATION, FRONT SEAT
BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-26
BUCKLE - INSTALLATION, REAR SEAT
BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-35
BUCKLE - REMOVAL, FRONT SEAT BELT . . 8O-25
BUCKLE - REMOVAL, REAR SEAT BELT . . . 8O-34
BUILT-IN INDICATOR TEST - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8F-10
BULB - INSTALLATION, ASH RECEIVER
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-71
BULB - INSTALLATION, CARGO LAMP . . . . 8L-73
BULB - INSTALLATION, CENTER HIGH
MOUNTED STOP LAMP . . . . . . . . . . . . . . . . 8L-19
BULB - INSTALLATION, COMPASS
MINI-TRIP ILLUMINATION. . . . . . . . . . . . . . 8L-75
BULB - INSTALLATION, COURTESY
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-76
BULB - INSTALLATION, FRONT FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-22
BULB - INSTALLATION, FRONT LAMP . . . . 8L-27
BULB - INSTALLATION, FRONT POSITION
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-28
BULB - INSTALLATION, HEADLAMP . . . . . . 8L-32
BULB - INSTALLATION, HEATER-A/C
CONTROL ILLUMINATION . . . . . . . . . . . . . . 8L-78
BULB - INSTALLATION, LICENSE PLATE
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-45
BULB - INSTALLATION, READING LAMP . . . 8L-79
BULB - INSTALLATION, REAR LAMP . . . . . 8L-59
BULB - INSTALLATION, REPEATER LAMP . . 8L-60
BULB - INSTALLATION, TRANSMISSION
RANGE INDICATOR ILLUMINATION. . . . . . . 8L-83
BULB - INSTALLATION, VANITY LAMP . . . . 8L-84
BULB - REMOVAL, ASH RECEIVER LAMP . . 8L-71
BULB - REMOVAL, CARGO LAMP . . . . . . . . 8L-72
BULB - REMOVAL, CENTER HIGH
MOUNTED STOP LAMP . . . . . . . . . . . . . . . . 8L-18
BULB - REMOVAL, COMPASS MINI-TRIP
ILLUMINATION . . . . . . . . . . . . . . . . . . . . . . 8L-74
BULB - REMOVAL, COURTESY LAMP . . . . . 8L-75
BULB - REMOVAL, FRONT FOG LAMP . . . . 8L-21
BULB - REMOVAL, FRONT LAMP . . . . . . . . 8L-26
BULB - REMOVAL, FRONT POSITION
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-28
BULB - REMOVAL, HEADLAMP . . . . . . . . . . 8L-31
BULB - REMOVAL, HEATER-A/C
CONTROL ILLUMINATION . . . . . . . . . . . . . . 8L-78
BULB - REMOVAL, LICENSE PLATE
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-44
BULB - REMOVAL, READING LAMP . . . . . . 8L-79
BULB - REMOVAL, REAR LAMP . . . . . . . . . 8L-58
BULB - REMOVAL, REPEATER LAMP . . . . . 8L-60
BULB - REMOVAL, TRANSMISSION
RANGE INDICATOR ILLUMINATION. . . . . . . 8L-82
BULB - REMOVAL, VANITY LAMP . . . . . . . . 8L-83
BUMPER - INSTALLATION, J OUNCE . . . . . . . 2-19
BUMPER - REMOVAL, J OUNCE . . . . . . . . . . . 2-19
BURNT FLUID - DIAGNOSIS AND
TESTING, CAUSES OF . . . . . . . . . . . . . . . . 21-125
BUSHING - NV3550 - INSTALLATION,
EXTENSION HOUSING. . . . . . . . . . . . . . . . . 21-74
BUSHING - NV3550 - REMOVAL,
EXTENSION HOUSING. . . . . . . . . . . . . . . . . 21-73
BUSHINGS - INSTALLATION, STABILIZER
BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
BUSHINGS - REMOVAL, STABILIZER BAR . . . 2-9
BUSHINGS, AND BALL J OINT -
DESCRIPTION, UPPER SUSPENSION
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
BUSHINGS, AND BALL J OINT -
OPERATION, UPPER SUSPENSION
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
CABLE - ADJ USTMENTS, GEARSHIFT . . . . 21-130
CABLE - ADJ USTMENTS, PARK-
INTERLOCK . . . . . . . . . . . . . . . . . . . . . . . . 21-154
CABLE - DESCRIPTION . . . . . . . . . . . . . . . . . 8P-3
CABLE - DESCRIPTION, ANTENNA BODY . . . 8A-4
CABLE - DIAGNOSIS AND TESTING,
ANTENNA BODY . . . . . . . . . . . . . . . . . . . . . . 8A-5
CABLE - DIAGNOSIS AND TESTING,
GEARSHIFT . . . . . . . . . . . . . . . . . . . . . . . . 21-128
CABLE - INSTALLATION, ANTENNA BODY . . 8A-6
CABLE - INSTALLATION, GEARSHIFT . . . . 21-129
CABLE - INSTALLATION, INSTRUMENT
PANEL ANTENNA. . . . . . . . . . . . . . . . . . . . . . 8A-8
CABLE - INSTALLATION, LATCH RELEASE . 23-120
CABLE - INSTALLATION, PARK -
INTERLOCK . . . . . . . . . . . . . . . . . . . . . . . . 21-153
CABLE - INSTALLATION, THROTTLE
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-46
CABLE - OPERATION . . . . . . . . . . . . . . . . . . . 8P-3
CABLE - OPERATION, ANTENNA BODY . . . . . 8A-5
CABLE - REMOVAL, ANTENNA BODY . . . . . . 8A-6
CABLE - REMOVAL, GEARSHIFT . . . . . . . . 21-128
CABLE - REMOVAL, INSTRUMENT PANEL
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-7
CABLE - REMOVAL, LATCH RELEASE . . . . 23-120
CABLE - REMOVAL, PARK - INTERLOCK . 21-153
CABLE - REMOVAL, THROTTLE
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-45
CABLE RESISTANCE, 2.4L - SPARK PLUG . . . 8I-3
CABLES - DESCRIPTION, BATTERY . . . . . . . 8F-18
CABLES - DIAGNOSIS AND TESTING,
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-19
CABLES - INSTALLATION . . . . . . . . . . . . . . . 5-30
CABLES - OPERATION, BATTERY . . . . . . . . 8F-18
CABLES - REMOVAL . . . . . . . . . . . . . . . . . . . 5-30
CALIBRATION - STANDARD PROCEDURE,
COMPASS. . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-2
CALIPER ADAPTER - INSTALLATION,
DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
CALIPER ADAPTER - REMOVAL, DISC
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
CALIPERS - ASSEMBLY, DISC BRAKE . . . . . . 5-16
CALIPERS - CLEANING, DISC BRAKE . . . . . . 5-16
CALIPERS - DESCRIPTION, DISC BRAKE . . . 5-13
CALIPERS - DISASSEMBLY, DISC BRAKE . . . 5-14
CALIPERS - INSPECTION, DISC BRAKE . . . . 5-16
CALIPERS - INSTALLATION, DISC BRAKE . . . 5-17
CALIPERS - OPERATION, DISC BRAKE . . . . . 5-14
CALIPERS - REMOVAL, DISC BRAKE . . . . . . 5-14
CAMBER AND CASTER ADJ USTMENT -
STANDARD PROCEDURE. . . . . . . . . . . . . . . . . 2-5
CAMBER, CASTER AND TOE
ADJ USTMENT - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
CAMSHAFT(S) - DESCRIPTION . . . . . . . 9-23,9-33
CAMSHAFT(S) - INSTALLATION . . . . . . 9-25,9-33
CAMSHAFT(S) - REMOVAL . . . . . . . . . . 9-24,9-33
CANISTER - DESCRIPTION, VAPOR . . . . . . 25-33
CANISTER - INSTALLATION, VAPOR . . . . . . 25-33
CANISTER - OPERATION, VAPOR . . . . . . . . 25-33
CANISTER - REMOVAL, VAPOR . . . . . . . . . . 25-33
CAP - CLEANING, RADIATOR PRESSURE . . . 7-25
CAP - DESCRIPTION, FUEL FILLER . . . . . . . 25-27
CAP - DESCRIPTION, RADIATOR
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
CAP - DIAGNOSIS AND TESTING,
RADIATOR PRESSURE . . . . . . . . . . . . . . . . . 7-25
CAP - INSPECTION, RADIATOR
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
CAP - INSTALLATION, INSTRUMENT
PANEL END . . . . . . . . . . . . . . . . . . . . . . . . 23-153
CAP - OPERATION, FUEL FILLER . . . . . . . . 25-27
CAP - OPERATION, RADIATOR
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
CAP - REMOVAL, INSTRUMENT PANEL
END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-153
CAPACITIES - SPECIFICATIONS, FLUID . . . . . . 0-4
CAPACITOR - DESCRIPTION, IGNITION
COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-16
CAPACITOR - INSTALLATION, IGNITION
COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-16
CAPACITOR - OPERATION, IGNITION
COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-16
CAPACITOR - REMOVAL, IGNITION COIL . . . 8I-16
CAPACITY - SPECIFICATIONS, CHARGE . . . 24-42
CAPACITY TEST - DIAGNOSIS AND
TESTING, FUEL PUMP . . . . . . . . . . . . . . . . . 14-15
CARDAN UNIVERSAL J OINTS -
ASSEMBLY, SINGLE. . . . . . . . . . . . . . . . . . . . . 3-9
CARDAN UNIVERSAL J OINTS -
DISASSEMBLY, SINGLE . . . . . . . . . . . . . . . . . . 3-8
CARGO LAMP BULB - INSTALLATION . . . . . 8L-73
CARGO LAMP BULB - REMOVAL . . . . . . . . 8L-72
CARGO LAMP SWITCH - INSTALLATION . . 8L-74
CARGO LAMP SWITCH - REMOVAL . . . . . . 8L-73
CARGO LAMP UNIT - INSTALLATION . . . . . 8L-74
CARGO LAMP UNIT - REMOVAL . . . . . . . . . 8L-74
CARPETS AND FLOOR MATS -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-158
CARPETS AND FLOOR MATS - REMOVAL . 23-158
CASE - NV231 - ASSEMBLY, TRANSFER . . 21-194
CASE - NV231 - CLEANING, TRANSFER . . 21-190
CASE - NV231 - DESCRIPTION,
TRANSFER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
CASE - NV231 - DESCRIPTION,
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-178
CASE - NV231 - DIAGNOSIS AND
TESTING, TRANSFER. . . . . . . . . . . . . . . . . 21-180
CASE - NV231 - DISASSEMBLY,
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-182
CASE - NV231 - INSPECTION, TRANSFER . 21-190
CASE - NV231 - INSTALLATION,
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-205
CASE - NV231 - OPERATION, TRANSFER . 21-179
CASE - NV231 - REMOVAL, TRANSFER . . 21-181
CASE - NV242 - ASSEMBLY, TRANSFER . . 21-230
CASE - NV242 - CLEANING, TRANSFER . . 21-227
CASE - NV242 - DESCRIPTION,
TRANSFER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
CASE - NV242 - DESCRIPTION,
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-215
CASE - NV242 - DIAGNOSIS AND
TESTING, TRANSFER. . . . . . . . . . . . . . . . . 21-216
CASE - NV242 - DISASSEMBLY,
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-218
CASE - NV242 - INSPECTION, TRANSFER . 21-228
CASE - NV242 - INSTALLATION,
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-243
CASE - NV242 - OPERATION, TRANSFER . 21-215
CASE - NV242 - REMOVAL, TRANSFER . . 21-217
CASE BEARINGS - INSTALLATION,
DIFFERENTIAL . . . . . . . . . . . . . . . 3-110,3-44,3-79
4 INDEX KJ
Description Group-Page Description Group-Page Description Group-Page
CASE BEARINGS - REMOVAL,
DIFFERENTIAL . . . . . . . . . . . . . . . 3-110,3-43,3-79
CASE, NV231 - TRANSFER . . . . . . . . . . . . 21-206
CASE, NV242 - TRANSFER . . . . . . . . . . . . 21-244
CASE SKID PLATE - INSTALLATION,
TRANSFER. . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
CASE SKID PLATE - REMOVAL,
TRANSFER. . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
CASE, SPECIFICATIONS - NV242
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-244
CASTER ADJ USTMENT - STANDARD
PROCEDURE, CAMBER . . . . . . . . . . . . . . . . . . 2-5
CASTER AND TOE ADJ USTMENT -
STANDARD PROCEDURE, CAMBER . . . . . . . . 2-5
CATALYTIC CONVERTER - DESCRIPTION . . . 11-2
CATALYTIC CONVERTER - INSPECTION . . . . 11-3
CATALYTIC CONVERTER - INSTALLATION . . . 11-3
CATALYTIC CONVERTER - REMOVAL . . . . . . 11-2
CAUSES OF BURNT FLUID - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 21-125
CAUTION - SERVICE CAUTIONS . . . . . . . . . 24-39
CAUTION, HALF SHAFT . . . . . . . . . . . . . . . . . 3-10
CAUTION, REFRIGERANT HOSES/LINES/
TUBES PRECAUTIONS . . . . . . . . . . . . . . . . . 24-40
CAUTIONS, CAUTION - SERVICE . . . . . . . . . 24-39
CD CHANGER - DESCRIPTION . . . . . . . . . . . 8A-7
CD CHANGER - INSTALLATION . . . . . . . . . . . 8A-7
CD CHANGER - OPERATION . . . . . . . . . . . . . 8A-7
CD CHANGER - REMOVAL . . . . . . . . . . . . . . 8A-7
CENTER - DESCRIPTION, POWER
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . 8W-97-6
CENTER - OPERATION, POWER
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . 8W-97-7
CENTER - REMOVAL, POWER
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . 8W-97-7
CENTER ASSEMBLY, ASSEMBLY -
POWER DISTRIBUTION. . . . . . . . . . . . . 8W-97-10
CENTER BEZEL - INSTALLATION,
INSTRUMENT PANEL. . . . . . . . . . . . . . . . . 23-154
CENTER BEZEL - REMOVAL,
INSTRUMENT PANEL. . . . . . . . . . . . . . . . . 23-154
CENTER DISASSEMBLY, DISASSEMBLY -
POWER DISTRIBUTION. . . . . . . . . . . . . . 8W-97-7
CENTER HIGH MOUNTED STOP LAMP
BULB - INSTALLATION . . . . . . . . . . . . . . . . 8L-19
CENTER HIGH MOUNTED STOP LAMP
BULB - REMOVAL . . . . . . . . . . . . . . . . . . . . 8L-18
CENTER HIGH MOUNTED STOP LAMP
UNIT - INSTALLATION . . . . . . . . . . . . . . . . . 8L-19
CENTER HIGH MOUNTED STOP LAMP
UNIT - REMOVAL . . . . . . . . . . . . . . . . . . . . 8L-19
CENTER SEAT BELT & RETRACTOR -
INSTALLATION, REAR . . . . . . . . . . . . . . . . . 8O-33
CENTER SEAT BELT & RETRACTOR -
REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . 8O-32
CENTERING - STANDARD PROCEDURE,
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . 8O-14
CERTIFICATION LABEL - DESCRIPTION,
VEHICLE SAFETY . . . . . . . . . . . . . . . . . . . Intro.-9
CHAIN COVER(S) - INSTALLATION,
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . 9-76
CHAIN COVER(S) - REMOVAL, TIMING
BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-74
CHAIN WEAR, STANDARD PROCEDURE -
MEASURING TIMING. . . . . . . . . . . . . . . . . . . 9-71
CHANGER - DESCRIPTION, CD . . . . . . . . . . . 8A-7
CHANGER - INSTALLATION, CD . . . . . . . . . . 8A-7
CHANGER - OPERATION, CD . . . . . . . . . . . . . 8A-7
CHANGER - REMOVAL, CD . . . . . . . . . . . . . . 8A-7
CHANNEL - INSTALLATION, GLASS RUN . 23-123,
23-130
CHANNEL - REMOVAL, GLASS RUN . . . . 23-123,
23-130
CHARGE - STANDARD PROCEDURE,
REFRIGERANT SYSTEM . . . . . . . . . . . . . . . 24-41
CHARGE CAPACITY - SPECIFICATIONS . . . . 24-42
CHARGING - STANDARD PROCEDURE,
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-8
CHARGING INDICATOR - DESCRIPTION . . . 8J -15
CHARGING INDICATOR - OPERATION . . . . . 8J -15
CHARGING SYSTEM - DESCRIPTION . . . . . 8F-22
CHARGING SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-22
CHARGING SYSTEM - OPERATION . . . . . . . 8F-22
CHART - DIAGNOSIS AND TESTING,
COOLING SYSTEM DIAGNOSIS . . . . . . . . . . . . 7-6
CHART, SPECIFICATIONS - TORQUE . . . . . 19-15,
19-19,19-8
CHART, SPECIFICATIONS - TORQUE . . . . 2-17,2-8
CHECK - STANDARD PROCEDURE, FLUID
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-126
CHECK - STANDARD PROCEDURE, OIL
PUMP VOLUME . . . . . . . . . . . . . . . . . . . . . 21-148
CHECK STRAP - INSTALLATION . . 23-121,23-128,
23-135
CHECK STRAP - REMOVAL . . . . . 23-121,23-128,
23-135
CHECK VALVE - DESCRIPTION, FRONT . . . . 8R-8
CHECK VALVE - DESCRIPTION, FUEL
TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
CHECK VALVE - DESCRIPTION, REAR . . . . 8R-34
CHECK VALVE - DESCRIPTION, VACUUM . . 24-28
CHECK VALVE - INSTALLATION, FRONT . . . . 8R-9
CHECK VALVE - INSTALLATION, FUEL
TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
CHECK VALVE - INSTALLATION, REAR . . . . 8R-35
CHECK VALVE - INSTALLATION, VACUUM . 24-28
CHECK VALVE - OPERATION, FRONT . . . . . . 8R-9
CHECK VALVE - OPERATION, FUEL TANK . . 14-28
CHECK VALVE - OPERATION, REAR . . . . . . 8R-34
CHECK VALVE - OPERATION, VACUUM . . . . 24-28
CHECK VALVE - REMOVAL, FRONT . . . . . . . 8R-9
CHECK VALVE - REMOVAL, FUEL TANK . . . 14-28
CHECK VALVE - REMOVAL, REAR . . . . . . . 8R-34
CHECK VALVE - REMOVAL, VACUUM . . . . . 24-28
CHECKING TRANSMISSION CLUTCH
OPERATION - DIAGNOSIS AND
TESTING, AIR . . . . . . . . . . . . . . . . . . . . . . . 21-80
CHECKS - DIAGNOSIS AND TESTING,
PRELIMINARY . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
CHILD TETHER ANCHOR - DESCRIPTION . . 8O-13
CHILD TETHER ANCHOR - OPERATION . . . 8O-13
CHIME WARNING SYSTEM -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8B-1
CHIME WARNING SYSTEM - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8B-6
CHIME WARNING SYSTEM - OPERATION . . . 8B-2
CHOKE AND RELAY - DESCRIPTION,
AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-3
CHOKE AND RELAY - DIAGNOSIS AND
TESTING, AMPLIFIER . . . . . . . . . . . . . . . . . . 8A-4
CHOKE AND RELAY - INSTALLATION,
AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-4
CHOKE AND RELAY - OPERATION,
AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-3
CHOKE AND RELAY - REMOVAL,
AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-4
CIGAR LIGHTER OUTLET -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 8W-97-2
CIGAR LIGHTER OUTLET - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . 8W-97-2
CIGAR LIGHTER OUTLET - OPERATION . 8W-97-2
CLEVIS BRACKET - INSTALLATION . . . . . . . . 2-13
CLEVIS BRACKET - REMOVAL . . . . . . . . . . . 2-13
CLOCKSPRING - DESCRIPTION . . . . . . . . . 8O-13
CLOCKSPRING - INSTALLATION . . . . . . . . . 8O-16
CLOCKSPRING - OPERATION . . . . . . . . . . . 8O-14
CLOCKSPRING - REMOVAL . . . . . . . . . . . . 8O-15
CLOCKSPRING CENTERING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8O-14
CLUSTER - ASSEMBLY, INSTRUMENT . . . . 8J -10
CLUSTER - DESCRIPTION, INSTRUMENT . . . 8J -2
CLUSTER - DIAGNOSIS AND TESTING,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . . 8J -7
CLUSTER - DISASSEMBLY, INSTRUMENT . . . 8J -9
CLUSTER - INSTALLATION, INSTRUMENT . 8J -11
CLUSTER - OPERATION, INSTRUMENT . . . . . 8J -4
CLUSTER - REMOVAL, INSTRUMENT . . . . . . 8J -9
CLUSTER BEZEL - INSTALLATION . . . . . . . 23-147
CLUSTER BEZEL - REMOVAL . . . . . . . . . . 23-147
CLUTCH - ASSEMBLY, LOW/REVERSE . . . 21-146
CLUTCH - CLEANING, LOW/REVERSE . . . . 21-146
CLUTCH - DESCRIPTION . . . . . . . . . . . . . . . . . 6-1
CLUTCH - DIAGNOSIS AND TESTING . . . . . . . 6-2
CLUTCH - DISASSEMBLY, LOW/REVERSE . 21-145
CLUTCH - INSPECTION, A/C
COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . 24-14
CLUTCH - INSPECTION, LOW/REVERSE . . 21-146
CLUTCH - INSTALLATION, A/C
COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . 24-14
CLUTCH - OPERATION . . . . . . . . . . . . . . . . . . 6-1
CLUTCH - REMOVAL, A/C COMPRESSOR . . 24-13
CLUTCH - SPECIFICATIONS . . . . . . . . . . . . . . . 6-5
CLUTCH - WARNING . . . . . . . . . . . . . . . . . . . . 6-2
CLUTCH ASSEMBLY - ASSEMBLY, INPUT . 21-138
CLUTCH ASSEMBLY - DESCRIPTION,
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-133
CLUTCH ASSEMBLY - DISASSEMBLY,
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-135
CLUTCH ASSEMBLY - OPERATION,
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-135
CLUTCH BREAK-IN - STANDARD
PROCEDURE, A/C COMPRESSOR . . . . . . . . 24-12
CLUTCH COIL - DIAGNOSIS AND
TESTING, A/C COMPRESSOR . . . . . . . . . . . 24-12
CLUTCH DISC - INSTALLATION . . . . . . . . . . . . 6-6
CLUTCH DISC - REMOVAL . . . . . . . . . . . . . . . 6-6
CLUTCH OPERATION - DIAGNOSIS AND
TESTING, AIR CHECKING
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . 21-80
CLUTCH PEDAL - INSTALLATION . . . . . . . . . 6-10
CLUTCH PEDAL - REMOVAL . . . . . . . . . . . . . 6-10
CLUTCH PEDAL POSITION SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 6-11
CLUTCH PEDAL POSITION SWITCH -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 6-11
CLUTCH PEDAL POSITION SWITCH -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
CLUTCH RELAY - DESCRIPTION, A/C
COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . 24-15
CLUTCH RELAY - DIAGNOSIS AND
TESTING, COMPRESSOR. . . . . . . . . . . . . . . 24-15
CLUTCH RELAY - INSTALLATION, A/C
COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . 24-16
CLUTCH RELAY - OPERATION, A/C
COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . 24-15
CLUTCH RELAY - REMOVAL, A/C
COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . . 24-16
CLUTCH RELEASE BEARING -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 6-6
CLUTCH RELEASE BEARING - REMOVAL . . . . 6-6
CLUTCH SWITCH OVERRIDE RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 6-10
CLUTCH SWITCH OVERRIDE RELAY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 6-10
CLUTCH SWITCH OVERRIDE RELAY -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
CLUTCH SWITCH OVERRIDE RELAY -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
CLUTCHES - DESCRIPTION, HOLDING . . . 21-131
CLUTCHES - OPERATION, HOLDING . . . . . 21-132
CMTC LAMP REPLACEMENT -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8M-2
COAT FINISH - DESCRIPTION, BASE
COAT/CLEAR . . . . . . . . . . . . . . . . . . . . . . . 23-162
COAT/CLEAR COAT FINISH -
DESCRIPTION, BASE . . . . . . . . . . . . . . . . . 23-162
CODE - DESCRIPTION, PAINT . . . . . . . . . . 23-162
CODES - DESCRIPTION, DIAGNOSTIC
TROUBLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
CODES - SPECIFICATIONS, PAINT . . . . . . . 23-162
CODES - STANDARD PROCEDURE,
ERASING TRANSMITTER . . . . . . . . . . . . . . . 8M-8
CODES - STANDARD PROCEDURE,
SETTING TRANSMITTER . . . . . . . . . . . . . . . 8M-9
COIL - DESCRIPTION, IGNITION . . . . . . . . . . 8I-9
COIL - DIAGNOSIS AND TESTING, A/C
COMPRESSOR CLUTCH . . . . . . . . . . . . . . . 24-12
COIL - INSTALLATION, IGNITION . . . . . . . . . 8I-10
COIL - OPERATION, IGNITION . . . . . . . . . . . . 8I-9
COIL - REMOVAL, IGNITION . . . . . . . . . . . . 8I-10
COIL CAPACITOR - DESCRIPTION,
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-16
COIL CAPACITOR - INSTALLATION,
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-16
COIL CAPACITOR - OPERATION,
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-16
COIL CAPACITOR - REMOVAL, IGNITION . . . 8I-16
COIL RESISTANCE, 2.4L - IGNITION . . . . . . . 8I-2
COIL RESISTANCE, 3.7L V-6 - IGNITION . . . . 8I-3
COLLAPSIBLE SPACER - INSTALLATION . . . . 3-70
COLLAPSIBLE SPACER - REMOVAL . . . . . . . 3-70
COLUMN - DESCRIPTION . . . . . . . . . . . . . . . 19-5
COLUMN - INSTALLATION . . . . . . . . . . . . . . . 19-7
COLUMN - REMOVAL . . . . . . . . . . . . . . . . . . 19-5
COLUMN, SPECIAL TOOLS - STEERING . . . . 19-8
COMBINATION FLASHER - DESCRIPTION . . 8L-19
COMBINATION FLASHER - OPERATION . . . 8L-19
COMBUSTION PRESSURE LEAKAGE -
DIAGNOSIS AND TESTING, CYLINDER . . . . . . 9-8
COMMUNICATION - DESCRIPTION . . . . . . . . 8E-8
COMMUNICATION - OPERATION . . . . . . . . . . 8E-8
KJ INDEX 5
Description Group-Page Description Group-Page Description Group-Page
COMPASS CALIBRATION - STANDARD
PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . 8M-2
COMPASS DEMAGNETIZING -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8M-2
COMPASS MINI-TRIP COMPUTER -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8M-6
COMPASS MINI-TRIP ILLUMINATION
BULB - INSTALLATION . . . . . . . . . . . . . . . . 8L-75
COMPASS MINI-TRIP ILLUMINATION
BULB - REMOVAL . . . . . . . . . . . . . . . . . . . . 8L-74
COMPASS VARIATION ADJ USTMENT -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8M-3
COMPASS/MINI-TRIP COMPUTER -
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 8M-4
COMPASS/MINI-TRIP COMPUTER -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8M-8
COMPASS/MINI-TRIP COMPUTER -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8M-5
COMPASS/MINI-TRIP COMPUTER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7
COMPRESSION PRESSURE - DIAGNOSIS
AND TESTING, CYLINDER . . . . . . . . . . . . . . . . 9-8
COMPRESSOR CLUTCH - INSPECTION,
A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-14
COMPRESSOR CLUTCH - INSTALLATION,
A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-14
COMPRESSOR CLUTCH - REMOVAL, A/C . . 24-13
COMPRESSOR CLUTCH BREAK-IN -
STANDARD PROCEDURE, A/C . . . . . . . . . . . 24-12
COMPRESSOR CLUTCH COIL -
DIAGNOSIS AND TESTING, A/C. . . . . . . . . . 24-12
COMPRESSOR CLUTCH RELAY -
DESCRIPTION, A/C . . . . . . . . . . . . . . . . . . . 24-15
COMPRESSOR CLUTCH RELAY -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 24-15
COMPRESSOR CLUTCH RELAY -
INSTALLATION, A/C . . . . . . . . . . . . . . . . . . . 24-16
COMPRESSOR CLUTCH RELAY -
OPERATION, A/C . . . . . . . . . . . . . . . . . . . . . 24-15
COMPRESSOR CLUTCH RELAY -
REMOVAL, A/C . . . . . . . . . . . . . . . . . . . . . . 24-16
COMPRESSOR NOISE - DIAGNOSIS AND
TESTING, A/C . . . . . . . . . . . . . . . . . . . . . . . 24-42
COMPUTER - DESCRIPTION, COMPASS/
MINI-TRIP . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-4
COMPUTER - DIAGNOSIS AND TESTING,
COMPASS MINI-TRIP . . . . . . . . . . . . . . . . . . 8M-6
COMPUTER - INSTALLATION, COMPASS/
MINI-TRIP . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-8
COMPUTER - OPERATION, COMPASS/
MINI-TRIP . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-5
COMPUTER - REMOVAL, COMPASS/
MINI-TRIP . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7
CONDENSER - DESCRIPTION, A/C . . . . . . . 24-45
CONDENSER - INSTALLATION, A/C . . . . . . . 24-46
CONDENSER - OPERATION, A/C . . . . . . . . . 24-45
CONDENSER - REMOVAL, A/C . . . . . . . . . . 24-45
CONDITIONER - DESCRIPTION, HEATER
AND AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1
CONDITIONER - OPERATION, HEATER
AND AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-2
CONDITIONS - DIAGNOSIS AND
TESTING, SPARK PLUG . . . . . . . . . . . . . . . . 8I-13
CONNECT FITTING - DESCRIPTION,
QUICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-10
CONNECTING ROD - DESCRIPTION,
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
CONNECTING ROD BEARING - FITTING -
STANDARD PROCEDURE. . . . . . . . . . . . . . . . 9-40
CONNECTING ROD BEARING, FITTING . . . . . 9-49
CONNECTOR - DESCRIPTION, DATA LINK . 8E-10
CONNECTOR - INSTALLATION . . . . . . . 8W-01-11
CONNECTOR - INSTALLATION, TRAILER
TOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-61
CONNECTOR - OPERATION, DATA LINK . . . 8E-10
CONNECTOR - REMOVAL . . . . . . . . . . . 8W-01-11
CONNECTOR - REMOVAL, TRAILER TOW . . 8L-61
CONNECTOR, GROUND AND SPLICE
INFORMATION - DESCRIPTION. . . . . . . . 8W-01-7
CONNECTOR/GROUND/SPLICE LOCATION
- DESCRIPTION. . . . . . . . . . . . . . . . . . . . 8W-91-1
CONSOLE - DESCRIPTION, OVERHEAD . . . . 8M-1
CONSOLE - INSTALLATION, FLOOR . . . . . 23-158
CONSOLE - OPERATION, OVERHEAD . . . . . . 8M-2
CONSOLE - REMOVAL, FLOOR . . . . . . . . . 23-158
CONSOLE DUCT - INSTALLATION, FLOOR . 24-31
CONSOLE DUCT - REMOVAL, FLOOR . . . . . 24-31
CONSOLE LID LATCH - INSTALLATION,
FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-158
CONSOLE LID LATCH - REMOVAL,
FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-158
CONSOLE, REMOVAL - OVERHEAD . . . . . . . 8M-4
CONTAINER - DESCRIPTION, COOLANT
RECOVERY PRESS . . . . . . . . . . . . . . . . . . . . 7-19
CONTAINER - OPERATION, COOLANT
RECOVERY PRESS . . . . . . . . . . . . . . . . . . . . 7-19
CONTAMINATION - DIAGNOSIS AND
TESTING, BRAKE FLUID . . . . . . . . . . . . . . . . 5-26
CONTAMINATION - DIAGNOSIS AND
TESTING, FLUID . . . . . . . . . . . . . . . . . . . . 21-125
CONTINUITY - STANDARD PROCEDURE,
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-9
CONTROL - DESCRIPTION, A/C HEATER . . . 24-16
CONTROL - DESCRIPTION, IGNITION . . . . . . 8I-1
CONTROL - DESCRIPTION, SPEED . . . . . . . . 8P-1
CONTROL - INSTALLATION, A/C HEATER . . 24-17
CONTROL - OPERATION, IGNITION . . . . . . . . 8I-1
CONTROL - OPERATION, SPEED . . . . . . . . . . 8P-1
CONTROL - REMOVAL, A/C HEATER . . . . . . 24-17
CONTROL - TORQUE, SPEED . . . . . . . . . . . . 8P-2
CONTROL ARM - DESCRIPTION, LOWER . . . 2-21
CONTROL ARM - INSTALLATION, LOWER . . 2-10,
2-21
CONTROL ARM - INSTALLATION, UPPER . . . 2-21
CONTROL ARM - OPERATION, LOWER . . . . . 2-21
CONTROL ARM - REMOVAL, LOWER . . 2-10,2-21
CONTROL ARM - REMOVAL, UPPER . . . . . . 2-20
CONTROL ASSEMBLY WINDOW
DEFOGGER FUNCTION - DIAGNOSIS
AND TESTING, REAR HVAC . . . . . . . . . . . . . 8G-9
CONTROL CABLE - INSTALLATION,
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-46
CONTROL CABLE - REMOVAL,
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-45
CONTROL ILLUMINATION BULB -
INSTALLATION, HEATER-A/C . . . . . . . . . . . . 8L-78
CONTROL ILLUMINATION BULB -
REMOVAL, HEATER-A/C . . . . . . . . . . . . . . . 8L-78
CONTROL INFORMATION (VECI) LABEL -
DESCRIPTION, VEHICLE EMISSION . . . . . Intro.-8
CONTROL MODULE - DESCRIPTION,
AIRBAG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-9
CONTROL MODULE - DESCRIPTION,
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-2
CONTROL MODULE - DESCRIPTION,
SIDE IMPACT AIRBAG. . . . . . . . . . . . . . . . . 8O-43
CONTROL MODULE - DESCRIPTION,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . 8E-18
CONTROL MODULE - DIAGNOSIS AND
TESTING, BODY . . . . . . . . . . . . . . . . . . . . . . . 8E-7
CONTROL MODULE - INSTALLATION . . . . 23-183
CONTROL MODULE - INSTALLATION,
AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-12
CONTROL MODULE - INSTALLATION,
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-7
CONTROL MODULE - INSTALLATION,
SIDE IMPACT AIRBAG. . . . . . . . . . . . . . . . . 8O-45
CONTROL MODULE - OPERATION,
AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-10
CONTROL MODULE - OPERATION, BODY . . . 8E-5
CONTROL MODULE - OPERATION, SIDE
IMPACT AIRBAG . . . . . . . . . . . . . . . . . . . . . 8O-43
CONTROL MODULE - OPERATION,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . 8E-18
CONTROL MODULE - REMOVAL . . . . . . . . 23-183
CONTROL MODULE - REMOVAL, AIRBAG . 8O-11
CONTROL MODULE - REMOVAL, BODY . . . . 8E-7
CONTROL MODULE - REMOVAL, SIDE
IMPACT AIRBAG . . . . . . . . . . . . . . . . . . . . . 8O-44
CONTROL MOTOR - DESCRIPTION, IDLE
AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
CONTROL MOTOR - INSTALLATION, IDLE
AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-36
CONTROL MOTOR - OPERATION, IDLE
AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
CONTROL MOTOR - REMOVAL, IDLE AIR . . 14-36
CONTROL RELAY - DESCRIPTION,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-168
CONTROL RELAY - OPERATION,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-168
CONTROL SWITCH - DESCRIPTION . . . . . 23-184
CONTROL SWITCH - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 23-184
CONTROL SWITCH - INSTALLATION . . . . . 23-184
CONTROL SWITCH - OPERATION . . . . . . . 23-184
CONTROL SWITCH - REMOVAL . . . . . . . . 23-184
CONTROL SYSTEM - DESCRIPTION,
EMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1
CONTROL SYSTEM - DESCRIPTION,
EVAPORATION . . . . . . . . . . . . . . . . . . . . . . . 25-24
CONTROLLER ANTILOCK BRAKE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8E-10
CONTROLLER ANTILOCK BRAKE -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-10
CONVERTER - DESCRIPTION, CATALYTIC . . . 11-2
CONVERTER - DESCRIPTION, TORQUE . . . 21-162
CONVERTER - INSPECTION, CATALYTIC . . . . 11-3
CONVERTER - INSTALLATION, CATALYTIC . . 11-3
CONVERTER - INSTALLATION, TORQUE . . 21-167
CONVERTER - OPERATION, TORQUE . . . . 21-166
CONVERTER - REMOVAL, CATALYTIC . . . . . . 11-2
CONVERTER - REMOVAL, TORQUE . . . . . . 21-167
CONVERTER HOUSING FLUID LEAK -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 21-80
COOLANT - DESCRIPTION, ENGINE . . . . . . . . 0-3
COOLANT LOW INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -15
COOLANT LOW INDICATOR - OPERATION . 8J -16
COOLANT RECOVERY PRESS
CONTAINER - DESCRIPTION . . . . . . . . . . . . . 7-19
COOLANT RECOVERY PRESS
CONTAINER - OPERATION. . . . . . . . . . . . . . . 7-19
COOLANT TEMPERATURE SENSOR -
DESCRIPTION, ENGINE . . . . . . . . . . . . . . . . . 7-19
COOLANT TEMPERATURE SENSOR -
INSTALLATION, ENGINE . . . . . . . . . . . . . . . . 7-21
COOLANT TEMPERATURE SENSOR -
OPERATION, ENGINE. . . . . . . . . . . . . . . . . . . 7-20
COOLANT TEMPERATURE SENSOR -
REMOVAL, ENGINE . . . . . . . . . . . . . . . . . . . . 7-20
COOLANT THERMOSTAT - OPERATION,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
COOLER - DESCRIPTION, FLUID . . . . . . . . . 19-20
COOLER - DESCRIPTION, TRANS . . . . . . . . . 7-32
COOLER - INSTALLATION, FLUID . . . . . . . . 19-20
COOLER - OPERATION, FLUID . . . . . . . . . . 19-20
COOLER - REMOVAL, FLUID . . . . . . . . . . . . 19-20
COOLING, SPECIAL TOOLS . . . . . . . . . . . . . . 7-14
COOLING SYSTEM - OPERATION . . . . . . . . . . 7-2
COOLING SYSTEM - REVERSE
FLUSHING - STANDARD PROCEDURE . . . . . 7-12
COOLING SYSTEM 3.7L ENGINE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
COOLING SYSTEM 3.7L ENGINE -
STANDARD PROCEDURE, DRAINING . . . . . . 7-12
COOLING SYSTEM 3.7L ENGINE -
STANDARD PROCEDURE, REFILLING . . . . . . 7-12
COOLING SYSTEM DIAGNOSIS CHART -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 7-6
COOLING SYSTEM LEAKS - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
COOLING SYSTEM REQUIREMENTS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 24-1
COOLING SYSTEM ROUTING 3.7L
ENGINE - DESCRIPTION . . . . . . . . . . . . . . . . . 7-2
CORE - DESCRIPTION, HEATER . . . . . . . . . 24-52
CORE - INSTALLATION, HEATER . . . . . . . . . 24-53
CORE - OPERATION, HEATER . . . . . . . . . . . 24-52
CORE - REMOVAL, HEATER . . . . . . . . . . . . 24-52
CORE AND OIL GALLERY PLUGS -
STANDARD PROCEDURE, ENGINE . . . . . . . . 9-10
COURTESY LAMP BULB - INSTALLATION . . 8L-76
COURTESY LAMP BULB - REMOVAL . . . . . 8L-75
COURTESY LAMP REPLACEMENT -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8M-2
COURTESY LAMP UNIT - INSTALLATION . . 8L-77
COURTESY LAMP UNIT - REMOVAL . . . . . . 8L-76
COVER - DESCRIPTION, STRUCTURAL . . . . . 9-55
COVER - FRONT - INSTALLATION, SEAT
BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
COVER - FRONT - INSTALLATION, SEAT
CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
COVER - FRONT - REMOVAL, SEAT BACK . 23-166
COVER - FRONT - REMOVAL, SEAT
CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
COVER - INSTALLATION, COWL TRIM . . . 23-157
COVER - INSTALLATION, INSTRUMENT
PANEL TOP . . . . . . . . . . . . . . . . . . . . . . . . 23-153
COVER - INSTALLATION, STRUCTURAL . . . . 9-55
COVER - OPERATION, STRUCTURAL . . . . . . 9-55
COVER - REAR - INSTALLATION, SEAT
BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-169
COVER - REAR - REMOVAL, SEAT BACK . 23-169
6 INDEX KJ
Description Group-Page Description Group-Page Description Group-Page
COVER - REMOVAL, COWL TRIM . . . . . . . 23-157
COVER - REMOVAL, INSTRUMENT
PANEL TOP . . . . . . . . . . . . . . . . . . . . . . . . 23-152
COVER - REMOVAL, STRUCTURAL . . . . . . . . 9-55
COVER(S) - DESCRIPTION, CYLINDER
HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
COVER(S) - INSTALLATION, CYLINDER
HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26,9-34
COVER(S) - INSTALLATION, TIMING
BELT / CHAIN . . . . . . . . . . . . . . . . . . . . . . . . 9-76
COVER(S) - REMOVAL, CYLINDER HEAD . . 9-25,
9-34
COVER(S) - REMOVAL, TIMING BELT /
CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-74
COWL GRILLE - INSTALLATION . . . . . . . . 23-140
COWL GRILLE - REMOVAL . . . . . . . . . . . . 23-140
COWL TRIM COVER - INSTALLATION . . . . 23-157
COWL TRIM COVER - REMOVAL . . . . . . . 23-157
COWL WEATHERSTRIP - INSTALLATION . 23-185
COWL WEATHERSTRIP - REMOVAL . . . . . 23-185
COWL/PLENUM SEAL - INSTALLATION . . . 23-187
COWL/PLENUM SEAL - REMOVAL . . . . . . 23-187
COWL/PLENUM WINDOW BAFFLE SEAL -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-187
COWL/PLENUM WINDOW BAFFLE SEAL -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-187
CRADLE CROSSMEMBER -
INSTALLATION, ENGINE . . . . . . . . . . . . . . . . 13-6
CRADLE CROSSMEMBER - REMOVAL,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
CRANKSHAFT - DESCRIPTION . . . . . . . . . . . 9-42
CRANKSHAFT - INSPECTION . . . . . . . . . . . . . 9-43
CRANKSHAFT - INSTALLATION . . . . . . . . . . . 9-43
CRANKSHAFT - REMOVAL . . . . . . . . . . . . . . 9-43
CRANKSHAFT OIL SEAL - FRONT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 9-47
CRANKSHAFT OIL SEAL - FRONT -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
CRANKSHAFT OIL SEAL - REAR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 9-48
CRANKSHAFT OIL SEAL - REAR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
CRANKSHAFT POSITION SENSOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-30
CRANKSHAFT POSITION SENSOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-32
CRANKSHAFT POSITION SENSOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-31
CRANKSHAFT POSITION SENSOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-31
CROSSMEMBER - INSTALLATION,
ENGINE CRADLE . . . . . . . . . . . . . . . . . . . . . . 13-6
CROSSMEMBER - INSTALLATION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . 23-146
CROSSMEMBER - INSTALLATION, REAR . . . 13-7
CROSSMEMBER - REMOVAL, ENGINE
CRADLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
CROSSMEMBER - REMOVAL, RADIATOR . 23-146
CROSSMEMBER - REMOVAL, REAR . . . . . . . 13-7
CROSS-OVER PIPE - INSTALLATION . . . . . . . 11-3
CROSS-OVER PIPE - REMOVAL . . . . . . . . . . 11-3
CRUISE INDICATOR - DESCRIPTION . . . . . . 8J -16
CRUISE INDICATOR - OPERATION . . . . . . . 8J -17
CURTAIN AIRBAG - DESCRIPTION, SIDE . . 8O-38
CURTAIN AIRBAG - INSTALLATION, SIDE . . 8O-41
CURTAIN AIRBAG - OPERATION, SIDE . . . . 8O-39
CURTAIN AIRBAG - REMOVAL, SIDE . . . . . 8O-40
CUSHION - FRONT - INSTALLATION,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
CUSHION - FRONT - INSTALLATION,
SEAT BACK . . . . . . . . . . . . . . . . . . . . . . . . 23-167
CUSHION - FRONT - REMOVAL, SEAT . . . 23-167
CUSHION - FRONT - REMOVAL, SEAT
BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
CUSHION - REAR - INSTALLATION, SEAT . 23-171
CUSHION - REAR - INSTALLATION, SEAT
BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
CUSHION - REAR - REMOVAL, SEAT . . . . 23-171
CUSHION - REAR - REMOVAL, SEAT
BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
CUSHION COVER - FRONT -
INSTALLATION, SEAT. . . . . . . . . . . . . . . . . 23-167
CUSHION COVER - FRONT - REMOVAL,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
CUSHION SIDE SHIELDS -
INSTALLATION, SEAT. . . . . . . . . . . . . . . . . 23-167
CUSHION SIDE SHIELDS - REMOVAL,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
CUSTOMER PREFERENCES - STANDARD
PROCEDURE, RKE TRANSMITTER . . . . . . . . 8N-8
CV J OINT/BOOT-INNER - INSTALLATION . . . 3-17
CV J OINT/BOOT-INNER - REMOVAL . . . . . . . 3-15
CV J OINT/BOOT-OUTER - INSTALLATION . . . 3-13
CV J OINT/BOOT-OUTER - REMOVAL . . . . . . . 3-12
CYLINDER - DESCRIPTION, MASTER . . . . . . 5-24
CYLINDER - INSPECTION, MASTER . . . . . . . . 6-9
CYLINDER - INSTALLATION, FLIP-UP
GLASS SUPPORT . . . . . . . . . . . . . . . . . . . 23-139
CYLINDER - INSTALLATION, LOCK . . . . . . 23-125,
23-138
CYLINDER - INSTALLATION, LOCK . . . . . . . 19-11
CYLINDER - INSTALLATION, MASTER . . . . . 5-25
CYLINDER - INSTALLATION, SUPPORT . . . 23-120
CYLINDER - OPERATION, MASTER . . . . . . . . 5-24
CYLINDER - REMOVAL, FLIP-UP GLASS
SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . 23-139
CYLINDER - REMOVAL, LOCK . . . . 23-125,23-137
CYLINDER - REMOVAL, LOCK . . . . . . . . . . . 19-10
CYLINDER - REMOVAL, MASTER . . . . . . . . . 5-25
CYLINDER - REMOVAL, SUPPORT . . . . . . 23-120
CYLINDER BLEEDING - STANDARD
PROCEDURE, MASTER . . . . . . . . . . . . . . . . . 5-24
CYLINDER BORE HONING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
CYLINDER COMBUSTION PRESSURE
LEAKAGE - DIAGNOSIS AND TESTING . . . . . . 9-8
CYLINDER COMPRESSION PRESSURE -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 9-8
CYLINDER FLUID LEVEL - STANDARD
PROCEDURES, MASTER . . . . . . . . . . . . . . . . 5-26
CYLINDER HEAD - DESCRIPTION . . . . . . . . . 9-30
CYLINDER HEAD COVER(S) -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 9-25
CYLINDER HEAD COVER(S) -
INSTALLATION. . . . . . . . . . . . . . . . . . . . 9-26,9-34
CYLINDER HEAD COVER(S) - REMOVAL . . . 9-25,
9-34
CYLINDER HEAD GASKET - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . 9-19,9-30
CYLINDER LOCK SWITCH -
DESCRIPTION, DOOR . . . . . . . . . . . . . . . . . . 8Q-9
CYLINDER LOCK SWITCH -
DESCRIPTION, TAILGATE . . . . . . . . . . . . . . . 8N-9
CYLINDER LOCK SWITCH - DIAGNOSIS
AND TESTING, DOOR . . . . . . . . . . . . . . . . . 8Q-10
CYLINDER LOCK SWITCH - DIAGNOSIS
AND TESTING, TAILGATE . . . . . . . . . . . . . . . 8N-9
CYLINDER LOCK SWITCH -
INSTALLATION, DOOR. . . . . . . . . . . . . . . . . 8Q-10
CYLINDER LOCK SWITCH -
INSTALLATION, TAILGATE. . . . . . . . . . . . . . 8N-10
CYLINDER LOCK SWITCH - OPERATION,
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
CYLINDER LOCK SWITCH - OPERATION,
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-9
CYLINDER LOCK SWITCH - REMOVAL,
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
CYLINDER LOCK SWITCH - REMOVAL,
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-10
CYLINDER/POWER BOOSTER -
DIAGNOSIS AND TESTING, MASTER . . 5-21,5-24
CYLINDERS - ASSEMBLY, WHEEL . . . . . . . . . 5-29
CYLINDERS - CLEANING, WHEEL . . . . . . . . . 5-28
CYLINDERS - DISASSEMBLY, WHEEL . . . . . . 5-28
CYLINDERS - INSPECTION, WHEEL . . . . . . . 5-29
CYLINDERS - INSTALLATION, WHEEL . . . . . 5-29
CYLINDERS - REMOVAL, WHEEL . . . . . . . . . 5-28
DAMAGED OR WORN THREADS -
STANDARD PROCEDURE, REPAIR . . . . . . . . . 9-9
DAMPER - INSTALLATION, VIBRATION . . . . . 9-55
DAMPER - REMOVAL, VIBRATION . . . . . . . . 9-54
DATA LINK CONNECTOR - DESCRIPTION . . 8E-10
DATA LINK CONNECTOR - OPERATION . . . . 8E-10
DAYTIME RUNNING LAMP RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-20
DAYTIME RUNNING LAMP RELAY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-21
DAYTIME RUNNING LAMP RELAY -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8L-20
DAYTIME RUNNING LAMP RELAY -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-21
DECOUPLER - DIAGNOSIS AND
TESTING, GENERATOR . . . . . . . . . . . . . . . . 8F-27
DECOUPLER PULLEY - DESCRIPTION,
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . 8F-26
DECOUPLER PULLEY - INSTALLATION,
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . 8F-30
DECOUPLER PULLEY - OPERATION,
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . 8F-27
DECOUPLER PULLEY - REMOVAL,
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . 8F-27
DEFINITION - DESCRIPTION, TRIP . . . . . . . 25-19
DEFLECTOR - INSTALLATION, WIND . . . . . 23-180
DEFLECTOR - REMOVAL, WIND . . . . . . . . 23-180
DEFOGGER - DESCRIPTION, REAR
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-3
DEFOGGER - OPERATION, REAR
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-3
DEFOGGER FUNCTION - DIAGNOSIS AND
TESTING, REAR HVAC CONTROL
ASSEMBLY WINDOW . . . . . . . . . . . . . . . . . . 8G-9
DEFOGGER GRID - DESCRIPTION, REAR
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-5
DEFOGGER GRID - DIAGNOSIS AND
TESTING, REAR WINDOW . . . . . . . . . . . . . . 8G-5
DEFOGGER GRID - OPERATION, REAR
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-5
DEFOGGER RELAY - DESCRIPTION,
REAR WINDOW. . . . . . . . . . . . . . . . . . . . . . . 8G-6
DEFOGGER RELAY - DIAGNOSIS AND
TESTING, REAR WINDOW . . . . . . . . . . . . . . 8G-6
DEFOGGER RELAY - INSTALLATION,
REAR WINDOW. . . . . . . . . . . . . . . . . . . . . . . 8G-7
DEFOGGER RELAY - OPERATION, REAR
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-6
DEFOGGER RELAY - REMOVAL, REAR
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-7
DEFOGGER SWITCH - DESCRIPTION,
REAR WINDOW. . . . . . . . . . . . . . . . . . . . . . . 8G-8
DEFOGGER SWITCH - DIAGNOSIS AND
TESTING, REAR WINDOW . . . . . . . . . . . . . . 8G-8
DEFOGGER SWITCH - OPERATION, REAR
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-8
DEFOGGER SYSTEM - DIAGNOSIS AND
TESTING, REAR WINDOW . . . . . . . . . . . . . . 8G-4
DEFROST DOO - INSTALLATION, FLOOR . . 24-37
DEFROST DOOR - REMOVAL . . . . . . . . . . . 24-35
DEFROST DOOR - REMOVAL, FLOOR . . . . . 24-36
DEFROST DOOR ACTUATOR -
INSTALLATION, FLOOR . . . . . . . . . . . . . . . . 24-25
DEFROST DOOR ACTUATOR - REMOVAL,
FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-24
DEFROST DUCT/DEMISTER ADAPTOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-32
DEFROST/DEMISTER DUCT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-32
DELIVERY - DESCRIPTION, FUEL . . . . . . . . . 14-2
DELIVERY - OPERATION, FUEL . . . . . . . . . . . 14-3
DEMAGNETIZING - STANDARD
PROCEDURE, COMPASS . . . . . . . . . . . . . . . 8M-2
DEMISTER OUTLETS - DESCRIPTION . . . . . 24-29
DEPLOYMENT - STANDARD
PROCEDURE, SERVICE AFTER A
SUPPLEMENTAL RESTRAINT . . . . . . . . . . . . 8O-6
DETECTION PUMP - DESCRIPTION, LEAK . 25-27
DETECTION PUMP - INSTALLATION,
LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-28
DETECTION PUMP - OPERATION, LEAK . . . 25-28
DETECTION PUMP - REMOVAL, LEAK . . . . 25-28
DEVICES - STANDARD PROCEDURE,
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE. . . . . . . . . . . . . . . . . . . . . . . . 8W-01-8
DIAGNOSIS CHART - DIAGNOSIS AND
TESTING, COOLING SYSTEM . . . . . . . . . . . . . 7-6
DIAGNOSIS, DIAGNOSIS AND TESTING -
WATER DRAINAGE AND WIND NOISE . . . 23-176
DIAGNOSTIC PROCEDURES, DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 23-176
DIAGNOSTIC TROUBLE CODES -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 25-2
DIAGNOSTICS (OBD) - DIAGNOSIS AND
TESTING, ON-BOARD . . . . . . . . . . . . . . . . . . . 7-3
DIAGRAMS - DESCRIPTION, HOW TO
USE WIRING. . . . . . . . . . . . . . . . . . . . . . 8W-01-1
DIAGRAMS - HYDRAULIC SCHEMATICS,
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . 21-100
DIESEL - TORQUE, EXCEPT . . . . . . . . . . . . . 8F-23
DIFFERENTIAL - ASSEMBLY . . . . . . . . 3-105,3-41
DIFFERENTIAL - DISASSEMBLY . . . . . 3-105,3-41
DIFFERENTIAL - INSTALLATION . 3-105,3-42,3-73
DIFFERENTIAL - REMOVAL . . . . . 3-104,3-40,3-71
DIFFERENTIAL - TRAC-LOK - ASSEMBLY . . 3-109,
3-77
KJ INDEX 7
Description Group-Page Description Group-Page Description Group-Page
DIFFERENTIAL - TRAC-LOK - CLEANING . . 3-109,
3-77
DIFFERENTIAL - TRAC-LOK -
DISASSEMBLY . . . . . . . . . . . . . . . . . . . 3-107,3-75
DIFFERENTIAL - TRAC-LOK -
INSPECTION . . . . . . . . . . . . . . . . . . . . 3-109,3-77
DIFFERENTIAL CASE BEARINGS -
INSTALLATION. . . . . . . . . . . . . . . 3-110,3-44,3-79
DIFFERENTIAL CASE BEARINGS -
REMOVAL . . . . . . . . . . . . . . . . . . 3-110,3-43,3-79
DIMENSIONS - SPECIFICATIONS, FRAME . . . 13-3
DIMENSIONS - SPECIFICATIONS,
OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . 23-111
DIODE - INSTALLATION . . . . . . . . . . . . 8W-01-14
DIODE - REMOVAL . . . . . . . . . . . . . . . . 8W-01-14
DIODE REPLACEMENT - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-9
DISASSEMBLY - POWER DISTRIBUTION
CENTER DISASSEMBLY . . . . . . . . . . . . . 8W-97-7
DISASSEMBLY, 4C RETAINER/BULKHEAD . 21-122
DISASSEMBLY, DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-83
DISASSEMBLY, DIFFERENTIAL . . . . . . 3-105,3-41
DISASSEMBLY, DIFFERENTIAL -
TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . 3-107,3-75
DISASSEMBLY, DISASSEMBLY - POWER
DISTRIBUTION CENTER . . . . . . . . . . . . . 8W-97-7
DISASSEMBLY, DISC BRAKE CALIPERS . . . . 5-14
DISASSEMBLY, HVAC HOUSING . . . . . . . . . 24-34
DISASSEMBLY, INPUT CLUTCH
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . 21-135
DISASSEMBLY, INSTRUMENT CLUSTER . . . . 8J -9
DISASSEMBLY, LOW/REVERSE CLUTCH . . 21-145
DISASSEMBLY, MANUAL - NV1500 . . . . . . . . 21-4
DISASSEMBLY, MANUAL - NV3550 . . . . . . . 21-35
DISASSEMBLY, OIL PUMP . . . . . . . . . . . . . . . 9-65
DISASSEMBLY, OIL PUMP . . . . . . . . . . . . . 21-149
DISASSEMBLY, PLANETARY GEARTRAIN . 21-159
DISASSEMBLY, SINGLE CARDAN
UNIVERSAL J OINTS . . . . . . . . . . . . . . . . . . . . 3-8
DISASSEMBLY, TRANSFER CASE -
NV231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-182
DISASSEMBLY, TRANSFER CASE -
NV242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-218
DISASSEMBLY, VALVE BODY . . . . . . . . . . . 21-173
DISASSEMBLY, WHEEL CYLINDERS . . . . . . . 5-28
DISC - INSTALLATION, CLUTCH . . . . . . . . . . . 6-6
DISC - REMOVAL, CLUTCH . . . . . . . . . . . . . . . 6-6
DISC BRAKE CALIPER ADAPTER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 5-18
DISC BRAKE CALIPER ADAPTER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
DISC BRAKE CALIPERS - ASSEMBLY . . . . . . 5-16
DISC BRAKE CALIPERS - CLEANING . . . . . . 5-16
DISC BRAKE CALIPERS - DESCRIPTION . . . . 5-13
DISC BRAKE CALIPERS - DISASSEMBLY . . . 5-14
DISC BRAKE CALIPERS - INSPECTION . . . . . 5-16
DISC BRAKE CALIPERS - INSTALLATION . . . 5-17
DISC BRAKE CALIPERS - OPERATION . . . . . 5-14
DISC BRAKE CALIPERS - REMOVAL . . . . . . . 5-14
DISC BRAKE ROTOR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
DISC BRAKE ROTOR - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
DISCHARGE (ESD) SENSITIVE DEVICES -
STANDARD PROCEDURE,
ELECTROSTATIC . . . . . . . . . . . . . . . . . . . 8W-01-8
DISCHARGE LINE - INSTALLATION, A/C . . . 24-47
DISCHARGE LINE - REMOVAL, A/C . . . . . . . 24-46
DISPLAY TEST MODE - DESCRIPTION,
STATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
DISTRIBUTION - DESCRIPTION, POWER . 8W-97-1
DISTRIBUTION - OPERATION, POWER . . 8W-97-1
DISTRIBUTION CENTER - DESCRIPTION,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-6
DISTRIBUTION CENTER - OPERATION,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-7
DISTRIBUTION CENTER - REMOVAL,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-7
DISTRIBUTION CENTER ASSEMBLY,
ASSEMBLY - POWER . . . . . . . . . . . . . . 8W-97-10
DISTRIBUTION CENTER DISASSEMBLY,
DISASSEMBLY - POWER . . . . . . . . . . . . 8W-97-7
DISTRIBUTION SYSTEMS, SPECIAL
TOOLS - POWER. . . . . . . . . . . . . . . . . . . 8W-97-2
DOO - INSTALLATION, FLOOR -
DEFROST . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-37
DOOR - INSTALLATION . . . . . . . . . 23-122,23-129
DOOR - INSTALLATION, BLEND . . . . . . . . . 24-35
DOOR - INSTALLATION, PANEL . . . . . . . . . . 24-36
DOOR - INSTALLATION, PASSENGER
AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-30
DOOR - INSTALLATION, RECIRC . . . . . . . . . 24-37
DOOR - REMOVAL . . . . . . . . . . . . . 23-122,23-129
DOOR - REMOVAL, BLEND . . . . . . . . . . . . . 24-35
DOOR - REMOVAL, DEFROST . . . . . . . . . . . 24-35
DOOR - REMOVAL, FLOOR - DEFROST . . . . 24-36
DOOR - REMOVAL, PASSENGER AIRBAG . . 8O-29
DOOR - REMOVAL, RECIRC . . . . . . . . . . . . 24-37
DOOR ACTUATOR - INSTALLATION,
BLEND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-20
DOOR ACTUATOR - INSTALLATION,
FLOOR - DEFROST . . . . . . . . . . . . . . . . . . . 24-25
DOOR ACTUATOR - INSTALLATION,
PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
DOOR ACTUATOR - INSTALLATION,
RECIRCULATION . . . . . . . . . . . . . . . . . . . . . 24-26
DOOR ACTUATOR - REMOVAL, BLEND . . . . 24-20
DOOR ACTUATOR - REMOVAL, FLOOR -
DEFROST . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-24
DOOR ACTUATOR - REMOVAL, PANEL . . . . 24-24
DOOR ACTUATOR - REMOVAL,
RECIRCULATION . . . . . . . . . . . . . . . . . . . . . 24-26
DOOR AJ AR INDICATOR - DESCRIPTION . . 8J -17
DOOR AJ AR INDICATOR - OPERATION . . . . 8J -17
DOOR AJ AR SWITCH - DESCRIPTION . . . . 8L-77
DOOR AJ AR SWITCH - OPERATION. . . . . . . . 8L-77
DOOR CYLINDER LOCK SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8Q-9
DOOR CYLINDER LOCK SWITCH -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8Q-10
DOOR CYLINDER LOCK SWITCH -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8Q-10
DOOR CYLINDER LOCK SWITCH -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
DOOR CYLINDER LOCK SWITCH -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
DOOR GLASS - INSTALLATION . . 23-122,23-129,
23-172
DOOR GLASS - REMOVAL . . . . . . 23-122,23-129,
23-172
DOOR LOCK / UNLOCK SWITCH -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8N-5
DOOR LOCK / UNLOCK SWITCH -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-4
DOOR LOCK MOTOR - DESCRIPTION . . . . . . 8N-5
DOOR LOCK MOTOR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-5
DOOR LOCK MOTOR - OPERATION . . . . . . . 8N-5
DOOR LOCK RELAY - DESCRIPTION . . . . . . 8N-6
DOOR LOCK RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-6
DOOR LOCK RELAY - INSTALLATION . . . . . . 8N-7
DOOR LOCK RELAY - OPERATION . . . . . . . . 8N-6
DOOR LOCK RELAY - REMOVAL . . . . . . . . . 8N-6
DOOR LOCK/UNLOCK SWITCH -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8N-4
DOOR LOWER WEATHERSTRIP -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-186
DOOR LOWER WEATHERSTRIP -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
DOOR OUTER BELT MOLDING -
INSTALLATION, FRONT . . . . . . . . . . . . . . . 23-186
DOOR OUTER BELT MOLDING -
INSTALLATION, REAR . . . . . . . . . . . . . . . . 23-186
DOOR OUTER BELT MOLDING -
REMOVAL, FRONT . . . . . . . . . . . . . . . . . . . 23-186
DOOR OUTER BELT MOLDING -
REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . 23-186
DOOR PRIMARY WEATHERSTRIP -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-185
DOOR PRIMARY WEATHERSTRIP -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-185
DOOR SCUFF PLATE - INSTALLATION,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-160
DOOR SCUFF PLATE - REMOVAL, REAR . . 23-160
DOOR SILL SCUFF PLATE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-157
DOOR SILL SCUFF PLATE - REMOVAL . . . 23-157
DOOR/HOUSING - INSTALLATION, FUEL
FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-141
DOOR/HOUSING - REMOVAL, FUEL FILL . 23-141
DOUBLE INVERTED FLARING -
STANDARD PROCEDURE. . . . . . . . . . . . . . . . . 5-8
DRAIN AND FILL - STANDARD
PROCEDURE, FLUID . . . . . . . . . . . 21-208,21-246
DRAIN TUBE - INSTALLATION . . . . . . . . . . 23-181
DRAIN TUBE - REMOVAL . . . . . . . . . . . . . 23-180
DRAINAGE AND WIND NOISE
DIAGNOSIS, DIAGNOSIS AND TESTING
- WATER . . . . . . . . . . . . . . . . . . . . . . . . . . 23-176
DRAINING COOLING SYSTEM 3.7L
ENGINE - STANDARD PROCEDURE. . . . . . . . 7-12
DRAW TEST - STANDARD PROCEDURE,
IGNITION-OFF . . . . . . . . . . . . . . . . . . . . . . . 8F-14
DRIVE - DIAGNOSIS AND TESTING,
VISCOUS FAN . . . . . . . . . . . . . . . . . . . . . . . . 7-28
DRIVE BELT - DIAGNOSIS AND TESTING,
SERPENTINE . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
DRIVE MOTOR - INSTALLATION . . . . . . . . 23-182
DRIVE MOTOR - REMOVAL . . . . . . . . . . . . 23-182
DRIVER AIRBAG - DESCRIPTION . . . . . . . . 8O-17
DRIVER AIRBAG - INSTALLATION . . . . . . . 8O-20
DRIVER AIRBAG - OPERATION . . . . . . . . . . 8O-18
DRIVER AIRBAG - REMOVAL . . . . . . . . . . . 8O-19
DRIVER SEAT HEATER SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8G-11
DRIVER SEAT HEATER SWITCH -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8G-13
DRIVER SEAT HEATER SWITCH -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8G-12
DRIVER SEAT HEATER SWITCH -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-13
DRIVER SIDE BEZELS - INSTALLATION,
INSTRUMENT PANEL. . . . . . . . . . . . . . . . . 23-154
DRIVER SIDE BEZELS - REMOVAL,
INSTRUMENT PANEL. . . . . . . . . . . . . . . . . 23-153
DROP - STANDARD PROCEDURE,
TESTING FOR A VOLTAGE. . . . . . . . . . . 8W-01-10
DRUM - DIAGNOSIS AND TESTING,
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
DRUM BRAKE - ADJ USTMENT, REAR . . . . . . 5-12
DRUM BRAKE - DESCRIPTION, REAR . . . . . 5-10
DRUM BRAKE - OPERATION, REAR . . . . . . . 5-11
DRUM BRAKE SHOES - INSTALLATION . . . . 5-11
DRUM BRAKE SHOES - REMOVAL . . . . . . . . 5-11
DRUM MACHINING - STANDARD
PROCEDURES, BRAKE . . . . . . . . . . . . . . . . . 5-27
DUCT - INSTALLATION, DEFROST/
DEMISTER . . . . . . . . . . . . . . . . . . . . . . . . . . 24-32
DUCT - INSTALLATION, FLOOR . . . . . . . . . . 24-32
DUCT - INSTALLATION, FLOOR CONSOLE . 24-31
DUCT - REMOVAL, FLOOR . . . . . . . . . . . . . 24-32
DUCT - REMOVAL, FLOOR CONSOLE . . . . . 24-31
DUCT/DEMISTER ADAPTOR - REMOVAL,
DEFROST . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-32
EFFECTS OF INCORRECT FLUID LEVEL -
DIAGNOSIS AND TESTING . . . . . . . . . . . . 21-125
ELECTRIC - DESCRIPTION, RADIATOR
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
ELECTRIC - INSTALLATION, RADIATOR
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
ELECTRIC - INSTALLATION, WINDOW
REGULATOR . . . . . . . . . . . . . . . . . 23-126,23-134
ELECTRIC - OPERATION, RADIATOR FAN . . . 7-26
ELECTRIC - REMOVAL, RADIATOR FAN . . . . 7-26
ELECTRIC - REMOVAL, WINDOW
REGULATOR . . . . . . . . . . . . . . . . . 23-126,23-134
ELECTRICAL - DESCRIPTION . . . . . . . . . . . . 5-34
ELECTRICAL - OPERATION . . . . . . . . . . . . . . 5-34
ELECTRICAL TESTER - STANDARD
PROCEDURE, USING MIDTRONICS . . . . . . . 8F-15
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 8W-01-8
ELEMENT - DESCRIPTION, HEATED SEAT . 8G-13
ELEMENT - DIAGNOSIS AND TESTING,
HEATED SEAT . . . . . . . . . . . . . . . . . . . . . . . 8G-13
ELEMENT - OPERATION, HEATED SEAT . . . 8G-13
EMISSION CONTROL INFORMATION
(VECI) LABEL - DESCRIPTION,
VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-8
EMISSION CONTROL SYSTEM -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 25-1
END - INSTALLATION, TIE ROD . . . . . . . . . 19-16
END - REMOVAL, TIE ROD . . . . . . . . . . . . . 19-16
END CAP - INSTALLATION, INSTRUMENT
PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-153
END CAP - REMOVAL, INSTRUMENT
PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-153
END REMOVAL TOOL, SPECIAL TOOLS -
OUTER TIE ROD . . . . . . . . . . . . . . . . . . . . . 19-15
ENGINE - 3.7L - DESCRIPTION . . . . . . . . . . . . 9-3
ENGINE - DESCRIPTION, 3.7L . . . . . . . . . . . . 7-21
8 INDEX KJ
Description Group-Page Description Group-Page Description Group-Page
ENGINE - DESCRIPTION, COOLING
SYSTEM 3.7L . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
ENGINE - DESCRIPTION, COOLING
SYSTEM ROUTING 3.7L . . . . . . . . . . . . . . . . . 7-2
ENGINE - INSTALLATION, 3.7L . . . 7-17,7-18,7-22
ENGINE - REMOVAL, 3.7L . . . . . . . . . . . 7-17,7-21
ENGINE - STANDARD PROCEDURE,
DRAINING COOLING SYSTEM 3.7L . . . . . . . . 7-12
ENGINE - STANDARD PROCEDURE,
REFILLING COOLING SYSTEM 3.7L . . . . . . . 7-12
ENGINE BLOCK - CLEANING . . . . . . . . . . . . . 9-39
ENGINE BLOCK - DESCRIPTION . . . . . . . . . . 9-39
ENGINE BLOCK - INSPECTION . . . . . . . . . . . 9-40
ENGINE COOLANT - DESCRIPTION . . . . . . . . . 0-3
ENGINE COOLANT TEMPERATURE
SENSOR - DESCRIPTION . . . . . . . . . . . . . . . 7-19
ENGINE COOLANT TEMPERATURE
SENSOR - INSTALLATION . . . . . . . . . . . . . . . 7-21
ENGINE COOLANT TEMPERATURE
SENSOR - OPERATION . . . . . . . . . . . . . . . . . 7-20
ENGINE COOLANT TEMPERATURE
SENSOR - REMOVAL . . . . . . . . . . . . . . . . . . . 7-20
ENGINE COOLANT THERMOSTAT -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
ENGINE CORE AND OIL GALLERY PLUGS
- STANDARD PROCEDURE . . . . . . . . . . . . . . 9-10
ENGINE CRADLE CROSSMEMBER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 13-6
ENGINE CRADLE CROSSMEMBER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
ENGINE DIAGNOSIS - INTRODUCTION -
DIAGNOSIS AND TESTING. . . . . . . . . . . . . . . . . 9-4
ENGINE DIAGNOSIS - LUBRICATION -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 9-7
ENGINE DIAGNOSIS - MECHANICAL -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 9-6
ENGINE DIAGNOSIS - PERFORMANCE -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 9-4
ENGINE FIRING ORDER, 2.4L 4-
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-2
ENGINE FIRING ORDER, 3.7L V-6 . . . . . . . . . 8I-2
ENGINE GASKET SURFACE
PREPARATION - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
ENGINE OIL - STANDARD PROCEDURE . . . . 9-61
ENGINE OIL LEAK - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60
ENGINE OIL PRESSURE - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 9-60
ENGINE, SPECIAL TOOLS - 3.7L . . . . . . . . . . 9-15
ENGINE, SPECIFICATIONS - 3.7L . . . . . . . . . 9-12
ENGINE TEMPERATURE GAUGE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -18
ENGINE TEMPERATURE GAUGE -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -18
ENGINES - GENERATOR RATINGS, GAS . . . 8F-23
ENTRY MODULE - DESCRIPTION,
REMOTE KEYLESS . . . . . . . . . . . . . . . . . . . . 8N-7
ENTRY MODULE - DIAGNOSIS AND
TESTING, REMOTE KEYLESS . . . . . . . . . . . . 8N-7
ENTRY MODULE - INSTALLATION,
REMOTE KEYLESS . . . . . . . . . . . . . . . . . . . . 8N-7
ENTRY MODULE - OPERATION, REMOTE
KEYLESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
ENTRY MODULE - REMOVAL, REMOTE
KEYLESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
ENTRY TRANSMITTER - DIAGNOSIS AND
TESTING, REMOTE KEYLESS . . . . . . . . . . . . 8N-8
ENTRY TRANSMITTER -
SPECIFICATIONS, REMOTE KEYLESS . . . . . . 8N-9
EQUIPMENT - STANDARD PROCEDURE,
REFRIGERANT SYSTEM SERVICE . . . . . . . . 24-40
ERASING TRANSMITTER CODES -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8M-8
EVACUATE - STANDARD PROCEDURE,
REFRIGERANT SYSTEM . . . . . . . . . . . . . . . 24-41
EVAPORATION CONTROL SYSTEM -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 25-24
EVAPORATOR - DESCRIPTION, A/C . . . . . . . 24-49
EVAPORATOR - INSTALLATION, A/C . . . . . . 24-49
EVAPORATOR - OPERATION, A/C . . . . . . . . 24-49
EVAPORATOR - REMOVAL, A/C . . . . . . . . . . 24-49
EVAP/PURGE SOLENOID - DESCRIPTION . . 25-27
EVAP/PURGE SOLENOID - INSTALLATION . 25-27
EVAP/PURGE SOLENOID - OPERATION . . . . 25-27
EVAP/PURGE SOLENOID - REMOVAL . . . . . 25-27
EXCEPT DIESEL - TORQUE . . . . . . . . . . . . . 8F-23
EXHAUST MANIFOLD - DESCRIPTION . . . . . 9-69
EXHAUST MANIFOLD - INSTALLATION . . . . . 9-70
EXHAUST MANIFOLD - REMOVAL . . . . . . . . . 9-69
EXHAUST SYSTEM - DESCRIPTION . . . . . . . 11-1
EXHAUST SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
EXTENSION HOUSING BUSHING -
NV3550 - INSTALLATION. . . . . . . . . . . . . . . 21-74
EXTENSION HOUSING BUSHING -
NV3550 - REMOVAL . . . . . . . . . . . . . . . . . . 21-73
EXTENSION HOUSING SEAL - NV1500 -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 21-32
EXTENSION HOUSING SEAL - NV1500 -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 21-32
EXTENSION HOUSING SEAL - NV3550 -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 21-74
EXTENSION HOUSING SEAL - NV3550 -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 21-74
EXTERIOR - DESCRIPTION, LAMPS/
LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-2
EXTERIOR - DIAGNOSIS AND TESTING,
LAMPS/LIGHTING . . . . . . . . . . . . . . . . . . . . . 8L-7
EXTERIOR - OPERATION, LAMPS/
LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-5
EXTERIOR - SPECIFICATIONS,
LAMPS/LIGHTING . . . . . . . . . . . . . . . . . . . . 8L-15
EXTERIOR HANDLE - INSTALLATION . . . . 23-123,
23-130,23-136
EXTERIOR HANDLE - REMOVAL . 23-123,23-130,
23-136
EXTERIOR NAME PLATES -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-141
EXTERIOR NAME PLATES - REMOVAL . . . 23-140
FAN - ELECTRIC - DESCRIPTION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
FAN - ELECTRIC - INSTALLATION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
FAN - ELECTRIC - OPERATION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
FAN - ELECTRIC - REMOVAL, RADIATOR . . . 7-26
FAN - VISCOUS - CLEANING, RADIATOR . . . 7-29
FAN - VISCOUS - DESCRIPTION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
FAN - VISCOUS - INSPECTION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
FAN - VISCOUS - INSTALLATION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
FAN - VISCOUS - OPERATION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
FAN - VISCOUS - REMOVAL, RADIATOR . . . . 7-28
FAN DRIVE - DIAGNOSIS AND TESTING,
VISCOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
FASCIA - INSTALLATION, FRONT . . . . . . . . . 13-2
FASCIA - INSTALLATION, REAR . . . . . . . . . . 13-2
FASCIA - REMOVAL, FRONT . . . . . . . . . . . . . 13-1
FASCIA - REMOVAL, REAR . . . . . . . . . . . . . . 13-2
FASCIA SUPPORT - INSTALLATION,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
FASCIA SUPPORT - REMOVAL, REAR . . . . . . 13-3
FASTENER IDENTIFICATION -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . Intro.-1
FENDER - INSTALLATION, FRONT . . . . . . . 23-141
FENDER - REMOVAL, FRONT . . . . . . . . . . 23-141
FILL - STANDARD PROCEDURE, FLUID
DRAIN . . . . . . . . . . . . . . . . . . . . . . 21-208,21-246
FILL - STANDARD PROCEDURE,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-128
FILL DOOR/HOUSING - INSTALLATION,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-141
FILL DOOR/HOUSING - REMOVAL, FUEL . 23-141
FILL/CHECK LOCATIONS - DESCRIPTION,
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
FILLER CAP - DESCRIPTION, FUEL . . . . . . . 25-27
FILLER CAP - OPERATION, FUEL . . . . . . . . 25-27
FILTER - DESCRIPTION, FUEL . . . . . . . . . . . . 14-7
FILTER - INSTALLATION, FUEL . . . . . . . . . . . 14-8
FILTER - INSTALLATION, INLET . . . . . . . . . . 14-28
FILTER - INSTALLATION, OIL . . . . . . . . . . . . 9-63
FILTER - REMOVAL, FUEL . . . . . . . . . . . . . . . 14-7
FILTER - REMOVAL, INLET . . . . . . . . . . . . . 14-28
FILTER - REMOVAL, OIL . . . . . . . . . . . . . . . . 9-63
FILTER REPLACEMENT - STANDARD
PROCEDURE, FLUID . . . . . . . . . . . . . . . . . 21-126
FINESSE SANDING/BUFFING &
POLISHING - DESCRIPTION . . . . . . . . . . . 23-163
FINISH - DESCRIPTION, BASE
COAT/CLEAR COAT . . . . . . . . . . . . . . . . . . 23-162
FIRING ORDER, 2.4L 4-CYLINDER -
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-2
FIRING ORDER, 3.7L V-6 - ENGINE . . . . . . . . 8I-2
FITTING - CONNECTING ROD BEARING . . . . 9-49
FITTING - DESCRIPTION, QUICK
CONNECT. . . . . . . . . . . . . . . . . . . . . . . . . . . 14-10
FITTING - MAIN BEARING . . . . . . . . . . . . . . . 9-45
FITTING - STANDARD PROCEDURE,
CONNECTING ROD BEARING . . . . . . . . . . . . 9-40
FITTING - STANDARD PROCEDURE,
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
FITTING - STANDARD PROCEDURE,
PISTON RING . . . . . . . . . . . . . . . . . . . . . . . . 9-52
FITTINGS - STANDARD PROCEDURE,
QUICK-CONNECT . . . . . . . . . . . . . . . . . . . . . 14-10
FLARE MOLDINGS - INSTALLATION,
FRONT WHEEL OPENING . . . . . . . . . . . . . 23-145
FLARE MOLDINGS - INSTALLATION,
REAR WHEEL OPENING . . . . . . . . . . . . . . 23-145
FLARE MOLDINGS - REMOVAL, FRONT
WHEEL OPENING . . . . . . . . . . . . . . . . . . . 23-145
FLARE MOLDINGS - REMOVAL, REAR
WHEEL OPENING . . . . . . . . . . . . . . . . . . . 23-145
FLARING - STANDARD PROCEDURE,
DOUBLE INVERTED . . . . . . . . . . . . . . . . . . . . . 5-8
FLARING - STANDARD PROCEDURE, ISO . . . . 5-8
FLASHER - DESCRIPTION, COMBINATION . 8L-19
FLASHER - OPERATION, COMBINATION . . . 8L-19
FLEX PLATE - INSTALLATION . . . . . . . . . . . . 9-49
FLEX PLATE - REMOVAL . . . . . . . . . . . . . . . . 9-49
FLIP-UP GLASS - INSTALLATION . . . . . . . 23-136
FLIP-UP GLASS - REMOVAL . . . . . . . . . . . 23-136
FLIP-UP GLASS AJ AR SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-77
FLIP-UP GLASS AJ AR SWITCH -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8L-77
FLIP-UP GLASS LATCH - INSTALLATION . 23-136
FLIP-UP GLASS LATCH - REMOVAL . . . . . 23-136
FLIP-UP GLASS RELEASE SWITCH -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8N-5
FLIP-UP GLASS SUPPORT CYLINDER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-139
FLIP-UP GLASS SUPPORT CYLINDER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-139
FLOOR - DEFROST DOO - INSTALLATION . . 24-37
FLOOR - DEFROST DOOR - REMOVAL . . . . 24-36
FLOOR - DEFROST DOOR ACTUATOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-25
FLOOR - DEFROST DOOR ACTUATOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-24
FLOOR CONSOLE - INSTALLATION . . . . . . 23-158
FLOOR CONSOLE - REMOVAL . . . . . . . . . . 23-158
FLOOR CONSOLE DUCT - INSTALLATION . . 24-31
FLOOR CONSOLE DUCT - REMOVAL . . . . . 24-31
FLOOR CONSOLE LID LATCH -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-158
FLOOR CONSOLE LID LATCH - REMOVAL . 23-158
FLOOR DUCT - INSTALLATION . . . . . . . . . . 24-32
FLOOR DUCT - REMOVAL . . . . . . . . . . . . . . 24-32
FLOOR MATS - INSTALLATION, CARPETS . 23-158
FLOOR MATS - REMOVAL, CARPETS . . . . 23-158
FLOOR SHIFT BOOT - INSTALLATION,
4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-156
FLOOR SHIFT BOOT - REMOVAL, 4WD . . . 23-156
FLOW AND PRESSURE - DIAGNOSIS
AND TESTING, POWER STEERING . . . . . . . . 19-3
FLOW MANAGEMENT VALVE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 14-6
FLOW MANAGEMENT VALVE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 14-7
FLOW MANAGEMENT VALVE -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
FLOW MANAGEMENT VALVE - REMOVAL . . . 14-6
FLUID - DESCRIPTION, AUTOMATIC
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 0-2
FLUID - DIAGNOSIS AND TESTING,
CAUSES OF BURNT . . . . . . . . . . . . . . . . . . 21-125
FLUID - OPERATION, AUTOMATIC
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 0-4
FLUID AND FILTER REPLACEMENT -
STANDARD PROCEDURE. . . . . . . . . . . . . . 21-126
FLUID CAPACITIES - SPECIFICATIONS . . . . . . 0-4
FLUID CONTAMINATION - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 21-125
FLUID CONTAMINATION - DIAGNOSIS
AND TESTING, BRAKE. . . . . . . . . . . . . . . . . . 5-26
FLUID COOLER - DESCRIPTION . . . . . . . . . 19-20
FLUID COOLER - INSTALLATION . . . . . . . . . 19-20
FLUID COOLER - OPERATION . . . . . . . . . . . 19-20
FLUID COOLER - REMOVAL . . . . . . . . . . . . 19-20
KJ INDEX 9
Description Group-Page Description Group-Page Description Group-Page
FLUID DRAIN AND FILL - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . 21-208,21-246
FLUID FILL/CHECK LOCATIONS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
FLUID INDICATOR - DESCRIPTION,
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -35
FLUID INDICATOR - DIAGNOSIS AND
TESTING, WASHER . . . . . . . . . . . . . . . . . . . 8J -36
FLUID INDICATOR - OPERATION,
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -36
FLUID LEAK - DIAGNOSIS AND TESTING,
CONVERTER HOUSING . . . . . . . . . . . . . . . . 21-80
FLUID LEVEL - DIAGNOSIS AND
TESTING, EFFECTS OF INCORRECT. . . . . . 21-125
FLUID LEVEL - STANDARD
PROCEDURES, MASTER CYLINDER . . . . . . . 5-26
FLUID LEVEL CHECK - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 21-126
FLUID LEVEL SWITCH - DESCRIPTION,
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
FLUID LEVEL SWITCH - INSTALLATION,
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-18
FLUID LEVEL SWITCH - OPERATION,
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
FLUID LEVEL SWITCH - REMOVAL,
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
FLUID RESERVOIR - INSTALLATION . . . . . . . 5-26
FLUID RESERVOIR - REMOVAL . . . . . . . . . . 5-26
FLUID, SPECIFICATIONS - BRAKE . . . . . . . . . 5-27
FLUID TYPES - DESCRIPTION . . . . . . . . . . . . . 0-1
FLUSH - SPECIFICATIONS, GAP . . . . . . . . 23-116
FLUSHING - STANDARD PROCEDURE,
COOLING SYSTEM - REVERSE . . . . . . . . . . . 7-12
FLYWHEEL - DESCRIPTION . . . . . . . . . . . . . . . 6-7
FLYWHEEL - DIAGNOSIS AND TESTING . . . . . 6-8
FLYWHEEL - OPERATION . . . . . . . . . . . . . . . . 6-7
FOG LAMP BULB - INSTALLATION,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-22
FOG LAMP BULB - REMOVAL, FRONT . . . . 8L-21
FOG LAMP INDICATOR - DESCRIPTION,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -19
FOG LAMP INDICATOR - DESCRIPTION,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -27
FOG LAMP INDICATOR - OPERATION,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -19
FOG LAMP INDICATOR - OPERATION,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -27
FOG LAMP RELAY - DESCRIPTION,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-22
FOG LAMP RELAY - DESCRIPTION, REAR . 8L-56
FOG LAMP RELAY - DIAGNOSIS AND
TESTING, FRONT . . . . . . . . . . . . . . . . . . . . . 8L-23
FOG LAMP RELAY - DIAGNOSIS AND
TESTING, REAR . . . . . . . . . . . . . . . . . . . . . . 8L-57
FOG LAMP RELAY - INSTALLATION,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-24
FOG LAMP RELAY - INSTALLATION,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-58
FOG LAMP RELAY - OPERATION, FRONT . . 8L-22
FOG LAMP RELAY - OPERATION, REAR . . . 8L-57
FOG LAMP RELAY - REMOVAL, FRONT . . . 8L-24
FOG LAMP RELAY - REMOVAL, REAR . . . . 8L-58
FOG LAMP UNIT - ADJ USTMENT, FRONT . . 8L-25
FOG LAMP UNIT - INSTALLATION,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-25
FOG LAMP UNIT - REMOVAL, FRONT . . . . . 8L-25
FOLDING REAR SEAT BACK LATCH /
LOCK - INSTALLATION . . . . . . . . . . . . . . . 23-170
FOLDING REAR SEAT BACK LATCH /
LOCK - REMOVAL . . . . . . . . . . . . . . . . . . . 23-170
FOUR LOW MODE INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -29
FOUR LOW MODE INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -30
FRAME - REAR - INSTALLATION, SEAT
BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-171
FRAME - REAR - REMOVAL, SEAT BACK . 23-171
FRAME DIMENSIONS - SPECIFICATIONS . . . 13-3
FRONT - DESCRIPTION . . . . . . . . . . . . . . . . . . 2-7
FRONT - INSTALLATION, CRANKSHAFT
OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
FRONT - INSTALLATION, PROPELLER
SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
FRONT - INSTALLATION, SEAT . . . . . . . . . 23-165
FRONT - INSTALLATION, SEAT BACK . . . . 23-166
FRONT - INSTALLATION, SEAT BACK
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
FRONT - INSTALLATION, SEAT BACK
CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
FRONT - INSTALLATION, SEAT BACK
RECLINER . . . . . . . . . . . . . . . . . . . . . . . . . 23-166
FRONT - INSTALLATION, SEAT CUSHION . 23-167
FRONT - INSTALLATION, SEAT CUSHION
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
FRONT - REMOVAL, CRANKSHAFT OIL
SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
FRONT - REMOVAL, PROPELLER SHAFT . . . . 3-6
FRONT - REMOVAL, SEAT . . . . . . . . . . . . . 23-165
FRONT - REMOVAL, SEAT BACK . . . . . . . . 23-166
FRONT - REMOVAL, SEAT BACK COVER . . 23-166
FRONT - REMOVAL, SEAT BACK
CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
FRONT - REMOVAL, SEAT BACK
RECLINER . . . . . . . . . . . . . . . . . . . . . . . . . 23-166
FRONT - REMOVAL, SEAT CUSHION . . . . . 23-167
FRONT - REMOVAL, SEAT CUSHION
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
FRONT - WARNING . . . . . . . . . . . . . . . . . . . . . 2-7
FRONT AXLE - 186FIA - ADJ USTMENTS . . . . 3-25
FRONT AXLE - 186FIA - DESCRIPTION . . . . . 3-19
FRONT AXLE - 186FIA - INSTALLATION . . . . 3-24
FRONT AXLE - 186FIA - OPERATION . . . . . . 3-19
FRONT AXLE - 186FIA - REMOVAL . . . . . . . . 3-24
FRONT AXLE - SPECIFICATIONS . . . . . . . . . . 3-33
FRONT AXLE, SPECIAL TOOLS . . . . . . . . . . . 3-34
FRONT BRAKE HOSE - INSTALLATION. . . . . . . 5-10
FRONT BRAKE PADS - INSTALLATION . . . . . 5-11
FRONT BRAKE PADS - REMOVAL . . . . . . . . . 5-11
FRONT CHECK VALVE - DESCRIPTION . . . . . 8R-8
FRONT CHECK VALVE - INSTALLATION . . . . 8R-9
FRONT CHECK VALVE - OPERATION . . . . . . . 8R-9
FRONT CHECK VALVE - REMOVAL . . . . . . . . 8R-9
FRONT DOOR OUTER BELT MOLDING -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-186
FRONT DOOR OUTER BELT MOLDING -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
FRONT FASCIA - INSTALLATION . . . . . . . . . . 13-2
FRONT FASCIA - REMOVAL . . . . . . . . . . . . . . 13-1
FRONT FENDER - INSTALLATION . . . . . . . 23-141
FRONT FENDER - REMOVAL . . . . . . . . . . . 23-141
FRONT FOG LAMP BULB -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-22
FRONT FOG LAMP BULB - REMOVAL . . . . . 8L-21
FRONT FOG LAMP INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -19
FRONT FOG LAMP INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -19
FRONT FOG LAMP RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-22
FRONT FOG LAMP RELAY - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8L-23
FRONT FOG LAMP RELAY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-24
FRONT FOG LAMP RELAY - OPERATION . . 8L-22
FRONT FOG LAMP RELAY - REMOVAL . . . . 8L-24
FRONT FOG LAMP UNIT - ADJ USTMENT . . 8L-25
FRONT FOG LAMP UNIT - INSTALLATION . . 8L-25
FRONT FOG LAMP UNIT - REMOVAL . . . . . 8L-25
FRONT HOSE - REMOVAL . . . . . . . . . . . . . . . . 5-9
FRONT IMPACT SENSOR - DESCRIPTION . 8O-21
FRONT IMPACT SENSOR -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-22
FRONT IMPACT SENSOR - OPERATION . . . 8O-21
FRONT IMPACT SENSOR - REMOVAL . . . . 8O-22
FRONT LAMP BULB - INSTALLATION . . . . . 8L-27
FRONT LAMP BULB - REMOVAL . . . . . . . . . 8L-26
FRONT LAMP UNIT - INSTALLATION . . . . . 8L-28
FRONT LAMP UNIT - REMOVAL . . . . . . . . . 8L-27
FRONT MOUNT - INSTALLATION . . . . . . . . . . 9-57
FRONT MOUNT - REMOVAL . . . . . . . . . . . . . 9-56
FRONT OUTPUT SHAFT SEAL -
INSTALLATION. . . . . . . . . . . . . . . . 21-208,21-246
FRONT OUTPUT SHAFT SEAL -
REMOVAL . . . . . . . . . . . . . . . . . . . 21-208,21-246
FRONT POSITION LAMP BULB -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-28
FRONT POSITION LAMP BULB -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-28
FRONT SEAL - INSTALLATION, OIL
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-152
FRONT SEAL - REMOVAL, OIL PUMP . . . . 21-152
FRONT SEAT BELT & RETRACTOR -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-24
FRONT SEAT BELT & RETRACTOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-23
FRONT SEAT BELT BUCKLE -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-26
FRONT SEAT BELT BUCKLE - REMOVAL . . 8O-25
FRONT SKID PLATE - INSTALLATION . . . . . . 13-6
FRONT SKID PLATE - REMOVAL . . . . . . . . . . 13-6
FRONT SUSPENSION, SPECIAL TOOLS . . . . . 2-8
FRONT TOW HOOK - INSTALLATION . . . . . . 13-8
FRONT TOW HOOK - REMOVAL . . . . . . . . . . 13-8
FRONT WASHER HOSES/TUBES -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-10
FRONT WASHER HOSES/TUBES -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8R-10
FRONT WASHER NOZZLE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-11
FRONT WASHER NOZZLE -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8R-11
FRONT WASHER NOZZLE - OPERATION . . . 8R-11
FRONT WASHER NOZZLE - REMOVAL . . . . 8R-11
FRONT WHEEL OPENING FLARE
MOLDINGS - INSTALLATION . . . . . . . . . . . 23-145
FRONT WHEEL OPENING FLARE
MOLDINGS - REMOVAL . . . . . . . . . . . . . . 23-145
FRONT WHEEL SPEED SENSOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 5-34
FRONT WHEEL SPEED SENSOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
FRONT WHEELHOUSE SPLASH SHIELD -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-143
FRONT WHEELHOUSE SPLASH SHIELD -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-143
FRONT WIPER & WASHER SYSTEM -
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-7
FRONT WIPER & WASHER SYSTEM -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8R-6
FRONT WIPER & WASHER SYSTEM -
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 8R-7
FRONT WIPER ARM - DESCRIPTION . . . . . 8R-12
FRONT WIPER ARM - INSTALLATION . . . . . 8R-13
FRONT WIPER ARM - OPERATION . . . . . . . 8R-12
FRONT WIPER ARM - REMOVAL . . . . . . . . 8R-12
FRONT WIPER BLADE - DESCRIPTION . . . . 8R-13
FRONT WIPER BLADE - INSTALLATION . . . 8R-14
FRONT WIPER BLADE - OPERATION . . . . . 8R-14
FRONT WIPER BLADE - REMOVAL . . . . . . . 8R-14
FRONT WIPER MODULE - DESCRIPTION . . 8R-15
FRONT WIPER MODULE - INSTALLATION . 8R-16
FRONT WIPER MODULE - OPERATION . . . . 8R-15
FRONT WIPER MODULE - REMOVAL . . . . . 8R-16
FRONT WIPERS/WASHERS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8R-2
FRONT WIPERS/WASHERS - OPERATION . . 8R-4
FRONT WIPER/WASHER SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-16
FRONT WIPER/WASHER SWITCH -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8R-16
FUEL DELIVERY - DESCRIPTION . . . . . . . . . . 14-2
FUEL DELIVERY - OPERATION . . . . . . . . . . . 14-3
FUEL FILL DOOR/HOUSING -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-141
FUEL FILL DOOR/HOUSING - REMOVAL . . 23-141
FUEL FILLER CAP - DESCRIPTION . . . . . . . 25-27
FUEL FILLER CAP - OPERATION . . . . . . . . . 25-27
FUEL FILTER - DESCRIPTION . . . . . . . . . . . . 14-7
FUEL FILTER - INSTALLATION . . . . . . . . . . . . 14-8
FUEL FILTER - REMOVAL . . . . . . . . . . . . . . . 14-7
FUEL GAUGE - DESCRIPTION . . . . . . . . . . . 8J -19
FUEL GAUGE - OPERATION . . . . . . . . . . . . . 8J -20
FUEL INDICATOR - DESCRIPTION, LOW . . . 8J -22
FUEL INDICATOR - OPERATION, LOW . . . . . 8J -22
FUEL INJ ECTION - DESCRIPTION . . . . . . . . 14-29
FUEL INJ ECTOR - DESCRIPTION . . . . . . . . . 14-33
FUEL INJ ECTOR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-33
FUEL INJ ECTOR - OPERATION . . . . . . . . . . 14-33
FUEL LEVEL SENDING UNIT -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 14-9
FUEL LEVEL SENDING UNIT / SENSOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 14-9
FUEL LEVEL SENDING UNIT / SENSOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-10
FUEL LEVEL SENDING UNIT / SENSOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
FUEL LEVEL SENDING UNIT / SENSOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
FUEL LINES - DESCRIPTION . . . . . . . . . . . . 14-10
FUEL PRESSURE LEAK DOWN TEST -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 14-3
10 INDEX KJ
Description Group-Page Description Group-Page Description Group-Page
FUEL PRESSURE REGULATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-13
FUEL PRESSURE REGULATOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-14
FUEL PRESSURE REGULATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
FUEL PRESSURE REGULATOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
FUEL PUMP - DESCRIPTION . . . . . . . . . . . . 14-15
FUEL PUMP - OPERATION . . . . . . . . . . . . . 14-15
FUEL PUMP AMPERAGE TEST -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 14-16
FUEL PUMP CAPACITY TEST -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 14-15
FUEL PUMP MODULE - DESCRIPTION . . . . 14-18
FUEL PUMP MODULE - INSTALLATION . . . 14-19
FUEL PUMP MODULE - OPERATION . . . . . . 14-18
FUEL PUMP MODULE - REMOVAL . . . . . . . 14-18
FUEL PUMP PRESSURE TEST -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 14-15
FUEL PUMP RELAY - DESCRIPTION . . . . . . 14-34
FUEL PUMP RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-34
FUEL PUMP RELAY - INSTALLATION . . . . . 14-34
FUEL PUMP RELAY - OPERATION . . . . . . . . 14-34
FUEL PUMP RELAY - REMOVAL . . . . . . . . . 14-34
FUEL PUMP RELAYS - DIAGNOSIS AND
TESTING, ASD . . . . . . . . . . . . . . . . . . . . . . . . 8I-4
FUEL RAIL - DESCRIPTION . . . . . . . . . . . . . 14-21
FUEL RAIL - INSTALLATION. . . . . . . . . . . . . . 14-24
FUEL RAIL - OPERATION . . . . . . . . . . . . . . . 14-21
FUEL RAIL - REMOVAL . . . . . . . . . . . . . . . . 14-22
FUEL SYSTEM PRESSURE RELEASE -
STANDARD PROCEDURE. . . . . . . . . . . . . . . . 14-4
FUEL SYSTEM PRESSURE,
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 14-5
FUEL SYSTEM, SPECIAL TOOLS . . . . . . . . . . 14-6
FUEL TANK - DESCRIPTION . . . . . . . . . . . . 14-24
FUEL TANK - INSTALLATION . . . . . . . . . . . . 14-27
FUEL TANK - OPERATION . . . . . . . . . . . . . . 14-24
FUEL TANK - REMOVAL . . . . . . . . . . . . . . . 14-25
FUEL TANK CHECK VALVE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-28
FUEL TANK CHECK VALVE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-28
FUEL TANK CHECK VALVE - OPERATION . . 14-28
FUEL TANK CHECK VALVE - REMOVAL . . . . 14-28
FUEL TANK SKID PLATE - INSTALLATION . . . 13-9
FUEL TANK SKID PLATE - REMOVAL . . . . . . 13-9
FULL TIME INDICATOR - DESCRIPTION . . . 8J -29
FULL TIME INDICATOR - OPERATION . . . . . 8J -30
FUNCTION - DIAGNOSIS AND TESTING,
REAR HVAC CONTROL ASSEMBLY
WINDOW DEFOGGER . . . . . . . . . . . . . . . . . . 8G-9
FUNCTIONS - DESCRIPTION, CIRCUIT . . 8W-01-6
FUSE - DESCRIPTION, IOD . . . . . . . . . . . 8W-97-3
FUSE - INSTALLATION, IOD . . . . . . . . . . 8W-97-3
FUSE - OPERATION, IOD . . . . . . . . . . . . . 8W-97-3
FUSE - REMOVAL, IOD . . . . . . . . . . . . . . 8W-97-3
FUSES POWERING SEVERAL LOADS -
STANDARD PROCEDURE, TESTING
FOR A SHORT TO GROUND ON . . . . . . . 8W-01-9
GALLERY PLUGS - STANDARD
PROCEDURE, ENGINE CORE AND OIL . . . . . 9-10
GAP AND FLUSH - SPECIFICATIONS . . . . . 23-116
GAS ENGINES - GENERATOR RATINGS . . . . 8F-23
GAS POWERED - STARTER MOTOR . . . . . . 8F-39
GAS POWERED - TORQUE . . . . . . . . . . . . . 8F-38
GASKET - DIAGNOSIS AND TESTING,
CYLINDER HEAD. . . . . . . . . . . . . . . . . . 9-19,9-30
GASKET SURFACE PREPARATION -
STANDARD PROCEDURE, ENGINE . . . . . . . . . 9-9
GATE - INSTALLATION, SWING . . . . . . . . . 23-138
GATE - REMOVAL, SWING . . . . . . . . . . . . 23-138
GATE AJ AR INDICATOR - DESCRIPTION . . . 8J -20
GATE AJ AR INDICATOR - OPERATION . . . . . 8J -20
GATE BELTLINE WEATHERSTRIP -
INSTALLATION, SWING . . . . . . . . . . . . . . . 23-186
GATE BELTLINE WEATHERSTRIP -
REMOVAL, SWING. . . . . . . . . . . . . . . . . . . 23-186
GATE OPENING WEATHERSTRIP -
INSTALLATION, SWING . . . . . . . . . . . . . . . 23-186
GATE OPENING WEATHERSTRIP -
REMOVAL, SWING. . . . . . . . . . . . . . . . . . . 23-186
GAUGE - DESCRIPTION, ENGINE
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 8J -18
GAUGE - DESCRIPTION, FUEL . . . . . . . . . . . 8J -19
GAUGE - OPERATION, ENGINE
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 8J -18
GAUGE - OPERATION, FUEL . . . . . . . . . . . . 8J -20
GEAR - DESCRIPTION . . . . . . . . . . . . . . . . . 19-13
GEAR - INSTALLATION, PINION
GEAR/RING . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
GEAR - OPERATION . . . . . . . . . . . . . . . . . . . 19-13
GEAR - REMOVAL, PINION GEAR/RING . . . . 3-44
GEAR/RING GEAR - INSTALLATION,
PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
GEAR/RING GEAR - REMOVAL, PINION . . . . 3-44
GEAR/RING GEAR/TONE RING -
INSTALLATION, PINION. . . . . . . . . . . . 3-112,3-82
GEAR/RING GEAR/TONE RING -
REMOVAL, PINION . . . . . . . . . . . . . . . 3-110,3-79
GEARSHIFT CABLE - ADJ USTMENTS . . . . 21-130
GEARSHIFT CABLE - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 21-128
GEARSHIFT CABLE - INSTALLATION . . . . . 21-129
GEARSHIFT CABLE - REMOVAL . . . . . . . . 21-128
GEAR/TONE RING - INSTALLATION,
PINION GEAR/RING. . . . . . . . . . . . . . . 3-112,3-82
GEAR/TONE RING - REMOVAL, PINION
GEAR/RING . . . . . . . . . . . . . . . . . . . . . 3-110,3-79
GEARTRAIN - ASSEMBLY, PLANETARY . . . 21-160
GEARTRAIN - CLEANING, PLANETARY . . . 21-159
GEARTRAIN - DESCRIPTION,
PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . 21-157
GEARTRAIN - DISASSEMBLY,
PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . 21-159
GEARTRAIN - INSPECTION, PLANETARY . 21-159
GEARTRAIN - OPERATION, PLANETARY . . 21-157
GENERAL - WARNINGS . . . . . . . . . . . . . 8W-01-7
GENERATOR - DESCRIPTION . . . . . . . . . . . 8F-25
GENERATOR - INSTALLATION . . . . . . . . . . . 8F-26
GENERATOR - OPERATION . . . . . . . . . . . . . 8F-25
GENERATOR - REMOVAL . . . . . . . . . . . . . . . 8F-25
GENERATOR DECOUPLER - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8F-27
GENERATOR DECOUPLER PULLEY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8F-26
GENERATOR DECOUPLER PULLEY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8F-30
GENERATOR DECOUPLER PULLEY -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8F-27
GENERATOR DECOUPLER PULLEY -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-27
GENERATOR RATINGS, GAS ENGINES . . . . 8F-23
GLASS - INSTALLATION, DOOR . . 23-122,23-129,
23-172
GLASS - INSTALLATION, FLIP-UP . . . . . . . 23-136
GLASS - REMOVAL, DOOR . . . . . . 23-122,23-129,
23-172
GLASS - REMOVAL, FLIP-UP . . . . . . . . . . 23-136
GLASS AJ AR INDICATOR - DESCRIPTION . . 8J -21
GLASS AJ AR INDICATOR - OPERATION . . . 8J -21
GLASS AJ AR SWITCH - DESCRIPTION,
FLIP-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-77
GLASS AJ AR SWITCH - OPERATION,
FLIP-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-77
GLASS HEATING GRID REPAIR -
STANDARD PROCEDURE, REAR . . . . . . . . . . 8G-4
GLASS LATCH - INSTALLATION, FLIP-UP . 23-136
GLASS LATCH - REMOVAL, FLIP-UP . . . . . 23-136
GLASS PANEL - INSTALLATION . . . . . . . . 23-178
GLASS PANEL - REMOVAL . . . . . . . . . . . . 23-178
GLASS PANEL ADJ USTMENT,
ADJ USTMENTS - SUNROOF . . . . . . . . . . . 23-178
GLASS PANEL SEAL - INSTALLATION . . . . 23-178
GLASS PANEL SEAL - REMOVAL . . . . . . . 23-178
GLASS RELEASE SWITCH - DIAGNOSIS
AND TESTING, FLIP-UP . . . . . . . . . . . . . . . . 8N-5
GLASS RUN CHANNEL - INSTALLATION . 23-123,
23-130
GLASS RUN CHANNEL - REMOVAL . . . . . 23-123,
23-130
GLASS SUPPORT CYLINDER -
INSTALLATION, FLIP-UP . . . . . . . . . . . . . . 23-139
GLASS SUPPORT CYLINDER -
REMOVAL, FLIP-UP . . . . . . . . . . . . . . . . . . 23-139
GLOVE BOX - INSTALLATION . . . . . . . . . . 23-148
GLOVE BOX - REMOVAL . . . . . . . . . . . . . . 23-148
GLOVE BOX LATCH - INSTALLATION . . . . 23-148
GLOVE BOX LATCH - REMOVAL . . . . . . . . 23-148
GLOVE BOX LATCH STRIKER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-149
GLOVE BOX LATCH STRIKER - REMOVAL . 23-148
GRAB HANDLE - INSTALLATION,
A-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . 23-156
GRAB HANDLE - REMOVAL, A-PILLAR
TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-156
GRID - DESCRIPTION, REAR WINDOW
DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-5
GRID - DIAGNOSIS AND TESTING, REAR
WINDOW DEFOGGER . . . . . . . . . . . . . . . . . . 8G-5
GRID - OPERATION, REAR WINDOW
DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-5
GRID REPAIR - STANDARD PROCEDURE,
REAR GLASS HEATING. . . . . . . . . . . . . . . . . 8G-4
GRILLE - INSTALLATION . . . . . . . . . . . . . . 23-142
GRILLE - INSTALLATION, COWL . . . . . . . . 23-140
GRILLE - REMOVAL . . . . . . . . . . . . . . . . . . 23-142
GRILLE - REMOVAL, COWL . . . . . . . . . . . 23-140
GRILLE OPENING REINFORCEMENT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-142
GRILLE OPENING REINFORCEMENT -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-142
GROUND - STANDARD PROCEDURE,
TESTING FOR A SHORT TO . . . . . . . . . . 8W-01-9
GROUND AND SPLICE INFORMATION -
DESCRIPTION, CONNECTOR . . . . . . . . . . 8W-01-7
GROUND ON FUSES POWERING
SEVERAL LOADS - STANDARD
PROCEDURE, TESTING FOR A SHORT
TO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-9
GROUND STRAP - DESCRIPTION, RADIO
NOISE SUPPRESSION. . . . . . . . . . . . . . . . . . 8A-9
GROUND STRAP - INSTALLATION,
RADIO NOISE SUPPRESSION . . . . . . . . . . . 8A-11
GROUND STRAP - OPERATION, RADIO
NOISE SUPPRESSION . . . . . . . . . . . . . . . . . 8A-10
GROUND STRAP - REMOVAL, RADIO
NOISE SUPPRESSION . . . . . . . . . . . . . . . . . 8A-10
GROUNDS - DESCRIPTION, POWER . . . . . . 8E-13
GUARD - DESCRIPTION, THERMAL . . . . . . 8F-20
GUARD - INSTALLATION, THERMAL . . . . . . 8F-20
GUARD - OPERATION, THERMAL . . . . . . . . 8F-20
GUARD - REMOVAL, THERMAL . . . . . . . . . . 8F-20
GUIDE ASSEMBLY - INSTALLATION . . . . . 23-179
GUIDE ASSEMBLY - REMOVAL . . . . . . . . . 23-179
GUIDE SEALS - DESCRIPTION, VALVE . 9-29,9-38
GUIDES - DESCRIPTION, VALVE . . . . . . 9-19,9-30
HALF SHAFT - CAUTION . . . . . . . . . . . . . . . . 3-10
HALF SHAFT - DIAGNOSIS AND TESTING . . 3-10
HALF SHAFT - INSTALLATION . . . . . . . . . . . . 3-11
HALF SHAFT - REMOVAL . . . . . . . . . . . . . . . 3-10
HALF SHAFT, SPECIFICATIONS . . . . . . . . . . . 3-11
HANDLE - INSTALLATION, A-PILLAR
TRIM AND GRAB. . . . . . . . . . . . . . . . . . . . 23-156
HANDLE - INSTALLATION, ASSIST . . . . . . 23-157
HANDLE - INSTALLATION, EXTERIOR . . . 23-123,
23-130,23-136
HANDLE - INSTALLATION, LATCH
RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . 23-120
HANDLE - REMOVAL, A-PILLAR TRIM
AND GRAB. . . . . . . . . . . . . . . . . . . . . . . . . 23-156
HANDLE - REMOVAL, ASSIST . . . . . . . . . . 23-157
HANDLE - REMOVAL, EXTERIOR . 23-123,23-130,
23-136
HANDLE - REMOVAL, LATCH RELEASE . . 23-120
HANDLING NON-DEPLOYED
SUPPLEMENTAL RESTRAINTS -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8O-6
HARNESS - DIAGNOSIS AND TESTING,
WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-7
HAZARD SWITCH - DESCRIPTION . . . . . . . 8L-29
HAZARD SWITCH - INSTALLATION . . . . . . . 8L-30
HAZARD SWITCH - OPERATION . . . . . . . . . 8L-29
HAZARD SWITCH - REMOVAL . . . . . . . . . . 8L-30
HCU (HYDRAULIC CONTROL UNIT) -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 5-35
HCU (HYDRAULIC CONTROL UNIT) -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 5-36
HCU (HYDRAULIC CONTROL UNIT) -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
HCU (HYDRAULIC CONTROL UNIT) -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
HEAD - DESCRIPTION, CYLINDER . . . . . . . . 9-30
HEAD COVER(S) - DESCRIPTION,
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
HEAD COVER(S) - INSTALLATION,
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 9-26,9-34
HEAD COVER(S) - REMOVAL, CYLINDER . . 9-25,
9-34
KJ INDEX 11
Description Group-Page Description Group-Page Description Group-Page
HEAD GASKET - DIAGNOSIS AND
TESTING, CYLINDER . . . . . . . . . . . . . . . 9-19,9-30
HEADLAMP BULB - INSTALLATION . . . . . . . 8L-32
HEADLAMP BULB - REMOVAL . . . . . . . . . . 8L-31
HEADLAMP HIGH BEAM RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-33
HEADLAMP HIGH BEAM RELAY -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8L-34
HEADLAMP HIGH BEAM RELAY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-35
HEADLAMP HIGH BEAM RELAY -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8L-33
HEADLAMP HIGH BEAM RELAY -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-34
HEADLAMP LEVELING MOTOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-35
HEADLAMP LEVELING MOTOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-36
HEADLAMP LEVELING MOTOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
HEADLAMP LEVELING MOTOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
HEADLAMP LEVELING SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-37
HEADLAMP LEVELING SWITCH -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8L-37
HEADLAMP LEVELING SWITCH -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-38
HEADLAMP LEVELING SWITCH -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8L-37
HEADLAMP LEVELING SWITCH -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-38
HEADLAMP LOW BEAM RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-39
HEADLAMP LOW BEAM RELAY -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8L-40
HEADLAMP LOW BEAM RELAY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-41
HEADLAMP LOW BEAM RELAY -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8L-39
HEADLAMP LOW BEAM RELAY -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-40
HEADLAMP UNIT - ADJ USTMENT . . . . . . . . 8L-42
HEADLAMP UNIT - INSTALLATION . . . . . . . 8L-42
HEADLAMP UNIT - REMOVAL . . . . . . . . . . . 8L-41
HEADLINER - INSTALLATION . . . . . . . . . . 23-159
HEADLINER - REMOVAL . . . . . . . . . . . . . . 23-159
HEADREST - INSTALLATION . . . . . . . . . . . 23-164
HEADREST - REMOVAL . . . . . . . . . . . . . . . 23-164
HEADREST SLEEVE - INSTALLATION . . . . 23-164
HEADREST SLEEVE - REMOVAL . . . . . . . . 23-164
HEAT SHIELDS - DESCRIPTION . . . . . . . . . . 11-4
HEAT STAKING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 23-3
HEATED MIRRORS - DESCRIPTION . . . . . . . 8G-1
HEATED MIRRORS - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-1
HEATED MIRRORS - OPERATION . . . . . . . . . 8G-1
HEATED SEAT ELEMENT - DESCRIPTION . . 8G-13
HEATED SEAT ELEMENT - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8G-13
HEATED SEAT ELEMENT - OPERATION . . . . 8G-13
HEATED SEAT MODULE - DESCRIPTION . . . 8E-21
HEATED SEAT MODULE - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8E-22
HEATED SEAT MODULE - INSTALLATION . . 8E-24
HEATED SEAT MODULE - OPERATION . . . . 8E-21
HEATED SEAT MODULE - REMOVAL . . . . . . 8E-24
HEATED SEAT SENSOR - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8G-14
HEATED SEAT SWITCH - DIAGNOSIS
AND TESTING. . . . . . . . . . . . . . . . . . 8G-12,8G-14
HEATED SEAT SYSTEM - DESCRIPTION . . . 8G-10
HEATED SEAT SYSTEM - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8G-11
HEATED SEAT SYSTEM - OPERATION . . . . 8G-10
HEATER AND AIR CONDITIONER -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 24-1
HEATER AND AIR CONDITIONER -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 24-2
HEATER CONTROL - DESCRIPTION, A/C . . . 24-16
HEATER CONTROL - INSTALLATION, A/C . . 24-17
HEATER CONTROL - REMOVAL, A/C . . . . . . 24-17
HEATER CORE - DESCRIPTION . . . . . . . . . . 24-52
HEATER CORE - INSTALLATION . . . . . . . . . 24-53
HEATER CORE - OPERATION . . . . . . . . . . . . 24-52
HEATER CORE - REMOVAL . . . . . . . . . . . . . 24-52
HEATER PERFORMANCE - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 24-6
HEATER SWITCH - DESCRIPTION,
DRIVER SEAT . . . . . . . . . . . . . . . . . . . . . . . 8G-11
HEATER SWITCH - DESCRIPTION,
PASSENGER SEAT. . . . . . . . . . . . . . . . . . . . 8G-14
HEATER SWITCH - INSTALLATION,
DRIVER SEAT . . . . . . . . . . . . . . . . . . . . . . . 8G-13
HEATER SWITCH - INSTALLATION,
PASSENGER SEAT. . . . . . . . . . . . . . . . . . . . 8G-15
HEATER SWITCH - OPERATION, DRIVER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-12
HEATER SWITCH - OPERATION,
PASSENGER SEAT. . . . . . . . . . . . . . . . . . . . 8G-14
HEATER SWITCH - REMOVAL, DRIVER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-13
HEATER SWITCH - REMOVAL,
PASSENGER SEAT. . . . . . . . . . . . . . . . . . . . 8G-15
HEATER-A/C CONTROL ILLUMINATION
BULB - INSTALLATION . . . . . . . . . . . . . . . . 8L-78
HEATER-A/C CONTROL ILLUMINATION
BULB - REMOVAL . . . . . . . . . . . . . . . . . . . . 8L-78
HEATING GRID REPAIR - STANDARD
PROCEDURE, REAR GLASS . . . . . . . . . . . . . 8G-4
HEIGHT MEASUREMENT - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
HIGH AND LOW LIMITS - DESCRIPTION . . 25-20
HIGH BEAM INDICATOR - DESCRIPTION . . 8J -22
HIGH BEAM INDICATOR - OPERATION . . . . 8J -22
HIGH BEAM RELAY - DESCRIPTION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-33
HIGH BEAM RELAY - DIAGNOSIS AND
TESTING, HEADLAMP . . . . . . . . . . . . . . . . . . . 8L-34
HIGH BEAM RELAY - INSTALLATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-35
HIGH BEAM RELAY - OPERATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-33
HIGH BEAM RELAY - REMOVAL,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-34
HIGH MOUNTED STOP LAMP BULB -
INSTALLATION, CENTER . . . . . . . . . . . . . . . 8L-19
HIGH MOUNTED STOP LAMP BULB -
REMOVAL, CENTER . . . . . . . . . . . . . . . . . . . 8L-18
HIGH MOUNTED STOP LAMP UNIT -
INSTALLATION, CENTER . . . . . . . . . . . . . . . 8L-19
HIGH MOUNTED STOP LAMP UNIT -
REMOVAL, CENTER . . . . . . . . . . . . . . . . . . . 8L-19
HIGH PRESSURE RELIEF VALVE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-42
HIGH PRESSURE RELIEF VALVE -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-42
HIGH PRESSURE SWITCH -
DESCRIPTION, A/C . . . . . . . . . . . . . . . . . . . 24-17
HIGH PRESSURE SWITCH - DIAGNOSIS
AND TESTING, A/C . . . . . . . . . . . . . . . . . . . 24-18
HIGH PRESSURE SWITCH -
INSTALLATION, A/C . . . . . . . . . . . . . . . . . . . 24-18
HIGH PRESSURE SWITCH - OPERATION,
A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
HIGH PRESSURE SWITCH - REMOVAL,
A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
HIGH/LOW RELAY - DESCRIPTION,
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-23
HIGH/LOW RELAY - DIAGNOSIS AND
TESTING, WIPER. . . . . . . . . . . . . . . . . . . . . 8R-24
HIGH/LOW RELAY - INSTALLATION,
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-24
HIGH/LOW RELAY - OPERATION, WIPER . . 8R-23
HIGH/LOW RELAY - REMOVAL, WIPER . . . 8R-24
HINGE - INSTALLATION . . 23-119,23-123,23-131,
23-137
HINGE - REMOVAL . . . . . . 23-119,23-123,23-131,
23-137
HITCH - INSTALLATION, TRAILER . . . . . . . . . 13-9
HITCH - REMOVAL, TRAILER . . . . . . . . . . . . 13-9
HOISTING RECOMMENDATIONS -
STANDARD PROCEDURE. . . . . . . . . . . . . . . . . 0-4
HOLDDOWN - DESCRIPTION, BATTERY . . . 8F-17
HOLDDOWN - INSTALLATION, BATTERY . . . 8F-17
HOLDDOWN - OPERATION, BATTERY . . . . . 8F-17
HOLDDOWN - REMOVAL, BATTERY . . . . . . 8F-17
HOLDING CLUTCHES - DESCRIPTION . . . . 21-131
HOLDING CLUTCHES - OPERATION . . . . . 21-132
HOLE REPAIR - DESCRIPTION,
THREADED . . . . . . . . . . . . . . . . . . . . . . . . Intro.-4
HONING - STANDARD PROCEDURE,
CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . 9-39
HOOD - INSTALLATION . . . . . . . . . . . . . . . 23-119
HOOD - REMOVAL . . . . . . . . . . . . . . . . . . . 23-119
HOOD AJ AR SWITCH - DESCRIPTION . . . . 8Q-11
HOOD AJ AR SWITCH - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-12
HOOD AJ AR SWITCH - INSTALLATION . . . . 8Q-12
HOOD AJ AR SWITCH - OPERATION . . . . . . 8Q-12
HOOD AJ AR SWITCH - REMOVAL . . . . . . . 8Q-12
HOOD AJ AR SWITCH BRACKET -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8Q-13
HOOD AJ AR SWITCH BRACKET -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
HOOD AJ AR SWITCH STRIKER -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8Q-14
HOOD AJ AR SWITCH STRIKER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
HOOK - INSTALLATION, FRONT TOW . . . . . . 13-8
HOOK - INSTALLATION, REAR TOW . . . . . . . 13-8
HOOK - REMOVAL, FRONT TOW . . . . . . . . . . 13-8
HOOK - REMOVAL, REAR TOW . . . . . . . . . . . 13-8
HORN - DIAGNOSIS AND TESTING . . . . . . . 8H-2
HORN - INSTALLATION . . . . . . . . . . . . . . . . . 8H-3
HORN - REMOVAL . . . . . . . . . . . . . . . . . . . . 8H-3
HORN RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-3
HORN RELAY - INSTALLATION . . . . . . . . . . . 8H-3
HORN RELAY - REMOVAL . . . . . . . . . . . . . . 8H-3
HORN SWITCH - DESCRIPTION . . . . . . . . . . 8H-4
HORN SWITCH - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-4
HORN SYSTEM - DESCRIPTION . . . . . . . . . . 8H-1
HORN SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-1
HORN SYSTEM - OPERATION . . . . . . . . . . . . 8H-1
HOSE - INSTALLATION, FRONT BRAKE . . . . . 5-10
HOSE - INSTALLATION, PRESSURE . . . . . . 19-21
HOSE - INSTALLATION, REAR BRAKE . . . . . . 5-10
HOSE - REMOVAL, FRONT . . . . . . . . . . . . . . . 5-9
HOSE - REMOVAL, PRESSURE . . . . . . . . . . 19-21
HOSE - REMOVAL, REAR BRAKE . . . . . . . . . . 5-9
HOSE CLAMPS - DESCRIPTION . . . . . . . . . . . 7-2
HOSE CLAMPS - OPERATION . . . . . . . . . . . . . 7-3
HOSE (GEAR TO THE COOLER) -
INSTALLATION, RETURN . . . . . . . . . . . . . . . 19-22
HOSE (GEAR TO THE COOLER) -
REMOVAL, RETURN . . . . . . . . . . . . . . . . . . 19-21
HOSE (RESERVOIR TO THE COOLER) -
INSTALLATION, RETURN . . . . . . . . . . . . . . . 19-22
HOSE (RESERVOIR TO THE COOLER) -
REMOVAL, RETURN . . . . . . . . . . . . . . . . . . 19-21
HOSES - DIAGNOSIS AND TESTING,
BRAKE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
HOSES/LINES/TUBES PRECAUTIONS -
CAUTION, REFRIGERANT . . . . . . . . . . . . . . 24-40
HOSES/TUBES - DESCRIPTION, FRONT
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-10
HOSES/TUBES - DESCRIPTION, REAR
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-35
HOSES/TUBES - OPERATION, FRONT
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-10
HOSES/TUBES - OPERATION, REAR
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-36
HOUSING - ASSEMBLY, HVAC . . . . . . . . . . . 24-34
HOUSING - DISASSEMBLY, HVAC . . . . . . . . 24-34
HOUSING - INSTALLATION, HVAC . . . . . . . . 24-34
HOUSING - REMOVAL, HVAC . . . . . . . . . . . 24-33
HOUSING BUSHING - NV3550 -
INSTALLATION, EXTENSION . . . . . . . . . . . . 21-74
HOUSING BUSHING - NV3550 -
REMOVAL, EXTENSION . . . . . . . . . . . . . . . . 21-73
HOUSING FLUID LEAK - DIAGNOSIS AND
TESTING, CONVERTER . . . . . . . . . . . . . . . . 21-80
HOUSING SEAL - INSTALLATION,
ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . 21-124
HOUSING SEAL - NV1500 -
INSTALLATION, EXTENSION . . . . . . . . . . . . 21-32
HOUSING SEAL - NV1500 - REMOVAL,
EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . 21-32
HOUSING SEAL - NV3550 -
INSTALLATION, EXTENSION . . . . . . . . . . . . 21-74
HOUSING SEAL - NV3550 - REMOVAL,
EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . 21-74
HOUSING SEAL - REMOVAL, ADAPTER . . 21-124
HOW TO USE WIRING DIAGRAMS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 8W-01-1
HUB / BEARING - INSTALLATION . . . . . . . . . . 2-9
HUB / BEARING - REMOVAL . . . . . . . . . . . . . . 2-9
12 INDEX KJ
Description Group-Page Description Group-Page Description Group-Page
HVAC CONTROL ASSEMBLY WINDOW
DEFOGGER FUNCTION - DIAGNOSIS
AND TESTING, REAR . . . . . . . . . . . . . . . . . . 8G-9
HVAC HOUSING - ASSEMBLY . . . . . . . . . . . 24-34
HVAC HOUSING - DISASSEMBLY . . . . . . . . 24-34
HVAC HOUSING - INSTALLATION . . . . . . . . 24-34
HVAC HOUSING - REMOVAL . . . . . . . . . . . . 24-33
HYDRAULIC LASH ADJ USTER -
DIAGNOSIS AND TESTING . . . . . . . . . . 9-19,9-30
HYDRAULIC PRESSURE TEST -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 21-79
HYDRAULIC SCHEMATICS, SCHEMATICS
AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . 21-100
HYDROMETER TEST - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8F-11
IDENTIFICATION - DESCRIPTION,
FASTENER . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-1
IDENTIFICATION AND INFORMATION -
DESCRIPTION, SECTION. . . . . . . . . . . . . 8W-01-6
IDENTIFICATION NUMBER -
DESCRIPTION, VEHICLE . . . . . . . . . . . . . . Intro.-8
IDLE AIR CONTROL MOTOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-35
IDLE AIR CONTROL MOTOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-36
IDLE AIR CONTROL MOTOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
IDLE AIR CONTROL MOTOR - REMOVAL . . 14-36
IDLER SHAFT - INSTALLATION . . . . . . . . . . . 9-77
IDLER SHAFT - REMOVAL . . . . . . . . . . . . . . . 9-77
IGNITION CIRCUIT SENSE -
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . 8E-13
IGNITION CIRCUIT SENSE - OPERATION . . 8E-15
IGNITION COIL - DESCRIPTION . . . . . . . . . . . 8I-9
IGNITION COIL - INSTALLATION . . . . . . . . . 8I-10
IGNITION COIL - OPERATION . . . . . . . . . . . . . 8I-9
IGNITION COIL - REMOVAL . . . . . . . . . . . . . 8I-10
IGNITION COIL CAPACITOR -
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 8I-16
IGNITION COIL CAPACITOR -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8I-16
IGNITION COIL CAPACITOR - OPERATION . . 8I-16
IGNITION COIL CAPACITOR - REMOVAL . . . 8I-16
IGNITION COIL RESISTANCE, 2.4L . . . . . . . . . 8I-2
IGNITION COIL RESISTANCE, 3.7L V-6 . . . . . 8I-3
IGNITION CONTROL - DESCRIPTION . . . . . . . 8I-1
IGNITION CONTROL - OPERATION . . . . . . . . . 8I-1
IGNITION SWITCH - DESCRIPTION . . . . . . . . 19-8
IGNITION SWITCH - DESCRIPTION,
KEY-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-10
IGNITION SWITCH - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-8
IGNITION SWITCH - DIAGNOSIS AND
TESTING, KEY-IN . . . . . . . . . . . . . . . . . . . . . 19-10
IGNITION SWITCH INSTALLATION,
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 19-9
IGNITION SWITCH REMOVAL, REMOVAL . . . 19-9
IGNITION SYSTEM - TORQUE . . . . . . . . . . . . 8I-3
IGNITION TIMING - SPECIFICATIONS . . . . . . 8I-2
IGNITION-OFF DRAW TEST - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8F-14
ILLUMINATION BULB - INSTALLATION,
COMPASS MINI-TRIP . . . . . . . . . . . . . . . . . 8L-75
ILLUMINATION BULB - INSTALLATION,
HEATER-A/C CONTROL . . . . . . . . . . . . . . . . 8L-78
ILLUMINATION BULB - INSTALLATION,
TRANSMISSION RANGE INDICATOR . . . . . . 8L-83
ILLUMINATION BULB - REMOVAL,
COMPASS MINI-TRIP . . . . . . . . . . . . . . . . . 8L-74
ILLUMINATION BULB - REMOVAL,
HEATER-A/C CONTROL . . . . . . . . . . . . . . . . 8L-78
ILLUMINATION BULB - REMOVAL,
TRANSMISSION RANGE INDICATOR . . . . . . 8L-82
IMMOBILIZER MODULE - DESCRIPTION,
SENTRY KEY . . . . . . . . . . . . . . . . . . . . . . . . 8E-15
IMMOBILIZER MODULE - INSTALLATION,
SENTRY KEY . . . . . . . . . . . . . . . . . . . . . . . . 8E-18
IMMOBILIZER MODULE - OPERATION,
SENTRY KEY . . . . . . . . . . . . . . . . . . . . . . . . 8E-16
IMMOBILIZER MODULE - REMOVAL,
SENTRY KEY . . . . . . . . . . . . . . . . . . . . . . . . 8E-17
IMPACT AIRBAG CONTROL MODULE -
DESCRIPTION, SIDE . . . . . . . . . . . . . . . . . . 8O-43
IMPACT AIRBAG CONTROL MODULE -
INSTALLATION, SIDE . . . . . . . . . . . . . . . . . 8O-45
IMPACT AIRBAG CONTROL MODULE -
OPERATION, SIDE . . . . . . . . . . . . . . . . . . . . 8O-43
IMPACT AIRBAG CONTROL MODULE -
REMOVAL, SIDE . . . . . . . . . . . . . . . . . . . . . 8O-44
IMPACT SENSOR - DESCRIPTION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-21
IMPACT SENSOR - INSTALLATION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-22
IMPACT SENSOR - OPERATION, FRONT . . . 8O-21
IMPACT SENSOR - REMOVAL, FRONT . . . . 8O-22
INCORRECT FLUID LEVEL - DIAGNOSIS
AND TESTING, EFFECTS OF. . . . . . . . . . . . 21-125
INDICATOR - DESCRIPTION, ABS . . . . . . . . 8J -11
INDICATOR - DESCRIPTION, AIRBAG . . . . . 8J -12
INDICATOR - DESCRIPTION, BRAKE/
PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 8J -13
INDICATOR - DESCRIPTION, CHARGING . . . 8J -15
INDICATOR - DESCRIPTION, COOLANT
LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -15
INDICATOR - DESCRIPTION, CRUISE . . . . . 8J -16
INDICATOR - DESCRIPTION, DOOR AJ AR . . 8J -17
INDICATOR - DESCRIPTION, FOUR LOW
MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -29
INDICATOR - DESCRIPTION, FRONT FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -19
INDICATOR - DESCRIPTION, FULL TIME . . . 8J -29
INDICATOR - DESCRIPTION, GATE AJ AR . . 8J -20
INDICATOR - DESCRIPTION, GLASS
AJ AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -21
INDICATOR - DESCRIPTION, HIGH BEAM . . 8J -22
INDICATOR - DESCRIPTION, LOW FUEL . . . 8J -22
INDICATOR - DESCRIPTION, LOW OIL
PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . 8J -23
INDICATOR - DESCRIPTION, OVERDRIVE
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -26
INDICATOR - DESCRIPTION, PART TIME . . 8J -29
INDICATOR - DESCRIPTION, REAR FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -27
INDICATOR - DESCRIPTION, SEATBELT . . . 8J -27
INDICATOR - DESCRIPTION, SECURITY . . . 8J -28
INDICATOR - DESCRIPTION, SKIS . . . . . . . . 8J -31
INDICATOR - DESCRIPTION, TRANS
TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -33
INDICATOR - DESCRIPTION, TURN
SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -34
INDICATOR - DESCRIPTION, WAIT-TO-
START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -35
INDICATOR - DESCRIPTION, WASHER
FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -35
INDICATOR - DESCRIPTION, WATER-IN-
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -37
INDICATOR - DIAGNOSIS AND TESTING,
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -14
INDICATOR - DIAGNOSIS AND TESTING,
WASHER FLUID. . . . . . . . . . . . . . . . . . . . . . 8J -36
INDICATOR - OPERATION, ABS . . . . . . . . . . 8J -11
INDICATOR - OPERATION, AIRBAG . . . . . . . 8J -12
INDICATOR - OPERATION, BRAKE/PARK
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -13
INDICATOR - OPERATION, CHARGING . . . . 8J -15
INDICATOR - OPERATION, COOLANT
LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -16
INDICATOR - OPERATION, CRUISE . . . . . . . 8J -17
INDICATOR - OPERATION, DOOR AJ AR . . . 8J -17
INDICATOR - OPERATION, FOUR LOW
MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -30
INDICATOR - OPERATION, FRONT FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -19
INDICATOR - OPERATION, FULL TIME . . . . 8J -30
INDICATOR - OPERATION, GATE AJ AR . . . . 8J -20
INDICATOR - OPERATION, GLASS AJ AR . . . 8J -21
INDICATOR - OPERATION, HIGH BEAM . . . . 8J -22
INDICATOR - OPERATION, LOW FUEL . . . . . 8J -22
INDICATOR - OPERATION, LOW OIL
PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . 8J -23
INDICATOR - OPERATION, OVERDRIVE
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -26
INDICATOR - OPERATION, PART TIME . . . . 8J -29
INDICATOR - OPERATION, REAR FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -27
INDICATOR - OPERATION, SEATBELT . . . . . 8J -28
INDICATOR - OPERATION, SECURITY . . . . . 8J -28
INDICATOR - OPERATION, SKIS . . . . . . . . . 8J -31
INDICATOR - OPERATION, TRANS TEMP . . 8J -34
INDICATOR - OPERATION, TURN SIGNAL . . 8J -34
INDICATOR - OPERATION, WAIT-TO-
START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -35
INDICATOR - OPERATION, WASHER
FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -36
INDICATOR - OPERATION, WATER-IN-
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -37
INDICATOR ILLUMINATION BULB -
INSTALLATION, TRANSMISSION
RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-83
INDICATOR ILLUMINATION BULB -
REMOVAL, TRANSMISSION RANGE . . . . . . 8L-82
INDICATOR LAMP (MIL) - DESCRIPTION,
MALFUNCTION. . . . . . . . . . . . . . . . . . . . . . . 8J -24
INDICATOR LAMP (MIL) - OPERATION,
MALFUNCTION. . . . . . . . . . . . . . . . . . . . . . . 8J -24
INDICATOR TEST - STANDARD
PROCEDURE, BUILT-IN . . . . . . . . . . . . . . . . 8F-10
INDICATORS - DIAGNOSIS AND
TESTING, TREAD WEAR . . . . . . . . . . . . . . . . 22-8
INFLATION - DIAGNOSIS AND TESTING,
TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-7
INITIAL OPERATION - STANDARD
PROCEDURE, POWER STEERING
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-18
INITIALIZATION - STANDARD
PROCEDURE, SKIS . . . . . . . . . . . . . . . . . . . . 8Q-8
INJ ECTION - DESCRIPTION, FUEL . . . . . . . . 14-29
INJ ECTOR - DESCRIPTION, FUEL . . . . . . . . 14-33
INJ ECTOR - DIAGNOSIS AND TESTING,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-33
INJ ECTOR - OPERATION, FUEL . . . . . . . . . . 14-33
INLET FILTER - INSTALLATION . . . . . . . . . . 14-28
INLET FILTER - REMOVAL . . . . . . . . . . . . . . 14-28
INPUT - OPERATION, ASD SENSE - PCM . . . 8I-4
INPUT CLUTCH ASSEMBLY - ASSEMBLY . 21-138
INPUT CLUTCH ASSEMBLY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-133
INPUT CLUTCH ASSEMBLY -
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-135
INPUT CLUTCH ASSEMBLY - OPERATION . 21-135
INPUT SPEED SENSOR - DESCRIPTION . . 21-143
INPUT SPEED SENSOR - INSTALLATION . 21-143
INPUT SPEED SENSOR - OPERATION . . . . 21-143
INPUT SPEED SENSOR - REMOVAL . . . . . 21-143
INSTRUMENT CLUSTER - ASSEMBLY . . . . . 8J -10
INSTRUMENT CLUSTER - DESCRIPTION . . . 8J -2
INSTRUMENT CLUSTER - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8J -7
INSTRUMENT CLUSTER - DISASSEMBLY . . . 8J -9
INSTRUMENT CLUSTER - INSTALLATION . . 8J -11
INSTRUMENT CLUSTER - OPERATION . . . . . 8J -4
INSTRUMENT CLUSTER - REMOVAL . . . . . . 8J -9
INSTRUMENT PANEL ANTENNA CABLE -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8A-8
INSTRUMENT PANEL ANTENNA CABLE -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-7
INSTRUMENT PANEL ASSEMBLY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-151
INSTRUMENT PANEL ASSEMBLY -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-149
INSTRUMENT PANEL CENTER BEZEL -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-154
INSTRUMENT PANEL CENTER BEZEL -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-154
INSTRUMENT PANEL DRIVER SIDE
BEZELS - INSTALLATION. . . . . . . . . . . . . . 23-154
INSTRUMENT PANEL DRIVER SIDE
BEZELS - REMOVAL . . . . . . . . . . . . . . . . . 23-153
INSTRUMENT PANEL END CAP -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-153
INSTRUMENT PANEL END CAP -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-153
INSTRUMENT PANEL PASSENGER SIDE
BEZEL - INSTALLATION. . . . . . . . . . . . . . . 23-154
INSTRUMENT PANEL PASSENGER SIDE
BEZEL - REMOVAL . . . . . . . . . . . . . . . . . . 23-154
INSTRUMENT PANEL TOP COVER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-153
INSTRUMENT PANEL TOP COVER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-152
INTAKE AIR TEMPERATURE SENSOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-36
INTAKE AIR TEMPERATURE SENSOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-38
INTAKE AIR TEMPERATURE SENSOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-36
INTAKE AIR TEMPERATURE SENSOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-37
INTAKE MANIFOLD - DESCRIPTION . . . . . . . 9-68
INTAKE MANIFOLD - INSTALLATION . . . . . . . 9-69
INTAKE MANIFOLD - REMOVAL . . . . . . . . . . 9-68
KJ INDEX 13
Description Group-Page Description Group-Page Description Group-Page
INTAKE MANIFOLD LEAKS - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 9-68
INTAKE/EXHAUST VALVES & SEATS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 9-26
INTAKE/EXHAUST VALVES & SEATS -
INSTALLATION. . . . . . . . . . . . . . . . . . . . 9-28,9-36
INTAKE/EXHAUST VALVES & SEATS -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 9-27,9-35
INTERIOR - DESCRIPTION, LAMPS/
LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-65
INTERIOR - DIAGNOSIS AND TESTING,
LAMPS/LIGHTING . . . . . . . . . . . . . . . . . . . . 8L-68
INTERIOR - OPERATION, LAMPS/
LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-67
INTERIOR - SPECIFICATIONS,
LAMPS/LIGHTING . . . . . . . . . . . . . . . . . . . . 8L-71
INTERLOCK CABLE - INSTALLATION,
PARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-153
INTERLOCK CABLE - REMOVAL, PARK . . . 21-153
INTERLOCK SYSTEM - DESCRIPTION,
BRAKE TRANSMISSION SHIFT . . . . . . . . . 21-124
INTERLOCK SYSTEM - DIAGNOSIS AND
TESTING, BRAKE TRANSMISSION
SHIFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-125
INTERLOCK SYSTEM - OPERATION,
BRAKE TRANSMISSION SHIFT . . . . . . . . . 21-125
INTERMEDIATE SHAFT - INSTALLATION . . . 19-11
INTERMEDIATE SHAFT - REMOVAL . . . . . . 19-11
INTERNATIONAL SYMBOLS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . Intro.-4
INTERNATIONAL SYMBOLS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-1
INTRODUCTION - DIAGNOSIS AND
TESTING, ENGINE DIAGNOSIS . . . . . . . . . . . . 9-4
INTRUSION TRANSCEIVER MODULE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8Q-14
INTRUSION TRANSCEIVER MODULE -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8Q-16
INTRUSION TRANSCEIVER MODULE -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8Q-15
INTRUSION TRANSCEIVER MODULE -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-15
INVERTED FLARING - STANDARD
PROCEDURE, DOUBLE . . . . . . . . . . . . . . . . . . 5-8
IOD FUSE - DESCRIPTION . . . . . . . . . . . 8W-97-3
IOD FUSE - INSTALLATION . . . . . . . . . . . 8W-97-3
IOD FUSE - OPERATION . . . . . . . . . . . . . 8W-97-3
IOD FUSE - REMOVAL . . . . . . . . . . . . . . 8W-97-3
ISO FLARING - STANDARD PROCEDURE . . . . 5-8
J OINT - DESCRIPTION, UPPER
SUSPENSION ARM, BUSHINGS, AND
BALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
J OINT - DIAGNOSIS AND TESTING,
LOWER BALL . . . . . . . . . . . . . . . . . . . . . . . . 2-10
J OINT - INSTALLATION, UPPER BALL . . . . . 2-20
J OINT - OPERATION, UPPER
SUSPENSION ARM, BUSHINGS, AND
BALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
J OINT - REMOVAL, UPPER BALL . . . . . . . . . 2-20
J OINT/BOOT-INNER - INSTALLATION, CV . . . 3-17
J OINT/BOOT-INNER - REMOVAL, CV . . . . . . . 3-15
J OINT/BOOT-OUTER - INSTALLATION, CV . . . 3-13
J OINT/BOOT-OUTER - REMOVAL, CV . . . . . . 3-12
J OINTS - ASSEMBLY, SINGLE CARDAN
UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
J OINTS - DISASSEMBLY, SINGLE
CARDAN UNIVERSAL . . . . . . . . . . . . . . . . . . . 3-8
J OUNCE BUMPER - INSTALLATION . . . . . . . 2-19
J OUNCE BUMPER - REMOVAL . . . . . . . . . . . 2-19
J UMP STARTING PROCEDURE -
STANDARD PROCEDURE. . . . . . . . . . . . . . . . . 0-5
J UNCTION BLOCK - DESCRIPTION . . . . . 8W-97-4
J UNCTION BLOCK - DESCRIPTION . . . . . . . . 5-20
J UNCTION BLOCK - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-4
J UNCTION BLOCK - INSTALLATION . . . . . . . 5-20
J UNCTION BLOCK - OPERATION . . . . . . 8W-97-4
J UNCTION BLOCK - OPERATION . . . . . . . . . . 5-20
J UNCTION BLOCK - REMOVAL . . . . . . . . . . . 5-20
KEY - DESCRIPTION, TRANSPONDER . . . . 8Q-18
KEY - OPERATION, TRANSPONDER . . . . . . 8Q-18
KEY IMMOBILIZER MODULE -
DESCRIPTION, SENTRY . . . . . . . . . . . . . . . . 8E-15
KEY IMMOBILIZER MODULE -
INSTALLATION, SENTRY . . . . . . . . . . . . . . . 8E-18
KEY IMMOBILIZER MODULE -
OPERATION, SENTRY . . . . . . . . . . . . . . . . . 8E-16
KEY IMMOBILIZER MODULE - REMOVAL,
SENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-17
KEY TRANSPONDER PROGRAMMING -
STANDARD PROCEDURE, SENTRY . . . . . . . . 8Q-8
KEY-IN IGNITION SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 19-10
KEY-IN IGNITION SWITCH - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 19-10
KEYLESS ENTRY MODULE -
DESCRIPTION, REMOTE . . . . . . . . . . . . . . . . 8N-7
KEYLESS ENTRY MODULE - DIAGNOSIS
AND TESTING, REMOTE . . . . . . . . . . . . . . . . 8N-7
KEYLESS ENTRY MODULE -
INSTALLATION, REMOTE . . . . . . . . . . . . . . . 8N-7
KEYLESS ENTRY MODULE - OPERATION,
REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
KEYLESS ENTRY MODULE - REMOVAL,
REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
KEYLESS ENTRY TRANSMITTER -
DIAGNOSIS AND TESTING, REMOTE . . . . . . 8N-8
KEYLESS ENTRY TRANSMITTER -
SPECIFICATIONS, REMOTE . . . . . . . . . . . . . . 8N-9
KNEE BLOCKER - INSTALLATION . . . . . . . 23-155
KNEE BLOCKER - REMOVAL . . . . . . . . . . . 23-155
KNOCK SENSOR - DESCRIPTION . . . . . . . . . 8I-11
KNOCK SENSOR - INSTALLATION . . . . . . . . 8I-12
KNOCK SENSOR - OPERATION . . . . . . . . . . 8I-11
KNOCK SENSOR - REMOVAL . . . . . . . . . . . . 8I-12
KNUCKLE - INSTALLATION . . . . . . . . . . . . . . . 2-9
KNUCKLE - REMOVAL . . . . . . . . . . . . . . . . . . . 2-9
LABEL - DESCRIPTION, VEHICLE
EMISSION CONTROL INFORMATION
(VECI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-8
LABEL - DESCRIPTION, VEHICLE SAFETY
CERTIFICATION . . . . . . . . . . . . . . . . . . . . . Intro.-9
LACE - INSTALLATION, OPENING TRIM . . 23-180
LACE - REMOVAL, OPENING TRIM . . . . . . 23-180
LAMP BULB - INSTALLATION, ASH
RECEIVER . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-71
LAMP BULB - INSTALLATION, CARGO . . . . 8L-73
LAMP BULB - INSTALLATION, CENTER
HIGH MOUNTED STOP . . . . . . . . . . . . . . . . 8L-19
LAMP BULB - INSTALLATION,
COURTESY . . . . . . . . . . . . . . . . . . . . . . . . . 8L-76
LAMP BULB - INSTALLATION, FRONT . . . . 8L-27
LAMP BULB - INSTALLATION, FRONT
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-22
LAMP BULB - INSTALLATION, FRONT
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-28
LAMP BULB - INSTALLATION, LICENSE
PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-45
LAMP BULB - INSTALLATION, READING . . . 8L-79
LAMP BULB - INSTALLATION, REAR . . . . . 8L-59
LAMP BULB - INSTALLATION, REPEATER . . 8L-60
LAMP BULB - INSTALLATION, VANITY . . . . 8L-84
LAMP BULB - REMOVAL, ASH RECEIVER . . 8L-71
LAMP BULB - REMOVAL, CARGO . . . . . . . . 8L-72
LAMP BULB - REMOVAL, CENTER HIGH
MOUNTED STOP . . . . . . . . . . . . . . . . . . . . . 8L-18
LAMP BULB - REMOVAL, COURTESY . . . . . 8L-75
LAMP BULB - REMOVAL, FRONT . . . . . . . . 8L-26
LAMP BULB - REMOVAL, FRONT FOG . . . . 8L-21
LAMP BULB - REMOVAL, FRONT
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-28
LAMP BULB - REMOVAL, LICENSE
PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-44
LAMP BULB - REMOVAL, READING . . . . . . 8L-79
LAMP BULB - REMOVAL, REAR . . . . . . . . . 8L-58
LAMP BULB - REMOVAL, REPEATER . . . . . 8L-60
LAMP BULB - REMOVAL, VANITY . . . . . . . . 8L-83
LAMP INDICATOR - DESCRIPTION,
FRONT FOG . . . . . . . . . . . . . . . . . . . . . . . . . 8J -19
LAMP INDICATOR - DESCRIPTION, REAR
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -27
LAMP INDICATOR - OPERATION, FRONT
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -19
LAMP INDICATOR - OPERATION, REAR
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -27
LAMP (MIL) - DESCRIPTION,
MALFUNCTION INDICATOR . . . . . . . . . . . . . 8J -24
LAMP (MIL) - OPERATION,
MALFUNCTION INDICATOR . . . . . . . . . . . . . 8J -24
LAMP RELAY - DESCRIPTION, DAYTIME
RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-20
LAMP RELAY - DESCRIPTION, FRONT
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-22
LAMP RELAY - DESCRIPTION, PARK . . . . . 8L-54
LAMP RELAY - DESCRIPTION, REAR FOG . 8L-56
LAMP RELAY - DIAGNOSIS AND
TESTING, FRONT FOG . . . . . . . . . . . . . . . . . 8L-23
LAMP RELAY - DIAGNOSIS AND
TESTING, PARK . . . . . . . . . . . . . . . . . . . . . . 8L-55
LAMP RELAY - DIAGNOSIS AND
TESTING, REAR FOG. . . . . . . . . . . . . . . . . . 8L-57
LAMP RELAY - INSTALLATION, DAYTIME
RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-21
LAMP RELAY - INSTALLATION, FRONT
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-24
LAMP RELAY - INSTALLATION, PARK . . . . . 8L-56
LAMP RELAY - INSTALLATION, REAR
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-58
LAMP RELAY - OPERATION, DAYTIME
RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-20
LAMP RELAY - OPERATION, FRONT FOG . . 8L-22
LAMP RELAY - OPERATION, PARK . . . . . . . 8L-54
LAMP RELAY - OPERATION, REAR FOG . . . 8L-57
LAMP RELAY - REMOVAL, DAYTIME
RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-21
LAMP RELAY - REMOVAL, FRONT FOG . . . 8L-24
LAMP RELAY - REMOVAL, PARK . . . . . . . . 8L-55
LAMP RELAY - REMOVAL, REAR FOG . . . . 8L-58
LAMP REPLACEMENT - STANDARD
PROCEDURE, CMTC . . . . . . . . . . . . . . . . . . . 8M-2
LAMP REPLACEMENT - STANDARD
PROCEDURE, COURTESY . . . . . . . . . . . . . . . 8M-2
LAMP SWITCH - DESCRIPTION, BACKUP . . 8L-15
LAMP SWITCH - DESCRIPTION, BRAKE . . . 8L-16
LAMP SWITCH - DIAGNOSIS AND
TESTING, BACKUP. . . . . . . . . . . . . . . . . . . . . 8L-15
LAMP SWITCH - DIAGNOSIS AND
TESTING, BRAKE . . . . . . . . . . . . . . . . . . . . . 8L-17
LAMP SWITCH - INSTALLATION, BRAKE . . 8L-18
LAMP SWITCH - INSTALLATION, CARGO . . 8L-74
LAMP SWITCH - INSTALLATION,
READING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-80
LAMP SWITCH - OPERATION, BACKUP . . . 8L-15
LAMP SWITCH - OPERATION, BRAKE . . . . . 8L-16
LAMP SWITCH - REMOVAL, BRAKE . . . . . . 8L-17
LAMP SWITCH - REMOVAL, CARGO . . . . . . 8L-73
LAMP SWITCH - REMOVAL, READING . . . . 8L-80
LAMP UNIT - ADJ USTMENT, FRONT FOG . . 8L-25
LAMP UNIT - INSTALLATION, ASH
RECEIVER . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-72
LAMP UNIT - INSTALLATION, CARGO . . . . . 8L-74
LAMP UNIT - INSTALLATION, CENTER
HIGH MOUNTED STOP . . . . . . . . . . . . . . . . 8L-19
LAMP UNIT - INSTALLATION, COURTESY . . 8L-77
LAMP UNIT - INSTALLATION, FRONT . . . . . 8L-28
LAMP UNIT - INSTALLATION, FRONT
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-25
LAMP UNIT - INSTALLATION, LICENSE
PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-46
LAMP UNIT - INSTALLATION, READING . . . 8L-81
LAMP UNIT - INSTALLATION, REAR . . . . . . 8L-60
LAMP UNIT - INSTALLATION, REPEATER . . 8L-61
LAMP UNIT - REMOVAL, ASH RECEIVER . . 8L-72
LAMP UNIT - REMOVAL, CARGO . . . . . . . . 8L-74
LAMP UNIT - REMOVAL, CENTER HIGH
MOUNTED STOP . . . . . . . . . . . . . . . . . . . . . 8L-19
LAMP UNIT - REMOVAL, COURTESY . . . . . 8L-76
LAMP UNIT - REMOVAL, FRONT . . . . . . . . . 8L-27
LAMP UNIT - REMOVAL, FRONT FOG . . . . . 8L-25
LAMP UNIT - REMOVAL, LICENSE PLATE . . 8L-45
LAMP UNIT - REMOVAL, READING . . . . . . . 8L-81
LAMP UNIT - REMOVAL, REAR . . . . . . . . . . 8L-59
LAMP UNIT - REMOVAL, REPEATER . . . . . . 8L-60
LAMPS/LIGHTING - EXTERIOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8L-2
LAMPS/LIGHTING - EXTERIOR -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8L-7
LAMPS/LIGHTING - EXTERIOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-5
LAMPS/LIGHTING - EXTERIOR -
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 8L-15
LAMPS/LIGHTING - INTERIOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-65
LAMPS/LIGHTING - INTERIOR -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8L-68
LAMPS/LIGHTING - INTERIOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8L-67
LAMPS/LIGHTING - INTERIOR -
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 8L-71
LASH ADJ USTER - DIAGNOSIS AND
TESTING, HYDRAULIC. . . . . . . . . . . . . . 9-19,9-30
LATCH - ACCESS PANEL - DESCRIPTION . 23-139
LATCH - ACCESS PANEL - INSTALLATION . 23-139
14 INDEX KJ
Description Group-Page Description Group-Page Description Group-Page
LATCH - ACCESS PANEL - REMOVAL . . . . 23-139
LATCH - INSTALLATION . . 23-120,23-124,23-131,
23-137
LATCH - INSTALLATION, FLIP-UP GLASS . 23-136
LATCH - INSTALLATION, FLOOR
CONSOLE LID . . . . . . . . . . . . . . . . . . . . . . 23-158
LATCH - INSTALLATION, GLOVE BOX . . . . 23-148
LATCH / LOCK - INSTALLATION,
FOLDING REAR SEAT BACK . . . . . . . . . . . 23-170
LATCH / LOCK - REMOVAL, FOLDING
REAR SEAT BACK . . . . . . . . . . . . . . . . . . . 23-170
LATCH - REMOVAL . . . . . . 23-120,23-124,23-131,
23-137
LATCH - REMOVAL, FLIP-UP GLASS . . . . . 23-136
LATCH - REMOVAL, FLOOR CONSOLE
LID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-158
LATCH - REMOVAL, GLOVE BOX . . . . . . . . 23-148
LATCH RELEASE CABLE - INSTALLATION . 23-120
LATCH RELEASE CABLE - REMOVAL . . . . 23-120
LATCH RELEASE HANDLE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-120
LATCH RELEASE HANDLE - REMOVAL . . . 23-120
LATCH STRIKER - INSTALLATION . . . . . . 23-124,
23-132,23-137
LATCH STRIKER - INSTALLATION, GLOVE
BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-149
LATCH STRIKER - INSTALLATION, REAR
SEAT BACK . . . . . . . . . . . . . . . . . . . . . . . . 23-171
LATCH STRIKER - REMOVAL . . . . 23-124,23-132,
23-137
LATCH STRIKER - REMOVAL, GLOVE
BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-148
LATCH STRIKER - REMOVAL, REAR
SEAT BACK . . . . . . . . . . . . . . . . . . . . . . . . 23-170
LEAK - DIAGNOSIS AND TESTING,
CONVERTER HOUSING FLUID. . . . . . . . . . . 21-80
LEAK - DIAGNOSIS AND TESTING,
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60
LEAK DETECTION PUMP - DESCRIPTION . . 25-27
LEAK DETECTION PUMP - INSTALLATION . 25-28
LEAK DETECTION PUMP - OPERATION . . . . 25-28
LEAK DETECTION PUMP - REMOVAL . . . . . 25-28
LEAK DOWN TEST - DIAGNOSIS AND
TESTING, FUEL PRESSURE. . . . . . . . . . . . . . 14-3
LEAKAGE - DIAGNOSIS AND TESTING,
CYLINDER COMBUSTION PRESSURE . . . . . . . 9-8
LEAKS - DIAGNOSIS AND TESTING,
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . 7-4
LEAKS - DIAGNOSIS AND TESTING,
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . 9-68
LEAKS - DIAGNOSIS AND TESTING,
REAR SEAL AREA . . . . . . . . . . . . . . . . . . . . . 9-61
LEAKS - DIAGNOSIS AND TESTING,
WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2
LEAKS - STANDARD PROCEDURE,
REPAIRING . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
LEARN - STANDARD PROCEDURE, TCM
QUICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-21
LEFT POWER SEAT SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8N-16
LEFT POWER SEAT SWITCH -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8N-17
LEFT POWER SEAT SWITCH -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8N-18
LEFT POWER SEAT SWITCH -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8N-17
LEFT POWER SEAT SWITCH - REMOVAL . . 8N-18
LEFT SIDE - INSTALLATION . . . . . . . . . 2-12,2-15
LEFT SIDE - REMOVAL . . . . . . . . . . . . . 2-11,2-15
LEVEL - DIAGNOSIS AND TESTING,
EFFECTS OF INCORRECT FLUID . . . . . . . . 21-125
LEVEL - STANDARD PROCEDURE,
REFRIGERANT OIL . . . . . . . . . . . . . . . . . . . 24-54
LEVEL - STANDARD PROCEDURES,
MASTER CYLINDER FLUID . . . . . . . . . . . . . . 5-26
LEVEL CHECK - STANDARD
PROCEDURE, FLUID . . . . . . . . . . . . . . . . . 21-126
LEVEL SENDING UNIT - DIAGNOSIS AND
TESTING, FUEL . . . . . . . . . . . . . . . . . . . . . . . 14-9
LEVEL SENDING UNIT / SENSOR -
DESCRIPTION, FUEL . . . . . . . . . . . . . . . . . . . 14-9
LEVEL SENDING UNIT / SENSOR -
INSTALLATION, FUEL . . . . . . . . . . . . . . . . . 14-10
LEVEL SENDING UNIT / SENSOR -
OPERATION, FUEL . . . . . . . . . . . . . . . . . . . . . 14-9
LEVEL SENDING UNIT / SENSOR -
REMOVAL, FUEL . . . . . . . . . . . . . . . . . . . . . . 14-9
LEVEL SWITCH - DESCRIPTION,
WASHER FLUID . . . . . . . . . . . . . . . . . . . . . 8R-17
LEVEL SWITCH - INSTALLATION,
WASHER FLUID . . . . . . . . . . . . . . . . . . . . . 8R-18
LEVEL SWITCH - OPERATION, WASHER
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
LEVEL SWITCH - REMOVAL, WASHER
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
LEVELING MOTOR - DESCRIPTION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-35
LEVELING MOTOR - INSTALLATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
LEVELING MOTOR - OPERATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
LEVELING MOTOR - REMOVAL,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
LEVELING SWITCH - DESCRIPTION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-37
LEVELING SWITCH - DIAGNOSIS AND
TESTING, HEADLAMP . . . . . . . . . . . . . . . . . 8L-37
LEVELING SWITCH - INSTALLATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-38
LEVELING SWITCH - OPERATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-37
LEVELING SWITCH - REMOVAL,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-38
LEVER - INSTALLATION . . . . . . . . . . . . . . . . 5-31
LEVER - INSTALLATION, SHIFT . . . 21-214,21-249
LEVER - REMOVAL . . . . . . . . . . . . . . . . . . . . 5-31
LEVER - REMOVAL, SHIFT . . . . . . 21-213,21-248
LHD - INSTALLATION . . . . . . . . . . . . . . . 8W-97-6
LHD - REMOVAL . . . . . . . . . . . . . . . . . . . . 8W-97-5
LICENSE PLATE LAMP BULB -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-45
LICENSE PLATE LAMP BULB - REMOVAL . . 8L-44
LICENSE PLATE LAMP UNIT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-46
LICENSE PLATE LAMP UNIT - REMOVAL . . 8L-45
LID LATCH - INSTALLATION, FLOOR
CONSOLE. . . . . . . . . . . . . . . . . . . . . . . . . . 23-158
LID LATCH - REMOVAL, FLOOR
CONSOLE. . . . . . . . . . . . . . . . . . . . . . . . . . 23-158
LIGHTER OUTLET - DESCRIPTION,
CIGAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-2
LIGHTER OUTLET - DIAGNOSIS AND
TESTING, CIGAR . . . . . . . . . . . . . . . . . . . 8W-97-2
LIGHTER OUTLET - OPERATION, CIGAR . 8W-97-2
LIMITS - DESCRIPTION, HIGH AND LOW . . 25-20
LINE - DESCRIPTION, REFRIGERANT . . . . . 24-38
LINE - INSTALLATION, A/C DISCHARGE . . . 24-47
LINE - INSTALLATION, A/C LIQUID . . . . . . . 24-47
LINE - INSTALLATION, A/C SUCTION . . . . . 24-49
LINE - REMOVAL, A/C DISCHARGE . . . . . . . 24-46
LINE - REMOVAL, A/C LIQUID . . . . . . . . . . . 24-47
LINE - REMOVAL, A/C SUCTION . . . . . . . . . 24-48
LINE AND HOSES - DIAGNOSIS AND
TESTING, BRAKE. . . . . . . . . . . . . . . . . . . . . . . 5-8
LINE PRESSURE (LP) SENSOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-144
LINE PRESSURE (LP) SENSOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-144
LINE PRESSURE (LP) SENSOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 21-144
LINE PRESSURE (LP) SENSOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 21-144
LINES - DESCRIPTION, BRAKE . . . . . . . . . . . . 5-8
LINES - DESCRIPTION, FUEL . . . . . . . . . . . 14-10
LINES - DESCRIPTION, VACUUM . . . . . . . . 25-33
LINK - INSTALLATION, STABILIZER . . . . . . . 2-14
LINK - REMOVAL, STABILIZER . . . . . . . . . . . 2-14
LINK CONNECTOR - DESCRIPTION, DATA . 8E-10
LINK CONNECTOR - OPERATION, DATA . . . 8E-10
LINKAGE - INSTALLATION . . . . . . . . . . . . . . . . 6-9
LINKAGE - REMOVAL . . . . . . . . . . . . . . . . . . . 6-8
LINKAGE - STANDARD PROCEDURE,
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 19-16
LIQUID LINE - INSTALLATION, A/C . . . . . . . 24-47
LIQUID LINE - REMOVAL, A/C . . . . . . . . . . . 24-47
LOAD TEST - STANDARD PROCEDURE . . . . 8F-12
LOAD VALUE - DESCRIPTION . . . . . . . . . . . 25-20
LOADS - STANDARD PROCEDURE,
TESTING FOR A SHORT TO GROUND
ON FUSES POWERING SEVERAL . . . . . . 8W-01-9
LOCATION - DESCRIPTION, CONNECTOR/
GROUND/SPLICE. . . . . . . . . . . . . . . . . . . 8W-91-1
LOCATIONS - DESCRIPTION, FLUID
FILL/CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
LOCATIONS - SPECIFICATIONS, SEALER . . 23-87
LOCATIONS - SPECIFICATIONS, WELD
AND STRUCTURAL ADHESIVE . . . . . . . . . . . 23-9
LOCK - INSTALLATION, FOLDING REAR
SEAT BACK LATCH . . . . . . . . . . . . . . . . . . 23-170
LOCK - REMOVAL, FOLDING REAR SEAT
BACK LATCH . . . . . . . . . . . . . . . . . . . . . . . 23-170
LOCK / UNLOCK SWITCH -
INSTALLATION, DOOR . . . . . . . . . . . . . . . . . 8N-5
LOCK / UNLOCK SWITCH - REMOVAL,
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-4
LOCK CYLINDER - INSTALLATION . . . . . . 23-125,
23-138
LOCK CYLINDER - INSTALLATION . . . . . . . 19-11
LOCK CYLINDER - REMOVAL . . . . 23-125,23-137
LOCK CYLINDER - REMOVAL . . . . . . . . . . . 19-10
LOCK MOTOR - DESCRIPTION, DOOR . . . . . 8N-5
LOCK MOTOR - DIAGNOSIS AND
TESTING, DOOR . . . . . . . . . . . . . . . . . . . . . . 8N-5
LOCK MOTOR - OPERATION, DOOR . . . . . . . 8N-5
LOCK OUT - ADJ USTMENT . . . . . . . . . . . . . . 5-30
LOCK RELAY - DESCRIPTION, DOOR . . . . . . 8N-6
LOCK RELAY - DIAGNOSIS AND
TESTING, DOOR . . . . . . . . . . . . . . . . . . . . . . 8N-6
LOCK RELAY - INSTALLATION, DOOR . . . . . 8N-7
LOCK RELAY - OPERATION, DOOR . . . . . . . . 8N-6
LOCK RELAY - REMOVAL, DOOR . . . . . . . . . 8N-6
LOCK SWITCH - DESCRIPTION, DOOR
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-9
LOCK SWITCH - DESCRIPTION,
TAILGATE CYLINDER. . . . . . . . . . . . . . . . . . . 8N-9
LOCK SWITCH - DIAGNOSIS AND
TESTING, DOOR CYLINDER . . . . . . . . . . . . 8Q-10
LOCK SWITCH - DIAGNOSIS AND
TESTING, TAILGATE CYLINDER . . . . . . . . . . 8N-9
LOCK SWITCH - INSTALLATION, DOOR
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
LOCK SWITCH - INSTALLATION,
TAILGATE CYLINDER. . . . . . . . . . . . . . . . . . 8N-10
LOCK SWITCH - OPERATION, DOOR
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
LOCK SWITCH - OPERATION, TAILGATE
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-9
LOCK SWITCH - REMOVAL, DOOR
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
LOCK SWITCH - REMOVAL, TAILGATE
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-10
LOCKS - DESCRIPTION, POWER . . . . . . . . . 8N-1
LOCKS - DIAGNOSIS AND TESTING,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-3
LOCKS - OPERATION, POWER . . . . . . . . . . . 8N-3
LOCK/UNLOCK SWITCH - DIAGNOSIS
AND TESTING, DOOR . . . . . . . . . . . . . . . . . . 8N-4
LOOP ADJ USTER - INSTALLATION, SEAT
BELT TURNING . . . . . . . . . . . . . . . . . . . . . . 8O-38
LOOP ADJ USTER - REMOVAL, SEAT
BELT TURNING . . . . . . . . . . . . . . . . . . . . . . 8O-37
LOW BEAM RELAY - DESCRIPTION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-39
LOW BEAM RELAY - DIAGNOSIS AND
TESTING, HEADLAMP . . . . . . . . . . . . . . . . . 8L-40
LOW BEAM RELAY - INSTALLATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-41
LOW BEAM RELAY - OPERATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-39
LOW BEAM RELAY - REMOVAL,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-40
LOW FUEL INDICATOR - DESCRIPTION . . . 8J -22
LOW FUEL INDICATOR - OPERATION . . . . . 8J -22
LOW INDICATOR - DESCRIPTION,
COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -15
LOW INDICATOR - OPERATION,
COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -16
LOW LIMITS - DESCRIPTION, HIGH . . . . . . 25-20
LOW MODE INDICATOR - DESCRIPTION,
FOUR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -29
LOW MODE INDICATOR - OPERATION,
FOUR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -30
LOW OIL PRESSURE INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -23
LOW OIL PRESSURE INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -23
LOW PRESSURE SWITCH -
DESCRIPTION, A/C . . . . . . . . . . . . . . . . . . . 24-18
LOW PRESSURE SWITCH - DIAGNOSIS
AND TESTING, A/C . . . . . . . . . . . . . . . . . . . 24-19
LOW PRESSURE SWITCH -
INSTALLATION, A/C . . . . . . . . . . . . . . . . . . . 24-19
KJ INDEX 15
Description Group-Page Description Group-Page Description Group-Page
LOW PRESSURE SWITCH - OPERATION,
A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
LOW PRESSURE SWITCH - REMOVAL,
A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
LOWER BALL J OINT - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
LOWER CONTROL ARM - DESCRIPTION . . . 2-21
LOWER CONTROL ARM - INSTALLATION . . 2-10,
2-21
LOWER CONTROL ARM - OPERATION . . . . . 2-21
LOWER CONTROL ARM - REMOVAL . . 2-10,2-21
LOWER TRIM - INSTALLATION,
B-PILLAR . . . . . . . . . . . . . . . . . . . . . . . . . . 23-157
LOWER TRIM - REMOVAL, B-PILLAR . . . . 23-157
LOWER WEATHERSTRIP -
INSTALLATION, DOOR . . . . . . . . . . . . . . . . 23-186
LOWER WEATHERSTRIP - REMOVAL,
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
LOW/REVERSE CLUTCH - ASSEMBLY . . . . 21-146
LOW/REVERSE CLUTCH - CLEANING . . . . 21-146
LOW/REVERSE CLUTCH - DISASSEMBLY . 21-145
LOW/REVERSE CLUTCH - INSPECTION . . 21-146
LUBRICATION - DESCRIPTION . . . . . . . . . . . 9-57
LUBRICATION - DIAGNOSIS AND
TESTING, ENGINE DIAGNOSIS . . . . . . . . . . . . 9-7
LUBRICATION - OPERATION . . . . . . . . . . . . . 9-58
LUBRICATION - STANDARD PROCEDURE,
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3
LUGGAGE RACK - INSTALLATION . . . . . . . 23-144
LUGGAGE RACK - REMOVAL . . . . . . . . . . . . 23-144
MACHINING - STANDARD PROCEDURES,
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . 5-27
MAIN BEARING, FITTING . . . . . . . . . . . . . . . . 9-45
MAINTENANCE SCHEDULES -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
MALFUNCTION INDICATOR LAMP (MIL) -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -24
MALFUNCTION INDICATOR LAMP (MIL) -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -24
MANAGEMENT VALVE - DESCRIPTION,
FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
MANAGEMENT VALVE - INSTALLATION,
FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
MANAGEMENT VALVE - OPERATION,
FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
MANAGEMENT VALVE - REMOVAL,
FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
MANAGER - DESCRIPTION, TASK . . . . . . . . 25-17
MANAGER - OPERATION, TASK . . . . . . . . . 25-21
MANIFOLD - DESCRIPTION, EXHAUST . . . . . 9-69
MANIFOLD - DESCRIPTION, INTAKE . . . . . . . 9-68
MANIFOLD - INSTALLATION, EXHAUST . . . . 9-70
MANIFOLD - INSTALLATION, INTAKE . . . . . . 9-69
MANIFOLD - REMOVAL, EXHAUST . . . . . . . . 9-69
MANIFOLD - REMOVAL, INTAKE . . . . . . . . . . 9-68
MANIFOLD LEAKS - DIAGNOSIS AND
TESTING, INTAKE . . . . . . . . . . . . . . . . . . . . . 9-68
MANUAL - INSTALLATION, WINDOW
REGULATOR . . . . . . . . . . . . 23-126,23-133 21-34
MANUAL - REMOVAL, WINDOW
REGULATOR . . . . . . . . . . . . . . . . . 23-126,23-133
MANUAL BLEEDING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
MANUAL, NV1500 . . . . . . . . . . . . . . . . . . . . 21-30
MANUAL, NV3550 . . . . . . . . . . . . . . . . . . . . 21-71
MANUAL SEAT RISER - INSTALLATION . . 23-168
MANUAL SEAT RISER - REMOVAL . . . . . . 23-167
MANUAL TRANSMISSION -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
MANUAL TRANSMISSION - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . 21-2,21-33
MAP SENSOR - DESCRIPTION . . . . . . . . . . 14-38
MAP SENSOR - INSTALLATION . . . . . . . . . . 14-40
MAP SENSOR - OPERATION . . . . . . . . . . . . 14-38
MAP SENSOR - REMOVAL . . . . . . . . . . . . . 14-39
MASTER CYLINDER - DESCRIPTION . . . . . . 5-24
MASTER CYLINDER - INSPECTION . . . . . . . . . 6-9
MASTER CYLINDER - INSTALLATION . . . . . . 5-25
MASTER CYLINDER - OPERATION . . . . . . . . 5-24
MASTER CYLINDER - REMOVAL . . . . . . . . . . 5-25
MASTER CYLINDER BLEEDING -
STANDARD PROCEDURE. . . . . . . . . . . . . . . . 5-24
MASTER CYLINDER FLUID LEVEL -
STANDARD PROCEDURES. . . . . . . . . . . . . . . 5-26
MASTER CYLINDER/POWER BOOSTER -
DIAGNOSIS AND TESTING . . . . . . . . . . 5-21,5-24
MATCH MOUNTING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 22-3
MATS - INSTALLATION, CARPETS AND
FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-158
MATS - REMOVAL, CARPETS AND
FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-158
MEASUREMENT - STANDARD
PROCEDURE, HEIGHT . . . . . . . . . . . . . . . . . . . 2-4
MEASURING TIMING CHAIN WEAR,
STANDARD PROCEDURE. . . . . . . . . . . . . . . . 9-71
MECHANICAL - DIAGNOSIS AND
TESTING, ENGINE DIAGNOSIS . . . . . . . . . . . . 9-6
MECHANISM - DESCRIPTION, SHIFT . . . . 21-160
MECHANISM - INSTALLATION, SHIFT . . . . 21-160
MECHANISM - OPERATION, SHIFT . . . . . . 21-160
MECHANISM - REMOVAL, SHIFT . . . . . . . 21-160
METRIC SYSTEM - DESCRIPTION . . . . . . Intro.-5
MICRO-RELAY - DESCRIPTION . . . . . . . 8W-97-14
MICRO-RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-14
MICRO-RELAY - INSTALLATION . . . . . . 8W-97-14
MICRO-RELAY - OPERATION . . . . . . . . 8W-97-14
MICRO-RELAY - REMOVAL . . . . . . . . . . 8W-97-14
MIDTRONICS ELECTRICAL TESTER -
STANDARD PROCEDURE, USING . . . . . . . . 8F-15
MINI-TRIP COMPUTER - DIAGNOSIS
AND TESTING, COMPASS . . . . . . . . . . . . . . 8M-6
MINI-TRIP ILLUMINATION BULB -
INSTALLATION, COMPASS . . . . . . . . . . . . . 8L-75
MINI-TRIP ILLUMINATION BULB -
REMOVAL, COMPASS . . . . . . . . . . . . . . . . . 8L-74
MIRROR - INSTALLATION, SIDE VIEW . . . 23-145
MIRROR - REMOVAL, REAR VIEW . . . . . . 23-161
MIRROR - REMOVAL, SIDE VIEW . . . . . . . 23-145
MIRROR - REMOVAL, SIDEVIEW . . . . . . . . 8N-13
MIRROR SUPPORT BRACKET -
INSTALLATION, REARVIEW . . . . . . . . . . . . 23-161
MIRROR SWITCH - DIAGNOSIS AND
TESTING, POWER . . . . . . . . . . . . . . . . . . . . 8N-12
MIRROR SWITCH - INSTALLATION,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-13
MIRROR SWITCH - REMOVAL, POWER . . . 8N-13
MIRRORS - DESCRIPTION, HEATED . . . . . . . 8G-1
MIRRORS - DESCRIPTION, POWER . . . . . . 8N-11
MIRRORS - DIAGNOSIS AND TESTING,
HEATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-1
MIRRORS - DIAGNOSIS AND TESTING,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-11
MIRRORS - OPERATION, HEATED . . . . . . . . 8G-1
MIRRORS - OPERATION, POWER . . . . . . . . 8N-11
MODE - DESCRIPTION, CIRCUIT
ACTUATION TEST . . . . . . . . . . . . . . . . . . . . . 25-2
MODE - DESCRIPTION, STATE DISPLAY
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
MODE INDICATOR - DESCRIPTION, FOUR
LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -29
MODE INDICATOR - OPERATION, FOUR
LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -30
MODES OF OPERATION - DESCRIPTION . . . 8E-11
MODULE - DESCRIPTION, AIRBAG
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-9
MODULE - DESCRIPTION, BODY
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-2
MODULE - DESCRIPTION, FRONT WIPER . 8R-15
MODULE - DESCRIPTION, FUEL PUMP . . . . 14-18
MODULE - DESCRIPTION, HEATED SEAT . . 8E-21
MODULE - DESCRIPTION, INTRUSION
TRANSCEIVER. . . . . . . . . . . . . . . . . . . . . . . 8Q-14
MODULE - DESCRIPTION, REMOTE
KEYLESS ENTRY . . . . . . . . . . . . . . . . . . . . . . 8N-7
MODULE - DESCRIPTION, SENTRY KEY
IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . 8E-15
MODULE - DESCRIPTION, SIDE IMPACT
AIRBAG CONTROL . . . . . . . . . . . . . . . . . . . 8O-43
MODULE - DESCRIPTION,
TRANSMISSION CONTROL . . . . . . . . . . . . . 8E-18
MODULE - DIAGNOSIS AND TESTING,
BODY CONTROL . . . . . . . . . . . . . . . . . . . . . . 8E-7
MODULE - DIAGNOSIS AND TESTING,
HEATED SEAT . . . . . . . . . . . . . . . . . . . . . . . 8E-22
MODULE - DIAGNOSIS AND TESTING,
REMOTE KEYLESS ENTRY . . . . . . . . . . . . . . 8N-7
MODULE - INSTALLATION, AIRBAG
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-12
MODULE - INSTALLATION, BODY
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-7
MODULE - INSTALLATION, CONTROL . . . . 23-183
MODULE - INSTALLATION, FRONT
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-16
MODULE - INSTALLATION, FUEL PUMP . . . 14-19
MODULE - INSTALLATION, HEATED SEAT . . 8E-24
MODULE - INSTALLATION, INTRUSION
TRANSCEIVER. . . . . . . . . . . . . . . . . . . . . . . 8Q-16
MODULE - INSTALLATION, REMOTE
KEYLESS ENTRY . . . . . . . . . . . . . . . . . . . . . . 8N-7
MODULE - INSTALLATION, SENTRY KEY
IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . 8E-18
MODULE - INSTALLATION, SIDE IMPACT
AIRBAG CONTROL . . . . . . . . . . . . . . . . . . . 8O-45
MODULE - OPERATION, AIRBAG
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-10
MODULE - OPERATION, BODY CONTROL . . . 8E-5
MODULE - OPERATION, FRONT WIPER . . . 8R-15
MODULE - OPERATION, FUEL PUMP . . . . . 14-18
MODULE - OPERATION, HEATED SEAT . . . . 8E-21
MODULE - OPERATION, INTRUSION
TRANSCEIVER. . . . . . . . . . . . . . . . . . . . . . . 8Q-15
MODULE - OPERATION, REMOTE
KEYLESS ENTRY . . . . . . . . . . . . . . . . . . . . . . 8N-7
MODULE - OPERATION, SENTRY KEY
IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . 8E-16
MODULE - OPERATION, SIDE IMPACT
AIRBAG CONTROL . . . . . . . . . . . . . . . . . . . 8O-43
MODULE - OPERATION, TRANSMISSION
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-18
MODULE - REMOVAL, AIRBAG CONTROL . 8O-11
MODULE - REMOVAL, BODY CONTROL . . . . 8E-7
MODULE - REMOVAL, CONTROL . . . . . . . 23-183
MODULE - REMOVAL, FRONT WIPER . . . . 8R-16
MODULE - REMOVAL, FUEL PUMP . . . . . . . 14-18
MODULE - REMOVAL, HEATED SEAT . . . . . 8E-24
MODULE - REMOVAL, INTRUSION
TRANSCEIVER. . . . . . . . . . . . . . . . . . . . . . . 8Q-15
MODULE - REMOVAL, REMOTE KEYLESS
ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
MODULE - REMOVAL, SENTRY KEY
IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . 8E-17
MODULE - REMOVAL, SIDE IMPACT
AIRBAG CONTROL . . . . . . . . . . . . . . . . . . . 8O-44
MODULE ASSEMBLY - INSTALLATION . . . 23-181
MODULE ASSEMBLY - REMOVAL . . . . . . . 23-181
MOLDING - INSTALLATION, FRONT
DOOR OUTER BELT . . . . . . . . . . . . . . . . . . 23-186
MOLDING - INSTALLATION, REAR DOOR
OUTER BELT . . . . . . . . . . . . . . . . . . . . . . . 23-186
MOLDING - REMOVAL, FRONT DOOR
OUTER BELT . . . . . . . . . . . . . . . . . . . . . . . 23-186
MOLDING - REMOVAL, REAR DOOR
OUTER BELT . . . . . . . . . . . . . . . . . . . . . . . 23-186
MOLDINGS - INSTALLATION, BODY SIDE . 23-140
MOLDINGS - INSTALLATION, FRONT
WHEEL OPENING FLARE . . . . . . . . . . . . . . 23-145
MOLDINGS - INSTALLATION, REAR
WHEEL OPENING FLARE . . . . . . . . . . . . . . 23-145
MOLDINGS - REMOVAL, BODY SIDE . . . . 23-140
MOLDINGS - REMOVAL, FRONT WHEEL
OPENING FLARE . . . . . . . . . . . . . . . . . . . . 23-145
MOLDINGS - REMOVAL, REAR WHEEL
OPENING FLARE . . . . . . . . . . . . . . . . . . . . 23-145
MONITORED SYSTEMS - DESCRIPTION . . . 25-17
MONITORS - DESCRIPTION,
COMPONENT . . . . . . . . . . . . . . . . . . . . . . . . 25-19
MOTOR - DESCRIPTION, BLOWER . . . . . . . 24-30
MOTOR - DESCRIPTION, DOOR LOCK . . . . . 8N-5
MOTOR - DESCRIPTION, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-35
MOTOR - DESCRIPTION, IDLE AIR
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
MOTOR - DESCRIPTION, REAR WIPER . . . 8R-41
MOTOR - DIAGNOSIS AND TESTING,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-30
MOTOR - DIAGNOSIS AND TESTING,
DOOR LOCK . . . . . . . . . . . . . . . . . . . . . . . . . 8N-5
MOTOR - DIAGNOSIS AND TESTING,
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-39
MOTOR - INSTALLATION, BLOWER . . . . . . 24-31
MOTOR - INSTALLATION, DRIVE . . . . . . . . 23-182
MOTOR - INSTALLATION, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
MOTOR - INSTALLATION, IDLE AIR
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-36
MOTOR - INSTALLATION, REAR WIPER . . . 8R-42
MOTOR - INSTALLATION, STARTER . . . . . . 8F-41
MOTOR - OPERATION, BLOWER . . . . . . . . . 24-30
MOTOR - OPERATION, DOOR LOCK . . . . . . . 8N-5
MOTOR - OPERATION, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
16 INDEX KJ
Description Group-Page Description Group-Page Description Group-Page
MOTOR - OPERATION, IDLE AIR
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
MOTOR - OPERATION, REAR WIPER . . . . . 8R-41
MOTOR - REMOVAL, BLOWER . . . . . . . . . . 24-30
MOTOR - REMOVAL, DRIVE . . . . . . . . . . . 23-182
MOTOR - REMOVAL, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
MOTOR - REMOVAL, IDLE AIR CONTROL . . 14-36
MOTOR - REMOVAL, REAR WIPER . . . . . . 8R-42
MOTOR - REMOVAL, STARTER . . . . . . . . . . 8F-39
MOTOR - REMOVAL, WINDOW . . . . . . . . . . 8N-22
MOTOR, GAS POWERED - STARTER . . . . . . 8F-39
MOTOR RELAY - DESCRIPTION,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-20
MOTOR RELAY - DESCRIPTION,
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-41
MOTOR RELAY - DIAGNOSIS AND
TESTING, BLOWER . . . . . . . . . . . . . . . . . . . 24-21
MOTOR RELAY - INSTALLATION,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
MOTOR RELAY - INSTALLATION,
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-43
MOTOR RELAY - OPERATION, BLOWER . . . 24-20
MOTOR RELAY - OPERATION, STARTER . . . 8F-42
MOTOR RELAY - REMOVAL, BLOWER . . . . 24-21
MOTOR RELAY - REMOVAL, STARTER . . . . 8F-43
MOTOR RESISTOR - DESCRIPTION,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
MOTOR RESISTOR - DIAGNOSIS AND
TESTING, BLOWER. . . . . . . . . . . . . . . . . . . . . 24-22
MOTOR RESISTOR - INSTALLATION,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
MOTOR RESISTOR - OPERATION,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
MOTOR RESISTOR - REMOVAL,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
MOTOR SWITCH - DESCRIPTION,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23
MOTOR SWITCH - DIAGNOSIS AND
TESTING, BLOWER . . . . . . . . . . . . . . . . . . . 24-23
MOTOR SWITCH - INSTALLATION,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23
MOTOR SWITCH - OPERATION, BLOWER . . 24-23
MOTOR SWITCH - REMOVAL, BLOWER . . . 24-23
MOUNT - INSTALLATION, FRONT . . . . . . . . . 9-57
MOUNT - INSTALLATION, REAR . . . . . . . . . . 9-57
MOUNT - REMOVAL, FRONT . . . . . . . . . . . . . 9-56
MOUNT - REMOVAL, REAR . . . . . . . . . . . . . . 9-57
MOUNTED STOP LAMP BULB -
INSTALLATION, CENTER HIGH . . . . . . . . . . 8L-19
MOUNTED STOP LAMP BULB -
REMOVAL, CENTER HIGH . . . . . . . . . . . . . . 8L-18
MOUNTED STOP LAMP UNIT -
INSTALLATION, CENTER HIGH . . . . . . . . . . 8L-19
MOUNTED STOP LAMP UNIT -
REMOVAL, CENTER HIGH . . . . . . . . . . . . . . 8L-19
MOUNTING - STANDARD PROCEDURE,
MATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-3
MOUNTING - STANDARD PROCEDURE,
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-10
MOUNTING BRACKET - INSTALLATION,
PASSENGER AIRBAG . . . . . . . . . . . . . . . . . 8O-31
MOUNTING BRACKET - REMOVAL,
PASSENGER AIRBAG . . . . . . . . . . . . . . . . . 8O-31
MUFFLER - DESCRIPTION . . . . . . . . . . . . . . . 11-4
MUFFLER - INSTALLATION . . . . . . . . . . . . . . 11-5
MUFFLER - REMOVAL . . . . . . . . . . . . . . . . . . 11-5
MULTI-FUNCTION SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-46
MULTI-FUNCTION SWITCH - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8L-50
MULTI-FUNCTION SWITCH -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-53
MULTI-FUNCTION SWITCH - OPERATION . . 8L-48
MULTI-FUNCTION SWITCH - REMOVAL . . . 8L-53
NAME PLATES - INSTALLATION,
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . 23-141
NAME PLATES - REMOVAL, EXTERIOR . . . 23-140
NOISE - DIAGNOSIS AND TESTING, A/C
COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . 24-42
NOISE - DIAGNOSIS AND TESTING,
WIND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3
NOISE DIAGNOSIS, DIAGNOSIS AND
TESTING - WATER DRAINAGE AND
WIND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-176
NOISE OR VIBRATION - DIAGNOSIS AND
TESTING, TIRE . . . . . . . . . . . . . . . . . . . . . . . 22-8
NOISE SUPPRESSION GROUND STRAP -
DESCRIPTION, RADIO. . . . . . . . . . . . . . . . . . 8A-9
NOISE SUPPRESSION GROUND STRAP -
INSTALLATION, RADIO . . . . . . . . . . . . . . . . 8A-11
NOISE SUPPRESSION GROUND STRAP -
OPERATION, RADIO . . . . . . . . . . . . . . . . . . 8A-10
NOISE SUPPRESSION GROUND STRAP -
REMOVAL, RADIO. . . . . . . . . . . . . . . . . . . . 8A-10
NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS - STANDARD
PROCEDURE, HANDLING . . . . . . . . . . . . . . . 8O-6
NON-MONITORED CIRCUITS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 25-20
NOZZLE - DESCRIPTION, FRONT
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-11
NOZZLE - DESCRIPTION, REAR WASHER . 8R-36
NOZZLE - INSTALLATION, FRONT
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-11
NOZZLE - INSTALLATION, REAR
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-37
NOZZLE - OPERATION, FRONT WASHER . . 8R-11
NOZZLE - OPERATION, REAR WASHER . . . 8R-36
NOZZLE - REMOVAL, FRONT WASHER . . . . 8R-11
NOZZLE - REMOVAL, REAR WASHER . . . . 8R-36
NUMBER - DESCRIPTION, VEHICLE
IDENTIFICATION . . . . . . . . . . . . . . . . . . . . Intro.-8
NV1500 - ASSEMBLY, MANUAL . . . . . . . . . 21-13
NV1500 - CLEANING, MANUAL . . . . . . . . . . 21-10
NV1500 - DESCRIPTION, MANUAL . . . . . . . . 21-1
NV1500 - DISASSEMBLY, MANUAL . . . . . . . . 21-4
NV1500 - INSPECTION, MANUAL . . . . . . . . . . 21-11
NV1500 - INSTALLATION, EXTENSION
HOUSING SEAL . . . . . . . . . . . . . . . . . . . . . . 21-32
NV1500 - INSTALLATION, MANUAL . . . . . . 21-29
NV1500 - MANUAL . . . . . . . . . . . . . . . . . . . 21-30
NV1500 - OPERATION, MANUAL . . . . . . . . . . 21-1
NV1500 - REMOVAL, EXTENSION
HOUSING SEAL . . . . . . . . . . . . . . . . . . . . . . 21-32
NV1500 - REMOVAL, MANUAL . . . . . . . . . . . 21-3
NV1500 - SPECIFICATIONS . . . . . . . . . . . . . 21-30
NV231 - ASSEMBLY, TRANSFER CASE . . . 21-194
NV231 - CLEANING, TRANSFER CASE . . . 21-190
NV231 - DESCRIPTION, TRANSFER CASE . . . 0-3
NV231 - DESCRIPTION, TRANSFER CASE . 21-178
NV231 - DIAGNOSIS AND TESTING,
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . 21-180
NV231 - DISASSEMBLY, TRANSFER
CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-182
NV231 - INSPECTION, TRANSFER CASE . . 21-190
NV231 - INSTALLATION, TRANSFER
CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-205
NV231 - OPERATION, TRANSFER CASE . . 21-179
NV231 - REMOVAL, TRANSFER CASE . . . . 21-181
NV231 - TRANSFER CASE . . . . . . . . . . . . . 21-206
NV242 - ASSEMBLY, TRANSFER CASE . . . 21-230
NV242 - CLEANING, TRANSFER CASE . . . 21-227
NV242 - DESCRIPTION, TRANSFER CASE . . . 0-3
NV242 - DESCRIPTION, TRANSFER CASE . 21-215
NV242 - DIAGNOSIS AND TESTING,
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . 21-216
NV242 - DISASSEMBLY, TRANSFER
CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-218
NV242 - INSPECTION, TRANSFER CASE . . 21-228
NV242 - INSTALLATION, TRANSFER
CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-243
NV242 - OPERATION, TRANSFER CASE . . 21-215
NV242 - REMOVAL, TRANSFER CASE . . . . 21-217
NV242 - TRANSFER CASE . . . . . . . . . . . . . 21-244
NV242 TRANSFER CASE,
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 21-244
NV3550 - ASSEMBLY, MANUAL . . . . . . . . . 21-48
NV3550 - CLEANING, MANUAL . . . . . . . . . . 21-46
NV3550 - DESCRIPTION, MANUAL . . . . . . . 21-33
NV3550 - DISASSEMBLY, MANUAL . . . . . . . 21-35
NV3550 - INSPECTION, MANUAL . . . . . . . . 21-46
NV3550 - INSTALLATION, EXTENSION
HOUSING BUSHING. . . . . . . . . . . . . . . . . . . 21-74
NV3550 - INSTALLATION, EXTENSION
HOUSING SEAL . . . . . . . . . . . . . . . . . . . . . . 21-74
NV3550 - INSTALLATION, MANUAL . . . . . . 21-70
NV3550 - MANUAL . . . . . . . . . . . . . . . . . . . 21-71
NV3550 - OPERATION, MANUAL . . . . . . . . . 21-33
NV3550 - REMOVAL, EXTENSION
HOUSING BUSHING. . . . . . . . . . . . . . . . . . . 21-73
NV3550 - REMOVAL, EXTENSION
HOUSING SEAL . . . . . . . . . . . . . . . . . . . . . . 21-74
NV3550 - REMOVAL, MANUAL . . . . . . . . . . 21-34
ODOMETER - DESCRIPTION . . . . . . . . . . . . 8J -25
ODOMETER - OPERATION . . . . . . . . . . . . . . 8J -25
OFF INDICATOR - DESCRIPTION,
OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . . 8J -26
OFF INDICATOR - OPERATION,
OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . . 8J -26
OIL - DESCRIPTION, REFRIGERANT . . . . . . 24-53
OIL - OPERATION, REFRIGERANT . . . . . . . . 24-54
OIL - STANDARD PROCEDURE, ENGINE . . . . 9-61
OIL FILTER - INSTALLATION . . . . . . . . . . . . . 9-63
OIL FILTER - REMOVAL . . . . . . . . . . . . . . . . . 9-63
OIL GALLERY PLUGS - STANDARD
PROCEDURE, ENGINE CORE . . . . . . . . . . . . . 9-10
OIL LEAK - DIAGNOSIS AND TESTING,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60
OIL LEVEL - STANDARD PROCEDURE,
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . 24-54
OIL PAN - CLEANING . . . . . . . . . . . . . . . . . . 9-63
OIL PAN - DESCRIPTION . . . . . . . . . . . . . . . . 9-63
OIL PAN - INSPECTION . . . . . . . . . . . . . . . . . 9-63
OIL PAN - INSTALLATION . . . . . . . . . . . . . . . 9-64
OIL PAN - REMOVAL . . . . . . . . . . . . . . . . . . . 9-63
OIL PRESSURE - DIAGNOSIS AND
TESTING, ENGINE . . . . . . . . . . . . . . . . . . . . . 9-60
OIL PRESSURE INDICATOR -
DESCRIPTION, LOW . . . . . . . . . . . . . . . . . . 8J -23
OIL PRESSURE INDICATOR -
OPERATION, LOW . . . . . . . . . . . . . . . . . . . . 8J -23
OIL PRESSURE SENSOR/SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 9-65
OIL PRESSURE SENSOR/SWITCH -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 9-65
OIL PRESSURE SENSOR/SWITCH -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
OIL PRESSURE SENSOR/SWITCH -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
OIL PUMP - ASSEMBLY . . . . . . . . . . . . . . . . 9-67
OIL PUMP - ASSEMBLY . . . . . . . . . . . . . . 21-151
OIL PUMP - CLEANING . . . . . . . . . . . . . . . 21-150
OIL PUMP - DESCRIPTION . . . . . . . . . . . . 21-147
OIL PUMP - DISASSEMBLY . . . . . . . . . . . . . 9-65
OIL PUMP - DISASSEMBLY . . . . . . . . . . . . 21-149
OIL PUMP - INSPECTION . . . . . . . . . . . . . . . 9-66
OIL PUMP - INSPECTION . . . . . . . . . . . . . 21-150
OIL PUMP - INSTALLATION . . . . . . . . . . . . . 9-67
OIL PUMP - OPERATION . . . . . . . . . . . . . . 21-147
OIL PUMP - REMOVAL . . . . . . . . . . . . . . . . . 9-65
OIL PUMP FRONT SEAL - INSTALLATION . 21-152
OIL PUMP FRONT SEAL - REMOVAL . . . . 21-152
OIL PUMP VOLUME CHECK - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 21-148
OIL SEAL - FRONT - INSTALLATION,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 9-47
OIL SEAL - FRONT - REMOVAL,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 9-46
OIL SEAL - REAR - INSTALLATION,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 9-48
OIL SEAL - REAR - REMOVAL,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 9-48
ON-BOARD DIAGNOSTICS (OBD) -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 7-3
ON/OFF RELAY - DESCRIPTION, WIPER . . . 8R-25
ON/OFF RELAY - DIAGNOSIS AND
TESTING, WIPER. . . . . . . . . . . . . . . . . . . . . 8R-26
ON/OFF RELAY - INSTALLATION, WIPER . . 8R-26
ON/OFF RELAY - OPERATION, WIPER . . . . 8R-25
ON/OFF RELAY - REMOVAL, WIPER . . . . . . 8R-26
OPEN-CIRCUIT VOLTAGE TEST -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8F-12
OPENING DIMENSIONS -
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 23-111
OPENING FLARE MOLDINGS -
INSTALLATION, FRONT WHEEL . . . . . . . . . 23-145
OPENING FLARE MOLDINGS -
INSTALLATION, REAR WHEEL . . . . . . . . . . 23-145
OPENING FLARE MOLDINGS -
REMOVAL, FRONT WHEEL . . . . . . . . . . . . 23-145
OPENING FLARE MOLDINGS -
REMOVAL, REAR WHEEL . . . . . . . . . . . . . 23-145
OPENING REINFORCEMENT -
INSTALLATION, GRILLE. . . . . . . . . . . . . . . 23-142
OPENING REINFORCEMENT - REMOVAL,
GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-142
OPENING TRIM LACE - INSTALLATION . . . 23-180
OPENING TRIM LACE - REMOVAL . . . . . . 23-180
OPENING WEATHERSTRIP -
INSTALLATION, SWING GATE . . . . . . . . . . 23-186
OPENING WEATHERSTRIP - REMOVAL,
SWING GATE . . . . . . . . . . . . . . . . . . . . . . . 23-186
KJ INDEX 17
Description Group-Page Description Group-Page Description Group-Page
OPERATION - DESCRIPTION, MODES OF . . 8E-11
OPERATION - DIAGNOSIS AND TESTING,
AIR CHECKING TRANSMISSION
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-80
ORDER, 2.4L 4-CYLINDER - ENGINE
FIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-2
ORDER, 3.7L V-6 - ENGINE FIRING . . . . . . . . 8I-2
ORIFICE TUBE - DESCRIPTION, A/C . . . . . . 24-50
ORIFICE TUBE - INSTALLATION, A/C . . . . . . 24-50
ORIFICE TUBE - OPERATION, A/C . . . . . . . . 24-50
ORIFICE TUBE - REMOVAL, A/C . . . . . . . . . 24-50
ORVR - DESCRIPTION . . . . . . . . . . . . . . . . . 25-29
ORVR - OPERATION . . . . . . . . . . . . . . . . . . 25-29
OUT - ADJ USTMENT, LOCK . . . . . . . . . . . . . . 5-30
OUTBOARD SEAT BELT & RETRACTOR -
INSTALLATION, REAR . . . . . . . . . . . . . . . . . 8O-34
OUTBOARD SEAT BELT & RETRACTOR -
REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . 8O-33
OUTER BELT MOLDING - INSTALLATION,
FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . 23-186
OUTER BELT MOLDING - INSTALLATION,
REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . 23-186
OUTER BELT MOLDING - REMOVAL,
FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . 23-186
OUTER BELT MOLDING - REMOVAL,
REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . 23-186
OUTER TIE ROD END REMOVAL TOOL,
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . 19-15
OUTLET - DESCRIPTION, CIGAR
LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-2
OUTLET - DESCRIPTION, POWER . . . . . . 8W-97-11
OUTLET - DIAGNOSIS AND TESTING,
CIGAR LIGHTER . . . . . . . . . . . . . . . . . . . 8W-97-2
OUTLET - DIAGNOSIS AND TESTING,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-11
OUTLET - INSTALLATION, POWER . . . . 8W-97-13
OUTLET - OPERATION, CIGAR LIGHTER . 8W-97-2
OUTLET - OPERATION, POWER . . . . . . 8W-97-11
OUTLET - REMOVAL, POWER . . . . . . . . 8W-97-12
OUTLET BARRELS - INSTALLATION,
PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-29
OUTLET BARRELS - REMOVAL, PANEL . . . 24-29
OUTLETS - DESCRIPTION, DEMISTER . . . . 24-29
OUTPUT - DESCRIPTION, PCM . . . . . . . . . . . 8I-4
OUTPUT - OPERATION, PCM . . . . . . . . . . . . 14-33
OUTPUT - OPERATION, PCM . . . . . . . . . . . . . 8I-4
OUTPUT SHAFT SEAL - INSTALLATION,
FRONT . . . . . . . . . . . . . . . . . . . . . . 21-208,21-246
OUTPUT SHAFT SEAL - INSTALLATION,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-212
OUTPUT SHAFT SEAL - REMOVAL,
FRONT . . . . . . . . . . . . . . . . . . . . . . 21-208,21-246
OUTPUT SHAFT SEAL - REMOVAL, REAR . 21-210
OUTPUT SPEED SENSOR - DESCRIPTION . 21-152
OUTPUT SPEED SENSOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-152
OUTPUT SPEED SENSOR - OPERATION . . 21-152
OUTPUT SPEED SENSOR - REMOVAL . . . 21-152
OVERDRIVE OFF INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -26
OVERDRIVE OFF INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -26
OVERDRIVE SWITCH - DESCRIPTION . . . . 21-153
OVERDRIVE SWITCH - OPERATION . . . . . 21-153
OVERHEAD CONSOLE - DESCRIPTION . . . . 8M-1
OVERHEAD CONSOLE - OPERATION . . . . . . 8M-2
OVERHEAD CONSOLE, REMOVAL . . . . . . . . 8M-4
OVERRIDE RELAY - DESCRIPTION,
CLUTCH SWITCH. . . . . . . . . . . . . . . . . . . . . . 6-10
OVERRIDE RELAY - INSTALLATION,
CLUTCH SWITCH. . . . . . . . . . . . . . . . . . . . . . 6-10
OVERRIDE RELAY - OPERATION,
CLUTCH SWITCH. . . . . . . . . . . . . . . . . . . . . . 6-10
OVERRIDE RELAY - REMOVAL, CLUTCH
SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
OXYGEN SENSOR - DESCRIPTION . . . . . . . 14-40
OXYGEN SENSOR - INSTALLATION . . . . . . . 14-43
OXYGEN SENSOR - OPERATION . . . . . . . . . 14-40
OXYGEN SENSOR - REMOVAL . . . . . . . . . . 14-41
PADS - INSTALLATION, FRONT BRAKE . . . . . 5-11
PADS - REMOVAL, FRONT BRAKE . . . . . . . . 5-11
PAINT CODE - DESCRIPTION . . . . . . . . . . 23-162
PAINT CODES - SPECIFICATIONS . . . . . . . 23-162
PAINT TOUCH-UP - DESCRIPTION . . . . . . 23-163
PAN - CLEANING, OIL . . . . . . . . . . . . . . . . . . 9-63
PAN - DESCRIPTION, OIL . . . . . . . . . . . . . . . 9-63
PAN - INSPECTION, OIL . . . . . . . . . . . . . . . . 9-63
PAN - INSTALLATION, OIL . . . . . . . . . . . . . . . 9-64
PAN - REMOVAL, OIL . . . . . . . . . . . . . . . . . . 9-63
PANEL - DESCRIPTION, LATCH - ACCESS . 23-139
PANEL - INSTALLATION, GLASS . . . . . . . . 23-178
PANEL - INSTALLATION, LATCH -
ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-139
PANEL - INSTALLATION, QUARTER TRIM . 23-159
PANEL - INSTALLATION, TRIM . . . 23-126,23-132,
23-138
PANEL - REMOVAL, GLASS . . . . . . . . . . . . 23-178
PANEL - REMOVAL, LATCH - ACCESS . . . 23-139
PANEL - REMOVAL, QUARTER TRIM . . . . 23-159
PANEL - REMOVAL, TRIM . 23-125,23-132,23-138
PANEL ADJ USTMENT, ADJ USTMENTS -
SUNROOF GLASS . . . . . . . . . . . . . . . . . . . 23-178
PANEL ANTENNA CABLE -
INSTALLATION, INSTRUMENT. . . . . . . . . . . . 8A-8
PANEL ANTENNA CABLE - REMOVAL,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . . 8A-7
PANEL ASSEMBLY - INSTALLATION,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-151
PANEL ASSEMBLY - REMOVAL,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-149
PANEL CENTER BEZEL - INSTALLATION,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-154
PANEL CENTER BEZEL - REMOVAL,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-154
PANEL DOOR - INSTALLATION . . . . . . . . . . 24-36
PANEL DOOR ACTUATOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-25
PANEL DOOR ACTUATOR - REMOVAL . . . . 24-24
PANEL DRIVER SIDE BEZELS -
INSTALLATION, INSTRUMENT . . . . . . . . . . 23-154
PANEL DRIVER SIDE BEZELS -
REMOVAL, INSTRUMENT . . . . . . . . . . . . . 23-153
PANEL END CAP - INSTALLATION,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-153
PANEL END CAP - REMOVAL,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-153
PANEL OUTLET BARRELS -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-29
PANEL OUTLET BARRELS - REMOVAL . . . . 24-29
PANEL PASSENGER SIDE BEZEL -
INSTALLATION, INSTRUMENT . . . . . . . . . . 23-154
PANEL PASSENGER SIDE BEZEL -
REMOVAL, INSTRUMENT . . . . . . . . . . . . . 23-154
PANEL SEAL - INSTALLATION, GLASS . . . 23-178
PANEL SEAL - REMOVAL, GLASS . . . . . . . 23-178
PANEL TOP COVER - INSTALLATION,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-153
PANEL TOP COVER - REMOVAL,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-152
PARK - INTERLOCK CABLE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-153
PARK - INTERLOCK CABLE - REMOVAL . . 21-153
PARK LAMP RELAY - DESCRIPTION . . . . . . 8L-54
PARK LAMP RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-55
PARK LAMP RELAY - INSTALLATION . . . . . 8L-56
PARK LAMP RELAY - OPERATION . . . . . . . 8L-54
PARK LAMP RELAY - REMOVAL . . . . . . . . . 8L-55
PARK RAMP - INSTALLATION, WIPER
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-43
PARK RAMP - REMOVAL, WIPER ARM . . . 8R-43
PARKING BRAKE - DESCRIPTION . . . . . . . . . 5-29
PARKING BRAKE - OPERATION . . . . . . . . . . . 5-29
PARK-INTERLOCK CABLE -
ADJ USTMENTS . . . . . . . . . . . . . . . . . . . . . 21-154
PART TIME INDICATOR - DESCRIPTION . . . 8J -29
PART TIME INDICATOR - OPERATION . . . . . 8J -29
PASSENGER AIRBAG - DESCRIPTION . . . . 8O-27
PASSENGER AIRBAG - INSTALLATION . . . . 8O-29
PASSENGER AIRBAG - OPERATION . . . . . . 8O-27
PASSENGER AIRBAG - REMOVAL . . . . . . . . 8O-28
PASSENGER AIRBAG DOOR -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-30
PASSENGER AIRBAG DOOR - REMOVAL . . 8O-29
PASSENGER AIRBAG MOUNTING
BRACKET - INSTALLATION . . . . . . . . . . . . . 8O-31
PASSENGER AIRBAG MOUNTING
BRACKET - REMOVAL . . . . . . . . . . . . . . . . . 8O-31
PASSENGER SEAT HEATER SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8G-14
PASSENGER SEAT HEATER SWITCH -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8G-15
PASSENGER SEAT HEATER SWITCH -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8G-14
PASSENGER SEAT HEATER SWITCH -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-15
PASSENGER SIDE BEZEL -
INSTALLATION, INSTRUMENT PANEL . . . . 23-154
PASSENGER SIDE BEZEL - REMOVAL,
INSTRUMENT PANEL. . . . . . . . . . . . . . . . . 23-154
PATTERNS - DIAGNOSIS AND TESTING,
TIRE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
PCM - DESCRIPTION . . . . . . . . . . . . . . . . . . 8E-11
PCM - OPERATION . . . . . . . . . . . . . . . . . . . 8E-14
PCM INPUT - OPERATION, ASD SENSE . . . . . 8I-4
PCM OUTPUT - DESCRIPTION . . . . . . . . . . . . 8I-4
PCM OUTPUT - OPERATION . . . . . . . . . . . . 14-33
PCM OUTPUT - OPERATION . . . . . . . . . . . . . 8I-4
PCM/SKIM PROGRAMMING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8E-1
PCV VALVE - DESCRIPTION . . . . . . . . . . . . 25-29
PCV VALVE - DIAGNOSIS AND TESTING . . . 25-31
PCV VALVE - INSTALLATION . . . . . . . . . . . . 25-32
PCV VALVE - OPERATION . . . . . . . . . . . . . . 25-31
PCV VALVE - REMOVAL . . . . . . . . . . . . . . . 25-32
PEDAL - DESCRIPTION . . . . . . . . . . . . . . . . . 5-20
PEDAL - INSTALLATION . . . . . . . . . . . . . . . . 5-20
PEDAL - INSTALLATION, ACCELERATOR . . . 14-30
PEDAL - INSTALLATION, CLUTCH . . . . . . . . . 6-10
PEDAL - OPERATION . . . . . . . . . . . . . . . . . . . 5-20
PEDAL - REMOVAL . . . . . . . . . . . . . . . . . . . . 5-20
PEDAL - REMOVAL, ACCELERATOR . . . . . . 14-29
PEDAL - REMOVAL, CLUTCH . . . . . . . . . . . . 6-10
PEDAL POSITION SWITCH -
DESCRIPTION, CLUTCH. . . . . . . . . . . . . . . . . 6-11
PEDAL POSITION SWITCH - DIAGNOSIS
AND TESTING, CLUTCH. . . . . . . . . . . . . . . . . 6-11
PEDAL POSITION SWITCH - OPERATION,
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
PERFORMANCE - DIAGNOSIS AND
TESTING, A/C . . . . . . . . . . . . . . . . . . . . . . . . 24-2
PERFORMANCE - DIAGNOSIS AND
TESTING, ENGINE DIAGNOSIS . . . . . . . . . . . . 9-4
PERFORMANCE - DIAGNOSIS AND
TESTING, HEATER . . . . . . . . . . . . . . . . . . . . . 24-6
PILOT BEARING - INSTALLATION . . . . . . . . . . 6-8
PILOT BEARING - REMOVAL . . . . . . . . . . . . . . 6-8
PINION GEAR/RING GEAR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 3-46
PINION GEAR/RING GEAR - REMOVAL . . . . . 3-44
PINION GEAR/RING GEAR/TONE RING -
INSTALLATION. . . . . . . . . . . . . . . . . . . 3-112,3-82
PINION GEAR/RING GEAR/TONE RING -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . 3-110,3-79
PINION SEAL - INSTALLATION . . 3-103,3-39,3-68
PINION SEAL - REMOVAL . . . . . . 3-102,3-38,3-68
PIPE - INSTALLATION, CROSS-OVER . . . . . . 11-3
PIPE - REMOVAL, CROSS-OVER . . . . . . . . . . 11-3
PISTON & CONNECTING ROD -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 9-49
PISTON FITTING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
PISTON RING FITTING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 9-52
PISTONS - DESCRIPTION . . . . . . . . . . . . . 21-155
PISTONS - OPERATION . . . . . . . . . . . . . . . 21-155
PLANETARY GEARTRAIN - ASSEMBLY . . . 21-160
PLANETARY GEARTRAIN - CLEANING . . . . 21-159
PLANETARY GEARTRAIN - DESCRIPTION . 21-157
PLANETARY GEARTRAIN -
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-159
PLANETARY GEARTRAIN - INSPECTION . . 21-159
PLANETARY GEARTRAIN - OPERATION . . 21-157
PLATE - INSTALLATION, DOOR SILL
SCUFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-157
PLATE - INSTALLATION, FLEX . . . . . . . . . . . . 9-49
PLATE - INSTALLATION, FRONT SKID . . . . . . 13-6
PLATE - INSTALLATION, FUEL TANK
SKID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
PLATE - INSTALLATION, REAR DOOR
SCUFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-160
PLATE - INSTALLATION, TRANSFER
CASE SKID . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
PLATE - REMOVAL, DOOR SILL SCUFF . . . 23-157
PLATE - REMOVAL, FLEX . . . . . . . . . . . . . . . 9-49
PLATE - REMOVAL, FRONT SKID . . . . . . . . . 13-6
PLATE - REMOVAL, FUEL TANK SKID . . . . . . 13-9
PLATE - REMOVAL, REAR DOOR SCUFF . . 23-160
PLATE - REMOVAL, TRANSFER CASE
SKID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
PLATE LAMP BULB - INSTALLATION,
LICENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-45
PLATE LAMP BULB - REMOVAL,
LICENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-44
18 INDEX KJ
Description Group-Page Description Group-Page Description Group-Page
PLATE LAMP UNIT - INSTALLATION,
LICENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-46
PLATE LAMP UNIT - REMOVAL, LICENSE . . 8L-45
PLATES - INSTALLATION, EXTERIOR
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-141
PLATES - REMOVAL, EXTERIOR NAME . . . 23-140
PLUG - CLEANING SPARK PLUGS,
SPARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-15
PLUG - DESCRIPTION, SPARK . . . . . . . . . . . 8I-12
PLUG - INSTALLATION, SPARK . . . . . . . . . . 8I-15
PLUG - OPERATION, SPARK . . . . . . . . . . . . 8I-12
PLUG - REMOVAL, SPARK . . . . . . . . . . . . . . 8I-15
PLUG CABLE RESISTANCE, 2.4L - SPARK . . . 8I-3
PLUG CONDITIONS - DIAGNOSIS AND
TESTING, SPARK . . . . . . . . . . . . . . . . . . . . . 8I-13
PLUGS - STANDARD PROCEDURE,
ENGINE CORE AND OIL GALLERY . . . . . . . . 9-10
PLUGS, SPARK PLUG - CLEANING
SPARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-15
PLUGS, SPECIFICATIONS - SPARK . . . . . . . . 8I-3
POLISHING - DESCRIPTION, FINESSE
SANDING/BUFFING . . . . . . . . . . . . . . . . . . 23-163
PORT - DESCRIPTION, REFRIGERANT
SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . 24-2
PORT - OPERATION, REFRIGERANT
SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . 24-2
POSITION LAMP BULB - INSTALLATION,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-28
POSITION LAMP BULB - REMOVAL,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-28
POSITION SENSOR - DESCRIPTION. 21-209,21-247
POSITION SENSOR - DESCRIPTION,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 14-30
POSITION SENSOR - DESCRIPTION,
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
POSITION SENSOR - INSTALLATION . . . . 21-210,
21-247
POSITION SENSOR - INSTALLATION,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 14-32
POSITION SENSOR - INSTALLATION,
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-48
POSITION SENSOR - OPERATION . 21-209,21-247
POSITION SENSOR - OPERATION,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 14-31
POSITION SENSOR - OPERATION,
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
POSITION SENSOR - REMOVAL . . 21-210,21-247
POSITION SENSOR - REMOVAL,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 14-31
POSITION SENSOR - REMOVAL,
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
POSITION SWITCH - DESCRIPTION,
CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . 6-11
POSITION SWITCH - DIAGNOSIS AND
TESTING, CLUTCH PEDAL . . . . . . . . . . . . . . . 6-11
POSITION SWITCH - OPERATION,
CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . 6-11
POTENTIAL - STANDARD PROCEDURE,
TESTING OF VOLTAGE . . . . . . . . . . . . . . 8W-01-9
POWER BRAKE BOOSTER -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 5-21
POWER BRAKE BOOSTER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 5-23
POWER BRAKE BOOSTER - OPERATION . . . 5-21
POWER BRAKE BOOSTER - REMOVAL . . . . . 5-22
POWER DISTRIBUTION - DESCRIPTION . 8W-97-1
POWER DISTRIBUTION - OPERATION . . 8W-97-1
POWER DISTRIBUTION CENTER -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 8W-97-6
POWER DISTRIBUTION CENTER -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . 8W-97-7
POWER DISTRIBUTION CENTER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-7
POWER DISTRIBUTION CENTER
ASSEMBLY, ASSEMBLY . . . . . . . . . . . . . 8W-97-10
POWER DISTRIBUTION CENTER
DISASSEMBLY, DISASSEMBLY . . . . . . . . 8W-97-7
POWER DISTRIBUTION SYSTEMS,
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . 8W-97-2
POWER GROUNDS - DESCRIPTION . . . . . . 8E-13
POWER LOCKS - DESCRIPTION . . . . . . . . . . 8N-1
POWER LOCKS - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-3
POWER LOCKS - OPERATION . . . . . . . . . . . . 8N-3
POWER MIRROR SWITCH - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8N-12
POWER MIRROR SWITCH -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8N-13
POWER MIRROR SWITCH - REMOVAL . . . 8N-13
POWER MIRRORS - DESCRIPTION . . . . . . 8N-11
POWER MIRRORS - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-11
POWER MIRRORS - OPERATION . . . . . . . . 8N-11
POWER OUTLET - DESCRIPTION . . . . . 8W-97-11
POWER OUTLET - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-11
POWER OUTLET - INSTALLATION . . . . 8W-97-13
POWER OUTLET - OPERATION . . . . . . . 8W-97-11
POWER OUTLET - REMOVAL . . . . . . . . 8W-97-12
POWER SEAT SWITCH - DESCRIPTION,
LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-16
POWER SEAT SWITCH - DESCRIPTION,
RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-19
POWER SEAT SWITCH - DIAGNOSIS
AND TESTING, LEFT . . . . . . . . . . . . . . . . . . 8N-17
POWER SEAT SWITCH - DIAGNOSIS
AND TESTING, RIGHT . . . . . . . . . . . . . . . . . 8N-19
POWER SEAT SWITCH - INSTALLATION,
LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-18
POWER SEAT SWITCH - INSTALLATION,
RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20
POWER SEAT SWITCH - OPERATION,
LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-17
POWER SEAT SWITCH - OPERATION,
RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-19
POWER SEAT SWITCH - REMOVAL, LEFT . 8N-18
POWER SEAT SWITCH - REMOVAL,
RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20
POWER SEATS - DESCRIPTION. . . . . . . . . . . 8N-14
POWER SEATS - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-15
POWER SEATS - OPERATION . . . . . . . . . . . 8N-15
POWER STEERING FLOW AND
PRESSURE - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-3
POWER STEERING PRESSURE SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 19-22
POWER STEERING PRESSURE SWITCH -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 19-22
POWER STEERING PRESSURE SWITCH -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 19-22
POWER STEERING PRESSURE SWITCH -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 19-22
POWER STEERING PUMP - INITIAL
OPERATION - STANDARD PROCEDURE . . . 19-18
POWER STEERING PUMP, SPECIAL
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20
POWER STEERING SYSTEM -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 19-1
POWER WINDOWS - DESCRIPTION . . . . . . 8N-21
POWER WINDOWS - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-21
POWER WINDOWS - OPERATION . . . . . . . . 8N-21
POWERED - STARTER MOTOR, GAS . . . . . . 8F-39
POWERED - TORQUE, GAS . . . . . . . . . . . . . 8F-38
POWERING SEVERAL LOADS -
STANDARD PROCEDURE, TESTING
FOR A SHORT TO GROUND ON FUSES . 8W-01-9
PRECAUTIONS - CAUTION,
REFRIGERANT HOSES/LINES/TUBES. . . . . . 24-40
PRECAUTIONS - OPERATION, SERVICE . . . . 19-5
PRECAUTIONS AND WARNINGS,
WARNING - SAFETY . . . . . . . . . . . . . . . . . . . 23-1
PRECAUTIONS, WARNING -
WINDSHIELD SAFETY . . . . . . . . . . . . . . . . 23-173
PREFERENCES - STANDARD
PROCEDURE, RKE TRANSMITTER
CUSTOMER . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-8
PRELIMINARY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-78
PRELIMINARY CHECKS - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
PREPARATION - STANDARD
PROCEDURE, ENGINE GASKET
SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
PRESS CONTAINER - DESCRIPTION,
COOLANT RECOVERY . . . . . . . . . . . . . . . . . . 7-19
PRESS CONTAINER - OPERATION,
COOLANT RECOVERY . . . . . . . . . . . . . . . . . . 7-19
PRESSURE - DIAGNOSIS AND TESTING,
CYLINDER COMPRESSION . . . . . . . . . . . . . . . 9-8
PRESSURE - DIAGNOSIS AND TESTING,
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60
PRESSURE - DIAGNOSIS AND TESTING,
POWER STEERING FLOW . . . . . . . . . . . . . . . 19-3
PRESSURE BLEEDING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
PRESSURE CAP - CLEANING, RADIATOR . . . 7-25
PRESSURE CAP - DESCRIPTION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
PRESSURE CAP - DIAGNOSIS AND
TESTING, RADIATOR . . . . . . . . . . . . . . . . . . . 7-25
PRESSURE CAP - INSPECTION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
PRESSURE CAP - OPERATION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
PRESSURE HOSE - INSTALLATION . . . . . . . 19-21
PRESSURE HOSE - REMOVAL . . . . . . . . . . 19-21
PRESSURE INDICATOR - DESCRIPTION,
LOW OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -23
PRESSURE INDICATOR - OPERATION,
LOW OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -23
PRESSURE LEAK DOWN TEST -
DIAGNOSIS AND TESTING, FUEL . . . . . . . . . 14-3
PRESSURE LEAKAGE - DIAGNOSIS AND
TESTING, CYLINDER COMBUSTION . . . . . . . . 9-8
PRESSURE (LP) SENSOR -
DESCRIPTION, LINE . . . . . . . . . . . . . . . . . 21-144
PRESSURE (LP) SENSOR -
INSTALLATION, LINE . . . . . . . . . . . . . . . . . 21-144
PRESSURE (LP) SENSOR - OPERATION,
LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-144
PRESSURE (LP) SENSOR - REMOVAL,
LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-144
PRESSURE REGULATOR - DESCRIPTION,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
PRESSURE REGULATOR -
INSTALLATION, FUEL. . . . . . . . . . . . . . . . . . . 14-14
PRESSURE REGULATOR - OPERATION,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
PRESSURE REGULATOR - REMOVAL,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
PRESSURE RELEASE - STANDARD
PROCEDURE, FUEL SYSTEM. . . . . . . . . . . . . 14-4
PRESSURE RELIEF VALVE -
DESCRIPTION, HIGH . . . . . . . . . . . . . . . . . . 24-42
PRESSURE RELIEF VALVE - OPERATION,
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-42
PRESSURE SENSOR/SWITCH -
DESCRIPTION, OIL . . . . . . . . . . . . . . . . . . . . 9-65
PRESSURE SENSOR/SWITCH -
INSTALLATION, OIL . . . . . . . . . . . . . . . . . . . . 9-65
PRESSURE SENSOR/SWITCH -
OPERATION, OIL . . . . . . . . . . . . . . . . . . . . . . 9-65
PRESSURE SENSOR/SWITCH -
REMOVAL, OIL . . . . . . . . . . . . . . . . . . . . . . . 9-65
PRESSURE, SPECIFICATIONS - FUEL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
PRESSURE SWITCH - DESCRIPTION, A/C
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-17
PRESSURE SWITCH - DESCRIPTION, A/C
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
PRESSURE SWITCH - DESCRIPTION,
POWER STEERING . . . . . . . . . . . . . . . . . . . 19-22
PRESSURE SWITCH - DIAGNOSIS AND
TESTING, A/C HIGH. . . . . . . . . . . . . . . . . . . 24-18
PRESSURE SWITCH - DIAGNOSIS AND
TESTING, A/C LOW . . . . . . . . . . . . . . . . . . . 24-19
PRESSURE SWITCH - INSTALLATION,
A/C HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
PRESSURE SWITCH - INSTALLATION,
A/C LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
PRESSURE SWITCH - INSTALLATION,
POWER STEERING . . . . . . . . . . . . . . . . . . . 19-22
PRESSURE SWITCH - OPERATION, A/C
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
PRESSURE SWITCH - OPERATION, A/C
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
PRESSURE SWITCH - OPERATION,
POWER STEERING . . . . . . . . . . . . . . . . . . . 19-22
PRESSURE SWITCH - REMOVAL, A/C
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
PRESSURE SWITCH - REMOVAL, A/C
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
PRESSURE SWITCH - REMOVAL,
POWER STEERING . . . . . . . . . . . . . . . . . . . 19-22
PRESSURE TEST - DIAGNOSIS AND
TESTING, FUEL PUMP . . . . . . . . . . . . . . . . . 14-15
PRESSURE TEST - DIAGNOSIS AND
TESTING, HYDRAULIC. . . . . . . . . . . . . . . . . 21-79
PRIMARY WEATHERSTRIP -
INSTALLATION, DOOR . . . . . . . . . . . . . . . . 23-185
KJ INDEX 19
Description Group-Page Description Group-Page Description Group-Page
PRIMARY WEATHERSTRIP - REMOVAL,
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-185
PROGRAMING - STANDARD
PROCEDURE, RKE TRANSMITTER . . . . . . . . 8N-9
PROGRAMMING - STANDARD
PROCEDURE, PCM/SKIM. . . . . . . . . . . . . . . . 8E-1
PROGRAMMING - STANDARD
PROCEDURE, SENTRY KEY
TRANSPONDER. . . . . . . . . . . . . . . . . . . . . . . 8Q-8
PROPELLER SHAFT - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PROPELLER SHAFT - FRONT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 3-6
PROPELLER SHAFT - FRONT - REMOVAL . . . 3-6
PROPELLER SHAFT - REAR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 3-7
PROPELLER SHAFT - REAR - REMOVAL . . . . 3-7
PROPELLER SHAFT ANGLE - STANDARD
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
PROPELLER SHAFT, SPECIFICATIONS . . . . . . . 3-6
PROPORTIONING VALVE - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 5-20
PULLEY - DESCRIPTION, GENERATOR
DECOUPLER . . . . . . . . . . . . . . . . . . . . . . . . 8F-26
PULLEY - INSTALLATION . . . . . . . . . . . . . . 19-23
PULLEY - INSTALLATION, GENERATOR
DECOUPLER . . . . . . . . . . . . . . . . . . . . . . . . 8F-30
PULLEY - OPERATION, GENERATOR
DECOUPLER . . . . . . . . . . . . . . . . . . . . . . . . 8F-27
PULLEY - REMOVAL . . . . . . . . . . . . . . . . . . 19-23
PULLEY - REMOVAL, GENERATOR
DECOUPLER . . . . . . . . . . . . . . . . . . . . . . . . 8F-27
PUMP - ASSEMBLY, OIL . . . . . . . . . . . . . . . . 9-67
PUMP - ASSEMBLY, OIL . . . . . . . . . . . . . . 21-151
PUMP - CLEANING, OIL . . . . . . . . . . . . . . 21-150
PUMP - DESCRIPTION . . . . . . . . . . . . . . . . 19-17
PUMP - DESCRIPTION, FUEL . . . . . . . . . . . 14-15
PUMP - DESCRIPTION, LEAK DETECTION . 25-27
PUMP - DESCRIPTION, OIL . . . . . . . . . . . . 21-147
PUMP - DESCRIPTION, WATER . . . . . . . . . . 7-29
PUMP - DISASSEMBLY, OIL . . . . . . . . . . . . . 9-65
PUMP - DISASSEMBLY, OIL . . . . . . . . . . . 21-149
PUMP - INITIAL OPERATION -
STANDARD PROCEDURE, POWER
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 19-18
PUMP - INSPECTION, OIL . . . . . . . . . . . . . . . 9-66
PUMP - INSPECTION, OIL . . . . . . . . . . . . . 21-150
PUMP - INSTALLATION, LEAK
DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . 25-28
PUMP - INSTALLATION, OIL . . . . . . . . . . . . . 9-67
PUMP - OPERATION . . . . . . . . . . . . . . . . . . 19-17
PUMP - OPERATION, FUEL . . . . . . . . . . . . . 14-15
PUMP - OPERATION, LEAK DETECTION . . . 25-28
PUMP - OPERATION, OIL . . . . . . . . . . . . . 21-147
PUMP - OPERATION, WATER . . . . . . . . . . . . 7-30
PUMP - REMOVAL, LEAK DETECTION . . . . 25-28
PUMP - REMOVAL, OIL . . . . . . . . . . . . . . . . . 9-65
PUMP AMPERAGE TEST - DIAGNOSIS
AND TESTING, FUEL . . . . . . . . . . . . . . . . . . 14-16
PUMP CAPACITY TEST - DIAGNOSIS
AND TESTING, FUEL . . . . . . . . . . . . . . . . . . 14-15
PUMP FRONT SEAL - INSTALLATION,
OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-152
PUMP FRONT SEAL - REMOVAL, OIL . . . . 21-152
PUMP MODULE - DESCRIPTION, FUEL . . . . 14-18
PUMP MODULE - INSTALLATION, FUEL . . . 14-19
PUMP MODULE - OPERATION, FUEL . . . . . 14-18
PUMP MODULE - REMOVAL, FUEL . . . . . . . 14-18
PUMP PRESSURE TEST - DIAGNOSIS
AND TESTING, FUEL . . . . . . . . . . . . . . . . . . 14-15
PUMP RELAY - DESCRIPTION, FUEL . . . . . 14-34
PUMP RELAY - DIAGNOSIS AND
TESTING, FUEL . . . . . . . . . . . . . . . . . . . . . . 14-34
PUMP RELAY - INSTALLATION, FUEL . . . . . 14-34
PUMP RELAY - OPERATION, FUEL . . . . . . . 14-34
PUMP RELAY - REMOVAL, FUEL . . . . . . . . 14-34
PUMP RELAYS - DIAGNOSIS AND
TESTING, ASD AND FUEL . . . . . . . . . . . . . . . 8I-4
PUMP, SPECIAL TOOLS - POWER
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20
PUMP VOLUME CHECK - STANDARD
PROCEDURE, OIL . . . . . . . . . . . . . . . . . . . 21-148
PUMP/MOTOR - DESCRIPTION, WASHER . 8R-18
PUMP/MOTOR - INSTALLATION,
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-20
PUMP/MOTOR - OPERATION, WASHER . . . 8R-19
PUMP/MOTOR - REMOVAL, WASHER . . . . 8R-19
QUARTER TRIM PANEL - INSTALLATION . 23-159
QUARTER TRIM PANEL - REMOVAL . . . . . 23-159
QUARTER WINDOW - INSTALLATION . . . . 23-172
QUARTER WINDOW - REMOVAL . . . . . . . . 23-172
QUICK CONNECT FITTING -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-10
QUICK LEARN - STANDARD
PROCEDURE, TCM . . . . . . . . . . . . . . . . . . . 8E-21
QUICK-CONNECT FITTINGS - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 14-10
RACK - INSTALLATION, LUGGAGE . . . . . . 23-144
RACK - REMOVAL, LUGGAGE . . . . . . . . . . 23-144
RADIAL-PLY TIRES - DESCRIPTION . . . . . . . 22-6
RADIATOR - CLEANING . . . . . . . . . . . . . . . . . 7-24
RADIATOR - DESCRIPTION . . . . . . . . . . . . . . 7-22
RADIATOR - FAN - VISCOUS - CLEANING . . 7-29
RADIATOR - FAN - VISCOUS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 7-27
RADIATOR - FAN - VISCOUS -
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
RADIATOR - FAN - VISCOUS -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 7-29
RADIATOR - FAN - VISCOUS -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
RADIATOR - FAN - VISCOUS - REMOVAL . . . 7-28
RADIATOR - INSPECTION . . . . . . . . . . . . . . . 7-24
RADIATOR - INSTALLATION . . . . . . . . . . . . . 7-24
RADIATOR - REMOVAL . . . . . . . . . . . . . . . . . 7-23
RADIATOR CROSSMEMBER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-146
RADIATOR CROSSMEMBER - REMOVAL . 23-146
RADIATOR FAN - ELECTRIC -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 7-26
RADIATOR FAN - ELECTRIC -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 7-27
RADIATOR FAN - ELECTRIC -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
RADIATOR FAN - ELECTRIC - REMOVAL . . . 7-26
RADIATOR PRESSURE CAP - CLEANING . . . 7-25
RADIATOR PRESSURE CAP -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 7-25
RADIATOR PRESSURE CAP - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 7-25
RADIATOR PRESSURE CAP -
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
RADIATOR PRESSURE CAP - OPERATION . . 7-25
RADIO - DESCRIPTION . . . . . . . . . . . . . . . . . 8A-8
RADIO - INSTALLATION . . . . . . . . . . . . . . . . 8A-9
RADIO - OPERATION . . . . . . . . . . . . . . . . . . . 8A-8
RADIO - REMOVAL . . . . . . . . . . . . . . . . . . . . 8A-9
RADIO NOISE SUPPRESSION GROUND
STRAP - DESCRIPTION. . . . . . . . . . . . . . . . . 8A-9
RADIO NOISE SUPPRESSION GROUND
STRAP - INSTALLATION . . . . . . . . . . . . . . . 8A-11
RADIO NOISE SUPPRESSION GROUND
STRAP - OPERATION . . . . . . . . . . . . . . . . . 8A-10
RADIO NOISE SUPPRESSION GROUND
STRAP - REMOVAL . . . . . . . . . . . . . . . . . . . 8A-10
RAIL - DESCRIPTION, FUEL . . . . . . . . . . . . 14-21
RAIL - INSTALLATION, FUEL . . . . . . . . . . . . 14-24
RAIL - OPERATION, FUEL . . . . . . . . . . . . . . 14-21
RAIL - REMOVAL, FUEL . . . . . . . . . . . . . . . 14-22
RAIL WEATHERSTRIP/RETAINER -
INSTALLATION, SIDE . . . . . . . . . . . . . . . . . 23-186
RAIL WEATHERSTRIP/RETAINER -
REMOVAL, SIDE . . . . . . . . . . . . . . . . . . . . 23-186
RAMP - INSTALLATION, WIPER ARM
PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-43
RAMP - REMOVAL, WIPER ARM PARK . . . 8R-43
RANGE INDICATOR ILLUMINATION BULB
- INSTALLATION, TRANSMISSION. . . . . . . . 8L-83
RANGE INDICATOR ILLUMINATION BULB
- REMOVAL, TRANSMISSION . . . . . . . . . . . 8L-82
RANGE SENSOR - DESCRIPTION,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-168
RANGE SENSOR - OPERATION,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-168
RATINGS, GAS ENGINES - GENERATOR . . . 8F-23
RBI AXLE - INSTALLATION, 198 . . . . . . . . . . 5-28
RBI AXLE - REMOVAL, 198 . . . . . . . . . . . . . . 5-27
READING LAMP BULB - INSTALLATION . . . 8L-79
READING LAMP BULB - REMOVAL . . . . . . . 8L-79
READING LAMP SWITCH -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-80
READING LAMP SWITCH - REMOVAL . . . . . 8L-80
READING LAMP UNIT - INSTALLATION . . . 8L-81
READING LAMP UNIT - REMOVAL . . . . . . . 8L-81
REAR - DESCRIPTION . . . . . . . . . . . . . . . . . . 2-16
REAR - INSTALLATION, CRANKSHAFT
OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
REAR - INSTALLATION, PROPELLER
SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
REAR - INSTALLATION, SEAT . . . . . . . . . . 23-168
REAR - INSTALLATION, SEAT BACK . . . . . 23-168
REAR - INSTALLATION, SEAT BACK
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-169
REAR - INSTALLATION, SEAT BACK
CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
REAR - INSTALLATION, SEAT BACK
FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-171
REAR - INSTALLATION, SEAT CUSHION . . 23-171
REAR - REMOVAL, CRANKSHAFT OIL
SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
REAR AXLE - 198RBI - DESCRIPTION . . . . . 3-49
REAR AXLE - 198RBI - INSTALLATION . . . . . 3-54
REAR AXLE - 198RBI - OPERATION . . . . . . . 3-49
REAR AXLE - 198RBI - REMOVAL . . . . . . . . 3-54
REAR AXLE - 8 1/4 - ADJ USTMENTS . . . . . . 3-92
REAR AXLE - 8 1/4 - DESCRIPTION . . . . . . . 3-86
REAR AXLE - 8 1/4 - INSTALLATION . . . . . . 3-91
REAR AXLE - 8 1/4 - OPERATION . . . . . . . . . 3-86
REAR AXLE - 8 1/4 - REMOVAL . . . . . . . . . . 3-91
REAR AXLE - SPECIFICATIONS . . . . . . . . . . . 3-62
REAR AXLE, SPECIAL TOOLS . . . . . . . . . . . . 3-63
REAR AXLE, SPECIFICATIONS . . . . . . . . . . . . 3-98
REAR BRAKE HOSE - INSTALLATION . . . . . . 5-10
REAR BRAKE HOSE - REMOVAL . . . . . . . . . . . 5-9
REAR CENTER SEAT BELT &
RETRACTOR - INSTALLATION. . . . . . . . . . . 8O-33
REAR CENTER SEAT BELT &
RETRACTOR - REMOVAL . . . . . . . . . . . . . . 8O-32
REAR CHECK VALVE - DESCRIPTION . . . . . 8R-34
REAR CHECK VALVE - INSTALLATION . . . . 8R-35
REAR CHECK VALVE - OPERATION . . . . . . . 8R-34
REAR CHECK VALVE - REMOVAL . . . . . . . . 8R-34
REAR CROSSMEMBER - INSTALLATION . . . . 13-7
REAR CROSSMEMBER - REMOVAL . . . . . . . 13-7
REAR DOOR OUTER BELT MOLDING -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-186
REAR DOOR OUTER BELT MOLDING -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
REAR DOOR SCUFF PLATE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-160
REAR DOOR SCUFF PLATE - REMOVAL . . 23-160
REAR DRUM BRAKE - ADJ USTMENT . . . . . . 5-12
REAR DRUM BRAKE - DESCRIPTION . . . . . . 5-10
REAR DRUM BRAKE - OPERATION . . . . . . . . 5-11
REAR FASCIA - INSTALLATION . . . . . . . . . . . 13-2
REAR FASCIA - REMOVAL . . . . . . . . . . . . . . . 13-2
REAR FASCIA SUPPORT - INSTALLATION . . 13-3
REAR FASCIA SUPPORT - REMOVAL . . . . . . 13-3
REAR FOG LAMP INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -27
REAR FOG LAMP INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -27
REAR FOG LAMP RELAY - DESCRIPTION . . 8L-56
REAR FOG LAMP RELAY - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8L-57
REAR FOG LAMP RELAY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-58
REAR FOG LAMP RELAY - OPERATION . . . 8L-57
REAR FOG LAMP RELAY - REMOVAL . . . . . 8L-58
REAR GLASS HEATING GRID REPAIR -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8G-4
REAR HVAC CONTROL ASSEMBLY
WINDOW DEFOGGER FUNCTION -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8G-9
REAR LAMP BULB - INSTALLATION . . . . . . 8L-59
REAR LAMP BULB - REMOVAL . . . . . . . . . . 8L-58
REAR LAMP UNIT - INSTALLATION . . . . . . 8L-60
REAR LAMP UNIT - REMOVAL . . . . . . . . . . 8L-59
REAR MOUNT - INSTALLATION . . . . . . . . . . 9-57
REAR MOUNT - REMOVAL . . . . . . . . . . . . . . 9-57
REAR OUTBOARD SEAT BELT &
RETRACTOR - INSTALLATION. . . . . . . . . . . 8O-34
REAR OUTBOARD SEAT BELT &
RETRACTOR - REMOVAL . . . . . . . . . . . . . . 8O-33
REAR OUTPUT SHAFT SEAL -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-212
REAR OUTPUT SHAFT SEAL - REMOVAL . 21-210
REAR SEAL AREA LEAKS - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 9-61
REAR SEAT BACK LATCH / LOCK -
INSTALLATION, FOLDING . . . . . . . . . . . . . 23-170
REAR SEAT BACK LATCH / LOCK -
REMOVAL, FOLDING . . . . . . . . . . . . . . . . . 23-170
20 INDEX KJ
Description Group-Page Description Group-Page Description Group-Page
REAR SEAT BACK LATCH STRIKER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-171
REAR SEAT BACK LATCH STRIKER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
REAR SEAT BELT BUCKLE -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-35
REAR SEAT BELT BUCKLE - REMOVAL . . . 8O-34
REAR SUSPENSION - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
REAR TOW HOOK - INSTALLATION . . . . . . . 13-8
REAR TOW HOOK - REMOVAL . . . . . . . . . . . 13-8
REAR VIEW MIRROR - REMOVAL . . . . . . . 23-161
REAR WASHER HOSES/TUBES -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-35
REAR WASHER HOSES/TUBES -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8R-36
REAR WASHER NOZZLE - DESCRIPTION . . 8R-36
REAR WASHER NOZZLE - INSTALLATION . 8R-37
REAR WASHER NOZZLE - OPERATION . . . . 8R-36
REAR WASHER NOZZLE - REMOVAL . . . . . 8R-36
REAR WHEEL OPENING FLARE
MOLDINGS - INSTALLATION . . . . . . . . . . . 23-145
REAR WHEEL OPENING FLARE
MOLDINGS - REMOVAL . . . . . . . . . . . . . . 23-145
REAR WHEEL SPEED SENSOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 5-35
REAR WHEEL SPEED SENSOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
REAR WHEELHOUSE SPLASH SHIELD -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-144
REAR WHEELHOUSE SPLASH SHIELD -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-144
REAR WINDOW DEFOGGER -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8G-3
REAR WINDOW DEFOGGER -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 8G-3
REAR WINDOW DEFOGGER GRID -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8G-5
REAR WINDOW DEFOGGER GRID -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8G-5
REAR WINDOW DEFOGGER GRID -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 8G-5
REAR WINDOW DEFOGGER RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8G-6
REAR WINDOW DEFOGGER RELAY -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8G-6
REAR WINDOW DEFOGGER RELAY -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8G-7
REAR WINDOW DEFOGGER RELAY -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 8G-6
REAR WINDOW DEFOGGER RELAY -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-7
REAR WINDOW DEFOGGER SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8G-8
REAR WINDOW DEFOGGER SWITCH -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8G-8
REAR WINDOW DEFOGGER SWITCH -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 8G-8
REAR WINDOW DEFOGGER SYSTEM -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8G-4
REAR WIPER & WASHER SYSTEM -
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . 8R-32
REAR WIPER & WASHER SYSTEM -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8R-30
REAR WIPER & WASHER SYSTEM -
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 8R-33
REAR WIPER ARM - DESCRIPTION . . . . . . 8R-37
REAR WIPER ARM - INSTALLATION . . . . . . 8R-38
REAR WIPER ARM - OPERATION . . . . . . . . 8R-38
REAR WIPER ARM - REMOVAL . . . . . . . . . 8R-38
REAR WIPER BLADE - DESCRIPTION . . . . . 8R-39
REAR WIPER BLADE - INSTALLATION . . . . 8R-40
REAR WIPER BLADE - OPERATION . . . . . . 8R-39
REAR WIPER BLADE - REMOVAL . . . . . . . . 8R-40
REAR WIPER MOTOR - DESCRIPTION . . . . 8R-41
REAR WIPER MOTOR - INSTALLATION . . . 8R-42
REAR WIPER MOTOR - OPERATION . . . . . . 8R-41
REAR WIPER MOTOR - REMOVAL . . . . . . . 8R-42
REAR WIPERS/WASHERS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-27
REAR WIPERS/WASHERS - OPERATION . . 8R-29
REAR WIPER/WASHER SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-43
REAR WIPER/WASHER SWITCH -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8R-43
REARVIEW MIRROR SUPPORT BRACKET
- INSTALLATION . . . . . . . . . . . . . . . . . . . . 23-161
RECEIVER LAMP BULB - INSTALLATION,
ASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-71
RECEIVER LAMP BULB - REMOVAL, ASH . . 8L-71
RECEIVER LAMP UNIT - INSTALLATION,
ASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-72
RECEIVER LAMP UNIT - REMOVAL, ASH . . 8L-72
RECIRC DOOR - INSTALLATION . . . . . . . . . 24-37
RECIRC DOOR - REMOVAL . . . . . . . . . . . . . 24-37
RECIRCULATION DOOR ACTUATOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-26
RECIRCULATION DOOR ACTUATOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-26
RECLINER - FRONT - INSTALLATION,
SEAT BACK . . . . . . . . . . . . . . . . . . . . . . . . 23-166
RECLINER - FRONT - REMOVAL, SEAT
BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-166
RECOMMENDATIONS - STANDARD
PROCEDURE, HOISTING . . . . . . . . . . . . . . . . . 0-4
RECOVERY - STANDARD PROCEDURE,
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . 24-41
RECOVERY PRESS CONTAINER -
DESCRIPTION, COOLANT . . . . . . . . . . . . . . . 7-19
RECOVERY PRESS CONTAINER -
OPERATION, COOLANT . . . . . . . . . . . . . . . . . 7-19
REFACING - STANDARD PROCEDURE . . 9-26,9-34
REFERENCES - DESCRIPTION, TORQUE . . Intro.-7
REFILLING COOLING SYSTEM 3.7L
ENGINE - STANDARD PROCEDURE. . . . . . . . 7-12
REFRIGERANT - DESCRIPTION . . . . . . . . . . 24-53
REFRIGERANT - OPERATION . . . . . . . . . . . . 24-53
REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS - CAUTION . . . . . . . . . . . . . 24-40
REFRIGERANT LINE - DESCRIPTION . . . . . . 24-38
REFRIGERANT OIL - DESCRIPTION . . . . . . 24-53
REFRIGERANT OIL - OPERATION . . . . . . . . 24-54
REFRIGERANT OIL LEVEL - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 24-54
REFRIGERANT RECOVERY - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 24-41
REFRIGERANT SYSTEM CHARGE -
STANDARD PROCEDURE. . . . . . . . . . . . . . . 24-41
REFRIGERANT SYSTEM EVACUATE -
STANDARD PROCEDURE. . . . . . . . . . . . . . . 24-41
REFRIGERANT SYSTEM SERVICE
EQUIPMENT - STANDARD PROCEDURE . . . 24-40
REFRIGERANT SYSTEM SERVICE PORT -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 24-2
REFRIGERANT SYSTEM SERVICE PORT -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 24-2
REGULATOR - DESCRIPTION, FUEL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
REGULATOR - DESCRIPTION, VOLTAGE . . . 8F-31
REGULATOR - ELECTRIC -
INSTALLATION, WINDOW . . . . . . . 23-126,23-134
REGULATOR - ELECTRIC - REMOVAL,
WINDOW . . . . . . . . . . . . . . . . . . . . 23-126,23-134
REGULATOR - INSTALLATION, FUEL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
REGULATOR - MANUAL - INSTALLATION,
WINDOW . . . . . . . . . . . . . . . . . . . . 23-126,23-133
REGULATOR - MANUAL - REMOVAL,
WINDOW . . . . . . . . . . . . . . . . . . . . 23-126,23-133
REGULATOR - OPERATION, FUEL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
REGULATOR - OPERATION, VOLTAGE . . . . . 8F-31
REGULATOR - REMOVAL, FUEL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
REINFORCEMENT - INSTALLATION,
GRILLE OPENING . . . . . . . . . . . . . . . . . . . 23-142
REINFORCEMENT - REMOVAL, GRILLE
OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . 23-142
RELAY - DESCRIPTION . . . . . . . . . . . . . 8W-97-13
RELAY - DESCRIPTION, A/C
COMPRESSOR CLUTCH . . . . . . . . . . . . . . . 24-15
RELAY - DESCRIPTION, AMPLIFIER
CHOKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-3
RELAY - DESCRIPTION, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-20
RELAY - DESCRIPTION, CLUTCH SWITCH
OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
RELAY - DESCRIPTION, DAYTIME
RUNNING LAMP . . . . . . . . . . . . . . . . . . . . . 8L-20
RELAY - DESCRIPTION, DOOR LOCK . . . . . . 8N-6
RELAY - DESCRIPTION, FRONT FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-22
RELAY - DESCRIPTION, FUEL PUMP . . . . . 14-34
RELAY - DESCRIPTION, HEADLAMP
HIGH BEAM . . . . . . . . . . . . . . . . . . . . . . . . . 8L-33
RELAY - DESCRIPTION, HEADLAMP LOW
BEAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-39
RELAY - DESCRIPTION, PARK LAMP . . . . . 8L-54
RELAY - DESCRIPTION, REAR FOG LAMP . 8L-56
RELAY - DESCRIPTION, REAR WINDOW
DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-6
RELAY - DESCRIPTION, STARTER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-41
RELAY - DESCRIPTION, TRAILER TOW . . . . 8L-61
RELAY - DESCRIPTION, TRANSMISSION
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 21-168
RELAY - DESCRIPTION, WIPER
HIGH/LOW. . . . . . . . . . . . . . . . . . . . . . . . . . 8R-23
RELAY - DESCRIPTION, WIPER ON/OFF . . . 8R-25
RELAY - DIAGNOSIS AND TESTING . . . 8W-97-13
RELAY - DIAGNOSIS AND TESTING,
AMPLIFIER CHOKE . . . . . . . . . . . . . . . . . . . . 8A-4
RELAY - DIAGNOSIS AND TESTING,
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . 24-21
RELAY - DIAGNOSIS AND TESTING,
COMPRESSOR CLUTCH . . . . . . . . . . . . . . . 24-15
RELAY - DIAGNOSIS AND TESTING,
DOOR LOCK . . . . . . . . . . . . . . . . . . . . . . . . . 8N-6
RELAY - DIAGNOSIS AND TESTING,
FRONT FOG LAMP . . . . . . . . . . . . . . . . . . . . 8L-23
RELAY - DIAGNOSIS AND TESTING,
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 14-34
RELAY - DIAGNOSIS AND TESTING,
HEADLAMP HIGH BEAM . . . . . . . . . . . . . . . 8L-34
RELAY - DIAGNOSIS AND TESTING,
HEADLAMP LOW BEAM . . . . . . . . . . . . . . . 8L-40
RELAY - DIAGNOSIS AND TESTING,
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-3
RELAY - DIAGNOSIS AND TESTING,
PARK LAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-55
RELAY - DIAGNOSIS AND TESTING,
REAR FOG LAMP . . . . . . . . . . . . . . . . . . . . . 8L-57
RELAY - DIAGNOSIS AND TESTING,
REAR WINDOW DEFOGGER . . . . . . . . . . . . . 8G-6
RELAY - DIAGNOSIS AND TESTING,
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-42
RELAY - DIAGNOSIS AND TESTING,
TRAILER TOW . . . . . . . . . . . . . . . . . . . . . . . 8L-62
RELAY - DIAGNOSIS AND TESTING,
WIPER HIGH/LOW . . . . . . . . . . . . . . . . . . . 8R-24
RELAY - DIAGNOSIS AND TESTING,
WIPER ON/OFF . . . . . . . . . . . . . . . . . . . . . . 8R-26
RELAY - INSTALLATION . . . . . . . . . . . . 8W-97-14
RELAY - INSTALLATION, A/C
COMPRESSOR CLUTCH . . . . . . . . . . . . . . . 24-16
RELAY - INSTALLATION, AMPLIFIER
CHOKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-4
RELAY - INSTALLATION, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
RELAY - INSTALLATION, CLUTCH
SWITCH OVERRIDE. . . . . . . . . . . . . . . . . . . . 6-10
RELAY - INSTALLATION, DAYTIME
RUNNING LAMP . . . . . . . . . . . . . . . . . . . . . 8L-21
RELAY - INSTALLATION, DOOR LOCK . . . . . 8N-7
RELAY - INSTALLATION, FRONT FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-24
RELAY - INSTALLATION, FUEL PUMP . . . . . 14-34
RELAY - INSTALLATION, HEADLAMP
HIGH BEAM . . . . . . . . . . . . . . . . . . . . . . . . . 8L-35
RELAY - INSTALLATION, HEADLAMP
LOW BEAM . . . . . . . . . . . . . . . . . . . . . . . . . 8L-41
RELAY - INSTALLATION, HORN . . . . . . . . . . 8H-3
RELAY - INSTALLATION, PARK LAMP . . . . . 8L-56
RELAY - INSTALLATION, REAR FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-58
RELAY - INSTALLATION, REAR WINDOW
DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-7
RELAY - INSTALLATION, STARTER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-43
RELAY - INSTALLATION, TRAILER TOW . . . 8L-64
RELAY - INSTALLATION, WIPER
HIGH/LOW. . . . . . . . . . . . . . . . . . . . . . . . . . 8R-24
RELAY - INSTALLATION, WIPER ON/OFF . . 8R-26
RELAY - OPERATION . . . . . . . . . . . . . . . 8W-97-13
RELAY - OPERATION, A/C COMPRESSOR
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-15
RELAY - OPERATION, AMPLIFIER CHOKE . . . 8A-3
RELAY - OPERATION, BLOWER MOTOR . . . 24-20
RELAY - OPERATION, CLUTCH SWITCH
OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
RELAY - OPERATION, DAYTIME
RUNNING LAMP . . . . . . . . . . . . . . . . . . . . . 8L-20
RELAY - OPERATION, DOOR LOCK . . . . . . . . 8N-6
KJ INDEX 21
Description Group-Page Description Group-Page Description Group-Page
RELAY - OPERATION, FRONT FOG LAMP . . 8L-22
RELAY - OPERATION, FUEL PUMP . . . . . . . 14-34
RELAY - OPERATION, HEADLAMP HIGH
BEAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-33
RELAY - OPERATION, HEADLAMP LOW
BEAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-39
RELAY - OPERATION, PARK LAMP . . . . . . . 8L-54
RELAY - OPERATION, REAR FOG LAMP . . . 8L-57
RELAY - OPERATION, REAR WINDOW
DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-6
RELAY - OPERATION, STARTER MOTOR . . . 8F-42
RELAY - OPERATION, TRAILER TOW . . . . . 8L-62
RELAY - OPERATION, TRANSMISSION
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 21-168
RELAY - OPERATION, WIPER HIGH/LOW . . 8R-23
RELAY - OPERATION, WIPER ON/OFF . . . . 8R-25
RELAY - REMOVAL . . . . . . . . . . . . . . . . 8W-97-14
RELAY - REMOVAL, A/C COMPRESSOR
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-16
RELAY - REMOVAL, AMPLIFIER CHOKE . . . . 8A-4
RELAY - REMOVAL, BLOWER MOTOR . . . . 24-21
RELAY - REMOVAL, CLUTCH SWITCH
OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
RELAY - REMOVAL, DAYTIME RUNNING
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-21
RELAY - REMOVAL, DOOR LOCK . . . . . . . . . 8N-6
RELAY - REMOVAL, FRONT FOG LAMP . . . 8L-24
RELAY - REMOVAL, FUEL PUMP . . . . . . . . 14-34
RELAY - REMOVAL, HEADLAMP HIGH
BEAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-34
RELAY - REMOVAL, HEADLAMP LOW
BEAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-40
RELAY - REMOVAL, HORN . . . . . . . . . . . . . . 8H-3
RELAY - REMOVAL, PARK LAMP . . . . . . . . 8L-55
RELAY - REMOVAL, REAR FOG LAMP . . . . 8L-58
RELAY - REMOVAL, REAR WINDOW
DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-7
RELAY - REMOVAL, STARTER MOTOR . . . . 8F-43
RELAY - REMOVAL, TRAILER TOW . . . . . . . 8L-63
RELAY - REMOVAL, WIPER HIGH/LOW . . . 8R-24
RELAY - REMOVAL, WIPER ON/OFF . . . . . . 8R-26
RELAYS - DIAGNOSIS AND TESTING,
ASD AND FUEL PUMP . . . . . . . . . . . . . . . . . . 8I-4
RELEASE - STANDARD PROCEDURE,
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . 14-4
RELEASE BEARING - INSTALLATION,
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
RELEASE BEARING - REMOVAL, CLUTCH . . . 6-6
RELEASE CABLE - INSTALLATION, LATCH . 23-120
RELEASE CABLE - REMOVAL, LATCH . . . . 23-120
RELEASE HANDLE - INSTALLATION,
LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-120
RELEASE HANDLE - REMOVAL, LATCH . . 23-120
RELEASE SWITCH - DIAGNOSIS AND
TESTING, FLIP-UP GLASS . . . . . . . . . . . . . . 8N-5
RELIEF VALVE - DESCRIPTION, HIGH
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-42
RELIEF VALVE - OPERATION, HIGH
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-42
REMOTE KEYLESS ENTRY MODULE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
REMOTE KEYLESS ENTRY MODULE -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8N-7
REMOTE KEYLESS ENTRY MODULE -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8N-7
REMOTE KEYLESS ENTRY MODULE -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
REMOTE KEYLESS ENTRY MODULE -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
REMOTE KEYLESS ENTRY
TRANSMITTER - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-8
REMOTE KEYLESS ENTRY
TRANSMITTER - SPECIFICATIONS . . . . . . . . 8N-9
REMOTE SWITCHES - DESCRIPTION . . . . . 8A-11
REMOTE SWITCHES - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-12
REMOTE SWITCHES - INSTALLATION . . . . . 8A-13
REMOTE SWITCHES - OPERATION . . . . . . . 8A-12
REMOTE SWITCHES - REMOVAL . . . . . . . . 8A-13
REPAIR - DESCRIPTION, THREADED
HOLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-4
REPAIR - STANDARD PROCEDURE,
ALUMINUM THREAD. . . . . . . . . . . . . . . . . . 21-81
REPAIR - STANDARD PROCEDURE,
REAR GLASS HEATING GRID . . . . . . . . . . . . 8G-4
REPAIR DAMAGED OR WORN THREADS
- STANDARD PROCEDURE . . . . . . . . . . . . . . . 9-9
REPAIRING LEAKS - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
REPEATER LAMP BULB - INSTALLATION . . 8L-60
REPEATER LAMP BULB - REMOVAL . . . . . . 8L-60
REPEATER LAMP UNIT - INSTALLATION . . 8L-61
REPEATER LAMP UNIT - REMOVAL . . . . . . 8L-60
REQUIREMENTS - DESCRIPTION,
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . 24-1
RESERVOIR - DESCRIPTION, VACUUM . . . . 8P-7
RESERVOIR - DESCRIPTION, WASHER . . . 8R-21
RESERVOIR - DIAGNOSIS AND TESTING,
VACUUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-7
RESERVOIR - INSTALLATION, FLUID . . . . . . 5-26
RESERVOIR - INSTALLATION, VACUUM . . . . 8P-8
RESERVOIR - INSTALLATION, WASHER . . . 8R-22
RESERVOIR - OPERATION, VACUUM . . . . . . 8P-7
RESERVOIR - OPERATION, WASHER . . . . . 8R-21
RESERVOIR - REMOVAL, FLUID . . . . . . . . . . 5-26
RESERVOIR - REMOVAL, VACUUM . . . . . . . . 8P-7
RESERVOIR - REMOVAL, WASHER . . . . . . 8R-21
RESISTANCE, 2.4L - IGNITION COIL . . . . . . . 8I-2
RESISTANCE, 2.4L - SPARK PLUG CABLE . . . 8I-3
RESISTANCE, 3.7L V-6 - IGNITION COIL . . . . 8I-3
RESISTOR - DESCRIPTION, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
RESISTOR - DIAGNOSIS AND TESTING,
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . 24-22
RESISTOR - INSTALLATION, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
RESISTOR - OPERATION, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
RESISTOR - REMOVAL, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
RESTRAINT DEPLOYMENT - STANDARD
PROCEDURE, SERVICE AFTER A
SUPPLEMENTAL . . . . . . . . . . . . . . . . . . . . . . 8O-6
RESTRAINT SYSTEM - DIAGNOSIS AND
TESTING, SUPPLEMENTAL . . . . . . . . . . . . . . 8O-6
RESTRAINT SYSTEM - WARNING . . . . . . . . 8O-5
RESTRAINTS - DESCRIPTION . . . . . . . . . . . . 8O-2
RESTRAINTS - OPERATION . . . . . . . . . . . . . 8O-4
RESTRAINTS - STANDARD PROCEDURE,
HANDLING NON-DEPLOYED
SUPPLEMENTAL . . . . . . . . . . . . . . . . . . . . . . 8O-6
RETAINER/BULKHEAD - ASSEMBLY, 4C . . 21-123
RETAINER/BULKHEAD - DISASSEMBLY,
4C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-122
RETRACTOR - INSTALLATION, FRONT
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-24
RETRACTOR - INSTALLATION, REAR
CENTER SEAT BELT . . . . . . . . . . . . . . . . . . 8O-33
RETRACTOR - INSTALLATION, REAR
OUTBOARD SEAT BELT . . . . . . . . . . . . . . . . 8O-34
RETRACTOR - REMOVAL, FRONT SEAT
BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-23
RETRACTOR - REMOVAL, REAR CENTER
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-32
RETRACTOR - REMOVAL, REAR
OUTBOARD SEAT BELT . . . . . . . . . . . . . . . . 8O-33
RETURN - DESCRIPTION, SENSOR . . . . . . . 8E-14
RETURN HOSE (GEAR TO THE COOLER)
- INSTALLATION . . . . . . . . . . . . . . . . . . . . . 19-22
RETURN HOSE (GEAR TO THE COOLER)
- REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 19-21
RETURN HOSE (RESERVOIR TO THE
COOLER) - INSTALLATION . . . . . . . . . . . . . 19-22
RETURN HOSE (RESERVOIR TO THE
COOLER) - REMOVAL . . . . . . . . . . . . . . . . . 19-21
REVERSE FLUSHING - STANDARD
PROCEDURE, COOLING SYSTEM . . . . . . . . . 7-12
RFE TRANSMISSION, SPECIAL TOOLS . . . 21-120
RHD - INSTALLATION . . . . . . . . . . . . . . . 8W-97-6
RHD - REMOVAL . . . . . . . . . . . . . . . . . . . 8W-97-5
RIGHT POWER SEAT SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8N-19
RIGHT POWER SEAT SWITCH -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8N-19
RIGHT POWER SEAT SWITCH -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8N-20
RIGHT POWER SEAT SWITCH -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8N-19
RIGHT POWER SEAT SWITCH -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20
RIGHT SIDE - INSTALLATION . . . . . . . . 2-12,2-15
RIGHT SIDE - REMOVAL . . . . . . . . . . . . 2-11,2-14
RING - INSTALLATION, PINION
GEAR/RING GEAR/TONE . . . . . . . . . . . 3-112,3-82
RING - REMOVAL, PINION GEAR/RING
GEAR/TONE . . . . . . . . . . . . . . . . . . . . . 3-110,3-79
RING FITTING - STANDARD
PROCEDURE, PISTON . . . . . . . . . . . . . . . . . . 9-52
RISER - INSTALLATION, MANUAL SEAT . . 23-168
RISER - REMOVAL, MANUAL SEAT . . . . . . 23-167
RKE TRANSMITTER BATTERIES -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8N-8
RKE TRANSMITTER CUSTOMER
PREFERENCES - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8N-8
RKE TRANSMITTER PROGRAMING -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8N-9
ROAD TEST - DIAGNOSIS AND TESTING . . . 8P-2
ROAD TESTING - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-78
ROCKER ARM - DESCRIPTION . . . . . . . 9-29,9-37
ROCKER ARM - INSTALLATION . . . . . . . . . . 9-37
ROCKER ARM - REMOVAL . . . . . . . . . . . . . . 9-37
ROD - DESCRIPTION, PISTON &
CONNECTING. . . . . . . . . . . . . . . . . . . . . . . . . 9-49
ROD BEARING - FITTING - STANDARD
PROCEDURE, CONNECTING . . . . . . . . . . . . . 9-40
ROD BEARING, FITTING - CONNECTING . . . . 9-49
ROD END - INSTALLATION, TIE . . . . . . . . . 19-16
ROD END - REMOVAL, TIE . . . . . . . . . . . . . 19-16
ROD END REMOVAL TOOL, SPECIAL
TOOLS - OUTER TIE . . . . . . . . . . . . . . . . . . 19-15
ROTATION - STANDARD PROCEDURE,
TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2
ROTOR - DIAGNOSIS AND TESTING,
DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
ROTOR - STANDARD PROCEDURE, DISC
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
ROTORS - INSTALLATION . . . . . . . . . . . . . . . 5-19
ROTORS - REMOVAL . . . . . . . . . . . . . . . . . . 5-19
ROUTING 3.7L ENGINE - DESCRIPTION,
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . 7-2
RUN CHANNEL - INSTALLATION, GLASS . 23-123,
23-130
RUN CHANNEL - REMOVAL, GLASS . . . . 23-123,
23-130
RUNNING LAMP RELAY - DESCRIPTION,
DAYTIME . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-20
RUNNING LAMP RELAY - INSTALLATION,
DAYTIME . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-21
RUNNING LAMP RELAY - OPERATION,
DAYTIME . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-20
RUNNING LAMP RELAY - REMOVAL,
DAYTIME . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-21
RUNOUT - DIAGNOSIS AND TESTING,
TIRES AND WHEEL . . . . . . . . . . . . . . . . . . . . 22-1
SAFETY CERTIFICATION LABEL -
DESCRIPTION, VEHICLE . . . . . . . . . . . . . . Intro.-9
SAFETY PRECAUTIONS AND WARNINGS,
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1
SAFETY PRECAUTIONS, WARNING -
WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . 23-173
SANDING/BUFFING & POLISHING -
DESCRIPTION, FINESSE . . . . . . . . . . . . . . 23-163
SCHEDULES - DESCRIPTION,
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 0-4
SCHEMATICS AND DIAGRAMS -
HYDRAULIC SCHEMATICS. . . . . . . . . . . . . 21-100
SCHEMATICS, SCHEMATICS AND
DIAGRAMS - HYDRAULIC . . . . . . . . . . . . . 21-100
SCUFF PLATE - INSTALLATION, DOOR
SILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-157
SCUFF PLATE - INSTALLATION, REAR
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-160
SCUFF PLATE - REMOVAL, DOOR SILL . . . 23-157
SCUFF PLATE - REMOVAL, REAR DOOR . . 23-160
SEAL - FRONT - INSTALLATION,
CRANKSHAFT OIL . . . . . . . . . . . . . . . . . . . . . 9-47
SEAL - FRONT - REMOVAL,
CRANKSHAFT OIL . . . . . . . . . . . . . . . . . . . . . 9-46
SEAL - INSTALLATION, ADAPTER
HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . 21-124
SEAL - INSTALLATION, A-PILLAR . . . . . . . 23-185
SEAL - INSTALLATION, COWL/PLENUM . . 23-187
SEAL - INSTALLATION, COWL/PLENUM
WINDOW BAFFLE . . . . . . . . . . . . . . . . . . . 23-187
SEAL - INSTALLATION, FRONT OUTPUT
SHAFT . . . . . . . . . . . . . . . . . . . . . . 21-208,21-246
SEAL - INSTALLATION, GLASS PANEL . . . 23-178
SEAL - INSTALLATION, OIL PUMP
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-152
SEAL - INSTALLATION, PINION . . 3-103,3-39,3-68
22 INDEX KJ
Description Group-Page Description Group-Page Description Group-Page
SEAL - INSTALLATION, REAR OUTPUT
SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-212
SEAL - NV1500 - INSTALLATION,
EXTENSION HOUSING. . . . . . . . . . . . . . . . . 21-32
SEAL - NV1500 - REMOVAL, EXTENSION
HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-32
SEAL - NV3550 - INSTALLATION,
EXTENSION HOUSING. . . . . . . . . . . . . . . . . 21-74
SEAL - NV3550 - REMOVAL, EXTENSION
HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-74
SEAL - REAR - INSTALLATION,
CRANKSHAFT OIL . . . . . . . . . . . . . . . . . . . . . 9-48
SEAL - REAR - REMOVAL, CRANKSHAFT
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
SEAL - REMOVAL, ADAPTER HOUSING . . 21-124
SEAL - REMOVAL, A-PILLAR . . . . . . . . . . . 23-185
SEAL - REMOVAL, COWL/PLENUM . . . . . . 23-187
SEAL - REMOVAL, COWL/PLENUM
WINDOW BAFFLE . . . . . . . . . . . . . . . . . . . 23-187
SEAL - REMOVAL, FRONT OUTPUT
SHAFT . . . . . . . . . . . . . . . . . . . . . . 21-208,21-246
SEAL - REMOVAL, GLASS PANEL . . . . . . . 23-178
SEAL - REMOVAL, OIL PUMP FRONT . . . . 21-152
SEAL - REMOVAL, PINION . . . . . 3-102,3-38,3-68
SEAL - REMOVAL, REAR OUTPUT SHAFT . 21-210
SEAL AREA LEAKS - DIAGNOSIS AND
TESTING, REAR . . . . . . . . . . . . . . . . . . . . . . . 9-61
SEALER LOCATIONS - SPECIFICATIONS . . . 23-87
SEALS - DESCRIPTION, VALVE GUIDE . 9-29,9-38
SEALS - INSTALLATION, AXLE SHAFT . . . . 3-102,
3-38
SEALS - REMOVAL, AXLE SHAFT . . . . 3-101,3-37
SEAT - FRONT - INSTALLATION . . . . . . . . 23-165
SEAT - FRONT - REMOVAL . . . . . . . . . . . . 23-165
SEAT - REAR - INSTALLATION . . . . . . . . . 23-168
SEAT - REAR - REMOVAL . . . . . . . . . . . . . 23-168
SEAT BACK - FRONT - INSTALLATION . . . 23-166
SEAT BACK - FRONT - REMOVAL . . . . . . . 23-166
SEAT BACK - REAR - INSTALLATION . . . . 23-168
SEAT BACK - REAR - REMOVAL . . . . . . . . 23-168
SEAT BACK COVER - FRONT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT BACK COVER - FRONT - REMOVAL . 23-166
SEAT BACK COVER - REAR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-169
SEAT BACK COVER - REAR - REMOVAL . . 23-169
SEAT BACK CUSHION - FRONT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT BACK CUSHION - FRONT -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT BACK CUSHION - REAR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-170
SEAT BACK CUSHION - REAR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
SEAT BACK FRAME - REAR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-171
SEAT BACK FRAME - REAR - REMOVAL . . 23-171
SEAT BACK LATCH / LOCK -
INSTALLATION, FOLDING REAR . . . . . . . . 23-170
SEAT BACK LATCH / LOCK - REMOVAL,
FOLDING REAR . . . . . . . . . . . . . . . . . . . . . 23-170
SEAT BACK LATCH STRIKER -
INSTALLATION, REAR . . . . . . . . . . . . . . . . 23-171
SEAT BACK LATCH STRIKER - REMOVAL,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
SEAT BACK RECLINER - FRONT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-166
SEAT BACK RECLINER - FRONT -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-166
SEAT BELT & RETRACTOR -
INSTALLATION, FRONT . . . . . . . . . . . . . . . . 8O-24
SEAT BELT & RETRACTOR -
INSTALLATION, REAR CENTER . . . . . . . . . . 8O-33
SEAT BELT & RETRACTOR -
INSTALLATION, REAR OUTBOARD . . . . . . . 8O-34
SEAT BELT & RETRACTOR - REMOVAL,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-23
SEAT BELT & RETRACTOR - REMOVAL,
REAR CENTER. . . . . . . . . . . . . . . . . . . . . . . 8O-32
SEAT BELT & RETRACTOR - REMOVAL,
REAR OUTBOARD. . . . . . . . . . . . . . . . . . . . 8O-33
SEAT BELT BUCKLE - INSTALLATION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-26
SEAT BELT BUCKLE - INSTALLATION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-35
SEAT BELT BUCKLE - REMOVAL, FRONT . . 8O-25
SEAT BELT BUCKLE - REMOVAL, REAR . . . 8O-34
SEAT BELT SWITCH - DESCRIPTION . . . . . 8O-35
SEAT BELT SWITCH - OPERATION . . . . . . . 8O-36
SEAT BELT TENSIONER - DESCRIPTION . . . 8O-36
SEAT BELT TENSIONER - OPERATION . . . . 8O-36
SEAT BELT TURNING LOOP ADJ USTER -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-38
SEAT BELT TURNING LOOP ADJ USTER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-37
SEAT CUSHION - FRONT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT CUSHION - FRONT - REMOVAL . . . . 23-167
SEAT CUSHION - REAR - INSTALLATION . 23-171
SEAT CUSHION - REAR - REMOVAL . . . . . 23-171
SEAT CUSHION COVER - FRONT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT CUSHION COVER - FRONT -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT CUSHION SIDE SHIELDS -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT CUSHION SIDE SHIELDS -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT ELEMENT - DESCRIPTION, HEATED . 8G-13
SEAT ELEMENT - DIAGNOSIS AND
TESTING, HEATED. . . . . . . . . . . . . . . . . . . . 8G-13
SEAT ELEMENT - OPERATION, HEATED . . . 8G-13
SEAT HEATER SWITCH - DESCRIPTION,
DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-11
SEAT HEATER SWITCH - DESCRIPTION,
PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8G-14
SEAT HEATER SWITCH - INSTALLATION,
DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-13
SEAT HEATER SWITCH - INSTALLATION,
PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8G-15
SEAT HEATER SWITCH - OPERATION,
DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-12
SEAT HEATER SWITCH - OPERATION,
PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8G-14
SEAT HEATER SWITCH - REMOVAL,
DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-13
SEAT HEATER SWITCH - REMOVAL,
PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8G-15
SEAT MODULE - DESCRIPTION, HEATED . . 8E-21
SEAT MODULE - DIAGNOSIS AND
TESTING, HEATED . . . . . . . . . . . . . . . . . . . . 8E-22
SEAT MODULE - INSTALLATION, HEATED . . 8E-24
SEAT MODULE - OPERATION, HEATED . . . . 8E-21
SEAT MODULE - REMOVAL, HEATED . . . . . 8E-24
SEAT RISER - INSTALLATION, MANUAL . . 23-168
SEAT RISER - REMOVAL, MANUAL . . . . . . 23-167
SEAT SENSOR - DIAGNOSIS AND
TESTING, HEATED. . . . . . . . . . . . . . . . . . . . 8G-14
SEAT SWITCH - DESCRIPTION, LEFT
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-16
SEAT SWITCH - DESCRIPTION, RIGHT
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-19
SEAT SWITCH - DIAGNOSIS AND
TESTING, HEATED . . . . . . . . . . . . . . 8G-12,8G-14
SEAT SWITCH - DIAGNOSIS AND
TESTING, LEFT POWER . . . . . . . . . . . . . . . 8N-17
SEAT SWITCH - DIAGNOSIS AND
TESTING, RIGHT POWER . . . . . . . . . . . . . . 8N-19
SEAT SWITCH - INSTALLATION, LEFT
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-18
SEAT SWITCH - INSTALLATION, RIGHT
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20
SEAT SWITCH - OPERATION, LEFT
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-17
SEAT SWITCH - OPERATION, RIGHT
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-19
SEAT SWITCH - REMOVAL, LEFT POWER . 8N-18
SEAT SWITCH - REMOVAL, RIGHT
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20
SEAT SYSTEM - DESCRIPTION, HEATED . . 8G-10
SEAT SYSTEM - DIAGNOSIS AND
TESTING, HEATED. . . . . . . . . . . . . . . . . . . . 8G-11
SEAT SYSTEM - OPERATION, HEATED . . . . 8G-10
SEAT TRACK - DESCRIPTION . . . . . . . . . . . 8N-15
SEAT TRACK - DIAGNOSIS AND TESTING . 8N-16
SEAT TRACK - INSTALLATION . . . . . . . . . . 23-168
SEAT TRACK - INSTALLATION . . . . . . . . . . 8N-16
SEAT TRACK - OPERATION . . . . . . . . . . . . . 8N-15
SEAT TRACK - REMOVAL . . . . . . . . . . . . . 23-168
SEAT TRACK - REMOVAL . . . . . . . . . . . . . . 8N-16
SEATBELT INDICATOR - DESCRIPTION . . . . 8J -27
SEATBELT INDICATOR - OPERATION . . . . . . 8J -28
SEATS - DESCRIPTION, INTAKE/
EXHAUST VALVES . . . . . . . . . . . . . . . . . . . . . 9-26
SEATS - DESCRIPTION, POWER . . . . . . . . . 8N-14
SEATS - DIAGNOSIS AND TESTING,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-15
SEATS - INSTALLATION, INTAKE/
EXHAUST VALVES . . . . . . . . . . . . . . . . . 9-28,9-36
SEATS - OPERATION, POWER . . . . . . . . . . 8N-15
SEATS - REMOVAL, INTAKE/EXHAUST
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . 9-27,9-35
SECTION IDENTIFICATION AND
INFORMATION - DESCRIPTION. . . . . . . . 8W-01-6
SECURITY - DESCRIPTION, VEHICLE
THEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-1
SECURITY - OPERATION, VEHICLE THEFT . . 8Q-3
SECURITY INDICATOR - DESCRIPTION . . . . 8J -28
SECURITY INDICATOR - OPERATION . . . . . 8J -28
SECURITY SYSTEM - DIAGNOSIS AND
TESTING, VEHICLE THEFT . . . . . . . . . . . . . . 8Q-6
SENDING UNIT - DIAGNOSIS AND
TESTING, FUEL LEVEL . . . . . . . . . . . . . . . . . 14-9
SENDING UNIT / SENSOR -
DESCRIPTION, FUEL LEVEL . . . . . . . . . . . . . 14-9
SENDING UNIT / SENSOR -
INSTALLATION, FUEL LEVEL . . . . . . . . . . . . 14-10
SENDING UNIT / SENSOR - OPERATION,
FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
SENDING UNIT / SENSOR - REMOVAL,
FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
SENSE - DESCRIPTION, IGNITION
CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-13
SENSE - OPERATION, IGNITION CIRCUIT . . 8E-15
SENSE - PCM INPUT - OPERATION, ASD . . . 8I-4
SENSITIVE DEVICES - STANDARD
PROCEDURE, ELECTROSTATIC
DISCHARGE (ESD) . . . . . . . . . . . . . . . . . 8W-01-8
SENSOR - DESCRIPTION, AMBIENT
TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-9
SENSOR - DESCRIPTION, BATTERY
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 8F-24
SENSOR - DESCRIPTION, CRANKSHAFT
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-30
SENSOR - DESCRIPTION, ENGINE
COOLANT TEMPERATURE . . . . . . . . . . . . . . . 7-19
SENSOR - DESCRIPTION, FRONT
IMPACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-21
SENSOR - DESCRIPTION, FUEL LEVEL
SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . . 14-9
SENSOR - DESCRIPTION, INPUT SPEED . 21-143
SENSOR - DESCRIPTION, INTAKE AIR
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-36
SENSOR - DESCRIPTION, KNOCK . . . . . . . . 8I-11
SENSOR - DESCRIPTION, LINE
PRESSURE (LP) . . . . . . . . . . . . . . . . . . . . 21-144
SENSOR - DESCRIPTION, MAP . . . . . . . . . . 14-38
SENSOR - DESCRIPTION, OUTPUT
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-152
SENSOR - DESCRIPTION, OXYGEN . . . . . . . 14-40
SENSOR - DESCRIPTION, POSITION . . . . 21-209,
21-247
SENSOR - DESCRIPTION, THROTTLE
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
SENSOR - DESCRIPTION,
TRANSMISSION RANGE . . . . . . . . . . . . . . 21-168
SENSOR - DESCRIPTION,
TRANSMISSION TEMPERATURE . . . . . . . . 21-170
SENSOR - DIAGNOSIS AND TESTING,
AMBIENT TEMPERATURE. . . . . . . . . . . . . . . 8M-9
SENSOR - DIAGNOSIS AND TESTING,
HEATED SEAT . . . . . . . . . . . . . . . . . . . . . . . 8G-14
SENSOR - INSTALLATION, BATTERY
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 8F-24
SENSOR - INSTALLATION, CRANKSHAFT
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-32
SENSOR - INSTALLATION, ENGINE
COOLANT TEMPERATURE . . . . . . . . . . . . . . . 7-21
SENSOR - INSTALLATION, FRONT
IMPACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-22
SENSOR - INSTALLATION, FRONT
WHEEL SPEED. . . . . . . . . . . . . . . . . . . . . . . . 5-34
SENSOR - INSTALLATION, FUEL LEVEL
SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . 14-10
SENSOR - INSTALLATION, INPUT SPEED . 21-143
SENSOR - INSTALLATION, INTAKE AIR
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-38
SENSOR - INSTALLATION, KNOCK . . . . . . . . 8I-12
SENSOR - INSTALLATION, LINE
PRESSURE (LP) . . . . . . . . . . . . . . . . . . . . 21-144
SENSOR - INSTALLATION, MAP . . . . . . . . . 14-40
SENSOR - INSTALLATION, OUTPUT
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-152
KJ INDEX 23
Description Group-Page Description Group-Page Description Group-Page
SENSOR - INSTALLATION, OXYGEN . . . . . . 14-43
SENSOR - INSTALLATION, POSITION . . . . 21-210,
21-247
SENSOR - INSTALLATION, REAR WHEEL
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
SENSOR - INSTALLATION, THROTTLE
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-48
SENSOR - OPERATION, AMBIENT TEMP . . . 8M-9
SENSOR - OPERATION, BATTERY
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 8F-24
SENSOR - OPERATION, CRANKSHAFT
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-31
SENSOR - OPERATION, ENGINE
COOLANT TEMPERATURE . . . . . . . . . . . . . . . 7-20
SENSOR - OPERATION, FRONT IMPACT . . . 8O-21
SENSOR - OPERATION, FUEL LEVEL
SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . . 14-9
SENSOR - OPERATION, INPUT SPEED . . . 21-143
SENSOR - OPERATION, INTAKE AIR
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-36
SENSOR - OPERATION, KNOCK . . . . . . . . . . 8I-11
SENSOR - OPERATION, LINE PRESSURE
(LP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-144
SENSOR - OPERATION, MAP . . . . . . . . . . . 14-38
SENSOR - OPERATION, OUTPUT SPEED . . 21-152
SENSOR - OPERATION, OXYGEN . . . . . . . . 14-40
SENSOR - OPERATION, POSITION . . . . . . 21-209,
21-247
SENSOR - OPERATION, THROTTLE
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
SENSOR - OPERATION, TRANSMISSION
RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-168
SENSOR - OPERATION, TRANSMISSION
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . 21-170
SENSOR - REMOVAL, BATTERY
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 8F-24
SENSOR - REMOVAL, CRANKSHAFT
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-31
SENSOR - REMOVAL, ENGINE COOLANT
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . 7-20
SENSOR - REMOVAL, FRONT IMPACT . . . . 8O-22
SENSOR - REMOVAL, FRONT WHEEL
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
SENSOR - REMOVAL, FUEL LEVEL
SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . . 14-9
SENSOR - REMOVAL, INPUT SPEED . . . . . 21-143
SENSOR - REMOVAL, INTAKE AIR
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-37
SENSOR - REMOVAL, KNOCK . . . . . . . . . . . 8I-12
SENSOR - REMOVAL, LINE PRESSURE
(LP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-144
SENSOR - REMOVAL, MAP . . . . . . . . . . . . . 14-39
SENSOR - REMOVAL, OUTPUT SPEED . . . 21-152
SENSOR - REMOVAL, OXYGEN . . . . . . . . . . 14-41
SENSOR - REMOVAL, POSITION . . 21-210,21-247
SENSOR - REMOVAL, REAR WHEEL
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
SENSOR - REMOVAL, THROTTLE
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
SENSOR CIRCUIT - DIAGNOSIS AND
TESTING, AMBIENT TEMPERATURE. . . . . . . 8M-9
SENSOR RETURN - DESCRIPTION . . . . . . . 8E-14
SENSOR/SWITCH - DESCRIPTION, OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
SENSOR/SWITCH - INSTALLATION, OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
SENSOR/SWITCH - OPERATION, OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
SENSOR/SWITCH - REMOVAL, OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
SENTRY KEY IMMOBILIZER MODULE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8E-15
SENTRY KEY IMMOBILIZER MODULE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8E-18
SENTRY KEY IMMOBILIZER MODULE -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8E-16
SENTRY KEY IMMOBILIZER MODULE -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-17
SENTRY KEY TRANSPONDER
PROGRAMMING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-8
SERPENTINE DRIVE BELT - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 7-15
SERVO - DESCRIPTION . . . . . . . . . . . . . . . . . 8P-4
SERVO - INSTALLATION . . . . . . . . . . . . . . . . 8P-5
SERVO - OPERATION . . . . . . . . . . . . . . . . . . 8P-4
SERVO - REMOVAL . . . . . . . . . . . . . . . . . . . . 8P-4
SETTING TRANSMITTER CODES -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8M-9
SEVERAL LOADS - STANDARD
PROCEDURE, TESTING FOR A SHORT
TO GROUND ON FUSES POWERING . . . 8W-01-9
SHAFT - CAUTION, HALF . . . . . . . . . . . . . . . . 3-10
SHAFT - DIAGNOSIS AND TESTING,
HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
SHAFT - DIAGNOSIS AND TESTING,
PROPELLER. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SHAFT - FRONT - INSTALLATION,
PROPELLER. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
SHAFT - FRONT - REMOVAL,
PROPELLER. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
SHAFT - INSTALLATION, BALANCE . . . . . . . . 9-74
SHAFT - INSTALLATION, HALF . . . . . . . . . . . 3-11
SHAFT - INSTALLATION, IDLER . . . . . . . . . . 9-77
SHAFT - INSTALLATION, INTERMEDIATE . . 19-11
SHAFT - REAR - INSTALLATION,
PROPELLER. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
SHAFT - REAR - REMOVAL, PROPELLER . . . . 3-7
SHAFT - REMOVAL, BALANCE . . . . . . . . . . . 9-74
SHAFT - REMOVAL, HALF . . . . . . . . . . . . . . . 3-10
SHAFT - REMOVAL, IDLER . . . . . . . . . . . . . . 9-77
SHAFT - REMOVAL, INTERMEDIATE . . . . . . 19-11
SHAFT ANGLE - STANDARD
PROCEDURES, PROPELLER . . . . . . . . . . . . . . 3-3
SHAFT SEAL - INSTALLATION, FRONT
OUTPUT. . . . . . . . . . . . . . . . . . . . . 21-208,21-246
SHAFT SEAL - INSTALLATION, REAR
OUTPUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-212
SHAFT SEAL - REMOVAL, FRONT
OUTPUT. . . . . . . . . . . . . . . . . . . . . 21-208,21-246
SHAFT SEAL - REMOVAL, REAR OUTPUT . 21-210
SHAFT SEALS - INSTALLATION, AXLE . . . . 3-102,
3-38
SHAFT SEALS - REMOVAL, AXLE . . . . 3-101,3-37
SHAFT, SPECIFICATIONS - HALF . . . . . . . . . . 3-11
SHAFT, SPECIFICATIONS - PROPELLER . . . . . 3-6
SHAFTS - INSTALLATION, AXLE . 3-101,3-37,3-65
SHAFTS - REMOVAL, AXLE . . . . . 3-101,3-37,3-65
SHIELD - INSTALLATION, FRONT
WHEELHOUSE SPLASH. . . . . . . . . . . . . . . 23-143
SHIELD - INSTALLATION, REAR
WHEELHOUSE SPLASH. . . . . . . . . . . . . . . 23-144
SHIELD - REMOVAL, FRONT
WHEELHOUSE SPLASH. . . . . . . . . . . . . . . 23-143
SHIELD - REMOVAL, REAR
WHEELHOUSE SPLASH. . . . . . . . . . . . . . . 23-144
SHIELDS - DESCRIPTION, HEAT . . . . . . . . . . 11-4
SHIELDS - INSTALLATION, SEAT
CUSHION SIDE . . . . . . . . . . . . . . . . . . . . . 23-167
SHIELDS - REMOVAL, SEAT CUSHION
SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
SHIFT BEZEL - INSTALLATION . . . . . . . . . 23-158
SHIFT BEZEL - REMOVAL . . . . . . . . . . . . . 23-158
SHIFT BOOT - INSTALLATION, 4WD
FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-156
SHIFT BOOT - REMOVAL, 4WD FLOOR . . . 23-156
SHIFT INTERLOCK SYSTEM -
DESCRIPTION, BRAKE TRANSMISSION . . 21-124
SHIFT INTERLOCK SYSTEM - DIAGNOSIS
AND TESTING, BRAKE TRANSMISSION . . 21-125
SHIFT INTERLOCK SYSTEM -
OPERATION, BRAKE TRANSMISSION . . . . 21-125
SHIFT LEVER - INSTALLATION . . . 21-214,21-249
SHIFT LEVER - REMOVAL . . . . . . . 21-213,21-248
SHIFT MECHANISM - DESCRIPTION . . . . . 21-160
SHIFT MECHANISM - INSTALLATION . . . . 21-160
SHIFT MECHANISM - OPERATION . . . . . . 21-160
SHIFT MECHANISM - REMOVAL . . . . . . . . 21-160
SHOCK - INSTALLATION . . . . . . . . . . . . . . . . 2-18
SHOCK - REMOVAL . . . . . . . . . . . . . . . . . . . . 2-18
SHOES - INSTALLATION, DRUM BRAKE . . . . 5-11
SHOES - REMOVAL, DRUM BRAKE . . . . . . . 5-11
SHORT TO GROUND - STANDARD
PROCEDURE, TESTING FOR A . . . . . . . . 8W-01-9
SHORT TO GROUND ON FUSES
POWERING SEVERAL LOADS -
STANDARD PROCEDURE, TESTING
FOR A . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-9
SIDE - INSTALLATION, LEFT . . . . . . . . . 2-12,2-15
SIDE - INSTALLATION, RIGHT . . . . . . . . 2-12,2-15
SIDE - REMOVAL, LEFT . . . . . . . . . . . . . 2-11,2-15
SIDE - REMOVAL, RIGHT . . . . . . . . . . . 2-11,2-14
SIDE BEZEL - INSTALLATION,
INSTRUMENT PANEL PASSENGER . . . . . . 23-154
SIDE BEZEL - REMOVAL, INSTRUMENT
PANEL PASSENGER. . . . . . . . . . . . . . . . . . 23-154
SIDE BEZELS - INSTALLATION,
INSTRUMENT PANEL DRIVER . . . . . . . . . . 23-154
SIDE BEZELS - REMOVAL, INSTRUMENT
PANEL DRIVER . . . . . . . . . . . . . . . . . . . . . 23-153
SIDE CURTAIN AIRBAG - DESCRIPTION . . . 8O-38
SIDE CURTAIN AIRBAG - INSTALLATION . . 8O-41
SIDE CURTAIN AIRBAG - OPERATION . . . . 8O-39
SIDE CURTAIN AIRBAG - REMOVAL . . . . . . 8O-40
SIDE IMPACT AIRBAG CONTROL
MODULE - DESCRIPTION . . . . . . . . . . . . . . 8O-43
SIDE IMPACT AIRBAG CONTROL
MODULE - INSTALLATION . . . . . . . . . . . . . 8O-45
SIDE IMPACT AIRBAG CONTROL
MODULE - OPERATION. . . . . . . . . . . . . . . . 8O-43
SIDE IMPACT AIRBAG CONTROL
MODULE - REMOVAL . . . . . . . . . . . . . . . . . 8O-44
SIDE MOLDINGS - INSTALLATION, BODY . 23-140
SIDE MOLDINGS - REMOVAL, BODY . . . . 23-140
SIDE RAIL WEATHERSTRIP/RETAINER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-186
SIDE RAIL WEATHERSTRIP/RETAINER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
SIDE SHIELDS - INSTALLATION, SEAT
CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
SIDE SHIELDS - REMOVAL, SEAT
CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
SIDE VIEW MIRROR - INSTALLATION . . . . 23-145
SIDE VIEW MIRROR - REMOVAL . . . . . . . 23-145
SIDEVIEW MIRROR - REMOVAL . . . . . . . . . . 8N-13
SIGNAL INDICATOR - DESCRIPTION,
TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -34
SIGNAL INDICATOR - OPERATION, TURN . . 8J -34
SILL SCUFF PLATE - INSTALLATION,
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-157
SILL SCUFF PLATE - REMOVAL, DOOR . . . 23-157
SINGLE CARDAN UNIVERSAL J OINTS -
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
SINGLE CARDAN UNIVERSAL J OINTS -
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
SIREN - DESCRIPTION . . . . . . . . . . . . . . . . 8Q-16
SIREN - INSTALLATION . . . . . . . . . . . . . . . 8Q-17
SIREN - OPERATION . . . . . . . . . . . . . . . . . . 8Q-17
SIREN - REMOVAL . . . . . . . . . . . . . . . . . . . 8Q-17
SKID PLATE - INSTALLATION, FRONT . . . . . . 13-6
SKID PLATE - INSTALLATION, FUEL
TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
SKID PLATE - INSTALLATION, TRANSFER
CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
SKID PLATE - REMOVAL, FRONT . . . . . . . . . 13-6
SKID PLATE - REMOVAL, FUEL TANK . . . . . . 13-9
SKID PLATE - REMOVAL, TRANSFER
CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
SKIS INDICATOR - DESCRIPTION . . . . . . . . 8J -31
SKIS INDICATOR - OPERATION . . . . . . . . . . 8J -31
SKIS INITIALIZATION - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-8
SLEEVE - INSTALLATION, HEADREST . . . . 23-164
SLEEVE - REMOVAL, HEADREST . . . . . . . 23-164
SOLENOID - DESCRIPTION, EVAP/PURGE . 25-27
SOLENOID - INSTALLATION, EVAP/
PURGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-27
SOLENOID - OPERATION, EVAP/PURGE . . . 25-27
SOLENOID - REMOVAL, EVAP/PURGE . . . . . 25-27
SOLENOID SWITCH VALVE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-161
SOLENOID SWITCH VALVE - OPERATION . 21-161
SOLENOIDS - DESCRIPTION . . . . . . . . . . . 21-161
SOLENOIDS - OPERATION . . . . . . . . . . . . . 21-162
SOLENOID/TRS ASSEMBLY -
DESCRIPTION, TRANSMISSION . . . . . . . . 21-169
SOLENOID/TRS ASSEMBLY -
INSTALLATION, TRANSMISSION . . . . . . . . 21-170
SOLENOID/TRS ASSEMBLY -
OPERATION, TRANSMISSION . . . . . . . . . . 21-169
SOLENOID/TRS ASSEMBLY - REMOVAL,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-170
SPACER - INSTALLATION, COLLAPSIBLE . . . 3-70
SPACER - REMOVAL, COLLAPSIBLE . . . . . . . 3-70
SPARE TIRE - INSTALLATION . . . . . . . . . . . . 22-9
SPARE TIRE - REMOVAL . . . . . . . . . . . . . . . . 22-8
SPARE TIRE &TEMPORARY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 22-6
SPARK PLUG - CLEANING SPARK
PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-15
SPARK PLUG - DESCRIPTION . . . . . . . . . . . 8I-12
SPARK PLUG - INSTALLATION . . . . . . . . . . . 8I-15
24 INDEX KJ
Description Group-Page Description Group-Page Description Group-Page
SPARK PLUG - OPERATION . . . . . . . . . . . . . 8I-12
SPARK PLUG - REMOVAL . . . . . . . . . . . . . . 8I-15
SPARK PLUG CABLE RESISTANCE, 2.4L . . . . 8I-3
SPARK PLUG CONDITIONS - DIAGNOSIS
AND TESTING. . . . . . . . . . . . . . . . . . . . . . . . 8I-13
SPARK PLUGS, SPARK PLUG -
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-15
SPARK PLUGS, SPECIFICATIONS . . . . . . . . . . 8I-3
SPEAKER - DESCRIPTION . . . . . . . . . . . . . . 8A-13
SPEAKER - INSTALLATION . . . . . . . . . . . . . 8A-15
SPEAKER - OPERATION . . . . . . . . . . . . . . . 8A-14
SPEAKER - REMOVAL . . . . . . . . . . . . . . . . . 8A-14
SPECIAL TOOLS - 3.7L ENGINE . . . . . . . . . . 9-15
SPECIAL TOOLS - 8 1/4 AXLE . . . . . . . . . . . 3-98
SPECIAL TOOLS - BASE BRAKES . . . . . . . . . . 5-7
SPECIAL TOOLS - BODY . . . . . . . . . . . . . . . . 23-5
SPECIAL TOOLS - COOLING . . . . . . . . . . . . . 7-14
SPECIAL TOOLS - FRONT AXLE . . . . . . . . . . 3-34
SPECIAL TOOLS - FRONT SUSPENSION . . . . . 2-8
SPECIAL TOOLS - FUEL SYSTEM . . . . . . . . . 14-6
SPECIAL TOOLS - OUTER TIE ROD END
REMOVAL TOOL . . . . . . . . . . . . . . . . . . . . . 19-15
SPECIAL TOOLS - POWER
DISTRIBUTION SYSTEMS . . . . . . . . . . . . 8W-97-2
SPECIAL TOOLS - POWER STEERING
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20
SPECIAL TOOLS - REAR AXLE . . . . . . . . . . . 3-63
SPECIAL TOOLS - RFE TRANSMISSION. . . . 21-120
SPECIAL TOOLS - STEERING COLUMN . . . . 19-8
SPECIAL TOOLS - WIRING/TERMINAL . 8W-01-10
SPECIAL TOOLS, BATTERY SYSTEM . . . . . . . 8F-7
SPECIFICATIONS, BATTERY SYSTEM . . . . . . 8F-6
SPECIFICATIONS, BRAKES - ABS . . . . . . . . . 5-33
SPECIFICATIONS, CHARGE CAPACITY . . . . . 24-42
SPECIFICATIONS, CLUTCH . . . . . . . . . . . . . . . 6-5
SPECIFICATIONS, DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
SPECIFICATIONS, FLUID CAPACITIES . . . . . . . 0-4
SPECIFICATIONS, FRAME DIMENSIONS . . . . 13-3
SPECIFICATIONS, FRONT AXLE . . . . . . . . . . . 3-33
SPECIFICATIONS, GAP AND FLUSH . . . . . 23-116
SPECIFICATIONS, IGNITION TIMING . . . . . . . 8I-2
SPECIFICATIONS, LAMPS/LIGHTING -
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-15
SPECIFICATIONS, LAMPS/LIGHTING -
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-71
SPECIFICATIONS, NV1500 . . . . . . . . . . . . . . 21-30
SPECIFICATIONS, OPENING DIMENSIONS . 23-111
SPECIFICATIONS, PAINT CODES . . . . . . . . 23-162
SPECIFICATIONS, REAR AXLE . . . . . . . . . . . . 3-62
SPECIFICATIONS, REMOTE KEYLESS
ENTRY TRANSMITTER . . . . . . . . . . . . . . . . . 8N-9
SPECIFICATIONS, SEALER LOCATIONS . . . . 23-87
SPECIFICATIONS, SPECIFICATIONS . . . . . . . 24-10
SPECIFICATIONS, STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
SPECIFICATIONS, TORQUE . . . . . . . . . . . . . . 13-6
SPECIFICATIONS, WELD AND
STRUCTURAL ADHESIVE LOCATIONS . . . . . . 23-9
SPEED CONTROL - DESCRIPTION . . . . . . . . 8P-1
SPEED CONTROL - OPERATION . . . . . . . . . . 8P-1
SPEED CONTROL - TORQUE . . . . . . . . . . . . . 8P-2
SPEED SENSOR - DESCRIPTION, INPUT . 21-143
SPEED SENSOR - DESCRIPTION,
OUTPUT. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-152
SPEED SENSOR - INSTALLATION, FRONT
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
SPEED SENSOR - INSTALLATION, INPUT . 21-143
SPEED SENSOR - INSTALLATION,
OUTPUT. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-152
SPEED SENSOR - INSTALLATION, REAR
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
SPEED SENSOR - OPERATION, INPUT . . . 21-143
SPEED SENSOR - OPERATION, OUTPUT . . 21-152
SPEED SENSOR - REMOVAL, FRONT
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
SPEED SENSOR - REMOVAL, INPUT . . . . . 21-143
SPEED SENSOR - REMOVAL, OUTPUT . . . 21-152
SPEED SENSOR - REMOVAL, REAR
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
SPEEDOMETER - DESCRIPTION . . . . . . . . . 8J -32
SPEEDOMETER - OPERATION . . . . . . . . . . . 8J -32
SPLASH SHIELD - INSTALLATION,
FRONT WHEELHOUSE . . . . . . . . . . . . . . . . 23-143
SPLASH SHIELD - INSTALLATION, REAR
WHEELHOUSE . . . . . . . . . . . . . . . . . . . . . . 23-144
SPLASH SHIELD - REMOVAL, FRONT
WHEELHOUSE . . . . . . . . . . . . . . . . . . . . . . 23-143
SPLASH SHIELD - REMOVAL, REAR
WHEELHOUSE . . . . . . . . . . . . . . . . . . . . . . 23-144
SPLICE INFORMATION - DESCRIPTION,
CONNECTOR, GROUND. . . . . . . . . . . . . . 8W-01-7
SPLICING - STANDARD PROCEDURE,
WIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-14
SPRING - INSTALLATION . . . . . . . . . . . 2-13,2-18
SPRING - REMOVAL . . . . . . . . . . . . . . . 2-13,2-18
SPRINGS - DESCRIPTION, VALVE . . . . . 9-29,9-38
SPRINGS - INSTALLATION, VALVE . . . . 9-29,9-38
SPRINGS - REMOVAL, VALVE . . . . . . . . 9-29,9-38
STABILIZER BAR - INSTALLATION . . . . 2-14,2-19
STABILIZER BAR - REMOVAL . . . . . . . . 2-14,2-19
STABILIZER BAR BUSHINGS -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 2-9
STABILIZER BAR BUSHINGS - REMOVAL . . . . 2-9
STABILIZER LINK - INSTALLATION . . . . . . . . 2-14
STABILIZER LINK - REMOVAL . . . . . . . . . . . . 2-14
STAKING - STANDARD PROCEDURE,
HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3
STARTER MOTOR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-39
STARTER MOTOR - INSTALLATION . . . . . . . 8F-41
STARTER MOTOR - REMOVAL . . . . . . . . . . 8F-39
STARTER MOTOR, GAS POWERED . . . . . . . 8F-39
STARTER MOTOR RELAY - DESCRIPTION . 8F-41
STARTER MOTOR RELAY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8F-43
STARTER MOTOR RELAY - OPERATION. . . . . 8F-42
STARTER MOTOR RELAY - REMOVAL . . . . . 8F-43
STARTER RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-42
STARTING PROCEDURE - STANDARD
PROCEDURE, J UMP . . . . . . . . . . . . . . . . . . . . 0-5
STARTING SYSTEM - DESCRIPTION . . . . . . 8F-32
STARTING SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-33
STARTING SYSTEM - INSPECTION . . . . . . . 8F-37
STARTING SYSTEM - OPERATION . . . . . . . . 8F-32
STATE DISPLAY TEST MODE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 25-2
STEERING - DESCRIPTION . . . . . . . . . . . . . . 19-1
STEERING - OPERATION . . . . . . . . . . . . . . . . 19-1
STEERING COLUMN, SPECIAL TOOLS . . . . . 19-8
STEERING FLOW AND PRESSURE -
DIAGNOSIS AND TESTING, POWER . . . . . . . 19-3
STEERING LINKAGE - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 19-16
STEERING PRESSURE SWITCH -
DESCRIPTION, POWER . . . . . . . . . . . . . . . . 19-22
STEERING PRESSURE SWITCH -
INSTALLATION, POWER . . . . . . . . . . . . . . . 19-22
STEERING PRESSURE SWITCH -
OPERATION, POWER . . . . . . . . . . . . . . . . . . 19-22
STEERING PRESSURE SWITCH -
REMOVAL, POWER . . . . . . . . . . . . . . . . . . . 19-22
STEERING PUMP - INITIAL OPERATION -
STANDARD PROCEDURE, POWER . . . . . . . 19-18
STEERING PUMP, SPECIAL TOOLS -
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20
STEERING SYSTEM - DIAGNOSIS AND
TESTING, POWER . . . . . . . . . . . . . . . . . . . . . 19-1
STEERING SYSTEM - DIAGNOSIS AND
TESTING, SUSPENSION . . . . . . . . . . . . . . . . . 2-1
STEERING WHEEL - INSTALLATION . . . . . . 19-12
STEERING WHEEL - REMOVAL . . . . . . . . . . 19-12
STOP LAMP BULB - INSTALLATION,
CENTER HIGH MOUNTED . . . . . . . . . . . . . . 8L-19
STOP LAMP BULB - REMOVAL, CENTER
HIGH MOUNTED . . . . . . . . . . . . . . . . . . . . . 8L-18
STOP LAMP UNIT - INSTALLATION,
CENTER HIGH MOUNTED . . . . . . . . . . . . . . 8L-19
STOP LAMP UNIT - REMOVAL, CENTER
HIGH MOUNTED . . . . . . . . . . . . . . . . . . . . . 8L-19
STRAP - DESCRIPTION, RADIO NOISE
SUPPRESSION GROUND. . . . . . . . . . . . . . . . 8A-9
STRAP - INSTALLATION, CHECK . 23-121,23-128,
23-135
STRAP - INSTALLATION, RADIO NOISE
SUPPRESSION GROUND. . . . . . . . . . . . . . . 8A-11
STRAP - OPERATION, RADIO NOISE
SUPPRESSION GROUND. . . . . . . . . . . . . . . 8A-10
STRAP - REMOVAL, CHECK . . . . . 23-121,23-128,
23-135
STRAP - REMOVAL, RADIO NOISE
SUPPRESSION GROUND. . . . . . . . . . . . . . . 8A-10
STRIKER - INSTALLATION, GLOVE BOX
LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-149
STRIKER - INSTALLATION, HOOD AJ AR
SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-14
STRIKER - INSTALLATION, LATCH . . . . . . 23-124,
23-132,23-137
STRIKER - INSTALLATION, REAR SEAT
BACK LATCH . . . . . . . . . . . . . . . . . . . . . . . 23-171
STRIKER - REMOVAL, GLOVE BOX
LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-148
STRIKER - REMOVAL, HOOD AJ AR
SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
STRIKER - REMOVAL, LATCH . . . 23-124,23-132,
23-137
STRIKER - REMOVAL, REAR SEAT BACK
LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
STRUCTURAL ADHESIVE LOCATIONS -
SPECIFICATIONS, WELD . . . . . . . . . . . . . . . . 23-9
STRUCTURAL COVER - DESCRIPTION . . . . . 9-55
STRUCTURAL COVER - INSTALLATION . . . . . 9-55
STRUCTURAL COVER - OPERATION . . . . . . . 9-55
STRUCTURAL COVER - REMOVAL . . . . . . . . 9-55
STUDS - INSTALLATION . . . . . . . . . . . . . . . 22-11
STUDS - REMOVAL . . . . . . . . . . . . . . . . . . . 22-11
SUCTION LINE - INSTALLATION, A/C . . . . . 24-49
SUCTION LINE - REMOVAL, A/C . . . . . . . . . 24-48
SUN VISOR - INSTALLATION . . . . . . . . . . 23-160
SUN VISOR - REMOVAL . . . . . . . . . . . . . . 23-160
SUN VISOR SUPPORT - INSTALLATION . . 23-160
SUN VISOR SUPPORT - REMOVAL . . . . . . 23-160
SUNROOF - DESCRIPTION . . . . . . . . . . . . 23-175
SUNROOF GLASS PANEL ADJ USTMENT,
ADJ USTMENTS . . . . . . . . . . . . . . . . . . . . . 23-178
SUNSHADE - INSTALLATION . . . . . . . . . . . 23-179
SUNSHADE - REMOVAL . . . . . . . . . . . . . . 23-179
SUPPLEMENTAL RESTRAINT
DEPLOYMENT - STANDARD
PROCEDURE, SERVICE AFTER A . . . . . . . . . 8O-6
SUPPLEMENTAL RESTRAINT SYSTEM -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8O-6
SUPPLEMENTAL RESTRAINTS -
STANDARD PROCEDURE, HANDLING
NON-DEPLOYED . . . . . . . . . . . . . . . . . . . . . . 8O-6
SUPPLIES - DESCRIPTION, 5 VOLT . . . . . . 8E-13
SUPPLIES - OPERATION, 5 VOLT . . . . . . . . 8E-15
SUPPORT - INSTALLATION, REAR
FASCIA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
SUPPORT - INSTALLATION, SUN VISOR . . 23-160
SUPPORT - REMOVAL, REAR FASCIA . . . . . . 13-3
SUPPORT - REMOVAL, SUN VISOR . . . . . 23-160
SUPPORT BRACKET - INSTALLATION,
REARVIEW MIRROR . . . . . . . . . . . . . . . . . 23-161
SUPPORT CYLINDER - INSTALLATION . . . 23-120
SUPPORT CYLINDER - INSTALLATION,
FLIP-UP GLASS . . . . . . . . . . . . . . . . . . . . . 23-139
SUPPORT CYLINDER - REMOVAL . . . . . . . 23-120
SUPPORT CYLINDER - REMOVAL,
FLIP-UP GLASS . . . . . . . . . . . . . . . . . . . . . 23-139
SUPPRESSION GROUND STRAP -
DESCRIPTION, RADIO NOISE . . . . . . . . . . . . 8A-9
SUPPRESSION GROUND STRAP -
INSTALLATION, RADIO NOISE. . . . . . . . . . . 8A-11
SUPPRESSION GROUND STRAP -
OPERATION, RADIO NOISE . . . . . . . . . . . . . 8A-10
SUPPRESSION GROUND STRAP -
REMOVAL, RADIO NOISE . . . . . . . . . . . . . . 8A-10
SURFACE PREPARATION - STANDARD
PROCEDURE, ENGINE GASKET . . . . . . . . . . . . 9-9
SUSPENSION - DIAGNOSIS AND
TESTING, REAR . . . . . . . . . . . . . . . . . . . . . . . 2-17
SUSPENSION AND STEERING SYSTEM -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 2-1
SUSPENSION ARM, BUSHINGS, AND
BALL J OINT - DESCRIPTION, UPPER . . . . . . 2-20
SUSPENSION ARM, BUSHINGS, AND
BALL J OINT - OPERATION, UPPER . . . . . . . . 2-20
SUSPENSION, SPECIAL TOOLS - FRONT . . . . 2-8
SWING GATE - INSTALLATION . . . . . . . . . 23-138
SWING GATE - REMOVAL . . . . . . . . . . . . . 23-138
SWING GATE BELTLINE WEATHERSTRIP
- INSTALLATION . . . . . . . . . . . . . . . . . . . . 23-186
SWING GATE BELTLINE WEATHERSTRIP
- REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 23-186
SWING GATE OPENING WEATHERSTRIP
- INSTALLATION . . . . . . . . . . . . . . . . . . . . 23-186
SWING GATE OPENING WEATHERSTRIP
- REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 23-186
SWITCH - DESCRIPTION . . . . . . . . . . . . . . . . 8P-5
SWITCH - DESCRIPTION, A/C HIGH
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-17
KJ INDEX 25
Description Group-Page Description Group-Page Description Group-Page
SWITCH - DESCRIPTION, A/C LOW
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
SWITCH - DESCRIPTION, BACKUP LAMP . . 8L-15
SWITCH - DESCRIPTION, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23
SWITCH - DESCRIPTION, BRAKE LAMP . . . 8L-16
SWITCH - DESCRIPTION, CLUTCH
PEDAL POSITION . . . . . . . . . . . . . . . . . . . . . 6-11
SWITCH - DESCRIPTION, CONTROL . . . . . 23-184
SWITCH - DESCRIPTION, DOOR AJ AR . . . . 8L-77
SWITCH - DESCRIPTION, DOOR
CYLINDER LOCK . . . . . . . . . . . . . . . . . . . . . . 8Q-9
SWITCH - DESCRIPTION, DRIVER SEAT
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-11
SWITCH - DESCRIPTION, FLIP-UP
GLASS AJ AR . . . . . . . . . . . . . . . . . . . . . . . . 8L-77
SWITCH - DESCRIPTION, FRONT
WIPER/WASHER . . . . . . . . . . . . . . . . . . . . . 8R-16
SWITCH - DESCRIPTION, HAZARD . . . . . . . 8L-29
SWITCH - DESCRIPTION, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-37
SWITCH - DESCRIPTION, HOOD AJ AR . . . . 8Q-11
SWITCH - DESCRIPTION, HORN . . . . . . . . . . 8H-4
SWITCH - DESCRIPTION, IGNITION . . . . . . . 19-8
SWITCH - DESCRIPTION, KEY-IN
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-10
SWITCH - DESCRIPTION, LEFT POWER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-16
SWITCH - DESCRIPTION, MULTI-
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-46
SWITCH - DESCRIPTION, OVERDRIVE. . . . . 21-153
SWITCH - DESCRIPTION, PASSENGER
SEAT HEATER . . . . . . . . . . . . . . . . . . . . . . . 8G-14
SWITCH - DESCRIPTION, POWER
STEERING PRESSURE. . . . . . . . . . . . . . . . . 19-22
SWITCH - DESCRIPTION, REAR
WINDOW DEFOGGER . . . . . . . . . . . . . . . . . . 8G-8
SWITCH - DESCRIPTION, REAR
WIPER/WASHER . . . . . . . . . . . . . . . . . . . . . 8R-43
SWITCH - DESCRIPTION, RIGHT POWER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-19
SWITCH - DESCRIPTION, SEAT BELT . . . . . 8O-35
SWITCH - DESCRIPTION, TAILGATE
AJ AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-82
SWITCH - DESCRIPTION, TAILGATE
CYLINDER LOCK . . . . . . . . . . . . . . . . . . . . . . 8N-9
SWITCH - DESCRIPTION, WASHER
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
SWITCH - DIAGNOSIS AND TESTING,
A/C HIGH PRESSURE . . . . . . . . . . . . . . . . . 24-18
SWITCH - DIAGNOSIS AND TESTING,
A/C LOW PRESSURE. . . . . . . . . . . . . . . . . . 24-19
SWITCH - DIAGNOSIS AND TESTING,
BACKUP LAMP . . . . . . . . . . . . . . . . . . . . . . 8L-15
SWITCH - DIAGNOSIS AND TESTING,
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . 24-23
SWITCH - DIAGNOSIS AND TESTING,
BRAKE LAMP . . . . . . . . . . . . . . . . . . . . . . . 8L-17
SWITCH - DIAGNOSIS AND TESTING,
CLUTCH PEDAL POSITION . . . . . . . . . . . . . . 6-11
SWITCH - DIAGNOSIS AND TESTING,
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 23-184
SWITCH - DIAGNOSIS AND TESTING,
DOOR CYLINDER LOCK . . . . . . . . . . . . . . . 8Q-10
SWITCH - DIAGNOSIS AND TESTING,
DOOR LOCK/UNLOCK . . . . . . . . . . . . . . . . . . 8N-4
SWITCH - DIAGNOSIS AND TESTING,
FLIP-UP GLASS RELEASE. . . . . . . . . . . . . . . 8N-5
SWITCH - DIAGNOSIS AND TESTING,
HEADLAMP LEVELING. . . . . . . . . . . . . . . . . 8L-37
SWITCH - DIAGNOSIS AND TESTING,
HEATED SEAT . . . . . . . . . . . . . . . . . . 8G-12,8G-14
SWITCH - DIAGNOSIS AND TESTING,
HOOD AJ AR . . . . . . . . . . . . . . . . . . . . . . . . 8Q-12
SWITCH - DIAGNOSIS AND TESTING,
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-4
SWITCH - DIAGNOSIS AND TESTING,
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-8
SWITCH - DIAGNOSIS AND TESTING,
KEY-IN IGNITION . . . . . . . . . . . . . . . . . . . . . 19-10
SWITCH - DIAGNOSIS AND TESTING,
LEFT POWER SEAT . . . . . . . . . . . . . . . . . . . 8N-17
SWITCH - DIAGNOSIS AND TESTING,
MULTI-FUNCTION . . . . . . . . . . . . . . . . . . . . 8L-50
SWITCH - DIAGNOSIS AND TESTING,
POWER MIRROR . . . . . . . . . . . . . . . . . . . . 8N-12
SWITCH - DIAGNOSIS AND TESTING,
REAR WINDOW DEFOGGER . . . . . . . . . . . . . 8G-8
SWITCH - DIAGNOSIS AND TESTING,
RIGHT POWER SEAT. . . . . . . . . . . . . . . . . . 8N-19
SWITCH - DIAGNOSIS AND TESTING,
TAILGATE CYLINDER LOCK. . . . . . . . . . . . . . 8N-9
SWITCH - DIAGNOSIS AND TESTING,
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-22
SWITCH - INSTALLATION . . . . . . . . . . . . . . . 8P-6
SWITCH - INSTALLATION, A/C HIGH
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
SWITCH - INSTALLATION, A/C LOW
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
SWITCH - INSTALLATION, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23
SWITCH - INSTALLATION, BRAKE LAMP . . 8L-18
SWITCH - INSTALLATION, CARGO LAMP . . 8L-74
SWITCH - INSTALLATION, CONTROL . . . . 23-184
SWITCH - INSTALLATION, DOOR
CYLINDER LOCK . . . . . . . . . . . . . . . . . . . . . 8Q-10
SWITCH - INSTALLATION, DOOR LOCK /
UNLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-5
SWITCH - INSTALLATION, DRIVER SEAT
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-13
SWITCH - INSTALLATION, HAZARD . . . . . . 8L-30
SWITCH - INSTALLATION, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-38
SWITCH - INSTALLATION, HOOD AJ AR . . . 8Q-12
SWITCH - INSTALLATION, LEFT POWER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-18
SWITCH - INSTALLATION, MULTI-
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-53
SWITCH - INSTALLATION, PASSENGER
SEAT HEATER. . . . . . . . . . . . . . . . . . . . . . . . . 8G-15
SWITCH - INSTALLATION, POWER
MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-13
SWITCH - INSTALLATION, POWER
STEERING PRESSURE. . . . . . . . . . . . . . . . . 19-22
SWITCH - INSTALLATION, READING
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-80
SWITCH - INSTALLATION, RIGHT POWER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20
SWITCH - INSTALLATION, TAILGATE
CYLINDER LOCK . . . . . . . . . . . . . . . . . . . . . 8N-10
SWITCH - INSTALLATION, WASHER
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . 8R-18
SWITCH - INSTALLATION, WINDOW . . . . . 8N-23
SWITCH - OPERATION . . . . . . . . . . . . . . . . . 8P-5
SWITCH - OPERATION, A/C HIGH
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
SWITCH - OPERATION, A/C LOW
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
SWITCH - OPERATION, BACKUP LAMP . . . 8L-15
SWITCH - OPERATION, BLOWER MOTOR . . 24-23
SWITCH - OPERATION, BRAKE LAMP . . . . . 8L-16
SWITCH - OPERATION, CLUTCH PEDAL
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
SWITCH - OPERATION, CONTROL . . . . . . . 23-184
SWITCH - OPERATION, DOOR AJ AR . . . . . . 8L-77
SWITCH - OPERATION, DOOR CYLINDER
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
SWITCH - OPERATION, DRIVER SEAT
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-12
SWITCH - OPERATION, FLIP-UP GLASS
AJ AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-77
SWITCH - OPERATION, FRONT
WIPER/WASHER . . . . . . . . . . . . . . . . . . . . . 8R-16
SWITCH - OPERATION, HAZARD . . . . . . . . . 8L-29
SWITCH - OPERATION, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-37
SWITCH - OPERATION, HOOD AJ AR . . . . . 8Q-12
SWITCH - OPERATION, LEFT POWER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-17
SWITCH - OPERATION, MULTI-FUNCTION . 8L-48
SWITCH - OPERATION, OVERDRIVE . . . . . 21-153
SWITCH - OPERATION, PASSENGER
SEAT HEATER . . . . . . . . . . . . . . . . . . . . . . . 8G-14
SWITCH - OPERATION, POWER
STEERING PRESSURE. . . . . . . . . . . . . . . . . 19-22
SWITCH - OPERATION, REAR WINDOW
DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-8
SWITCH - OPERATION, REAR WIPER/
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-43
SWITCH - OPERATION, RIGHT POWER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-19
SWITCH - OPERATION, SEAT BELT . . . . . . . 8O-36
SWITCH - OPERATION, TAILGATE AJ AR . . . 8L-82
SWITCH - OPERATION, TAILGATE
CYLINDER LOCK . . . . . . . . . . . . . . . . . . . . . . 8N-9
SWITCH - OPERATION, WASHER FLUID
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
SWITCH - REMOVAL . . . . . . . . . . . . . . . . . . . 8P-6
SWITCH - REMOVAL, A/C HIGH
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
SWITCH - REMOVAL, A/C LOW
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
SWITCH - REMOVAL, BLOWER MOTOR . . . 24-23
SWITCH - REMOVAL, BRAKE LAMP . . . . . . 8L-17
SWITCH - REMOVAL, CARGO LAMP . . . . . . 8L-73
SWITCH - REMOVAL, CONTROL . . . . . . . . 23-184
SWITCH - REMOVAL, DOOR CYLINDER
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
SWITCH - REMOVAL, DOOR LOCK /
UNLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-4
SWITCH - REMOVAL, DRIVER SEAT
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-13
SWITCH - REMOVAL, HAZARD . . . . . . . . . . 8L-30
SWITCH - REMOVAL, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-38
SWITCH - REMOVAL, HOOD AJ AR . . . . . . . 8Q-12
SWITCH - REMOVAL, LEFT POWER SEAT . 8N-18
SWITCH - REMOVAL, MULTI-FUNCTION . . . 8L-53
SWITCH - REMOVAL, PASSENGER SEAT
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-15
SWITCH - REMOVAL, POWER MIRROR . . . 8N-13
SWITCH - REMOVAL, POWER STEERING
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 19-22
SWITCH - REMOVAL, READING LAMP . . . . 8L-80
SWITCH - REMOVAL, RIGHT POWER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20
SWITCH - REMOVAL, TAILGATE
CYLINDER LOCK . . . . . . . . . . . . . . . . . . . . . 8N-10
SWITCH - REMOVAL, WASHER FLUID
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
SWITCH - REMOVAL, WINDOW . . . . . . . . . 8N-23
SWITCH BRACKET - INSTALLATION,
HOOD AJ AR . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
SWITCH BRACKET - REMOVAL, HOOD
AJ AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
SWITCH INSTALLATION, INSTALLATION -
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-9
SWITCH OVERRIDE RELAY -
DESCRIPTION, CLUTCH. . . . . . . . . . . . . . . . . 6-10
SWITCH OVERRIDE RELAY -
INSTALLATION, CLUTCH . . . . . . . . . . . . . . . . 6-10
SWITCH OVERRIDE RELAY -
OPERATION, CLUTCH . . . . . . . . . . . . . . . . . . 6-10
SWITCH OVERRIDE RELAY - REMOVAL,
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
SWITCH REMOVAL, REMOVAL -
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-9
SWITCH STRIKER - INSTALLATION,
HOOD AJ AR . . . . . . . . . . . . . . . . . . . . . . . . 8Q-14
SWITCH STRIKER - REMOVAL, HOOD
AJ AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
SWITCH VALVE - DESCRIPTION,
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . 21-161
SWITCH VALVE - OPERATION, SOLENOID . 21-161
SWITCHES - DESCRIPTION, REMOTE . . . . . 8A-11
SWITCHES - DIAGNOSIS AND TESTING,
REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-12
SWITCHES - INSTALLATION, REMOTE . . . . 8A-13
SWITCHES - OPERATION, REMOTE . . . . . . 8A-12
SWITCHES - REMOVAL, REMOTE . . . . . . . . 8A-13
SYMBOLS - DESCRIPTION,
INTERNATIONAL . . . . . . . . . . . . . . . . . . . . Intro.-4
SYMBOLS - DESCRIPTION,
INTERNATIONAL . . . . . . . . . . . . . . . . . . . . . . . 0-1
TABLE, SPECIFICATIONS - A/C
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . 24-9
TACHOMETER - DESCRIPTION . . . . . . . . . . 8J -33
TACHOMETER - OPERATION . . . . . . . . . . . . 8J -33
TAILGATE AJ AR SWITCH - DESCRIPTION . . 8L-82
TAILGATE AJ AR SWITCH - OPERATION . . . 8L-82
TAILGATE CYLINDER LOCK SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8N-9
TAILGATE CYLINDER LOCK SWITCH -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8N-9
TAILGATE CYLINDER LOCK SWITCH -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8N-10
TAILGATE CYLINDER LOCK SWITCH -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 8N-9
TAILGATE CYLINDER LOCK SWITCH -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-10
TANK - DESCRIPTION, FUEL . . . . . . . . . . . . 14-24
TANK - INSTALLATION, FUEL . . . . . . . . . . . 14-27
TANK - OPERATION, FUEL . . . . . . . . . . . . . . 14-24
26 INDEX KJ
Description Group-Page Description Group-Page Description Group-Page
TANK - REMOVAL, FUEL . . . . . . . . . . . . . . . 14-25
TANK CHECK VALVE - DESCRIPTION,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
TANK CHECK VALVE - INSTALLATION,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
TANK CHECK VALVE - OPERATION, FUEL . . 14-28
TANK CHECK VALVE - REMOVAL, FUEL . . . 14-28
TANK SKID PLATE - INSTALLATION,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
TANK SKID PLATE - REMOVAL, FUEL . . . . . . 13-9
TASK MANAGER - DESCRIPTION . . . . . . . . 25-17
TASK MANAGER - OPERATION . . . . . . . . . . 25-21
TCM QUICK LEARN - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8E-21
TEMP INDICATOR - DESCRIPTION,
TRANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -33
TEMP INDICATOR - OPERATION, TRANS . . 8J -34
TEMP SENSOR - DESCRIPTION,
AMBIENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-9
TEMP SENSOR - OPERATION, AMBIENT . . . 8M-9
TEMPERATURE GAUGE - DESCRIPTION,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -18
TEMPERATURE GAUGE - OPERATION,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -18
TEMPERATURE SENSOR - DESCRIPTION,
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-24
TEMPERATURE SENSOR - DESCRIPTION,
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . 7-19
TEMPERATURE SENSOR - DESCRIPTION,
INTAKE AIR . . . . . . . . . . . . . . . . . . . . . . . . . 14-36
TEMPERATURE SENSOR - DESCRIPTION,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-170
TEMPERATURE SENSOR - DIAGNOSIS
AND TESTING, AMBIENT . . . . . . . . . . . . . . . 8M-9
TEMPERATURE SENSOR -
INSTALLATION, BATTERY . . . . . . . . . . . . . . 8F-24
TEMPERATURE SENSOR -
INSTALLATION, ENGINE COOLANT . . . . . . . . 7-21
TEMPERATURE SENSOR -
INSTALLATION, INTAKE AIR . . . . . . . . . . . . 14-38
TEMPERATURE SENSOR - OPERATION,
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-24
TEMPERATURE SENSOR - OPERATION,
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . 7-20
TEMPERATURE SENSOR - OPERATION,
INTAKE AIR . . . . . . . . . . . . . . . . . . . . . . . . . 14-36
TEMPERATURE SENSOR - OPERATION,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-170
TEMPERATURE SENSOR - REMOVAL,
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-24
TEMPERATURE SENSOR - REMOVAL,
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . 7-20
TEMPERATURE SENSOR - REMOVAL,
INTAKE AIR . . . . . . . . . . . . . . . . . . . . . . . . . 14-37
TEMPERATURE SENSOR CIRCUIT -
DIAGNOSIS AND TESTING, AMBIENT . . . . . 8M-9
TENSIONER - DESCRIPTION, SEAT BELT . . 8O-36
TENSIONER - OPERATION, SEAT BELT . . . . 8O-36
TERMINAL - INSTALLATION . . . . . . . . . 8W-01-14
TERMINAL - REMOVAL . . . . . . . . . . . . . 8W-01-14
TEST - DIAGNOSIS AND TESTING, FUEL
PRESSURE LEAK DOWN . . . . . . . . . . . . . . . . 14-3
TEST - DIAGNOSIS AND TESTING, FUEL
PUMP AMPERAGE. . . . . . . . . . . . . . . . . . . . 14-16
TEST - DIAGNOSIS AND TESTING, FUEL
PUMP CAPACITY . . . . . . . . . . . . . . . . . . . . . 14-15
TEST - DIAGNOSIS AND TESTING, FUEL
PUMP PRESSURE . . . . . . . . . . . . . . . . . . . . 14-15
TEST - DIAGNOSIS AND TESTING,
HYDRAULIC PRESSURE . . . . . . . . . . . . . . . 21-79
TEST - DIAGNOSIS AND TESTING, ROAD . . . 8P-2
TEST - STANDARD PROCEDURE,
BUILT-IN INDICATOR . . . . . . . . . . . . . . . . . . 8F-10
TEST - STANDARD PROCEDURE,
HYDROMETER . . . . . . . . . . . . . . . . . . . . . . . 8F-11
TEST - STANDARD PROCEDURE,
IGNITION-OFF DRAW. . . . . . . . . . . . . . . . . . 8F-14
TEST - STANDARD PROCEDURE, LOAD . . . 8F-12
TEST - STANDARD PROCEDURE,
OPEN-CIRCUIT VOLTAGE . . . . . . . . . . . . . . . 8F-12
TEST - STANDARD PROCEDURE,
VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . 8O-8
TEST MODE - DESCRIPTION, CIRCUIT
ACTUATION . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
TEST MODE - DESCRIPTION, STATE
DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
TESTER - STANDARD PROCEDURE,
USING MIDTRONICS ELECTRICAL . . . . . . . 8F-15
TETHER ANCHOR - DESCRIPTION, CHILD . 8O-13
TETHER ANCHOR - OPERATION, CHILD . . . 8O-13
THEFT SECURITY - DESCRIPTION,
VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-1
THEFT SECURITY - OPERATION, VEHICLE . . 8Q-3
THEFT SECURITY SYSTEM - DIAGNOSIS
AND TESTING, VEHICLE . . . . . . . . . . . . . . . . 8Q-6
THERMAL GUARD - DESCRIPTION . . . . . . . 8F-20
THERMAL GUARD - INSTALLATION . . . . . . 8F-20
THERMAL GUARD - OPERATION . . . . . . . . . 8F-20
THERMAL GUARD - REMOVAL . . . . . . . . . . 8F-20
THERMOSTAT - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
THERMOSTAT - OPERATION, ENGINE
COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
THREAD REPAIR - STANDARD
PROCEDURE, ALUMINUM . . . . . . . . . . . . . . 21-81
THREADED HOLE REPAIR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . Intro.-4
THREADS - STANDARD PROCEDURE,
REPAIR DAMAGED OR WORN . . . . . . . . . . . . 9-9
THROTTLE BODY - DESCRIPTION . . . . . . . . 14-43
THROTTLE BODY - INSTALLATION . . . . . . . 14-44
THROTTLE BODY - OPERATION . . . . . . . . . 14-43
THROTTLE BODY - REMOVAL . . . . . . . . . . . 14-43
THROTTLE CONTROL CABLE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-46
THROTTLE CONTROL CABLE - REMOVAL . . 14-45
THROTTLE POSITION SENSOR -
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . 14-47
THROTTLE POSITION SENSOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-48
THROTTLE POSITION SENSOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
THROTTLE POSITION SENSOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
TIE ROD END - INSTALLATION . . . . . . . . . . 19-16
TIE ROD END - REMOVAL . . . . . . . . . . . . . . 19-16
TIE ROD END REMOVAL TOOL, SPECIAL
TOOLS - OUTER . . . . . . . . . . . . . . . . . . . . . 19-15
TIME INDICATOR - DESCRIPTION, FULL . . . 8J -29
TIME INDICATOR - DESCRIPTION, PART . . 8J -29
TIME INDICATOR - OPERATION, FULL . . . . 8J -30
TIME INDICATOR - OPERATION, PART . . . . 8J -29
TIMING - DESCRIPTION, VALVE . . . . . . . . . . 9-71
TIMING - OPERATION, VALVE . . . . . . . . . . . . 9-71
TIMING - SPECIFICATIONS, IGNITION . . . . . . 8I-2
TIMING BELT / CHAIN COVER(S) -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 9-76
TIMING BELT / CHAIN COVER(S) -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-74
TIMING CHAIN WEAR, STANDARD
PROCEDURE - MEASURING . . . . . . . . . . . . . 9-71
TIRE - INSTALLATION, SPARE . . . . . . . . . . . 22-9
TIRE - REMOVAL, SPARE . . . . . . . . . . . . . . . 22-8
TIRE INFLATION - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-7
TIRE NOISE OR VIBRATION - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 22-8
TIRE ROTATION - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 22-2
TIRE &TEMPORARY - DESCRIPTION,
SPARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-6
TIRE WEAR PATTERNS - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 22-8
TIRES - DESCRIPTION . . . . . . . . . . . . . . . . . 22-6
TIRES - DESCRIPTION, RADIAL-PLY . . . . . . . 22-6
TIRES - DESCRIPTION, REPLACEMENT . . . . 22-7
TIRES AND WHEEL RUNOUT -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 22-1
TO GROUND - STANDARD PROCEDURE,
TESTING FOR A SHORT . . . . . . . . . . . . . 8W-01-9
TO GROUND ON FUSES POWERING
SEVERAL LOADS - STANDARD
PROCEDURE, TESTING FOR A SHORT . . 8W-01-9
TO USE WIRING DIAGRAMS -
DESCRIPTION, HOW. . . . . . . . . . . . . . . . 8W-01-1
TOE ADJ USTMENT - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
TOE ADJ USTMENT - STANDARD
PROCEDURE, CAMBER, CASTER . . . . . . . . . . 2-5
TOOL, SPECIAL TOOLS - OUTER TIE
ROD END REMOVAL . . . . . . . . . . . . . . . . . . 19-15
TOOLS - 3.7L ENGINE, SPECIAL . . . . . . . . . . 9-15
TOOLS - 8 1/4 AXLE, SPECIAL . . . . . . . . . . . 3-98
TOOLS - BASE BRAKES, SPECIAL . . . . . . . . . 5-7
TOOLS - BODY, SPECIAL . . . . . . . . . . . . . . . . 23-5
TOOLS - COOLING, SPECIAL . . . . . . . . . . . . . 7-14
TOOLS - FRONT AXLE, SPECIAL . . . . . . . . . . 3-34
TOOLS - FRONT SUSPENSION, SPECIAL . . . . 2-8
TOOLS - FUEL SYSTEM, SPECIAL . . . . . . . . 14-6
TOOLS - OUTER TIE ROD END REMOVAL
TOOL, SPECIAL . . . . . . . . . . . . . . . . . . . . . . 19-15
TOOLS - POWER DISTRIBUTION
SYSTEMS, SPECIAL . . . . . . . . . . . . . . . . 8W-97-2
TOOLS - POWER STEERING PUMP,
SPECIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20
TOOLS - REAR AXLE, SPECIAL . . . . . . . . . . . 3-63
TOOLS - RFE TRANSMISSION, SPECIAL . . 21-120
TOOLS - STEERING COLUMN, SPECIAL . . . . 19-8
TOOLS - WIRING/TERMINAL, SPECIAL . 8W-01-10
TOOLS, BATTERY SYSTEM - SPECIAL . . . . . 8F-7
TOOLS, SPECIFICATIONS - SPECIAL . . . . 3-12,3-6
TOOLS, SPECIFICATIONS - SPECIAL . . . . . . 8F-24
TOP COVER - INSTALLATION,
INSTRUMENT PANEL. . . . . . . . . . . . . . . . . 23-153
TOP COVER - REMOVAL, INSTRUMENT
PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-152
TORQUE - SPECIFICATIONS . . . . . . . . . . . . . 13-6
TORQUE CHART, SPECIFICATIONS . . 19-15,19-19,
19-8
TORQUE CHART, SPECIFICATIONS . . . . . 2-17,2-8
TORQUE CONVERTER - DESCRIPTION . . . 21-162
TORQUE CONVERTER - INSTALLATION . . . 21-167
TORQUE CONVERTER - OPERATION . . . . . 21-166
TORQUE CONVERTER - REMOVAL . . . . . . 21-167
TORQUE, EXCEPT DIESEL . . . . . . . . . . . . . . 8F-23
TORQUE, GAS POWERED . . . . . . . . . . . . . . 8F-38
TORQUE, IGNITION SYSTEM . . . . . . . . . . . . . 8I-3
TORQUE REFERENCES - DESCRIPTION . . Intro.-7
TORQUE, SPECIFICATIONS . . . . . . . . . . . . . . . 5-7
TORQUE, SPECIFICATIONS . . . . . . . . . . . . . . 7-13
TORQUE, SPECIFICATIONS . . . . . . . . . . . . . 25-26
TORQUE, SPECIFICATIONS . . . . . . . . . . . . . . 9-12
TORQUE, SPECIFICATIONS . . . . . . . . . . . . . . 14-5
TORQUE, SPEED CONTROL . . . . . . . . . . . . . 8P-2
TOUCH-UP - DESCRIPTION, PAINT . . . . . . 23-163
TOW CONNECTOR - INSTALLATION,
TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-61
TOW CONNECTOR - REMOVAL, TRAILER . . 8L-61
TOW HOOK - INSTALLATION, FRONT . . . . . . 13-8
TOW HOOK - INSTALLATION, REAR . . . . . . . 13-8
TOW HOOK - REMOVAL, FRONT . . . . . . . . . . 13-8
TOW HOOK - REMOVAL, REAR . . . . . . . . . . . 13-8
TOW RELAY - DESCRIPTION, TRAILER . . . . 8L-61
TOW RELAY - DIAGNOSIS AND TESTING,
TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-62
TOW RELAY - INSTALLATION, TRAILER . . . 8L-64
TOW RELAY - OPERATION, TRAILER . . . . . 8L-62
TOW RELAY - REMOVAL, TRAILER . . . . . . . 8L-63
TOW WIRING - DESCRIPTION, TRAILER . . 8L-64
TOWING - STANDARD PROCEDURE . . . . . . . . 0-6
TRACK - DESCRIPTION, SEAT . . . . . . . . . . 8N-15
TRACK - DIAGNOSIS AND TESTING,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-16
TRACK - INSTALLATION, SEAT . . . . . . . . . 23-168
TRACK - INSTALLATION, SEAT . . . . . . . . . . 8N-16
TRACK - OPERATION, SEAT . . . . . . . . . . . . 8N-15
TRACK - REMOVAL, SEAT . . . . . . . . . . . . . 23-168
TRACK - REMOVAL, SEAT . . . . . . . . . . . . . . 8N-16
TRAC-LOK - ASSEMBLY, DIFFERENTIAL . . . 3-109,
3-77
TRAC-LOK - CLEANING, DIFFERENTIAL . . . 3-109,
3-77
TRAC-LOK - DISASSEMBLY,
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . 3-107,3-75
TRAC-LOK - INSPECTION, DIFFERENTIAL . 3-109,
3-77
TRAC-LOKா - DIAGNOSIS AND TESTING . . 3-106,
3-74
TRAILER HITCH - INSTALLATION . . . . . . . . . 13-9
TRAILER HITCH - REMOVAL . . . . . . . . . . . . . 13-9
TRAILER TOW CONNECTOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-61
TRAILER TOW CONNECTOR - REMOVAL . . 8L-61
TRAILER TOW RELAY - DESCRIPTION . . . . 8L-61
TRAILER TOW RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-62
TRAILER TOW RELAY - INSTALLATION . . . 8L-64
TRAILER TOW RELAY - OPERATION . . . . . . 8L-62
TRAILER TOW RELAY - REMOVAL . . . . . . . 8L-63
TRAILER TOW WIRING - DESCRIPTION . . . 8L-64
TRANS COOLER - DESCRIPTION . . . . . . . . . 7-32
TRANS TEMP INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -33
TRANS TEMP INDICATOR - OPERATION . . . 8J -34
KJ INDEX 27
Description Group-Page Description Group-Page Description Group-Page
TRANSCEIVER MODULE - DESCRIPTION,
INTRUSION . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-14
TRANSCEIVER MODULE -
INSTALLATION, INTRUSION . . . . . . . . . . . . 8Q-16
TRANSCEIVER MODULE - OPERATION,
INTRUSION . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-15
TRANSCEIVER MODULE - REMOVAL,
INTRUSION . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-15
TRANSFER CASE - NV231 - ASSEMBLY . . 21-194
TRANSFER CASE - NV231 - CLEANING . . 21-190
TRANSFER CASE - NV231 -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
TRANSFER CASE - NV231 -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-178
TRANSFER CASE - NV231 - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 21-180
TRANSFER CASE - NV231 -
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-182
TRANSFER CASE - NV231 - INSPECTION . 21-190
TRANSFER CASE - NV231 -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-205
TRANSFER CASE - NV231 - OPERATION . 21-179
TRANSFER CASE - NV231 - REMOVAL . . . 21-181
TRANSFER CASE - NV242 - ASSEMBLY . . 21-230
TRANSFER CASE - NV242 - CLEANING . . 21-227
TRANSFER CASE - NV242 -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
TRANSFER CASE - NV242 -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-215
TRANSFER CASE - NV242 - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 21-216
TRANSFER CASE - NV242 -
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-218
TRANSFER CASE - NV242 - INSPECTION . 21-228
TRANSFER CASE - NV242 -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-243
TRANSFER CASE - NV242 - OPERATION . 21-215
TRANSFER CASE - NV242 - REMOVAL . . . 21-217
TRANSFER CASE, NV231 . . . . . . . . . . . . . 21-206
TRANSFER CASE, NV242 . . . . . . . . . . . . . 21-244
TRANSFER CASE SKID PLATE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 13-7
TRANSFER CASE SKID PLATE -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
TRANSFER CASE, SPECIFICATIONS -
NV242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-244
TRANSMISSION - 45RFE -
DESCRIPTION, AUTOMATIC. . . . . . . . . . . . . 21-76
TRANSMISSION - 45RFE - OPERATION,
AUTOMATIC. . . . . . . . . . . . . . . . . . . . . . . . . 21-77
TRANSMISSION - DESCRIPTION,
MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
TRANSMISSION - DIAGNOSIS AND
TESTING, AUTOMATIC. . . . . . . . . . . . . . . . . 21-77
TRANSMISSION - DIAGNOSIS AND
TESTING, MANUAL . . . . . . . . . . . . . . . 21-2,21-33
TRANSMISSION CLUTCH OPERATION -
DIAGNOSIS AND TESTING, AIR
CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . 21-80
TRANSMISSION CONTROL MODULE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8E-18
TRANSMISSION CONTROL MODULE -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8E-18
TRANSMISSION CONTROL RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-168
TRANSMISSION CONTROL RELAY -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 21-168
TRANSMISSION FILL - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 21-128
TRANSMISSION FLUID - DESCRIPTION,
AUTOMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
TRANSMISSION FLUID - OPERATION,
AUTOMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
TRANSMISSION RANGE INDICATOR
ILLUMINATION BULB - INSTALLATION . . . . 8L-83
TRANSMISSION RANGE INDICATOR
ILLUMINATION BULB - REMOVAL. . . . . . . . 8L-82
TRANSMISSION RANGE SENSOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-168
TRANSMISSION RANGE SENSOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 21-168
TRANSMISSION SHIFT INTERLOCK
SYSTEM - DESCRIPTION, BRAKE . . . . . . . 21-124
TRANSMISSION SHIFT INTERLOCK
SYSTEM - DIAGNOSIS AND TESTING,
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-125
TRANSMISSION SHIFT INTERLOCK
SYSTEM - OPERATION, BRAKE. . . . . . . . . 21-125
TRANSMISSION SOLENOID/TRS
ASSEMBLY - DESCRIPTION. . . . . . . . . . . . 21-169
TRANSMISSION SOLENOID/TRS
ASSEMBLY - INSTALLATION . . . . . . . . . . . 21-170
TRANSMISSION SOLENOID/TRS
ASSEMBLY - OPERATION . . . . . . . . . . . . . 21-169
TRANSMISSION SOLENOID/TRS
ASSEMBLY - REMOVAL . . . . . . . . . . . . . . . 21-170
TRANSMISSION, SPECIAL TOOLS - RFE . . 21-120
TRANSMISSION, SPECIFICATIONS . . . . . . 21-119
TRANSMISSION TEMPERATURE SENSOR
- DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 21-170
TRANSMISSION TEMPERATURE SENSOR
- OPERATION. . . . . . . . . . . . . . . . . . . . . . . 21-170
TRANSMITTER - DESCRIPTION,
UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . 8M-8
TRANSMITTER - DIAGNOSIS AND
TESTING, REMOTE KEYLESS ENTRY . . . . . . 8N-8
TRANSMITTER - DIAGNOSIS AND
TESTING, UNIVERSAL . . . . . . . . . . . . . . . . . 8M-8
TRANSMITTER - OPERATION,
UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . 8M-8
TRANSMITTER - SPECIFICATIONS,
REMOTE KEYLESS ENTRY . . . . . . . . . . . . . . 8N-9
TRANSMITTER BATTERIES - STANDARD
PROCEDURE, RKE. . . . . . . . . . . . . . . . . . . . . 8N-8
TRANSMITTER CODES - STANDARD
PROCEDURE, ERASING . . . . . . . . . . . . . . . . 8M-8
TRANSMITTER CODES - STANDARD
PROCEDURE, SETTING. . . . . . . . . . . . . . . . . 8M-9
TRANSMITTER CUSTOMER
PREFERENCES - STANDARD
PROCEDURE, RKE. . . . . . . . . . . . . . . . . . . . . 8N-8
TRANSMITTER PROGRAMING -
STANDARD PROCEDURE, RKE . . . . . . . . . . . 8N-9
TRANSPONDER KEY - DESCRIPTION . . . . . 8Q-18
TRANSPONDER KEY - OPERATION . . . . . . . 8Q-18
TRANSPONDER PROGRAMMING -
STANDARD PROCEDURE, SENTRY KEY . . . . 8Q-8
TRAY - DESCRIPTION, BATTERY . . . . . . . . . 8F-21
TRAY - INSTALLATION, BATTERY . . . . . . . . 8F-21
TRAY - OPERATION, BATTERY . . . . . . . . . . 8F-21
TRAY - REMOVAL, BATTERY . . . . . . . . . . . . 8F-21
TREAD WEAR INDICATORS - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 22-8
TRIM - INSTALLATION, B-PILLAR
LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-157
TRIM - INSTALLATION, B-PILLAR UPPER . 23-158
TRIM - REMOVAL, B-PILLAR LOWER . . . . 23-157
TRIM - REMOVAL, B-PILLAR UPPER . . . . 23-157
TRIM AND GRAB HANDLE -
INSTALLATION, A-PILLAR . . . . . . . . . . . . . 23-156
TRIM AND GRAB HANDLE - REMOVAL,
A-PILLAR . . . . . . . . . . . . . . . . . . . . . . . . . . 23-156
TRIM COVER - INSTALLATION, COWL . . . 23-157
TRIM COVER - REMOVAL, COWL . . . . . . . 23-157
TRIM LACE - INSTALLATION, OPENING . . 23-180
TRIM LACE - REMOVAL, OPENING . . . . . . 23-180
TRIM PANEL - INSTALLATION . . . 23-126,23-132,
23-138
TRIM PANEL - INSTALLATION, QUARTER . 23-159
TRIM PANEL - REMOVAL . 23-125,23-132,23-138
TRIM PANEL - REMOVAL, QUARTER . . . . 23-159
TRIP DEFINITION - DESCRIPTION . . . . . . . . 25-19
TROUBLE CODES - DESCRIPTION,
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
TUBE - DESCRIPTION, A/C ORIFICE . . . . . . 24-50
TUBE - INSTALLATION, A/C ORIFICE . . . . . . 24-50
TUBE - INSTALLATION, DRAIN . . . . . . . . . 23-181
TUBE - OPERATION, A/C ORIFICE . . . . . . . . 24-50
TUBE - REMOVAL, A/C ORIFICE . . . . . . . . . 24-50
TUBE - REMOVAL, DRAIN . . . . . . . . . . . . . 23-180
TURN SIGNAL INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -34
TURN SIGNAL INDICATOR - OPERATION . . 8J -34
TURNING LOOP ADJ USTER -
INSTALLATION, SEAT BELT . . . . . . . . . . . . . 8O-38
TURNING LOOP ADJ USTER - REMOVAL,
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-37
UNIT - ADJ USTMENT, FRONT FOG LAMP . . 8L-25
UNIT - ADJ USTMENT, HEADLAMP . . . . . . . 8L-42
UNIT - DIAGNOSIS AND TESTING, FUEL
LEVEL SENDING . . . . . . . . . . . . . . . . . . . . . . 14-9
UNIT - INSTALLATION, ASH RECEIVER
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-72
UNIT - INSTALLATION, CARGO LAMP . . . . . 8L-74
UNIT - INSTALLATION, CENTER HIGH
MOUNTED STOP LAMP . . . . . . . . . . . . . . . . 8L-19
UNIT - INSTALLATION, COURTESY LAMP . . 8L-77
UNIT - INSTALLATION, FRONT FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-25
UNIT - INSTALLATION, FRONT LAMP . . . . . 8L-28
UNIT - INSTALLATION, HEADLAMP . . . . . . . 8L-42
UNIT - INSTALLATION, LICENSE PLATE
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-46
UNIT - INSTALLATION, READING LAMP . . . 8L-81
UNIT - INSTALLATION, REAR LAMP . . . . . . 8L-60
UNIT - INSTALLATION, REPEATER LAMP . . 8L-61
UNIT - REMOVAL, ASH RECEIVER LAMP . . 8L-72
UNIT - REMOVAL, CARGO LAMP . . . . . . . . 8L-74
UNIT - REMOVAL, CENTER HIGH
MOUNTED STOP LAMP . . . . . . . . . . . . . . . . 8L-19
UNIT - REMOVAL, COURTESY LAMP . . . . . 8L-76
UNIT - REMOVAL, FRONT FOG LAMP . . . . . 8L-25
UNIT - REMOVAL, FRONT LAMP . . . . . . . . . 8L-27
UNIT - REMOVAL, HEADLAMP . . . . . . . . . . 8L-41
UNIT - REMOVAL, LICENSE PLATE LAMP . . 8L-45
UNIT - REMOVAL, READING LAMP . . . . . . . 8L-81
UNIT - REMOVAL, REAR LAMP . . . . . . . . . . 8L-59
UNIT - REMOVAL, REPEATER LAMP . . . . . . 8L-60
UNIT / SENSOR - DESCRIPTION, FUEL
LEVEL SENDING . . . . . . . . . . . . . . . . . . . . . . 14-9
UNIT / SENSOR - INSTALLATION, FUEL
LEVEL SENDING . . . . . . . . . . . . . . . . . . . . . 14-10
UNIT / SENSOR - OPERATION, FUEL
LEVEL SENDING . . . . . . . . . . . . . . . . . . . . . . 14-9
UNIT / SENSOR - REMOVAL, FUEL
LEVEL SENDING . . . . . . . . . . . . . . . . . . . . . . 14-9
UNIVERSAL J OINTS - ASSEMBLY,
SINGLE CARDAN. . . . . . . . . . . . . . . . . . . . . . . 3-9
UNIVERSAL J OINTS - DISASSEMBLY,
SINGLE CARDAN. . . . . . . . . . . . . . . . . . . . . . . 3-8
UNIVERSAL TRANSMITTER -
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 8M-8
UNIVERSAL TRANSMITTER - DIAGNOSIS
AND TESTING. . . . . . . . . . . . . . . . . . . . . . . . 8M-8
UNIVERSAL TRANSMITTER - OPERATION . . 8M-8
UNLOCK SWITCH - INSTALLATION,
DOOR LOCK . . . . . . . . . . . . . . . . . . . . . . . . . 8N-5
UNLOCK SWITCH - REMOVAL, DOOR
LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-4
UPPER BALL J OINT - INSTALLATION . . . . . . 2-20
UPPER BALL J OINT - REMOVAL . . . . . . . . . . 2-20
UPPER CONTROL ARM - INSTALLATION . . . 2-21
UPPER CONTROL ARM - REMOVAL . . . . . . . 2-20
UPPER SUSPENSION ARM, BUSHINGS,
AND BALL J OINT - DESCRIPTION. . . . . . . . . 2-20
UPPER SUSPENSION ARM, BUSHINGS,
AND BALL J OINT - OPERATION . . . . . . . . . . 2-20
UPPER TRIM - INSTALLATION, B-PILLAR . 23-158
UPPER TRIM - REMOVAL, B-PILLAR . . . . 23-157
USE WIRING DIAGRAMS -
DESCRIPTION, HOW TO . . . . . . . . . . . . . 8W-01-1
USING MIDTRONICS ELECTRICAL
TESTER - STANDARD PROCEDURE. . . . . . . 8F-15
V-6 - ENGINE FIRING ORDER, 3.7L . . . . . . . . 8I-2
V-6 - IGNITION COIL RESISTANCE, 3.7L . . . . 8I-3
VACUUM CHECK VALVE - DESCRIPTION . . 24-28
VACUUM CHECK VALVE - INSTALLATION . . 24-28
VACUUM CHECK VALVE - OPERATION . . . . 24-28
VACUUM CHECK VALVE - REMOVAL . . . . . . 24-28
VACUUM LINES - DESCRIPTION . . . . . . . . . 25-33
VACUUM RESERVOIR - DESCRIPTION . . . . . 8P-7
VACUUM RESERVOIR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-7
VACUUM RESERVOIR - INSTALLATION . . . . 8P-8
VACUUM RESERVOIR - OPERATION . . . . . . . 8P-7
VACUUM RESERVOIR - REMOVAL . . . . . . . . 8P-7
VACUUM SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-6
VALUE - DESCRIPTION, LOAD . . . . . . . . . . 25-20
VALVE - DESCRIPTION, FLOW
MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . 14-6
VALVE - DESCRIPTION, FRONT CHECK . . . . 8R-8
VALVE - DESCRIPTION, FUEL TANK
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
VALVE - DESCRIPTION, HIGH PRESSURE
RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-42
VALVE - DESCRIPTION, PCV . . . . . . . . . . . . 25-29
VALVE - DESCRIPTION, REAR CHECK . . . . 8R-34
VALVE - DESCRIPTION, SOLENOID
SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-161
VALVE - DESCRIPTION, VACUUM CHECK . . 24-28
VALVE - DIAGNOSIS AND TESTING, PCV . . 25-31
VALVE - DIAGNOSIS AND TESTING,
PROPORTIONING . . . . . . . . . . . . . . . . . . . . . 5-20
28 INDEX KJ
Description Group-Page Description Group-Page Description Group-Page
VALVE - INSTALLATION, FLOW
MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . 14-7
VALVE - INSTALLATION, FRONT CHECK . . . . 8R-9
VALVE - INSTALLATION, FUEL TANK
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
VALVE - INSTALLATION, PCV . . . . . . . . . . . 25-32
VALVE - INSTALLATION, REAR CHECK . . . . 8R-35
VALVE - INSTALLATION, VACUUM CHECK . 24-28
VALVE - OPERATION, FLOW
MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . 14-6
VALVE - OPERATION, FRONT CHECK . . . . . . 8R-9
VALVE - OPERATION, FUEL TANK CHECK . . 14-28
VALVE - OPERATION, HIGH PRESSURE
RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-42
VALVE - OPERATION, PCV . . . . . . . . . . . . . . 25-31
VALVE - OPERATION, REAR CHECK . . . . . . 8R-34
VALVE - OPERATION, SOLENOID SWITCH . 21-161
VALVE - OPERATION, VACUUM CHECK . . . . 24-28
VALVE - REMOVAL, FLOW
MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . 14-6
VALVE - REMOVAL, FRONT CHECK . . . . . . . 8R-9
VALVE - REMOVAL, FUEL TANK CHECK . . . 14-28
VALVE - REMOVAL, PCV . . . . . . . . . . . . . . . 25-32
VALVE - REMOVAL, REAR CHECK . . . . . . . 8R-34
VALVE - REMOVAL, VACUUM CHECK . . . . . 24-28
VALVE BODY - ASSEMBLY . . . . . . . . . . . . 21-176
VALVE BODY - CLEANING . . . . . . . . . . . . . 21-175
VALVE BODY - DESCRIPTION. . . . . . . . . . . . 21-171
VALVE BODY - DISASSEMBLY . . . . . . . . . . 21-173
VALVE BODY - INSPECTION . . . . . . . . . . . 21-175
VALVE BODY - INSTALLATION . . . . . . . . . . 21-177
VALVE BODY - OPERATION . . . . . . . . . . . . 21-171
VALVE BODY - REMOVAL . . . . . . . . . . . . . 21-172
VALVE GUIDE SEALS - DESCRIPTION . . 9-29,9-38
VALVE GUIDES - DESCRIPTION . . . . . . 9-19,9-30
VALVE SPRINGS - DESCRIPTION . . . . . 9-29,9-38
VALVE SPRINGS - INSTALLATION . . . . . 9-29,9-38
VALVE SPRINGS - REMOVAL . . . . . . . . 9-29,9-38
VALVE TIMING - DESCRIPTION . . . . . . . . . . . 9-71
VALVE TIMING - OPERATION . . . . . . . . . . . . 9-71
VALVES & SEATS - DESCRIPTION,
INTAKE/EXHAUST . . . . . . . . . . . . . . . . . . . . . 9-26
VALVES & SEATS - INSTALLATION,
INTAKE/EXHAUST . . . . . . . . . . . . . . . . . 9-28,9-36
VALVES & SEATS - REMOVAL,
INTAKE/EXHAUST . . . . . . . . . . . . . . . . . 9-27,9-35
VANITY LAMP BULB - INSTALLATION . . . . . 8L-84
VANITY LAMP BULB - REMOVAL . . . . . . . . 8L-83
VAPOR CANISTER - DESCRIPTION . . . . . . . 25-33
VAPOR CANISTER - INSTALLATION . . . . . . 25-33
VAPOR CANISTER - OPERATION . . . . . . . . . 25-33
VAPOR CANISTER - REMOVAL . . . . . . . . . . 25-33
VARIATION ADJ USTMENT - STANDARD
PROCEDURE, COMPASS . . . . . . . . . . . . . . . 8M-3
VEHICLE EMISSION CONTROL
INFORMATION (VECI) LABEL -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . Intro.-8
VEHICLE IDENTIFICATION NUMBER -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . Intro.-8
VEHICLE SAFETY CERTIFICATION LABEL
- DESCRIPTION. . . . . . . . . . . . . . . . . . . . . Intro.-9
VEHICLE THEFT SECURITY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8Q-1
VEHICLE THEFT SECURITY - OPERATION . . 8Q-3
VEHICLE THEFT SECURITY SYSTEM -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8Q-6
VERIFICATION TEST - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8O-8
VIBRATION - DIAGNOSIS AND TESTING,
TIRE NOISE OR . . . . . . . . . . . . . . . . . . . . . . . 22-8
VIBRATION DAMPER - INSTALLATION . . . . . 9-55
VIBRATION DAMPER - REMOVAL . . . . . . . . . 9-54
VIEW MIRROR - INSTALLATION, SIDE . . . 23-145
VIEW MIRROR - REMOVAL, REAR . . . . . . 23-161
VIEW MIRROR - REMOVAL, SIDE . . . . . . . 23-145
VISCOUS - CLEANING, RADIATOR - FAN . . . 7-29
VISCOUS - DESCRIPTION, RADIATOR -
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
VISCOUS - INSPECTION, RADIATOR -
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
VISCOUS - INSTALLATION, RADIATOR -
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
VISCOUS - OPERATION, RADIATOR -
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
VISCOUS - REMOVAL, RADIATOR - FAN . . . . 7-28
VISCOUS FAN DRIVE - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
VISOR - INSTALLATION, SUN . . . . . . . . . . 23-160
VISOR - REMOVAL, SUN . . . . . . . . . . . . . . 23-160
VISOR SUPPORT - INSTALLATION, SUN . . 23-160
VISOR SUPPORT - REMOVAL, SUN . . . . . 23-160
VOLT SUPPLIES - DESCRIPTION, 5 . . . . . . 8E-13
VOLT SUPPLIES - OPERATION, 5 . . . . . . . . 8E-15
VOLTAGE DROP - STANDARD
PROCEDURE, TESTING FOR A . . . . . . . 8W-01-10
VOLTAGE POTENTIAL - STANDARD
PROCEDURE, TESTING OF . . . . . . . . . . . 8W-01-9
VOLTAGE REGULATOR - DESCRIPTION . . . . 8F-31
VOLTAGE REGULATOR - OPERATION . . . . . 8F-31
VOLTAGE TEST - STANDARD
PROCEDURE, OPEN-CIRCUIT . . . . . . . . . . . 8F-12
VOLUME CHECK - STANDARD
PROCEDURE, OIL PUMP . . . . . . . . . . . . . . 21-148
WAIT-TO-START INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -35
WAIT-TO-START INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -35
WARNING - INSTALLATION . . . . . . . . . . . . 23-173
WARNING - REMOVAL . . . . . . . . . . . . . . . 23-173
WARNING - SAFETY PRECAUTIONS AND
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1
WARNING - SERVICE WARNINGS . . . . . . . . 24-39
WARNING - WINDSHIELD SAFETY
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . 23-173
WARNING, BRAKES - BASE . . . . . . . . . . . . . . 5-2
WARNING, CLUTCH . . . . . . . . . . . . . . . . . . . . . 6-2
WARNING, FRONT . . . . . . . . . . . . . . . . . . . . . . 2-7
WARNING, REAR . . . . . . . . . . . . . . . . . . . . . . 2-16
WARNING, RESTRAINT SYSTEM . . . . . . . . . 8O-5
WARNING SYSTEM - DESCRIPTION,
CHIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-1
WARNING SYSTEM - DIAGNOSIS AND
TESTING, CHIME. . . . . . . . . . . . . . . . . . . . . . 8B-6
WARNING SYSTEM - OPERATION,
CHIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-2
WARNINGS, GENERAL . . . . . . . . . . . . . . 8W-01-7
WARNINGS, WARNING - SAFETY
PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . 23-1
WARNINGS, WARNING - SERVICE . . . . . . . 24-39
WASHER FLUID INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -35
WASHER FLUID INDICATOR -
DIAGNOSIS AND TESTING. . . . . . . . . . . . . . 8J -36
WASHER FLUID INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -36
WASHER FLUID LEVEL SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-17
WASHER FLUID LEVEL SWITCH -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8R-18
WASHER FLUID LEVEL SWITCH -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
WASHER FLUID LEVEL SWITCH -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
WASHER HOSES/TUBES - DESCRIPTION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-10
WASHER HOSES/TUBES - DESCRIPTION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-35
WASHER HOSES/TUBES - OPERATION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-10
WASHER HOSES/TUBES - OPERATION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-36
WASHER NOZZLE - DESCRIPTION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-11
WASHER NOZZLE - DESCRIPTION, REAR . 8R-36
WASHER NOZZLE - INSTALLATION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-11
WASHER NOZZLE - INSTALLATION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-37
WASHER NOZZLE - OPERATION, FRONT . . 8R-11
WASHER NOZZLE - OPERATION, REAR . . . 8R-36
WASHER NOZZLE - REMOVAL, FRONT . . . . 8R-11
WASHER NOZZLE - REMOVAL, REAR . . . . 8R-36
WASHER PUMP/MOTOR - DESCRIPTION . . 8R-18
WASHER PUMP/MOTOR - INSTALLATION . 8R-20
WASHER PUMP/MOTOR - OPERATION . . . 8R-19
WASHER PUMP/MOTOR - REMOVAL . . . . . 8R-19
WASHER RESERVOIR - DESCRIPTION . . . . 8R-21
WASHER RESERVOIR - INSTALLATION . . . 8R-22
WASHER RESERVOIR - OPERATION . . . . . . 8R-21
WASHER RESERVOIR - REMOVAL . . . . . . . 8R-21
WASHER SYSTEM - CLEANING, FRONT
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-7
WASHER SYSTEM - CLEANING, REAR
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-32
WASHER SYSTEM - DIAGNOSIS AND
TESTING, FRONT WIPER . . . . . . . . . . . . . . . 8R-6
WASHER SYSTEM - DIAGNOSIS AND
TESTING, REAR WIPER . . . . . . . . . . . . . . . 8R-30
WASHER SYSTEM - INSPECTION, FRONT
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-7
WASHER SYSTEM - INSPECTION, REAR
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-33
WATER DRAINAGE AND WIND NOISE
DIAGNOSIS, DIAGNOSIS AND TESTING . . 23-176
WATER LEAKS - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2
WATER PUMP - DESCRIPTION . . . . . . . . . . . 7-29
WATER PUMP - OPERATION . . . . . . . . . . . . . 7-30
WATERDAM - INSTALLATION . . . . 23-126,23-133
WATERDAM - REMOVAL . . . . . . . . 23-126,23-133
WATER-IN-FUEL INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -37
WATER-IN-FUEL INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -37
WEAR INDICATORS - DIAGNOSIS AND
TESTING, TREAD. . . . . . . . . . . . . . . . . . . . . . 22-8
WEAR PATTERNS - DIAGNOSIS AND
TESTING, TIRE . . . . . . . . . . . . . . . . . . . . . . . 22-8
WEAR, STANDARD PROCEDURE -
MEASURING TIMING CHAIN . . . . . . . . . . . . . 9-71
WEATHERSTRIP - INSTALLATION, COWL . 23-185
WEATHERSTRIP - INSTALLATION, DOOR
LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
WEATHERSTRIP - INSTALLATION, DOOR
PRIMARY . . . . . . . . . . . . . . . . . . . . . . . . . . 23-185
WEATHERSTRIP - INSTALLATION,
SWING GATE BELTLINE. . . . . . . . . . . . . . . 23-186
WEATHERSTRIP - INSTALLATION,
SWING GATE OPENING . . . . . . . . . . . . . . . 23-186
WEATHERSTRIP - REMOVAL, COWL . . . . . 23-185
WEATHERSTRIP - REMOVAL, DOOR
LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
WEATHERSTRIP - REMOVAL, DOOR
PRIMARY . . . . . . . . . . . . . . . . . . . . . . . . . . 23-185
WEATHERSTRIP - REMOVAL, SWING
GATE BELTLINE . . . . . . . . . . . . . . . . . . . . . 23-186
WEATHERSTRIP - REMOVAL, SWING
GATE OPENING . . . . . . . . . . . . . . . . . . . . . 23-186
WEATHERSTRIP/RETAINER -
INSTALLATION, SIDE RAIL . . . . . . . . . . . . 23-186
WEATHERSTRIP/RETAINER -
INSTALLATION, WINDSHIELD A-PILLAR . . 23-187
WEATHERSTRIP/RETAINER - REMOVAL,
SIDE RAIL . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
WEATHERSTRIP/RETAINER - REMOVAL,
WINDSHIELD A-PILLAR. . . . . . . . . . . . . . . 23-186
WELD AND STRUCTURAL ADHESIVE
LOCATIONS - SPECIFICATIONS . . . . . . . . . . . 23-9
WHEEL - INSTALLATION, STEERING . . . . . . 19-12
WHEEL - REMOVAL, STEERING . . . . . . . . . 19-12
WHEEL ALIGNMENT - DESCRIPTION . . . . . . . 2-3
WHEEL ALIGNMENT - OPERATION . . . . . . . . . 2-3
WHEEL BALANCING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 22-4
WHEEL CYLINDERS - ASSEMBLY . . . . . . . . . 5-29
WHEEL CYLINDERS - CLEANING . . . . . . . . . 5-28
WHEEL CYLINDERS - DISASSEMBLY . . . . . . 5-28
WHEEL CYLINDERS - INSPECTION . . . . . . . . 5-29
WHEEL CYLINDERS - INSTALLATION . . . . . . 5-29
WHEEL CYLINDERS - REMOVAL . . . . . . . . . . 5-28
WHEEL MOUNTING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 22-10
WHEEL OPENING FLARE MOLDINGS -
INSTALLATION, FRONT . . . . . . . . . . . . . . . 23-145
WHEEL OPENING FLARE MOLDINGS -
INSTALLATION, REAR . . . . . . . . . . . . . . . . 23-145
WHEEL OPENING FLARE MOLDINGS -
REMOVAL, FRONT . . . . . . . . . . . . . . . . . . . 23-145
WHEEL OPENING FLARE MOLDINGS -
REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . 23-145
WHEEL REPLACEMENT - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 22-10
WHEEL RUNOUT - DIAGNOSIS AND
TESTING, TIRES . . . . . . . . . . . . . . . . . . . . . . 22-1
WHEEL SPEED SENSOR -
INSTALLATION, FRONT . . . . . . . . . . . . . . . . . 5-34
WHEEL SPEED SENSOR -
INSTALLATION, REAR . . . . . . . . . . . . . . . . . . 5-35
WHEEL SPEED SENSOR - REMOVAL,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
WHEEL SPEED SENSOR - REMOVAL,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
WHEELHOUSE SPLASH SHIELD -
INSTALLATION, FRONT . . . . . . . . . . . . . . . 23-143
KJ INDEX 29
Description Group-Page Description Group-Page Description Group-Page
WHEELHOUSE SPLASH SHIELD -
INSTALLATION, REAR . . . . . . . . . . . . . . . . 23-144
WHEELHOUSE SPLASH SHIELD -
REMOVAL, FRONT . . . . . . . . . . . . . . . . . . . 23-143
WHEELHOUSE SPLASH SHIELD -
REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . 23-144
WHEELS - DESCRIPTION . . . . . . . . . . . . . . . 22-9
WHEELS - DIAGNOSIS AND TESTING . . . . . 22-10
WIND DEFLECTOR - INSTALLATION . . . . . 23-180
WIND DEFLECTOR - REMOVAL . . . . . . . . . 23-180
WIND NOISE - DIAGNOSIS AND TESTING . . 23-3
WIND NOISE DIAGNOSIS, DIAGNOSIS
AND TESTING - WATER DRAINAGE . . . . . 23-176
WINDOW - INSTALLATION, QUARTER . . . 23-172
WINDOW - REMOVAL, QUARTER . . . . . . . 23-172
WINDOW BAFFLE SEAL - INSTALLATION,
COWL/PLENUM . . . . . . . . . . . . . . . . . . . . . 23-187
WINDOW BAFFLE SEAL - REMOVAL,
COWL/PLENUM . . . . . . . . . . . . . . . . . . . . . 23-187
WINDOW DEFOGGER - DESCRIPTION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-3
WINDOW DEFOGGER - OPERATION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-3
WINDOW DEFOGGER FUNCTION -
DIAGNOSIS AND TESTING, REAR HVAC
CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . 8G-9
WINDOW DEFOGGER GRID -
DESCRIPTION, REAR . . . . . . . . . . . . . . . . . . 8G-5
WINDOW DEFOGGER GRID - DIAGNOSIS
AND TESTING, REAR . . . . . . . . . . . . . . . . . . 8G-5
WINDOW DEFOGGER GRID -
OPERATION, REAR. . . . . . . . . . . . . . . . . . . . . . 8G-5
WINDOW DEFOGGER RELAY -
DESCRIPTION, REAR . . . . . . . . . . . . . . . . . . 8G-6
WINDOW DEFOGGER RELAY -
DIAGNOSIS AND TESTING, REAR. . . . . . . . . 8G-6
WINDOW DEFOGGER RELAY -
INSTALLATION, REAR . . . . . . . . . . . . . . . . . . 8G-7
WINDOW DEFOGGER RELAY -
OPERATION, REAR . . . . . . . . . . . . . . . . . . . . 8G-6
WINDOW DEFOGGER RELAY -
REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . . 8G-7
WINDOW DEFOGGER SWITCH -
DESCRIPTION, REAR . . . . . . . . . . . . . . . . . . 8G-8
WINDOW DEFOGGER SWITCH -
DIAGNOSIS AND TESTING, REAR. . . . . . . . . 8G-8
WINDOW DEFOGGER SWITCH -
OPERATION, REAR . . . . . . . . . . . . . . . . . . . . 8G-8
WINDOW DEFOGGER SYSTEM -
DIAGNOSIS AND TESTING, REAR. . . . . . . . . 8G-4
WINDOW MOTOR - REMOVAL . . . . . . . . . . 8N-22
WINDOW REGULATOR - ELECTRIC -
INSTALLATION. . . . . . . . . . . . . . . . 23-126,23-134
WINDOW REGULATOR - ELECTRIC -
REMOVAL . . . . . . . . . . . . . . . . . . . 23-126,23-134
WINDOW REGULATOR - MANUAL -
INSTALLATION. . . . . . . . . . . . . . . . 23-126,23-133
WINDOW REGULATOR - MANUAL -
REMOVAL . . . . . . . . . . . . . . . . . . . 23-126,23-133
WINDOW SWITCH - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-22
WINDOW SWITCH - INSTALLATION . . . . . . 8N-23
WINDOW SWITCH - REMOVAL . . . . . . . . . . 8N-23
WINDOWS - DESCRIPTION, POWER . . . . . 8N-21
WINDOWS - DIAGNOSIS AND TESTING,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-21
WINDOWS - OPERATION, POWER . . . . . . . 8N-21
WINDSHIELD A-PILLAR WEATHERSTRIP/
RETAINER - INSTALLATION. . . . . . . . . . . . 23-187
WINDSHIELD A-PILLAR WEATHERSTRIP/
RETAINER - REMOVAL . . . . . . . . . . . . . . . 23-186
WINDSHIELD SAFETY PRECAUTIONS,
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . 23-173
WIPER & WASHER SYSTEM -
CLEANING, FRONT . . . . . . . . . . . . . . . . . . . . 8R-7
WIPER & WASHER SYSTEM -
CLEANING, REAR . . . . . . . . . . . . . . . . . . . . 8R-32
WIPER & WASHER SYSTEM -
DIAGNOSIS AND TESTING, FRONT. . . . . . . . 8R-6
WIPER & WASHER SYSTEM -
DIAGNOSIS AND TESTING, REAR. . . . . . . . 8R-30
WIPER & WASHER SYSTEM -
INSPECTION, FRONT. . . . . . . . . . . . . . . . . . . 8R-7
WIPER & WASHER SYSTEM -
INSPECTION, REAR. . . . . . . . . . . . . . . . . . . 8R-33
WIPER ARM - DESCRIPTION, FRONT . . . . . 8R-12
WIPER ARM - DESCRIPTION, REAR . . . . . . 8R-37
WIPER ARM - INSTALLATION, FRONT . . . . 8R-13
WIPER ARM - INSTALLATION, REAR . . . . . 8R-38
WIPER ARM - OPERATION, FRONT . . . . . . 8R-12
WIPER ARM - OPERATION, REAR . . . . . . . 8R-38
WIPER ARM - REMOVAL, FRONT . . . . . . . . 8R-12
WIPER ARM - REMOVAL, REAR . . . . . . . . . 8R-38
WIPER ARM PARK RAMP -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8R-43
WIPER ARM PARK RAMP - REMOVAL . . . . 8R-43
WIPER BLADE - DESCRIPTION, FRONT . . . 8R-13
WIPER BLADE - DESCRIPTION, REAR . . . . 8R-39
WIPER BLADE - INSTALLATION, FRONT . . . 8R-14
WIPER BLADE - INSTALLATION, REAR . . . . 8R-40
WIPER BLADE - OPERATION, FRONT . . . . . 8R-14
WIPER BLADE - OPERATION, REAR . . . . . . 8R-39
WIPER BLADE - REMOVAL, FRONT . . . . . . 8R-14
WIPER BLADE - REMOVAL, REAR . . . . . . . 8R-40
WIPER HIGH/LOW RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-23
WIPER HIGH/LOW RELAY - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8R-24
WIPER HIGH/LOW RELAY -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8R-24
WIPER HIGH/LOW RELAY - OPERATION . . 8R-23
WIPER HIGH/LOW RELAY - REMOVAL . . . . 8R-24
WIPER MODULE - DESCRIPTION, FRONT . 8R-15
WIPER MODULE - INSTALLATION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-16
WIPER MODULE - OPERATION, FRONT . . . 8R-15
WIPER MODULE - REMOVAL, FRONT . . . . 8R-16
WIPER MOTOR - DESCRIPTION, REAR . . . 8R-41
WIPER MOTOR - INSTALLATION, REAR . . . 8R-42
WIPER MOTOR - OPERATION, REAR . . . . . 8R-41
WIPER MOTOR - REMOVAL, REAR . . . . . . 8R-42
WIPER ON/OFF RELAY - DESCRIPTION . . . 8R-25
WIPER ON/OFF RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-26
WIPER ON/OFF RELAY - INSTALLATION . . . 8R-26
WIPER ON/OFF RELAY - OPERATION . . . . . 8R-25
WIPER ON/OFF RELAY - REMOVAL . . . . . . 8R-26
WIPERS/WASHERS - DESCRIPTION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-2
WIPERS/WASHERS - DESCRIPTION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-27
WIPERS/WASHERS - OPERATION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-4
WIPERS/WASHERS - OPERATION, REAR . . 8R-29
WIPER/WASHER SWITCH -
DESCRIPTION, FRONT . . . . . . . . . . . . . . . . 8R-16
WIPER/WASHER SWITCH -
DESCRIPTION, REAR . . . . . . . . . . . . . . . . . 8R-43
WIPER/WASHER SWITCH - OPERATION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-16
WIPER/WASHER SWITCH - OPERATION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-43
WIRE SPLICING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . 8W-01-14
WIRING - DESCRIPTION, TRAILER TOW . . 8L-64
WIRING DIAGRAMS - DESCRIPTION,
HOW TO USE . . . . . . . . . . . . . . . . . . . . . 8W-01-1
WIRING HARNESS - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-7
WIRING/TERMINAL, SPECIAL TOOLS . . 8W-01-10
WORN THREADS - STANDARD
PROCEDURE, REPAIR DAMAGED OR . . . . . . . 9-9
30 INDEX KJ
Description Group-Page Description Group-Page Description Group-Page
LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
INTERNATIONAL SYMBOLS
DESCRIPTION — INTERNATIONAL SYMBOLS . . 1
FLUID TYPES
DESCRIPTION
DESCRIPTION - FLUID TYPES . . . . . . . . . . . . 1
DESCRIPTION - AXLE . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - MANUAL TRANSMISSION . . . 2
DESCRIPTION - AUTOMATIC
TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - TRANSFER CASE - NV231 . . 3
DESCRIPTION - TRANSFER CASE - NV242 . . 3
DESCRIPTION - ENGINE COOLANT . . . . . . . . 3
OPERATION - AUTOMATIC TRANSMISSION
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES . . . . . . . 4
FLUID FILL/CHECK LOCATIONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MAINTENANCE SCHEDULES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HOISTING
STANDARD PROCEDURE - HOISTING
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 5
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 6
TOWING
STANDARD PROCEDURE - TOWING . . . . . . . . . 6
INTERNATIONAL SYMBOLS
DESCRIPTION — INTERNATIONAL SYMBOLS
Dai ml erChrysl er Corporati on uses i nternati onal
symbol s to i denti fy engi ne compartment l ubri cant
and fl ui d i nspecti on and fi l l l ocati ons (Fi g. 1).
FLUID TYPES
DESCRIPTION
DESCRIPTION - FLUID TYPES
When servi ce i s requi red, Dai ml erChrysl er Corpo-
rati on recommends that onl y Mopar௡ brand parts,
l ubri cants and chemi cal s be used. Mopar௡ provi des
the best engi neered products for servi ci ng
Dai ml erChrysl er Corporati on vehi cl es.
Onl y l ubri cants beari ng desi gnati ons defi ned by
the fol l owi ng organi zati on shoul d be used to servi ce a
Chrysl er Corporati on vehi cl e.
• Soci ety of Automoti ve Engi neers (SAE)
• Ameri can Petrol eum I nsti tute (API ) (Fi g. 2)
• Nati onal Lubri cati ng Grease I nsti tute (NLGI )
(Fi g. 3)
SAE VISCOSITY RATING
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . These are speci fi ed wi th a dual
SAE vi scosi ty grade whi ch i ndi cates the col d-to-hot
temperature vi scosi ty range. Exampl e SAE 5W-30 =
mul ti grade engi ne oi l .
Dai ml erChrysl er Corporati on onl y recommends
mul ti grade engi ne oi l s.
Fig. 1 International Symbols
KJ LUBRICATION & MAINTENANCE 0 - 1
API QUALITY CLASSIFICATION
Thi s symbol (Fi g. 2) on the front of an oi l contai ner
means that the oi l has been certi fi ed by the Ameri -
can Petrol eum I nsti tute (API ) to meet al l the l ubri -
cati on requi rements speci fi ed by Dai ml erChrysl er
Corporati on.
GEAR LUBRICANTS
SAE rati ngs al so appl y to mul ti grade gear l ubri -
cants. I n addi ti on, API cl assi fi cati on defi nes the
l ubri cants usage. Such as API GL-5 and SAE 75W-
90.
LUBRICANTS AND GREASES
Lubri cati ng grease i s rated for qual i ty and usage
by the NLGI . Al l approved products have the NLGI
symbol (Fi g. 3) on the l abel . At the bottom NLGI
symbol i s the usage and qual i ty i denti fi cati on l etters.
Wheel beari ng l ubri cant i s i denti fi ed by the l etter
“G”. Chassi s l ubri cant i s i denti fi ed by the l atter “L”.
The l etter fol l owi ng the usage l etter i ndi cates the
qual i ty of the l ubri cant. The fol l owi ng symbol s i ndi -
cate the hi ghest qual i ty.
SPECIALIZED LUBRICANTS AND OILS
Some mai ntenance or repai r procedures may
requi re the use of speci al i zed l ubri cants or oi l s. Con-
sul t the appropri ate secti ons i n thi s manual for the
correct appl i cati on of these l ubri cants.
DESCRIPTION - AXLE
A mul ti -purpose, hypoi d gear l ubri cant whi ch con-
forms to MI L-L-2105C and API GL 5 qual i ty speci fi -
cati ons shoul d be used. Mopar Hypoi d Gear
Lubri cants conforms to these speci fi cati ons.
FRONT AXLE
• Lubri cant for 186FI A (Model 30) axl e i s SAE
75W-140 SYNTHETI C.
REAR AXLE
• Lubri cant for 198RBI (Model 35) axl e i s SAE
75W-140 SYNTHETI C.
• Lubri cant for 8 1/4 axl e i s a thermal l y stabl e
SAE 75W-90. For trai l er tow or heavy duty appl i ca-
ti ons the l ubri cant shoul d be repl aced wi th SAE
75W-140 SYNTHETI C.
NOTE: Trac-lokா equipped axles require a friction
modifier be added to the lubricant.
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
DESCRIPTION - MANUAL TRANSMISSION
Mopar௡ manual transmi ssi on fl ui d i s the l ubri cant
recommended for the NV1500 and the NV3550 trans-
mi ssi ons.
DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to the maintenance schedules in this
group for the recommended maintenance (fluid/filter
change) intervals for this transmission.
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
Mopar௡ ATF +4, type 9602, Automati c Transmi s-
si on Fl ui d i s the recommended fl ui d for
Dai ml erChrysl er automati c transmi ssi ons.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
Mopar௡ ATF +4, type 9602, Automati c Transmi s-
si on Fl ui d when new i s red i n col or. The ATF i s dyed
red so i t can be i denti fi ed from other fl ui ds used i n
the vehi cl e such as engi ne oi l or anti freeze. The red
col or i s not permanent and i s not an i ndi cator of fl ui d
condi ti on. As the vehi cl e i s dri ven, the ATF wi l l begi n
to l ook darker i n col or and may eventual l y become
brown. This is normal. ATF+4 al so has a uni que
Fig. 2 API Symbol
Fig. 3 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
0 - 2 LUBRICATION & MAINTENANCE KJ
FLUID TYPES (Continued)
odor that may change wi th age. Consequentl y, odor
and col or cannot be used to i ndi cate the fl ui d condi -
ti on or the need for a fl ui d change.
FLUID ADDITIVES
Dai ml erChrysl er strongl y recommends agai nst the
addi ti on of any fl ui ds to the transmi ssi on, other than
those automati c transmi ssi on fl ui ds l i sted above.
Excepti ons to thi s pol i cy are the use of speci al dyes
to ai d i n detecti ng fl ui d l eaks.
Vari ous “speci al ” addi ti ves and suppl ements exi st
that cl ai m to i mprove shi ft feel and/or qual i ty. These
addi ti ves and others al so cl ai m to i mprove converter
cl utch operati on and i nhi bi t overheati ng, oxi dati on,
varni sh, and sl udge. These cl ai ms have not been sup-
ported to the sati sfacti on of Dai ml erChrysl er and
these addi ti ves must not be used. The use of trans-
mi ssi on “seal ers” shoul d al so be avoi ded, si nce they
may adversel y affect the i ntegri ty of transmi ssi on
seal s.
DESCRIPTION - TRANSFER CASE - NV231
Recommended l ubri cant for the NV231 transfer
case i s Mopar௡ ATF +4, type 9602, Automati c Trans-
mi ssi on Fl ui d.
DESCRIPTION - TRANSFER CASE - NV242
Recommended l ubri cant for the NV242 transfer
case i s Mopar௡ ATF+4, type 9602 Automati c Trans-
mi ssi on Fl ui d.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
The cool i ng system i s desi gned around the cool ant.
The cool ant must accept heat from engi ne metal , i n
the cyl i nder head area near the exhaust val ves and
engi ne bl ock. Then cool ant carri es the heat to the
radi ator where the tube/fi n radi ator can transfer the
heat to the ai r.
The use of al umi num cyl i nder bl ocks, cyl i nder
heads, and water pumps requi res speci al corrosi on
protecti on. Mopar௡ Anti freeze/Cool ant, 5
Year/100,000 Mi l e Formul a (MS-9769), or the equi va-
l ent ethyl ene gl ycol base cool ant wi th organi c corro-
si on i nhi bi tors (cal l ed HOAT, for Hybri d Organi c
Addi ti ve Technol ogy) i s recommended. Thi s cool ant
offers the best engi ne cool i ng wi thout corrosi on when
mi xed wi th 50% Ethyl ene Gl ycol and 50% di sti l l ed
water to obtai n a freeze poi nt of -37°C (-35°F). I f i t
l oses col or or becomes contami nated, drai n, fl ush,
and repl ace wi th fresh properl y mi xed cool ant sol u-
ti on.
CAUTION: Moparா Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection.
COOLANT PERFORMANCE
The requi red ethyl ene-gl ycol (anti freeze) and water
mi xture depends upon cl i mate and vehi cl e operati ng
condi ti ons. The cool ant performance of vari ous mi x-
tures fol l ows:
Pure Water-Water can absorb more heat than a
mi xture of water and ethyl ene-gl ycol . Thi s i s for pur-
pose of heat transfer onl y. Water al so freezes at a
hi gher temperature and al l ows corrosi on.
100 percent Ethylene-Glycol-The corrosi on
i nhi bi ti ng addi ti ves i n ethyl ene-gl ycol need the pres-
ence of water to di ssol ve. Wi thout water, addi ti ves
form deposi ts i n system. These act as i nsul ati on
causi ng temperature to ri se to as hi gh as 149°C
(300°F). Thi s temperature i s hot enough to mel t pl as-
ti c and soften sol der. The i ncreased temperature can
resul t i n engi ne detonati on. I n addi ti on, 100 percent
ethyl ene-gl ycol freezes at -22°C (-8°F).
50/50 Ethylene-Glycol and Water-I s the recom-
mended mi xture, i t provi des protecti on agai nst freez-
i ng to -37°C (-34°F). The anti freeze concentrati on
must always be a mi ni mum of 44 percent, year-
round i n al l cl i mates. I f percentage i s l ower, engi ne
parts may be eroded by cavi tati on. Maxi mum protec-
ti on agai nst freezi ng i s provi ded wi th a 68 percent
anti freeze concentrati on, whi ch prevents freezi ng
down to -67.7°C (-90°F). A hi gher percentage wi l l
freeze at a warmer temperature. Al so, a hi gher per-
KJ LUBRICATION & MAINTENANCE 0 - 3
FLUID TYPES (Continued)
centage of anti freeze can cause the engi ne to over-
heat because speci fi c heat of anti freeze i s l ower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automati c transmi ssi on fl ui d i s sel ected based
upon several qual i ti es. The fl ui d must provi de a hi gh
l evel of protecti on for the i nternal components by
provi di ng a l ubri cati ng fi l m between adjacent metal
components. The fl ui d must al so be thermal l y stabl e
so that i t can mai ntai n a consi stent vi scosi ty through
a l arge temperature range. I f the vi scosi ty stays con-
stant through the temperature range of operati on,
transmi ssi on operati on and shi ft feel wi l l remai n con-
si stent. Transmi ssi on fl ui d must al so be a good con-
ductor of heat. The fl ui d must absorb heat from the
i nternal transmi ssi on components and transfer that
heat to the transmi ssi on case.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK 18.5 U.S. Gallons (70
Liters)****
ENGINE OIL
Engine Oil - with Filter -
2.4L
2.4L (5.0 qts.)
Engine Oil - with Filter -
3.7L
3.7L (5.0 qts.)
Engine Oil - With Filter -
2.5L Diesel
6.5L (6.9 qts.)
ENGINE COOLANT
Cooling System - 2.4L 9.6L (10.1 qts.)
Cooling System - 3.7L 12.3L (13.0 qts.)
Cooling System - 2.5L
Diesel
12.5L (13.2 qts.)
AUTOMATIC TRANSMISSION
Service Fill - 45RFE 4.73L (10.0 pts)
O-haul Fill - 45RFE 13.33L (28.0 pts)
Dry fill capacity Depending on type and size of
internal cooler, length and inside diameter of cooler
lines, or use of an auxiliary cooler, these figures may
vary. (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC/FLUID - STANDARD PROCEDURE)
TRANSFER CASE
NV231 1.4L (2.95 pts.)
NV242 1.6L (3.4 pts.)
MANUAL TRANSMISSION
NV1500 (Approximate dry
fill or fill to bottom edge of
the fill plug hole.)
2.28L (2.41 qts.)
NV3550 (Approximate dry
fill or fill to bottom edge of
fill plug hole.)
2.28L (2.41 qts.)
FRONT AXLE
186 FIA (Model 30) 1.24L (41.9 fl. oz.)
REAR AXLE
198 RBI (Model 35) 1.78L (60.2 fl. oz.)*
8 1/4 2.08L (4.4 pts.)*
* When equipped with Trac-lok, include 4.0 ounces of
Friction Modifier.
****Nominal refill capacities are shown. A variation
may be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
0 - 4 LUBRICATION & MAINTENANCE KJ
FLUID TYPES (Continued)
FLUID FILL/CHECK
LOCATIONS
DESCRIPTION
The fl ui d check/fi l l poi nt l ocati ons are l ocated i n
each appl i cabl e servi ce manual secti on.
MAINTENANCE SCHEDULES
DESCRIPTION
ЉMai ntenance Schedul e I nformati on not i ncl uded i n
thi s secti on, i s l ocated i n the appropri ate Owner’s
Manual .Љ
HOISTING
STANDARD PROCEDURE - HOISTING
RECOMMENDATIONS
Refer to the Owner’s Manual for emergency vehi cl e
l i fti ng procedures.
When properl y posi ti oned, a fl oor jack can be used
to l i ft a Jeep vehi cl e (Fi g. 4). Support the vehi cl e i n
the rai sed posi ti on wi th jack stands at the front and
rear ends of the frame rai l s.
CAUTION: Do not attempt to lift a Jeep vehicle with
a floor jack positioned under:
• A body si de si l l .
• A steeri ng l i nkage component.
• A dri ve shaft.
• The engi ne or transmi ssi on oi l pan.
• The fuel tank.
• A front suspensi on arm.
• Transfer case.
NOTE: Use the correct sub-frame rail or frame rail
lifting locations only.
HOIST
Refer to the Owner’s Manual for emergency vehi cl e
l i fti ng procedures.
A vehi cl e can be l i fted wi th:
• A si ngl e-post, frame-contact hoi st.
• A twi n-post, chassi s hoi st.
• A ramp-type, dri ve-on hoi st.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
Fig. 4 Correct Vehicle Lifting Locations
1 - Frame Contact Lift (Single Post)
Chassis Lift (Non-Axle Dual Post)
Outboard Lift (Dual Post)
Floor Jack
2 - Floor Jack
KJ LUBRICATION & MAINTENANCE 0 - 5
J UMP STARTING
STANDARD PROCEDURE - JUMP STARTING
PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS.
• DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.
• DO NOT JUMP START WHEN BATTERY INDI-
CATOR DOT IS YELLOW OR BRIGHT COLOR. BAT-
TERY CAN EXPLODE.
• DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
• DO NOT USE OPEN FLAME NEAR BATTERY.
• REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCHING OF BATTERY CURRENT.
• WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW DISABLED VEHICLE’S
BATTERY TO EXCEED 16 VOLTS. PERSONAL
INJURY OR DAMAGE TO ELECTRICAL SYSTEM
CAN RESULT.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Rai se hood on di sabl ed vehi cl e and vi sual l y
i nspect engi ne compartment for:
• Generator dri ve bel t condi ti on and tensi on.
• Fuel fumes or l eakage, correct i f necessary.
• Frozen battery.
• Yel l ow or bri ght col or test i ndi cator, i f equi pped.
• Low battery fl ui d l evel .
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When usi ng another vehi cl e as a booster
source, turn off al l accessori es, pl ace gear sel ector i n
park or neutral , set park brake or equi val ent and
operate engi ne at 1200 rpm.
(3) On di sabl ed vehi cl e, pl ace gear sel ector i n park
or neutral and set park brake or equi val ent. Turn
OFF al l accessori es.
(4) Connect jumper cabl es to booster battery. RED
cl amp to posi ti ve termi nal (+). BLACK cl amp to neg-
ati ve termi nal (-). DO NOT al l ow cl amps at opposi te
end of cabl es to touch, el ectri cal arc wi l l resul t (Fi g.
5). Revi ew al l warni ngs i n thi s procedure.
(5) On di sabl ed vehi cl e, connect RED jumper cabl e
cl amp to battery posi ti ve (+) termi nal . Connect
BLACK jumper cabl e cl amp to the engi ne as cl ose to
the ground cabl e connecti on as possi bl e (Fi g. 5).
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(6) Al l ow battery i n di sabl ed vehi cl e to charge to
at l east 12.4 vol ts (75% charge) before attempti ng to
start engi ne. I f engi ne does not start wi thi n 15 sec-
onds, stop cranki ng engi ne and al l ow starter to cool
(15 mi n.), before cranki ng agai n.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
• Di sconnect BLACK cabl e cl amp from engi ne
ground on di sabl ed vehi cl e.
• When usi ng a Booster vehi cl e, di sconnect
BLACK cabl e cl amp from battery negati ve termi nal .
Di sconnect RED cabl e cl amp from battery posi ti ve
termi nal .
• Di sconnect RED cabl e cl amp from battery posi -
ti ve termi nal on di sabl ed vehi cl e.
TOWING
STANDARD PROCEDURE - TOWING
A vehi cl e equi pped wi th SAE approved wheel l i ft-
type towi ng equi pment can be used to tow Jeep vehi -
cl es. When towi ng a 4WD vehi cl e usi ng a wheel -l i ft
Fig. 5 Jumper Cable Clamp Connections
1 - BOOSTER BATTERY
2 - NEGATIVE JUMPER CABLE
3 - ENGINE GROUND
4 - DO NOT ALLOW VEHICLES TO TOUCH
5 - BATTERY NEGATIVE CABLE
6 - DISCHARGED BATTERY
7 - POSITIVE JUMPER CABLE
0 - 6 LUBRICATION & MAINTENANCE KJ
towi ng devi ce, use tow dol l i es under the opposi te end
of the vehi cl e. A vehi cl e wi th fl atbed devi ce can al so
be used to transport a di sabl ed vehi cl e (Fi g. 6).
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must be
observed when towing a vehicle:
• Secure l oose and protrudi ng parts.
• Al ways use a safety chai n system that i s i nde-
pendent of the l i fti ng and towi ng equi pment.
• Do not al l ow towi ng equi pment to contact the
di sabl ed vehi cl e’s fuel tank.
• Do not al l ow anyone under the di sabl ed vehi cl e
whi l e i t i s l i fted by the towi ng devi ce.
• Do not al l ow passengers to ri de i n a vehi cl e
bei ng towed.
• Al ways observe state and l ocal l aws regardi ng
towi ng regul ati ons.
• Do not tow a vehi cl e i n a manner that coul d
jeopardi ze the safety of the operator, pedestri ans or
other motori sts.
• Do not attach tow chai ns, T-hooks, or J-hooks to
a bumper, steeri ng l i nkage, dri ve shafts or a non-re-
i nforced frame hol e.
• Do not tow a heavi l y l oaded vehi cl e. Use a fl at-
bed devi ce to transport a l oaded vehi cl e.
TWO-WHEEL-DRIVE VEHICLE TOWING
Dai ml erChrysl er Corporati on recommends that a
vehi cl e be towed wi th the rear end l i fted, whenever
possi bl e.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
FACE OR THE WHEELS ARE BLOCKED TO PRE-
VENT VEHICLE FROM ROLLING.
TWO WHEEL DRIVE TOWING-REAR END LIFTED
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
2WD vehi cl es can be towed wi th the front wheel s
on the surface for extended di stances at speeds not
exceedi ng 48 km/h (30 mph).
(1) Attach wheel l i ft devi ce to rear wheel s.
(2) Pl ace the transmi ssi on i n neutral .
(3) Rai se vehi cl e to towi ng posi ti on.
(4) Attach safety chai ns. Route chai ns so not to
i nterfere wi th tai l pi pe when vehi cl e i s l i fted.
(5) Turn the i gni ti on swi tch to the OFF posi ti on to
unl ock the steeri ng wheel .
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
(6) Secure steeri ng wheel i n strai ght ahead posi -
ti on wi th a cl amp devi ce desi gned for towi ng.
(7) Pl ace transmi ssi on i n park.
TWO WHEEL DRIVE TOWING-FRONT END LIFTED
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
(1) Attach wheel l i ft devi ce to rear wheel s.
(2) Pl ace the transmi ssi on i n neutral .
(3) Rai se the rear of the vehi cl e off the ground and
i nstal l tow dol l i es under rear wheel s.
(4) Attach wheel l i ft devi ce to front wheel s and
rai se vehi cl e to towi ng posi ti on.
(5) Attach the safety chai ns.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
(6) Turn the i gni ti on swi tch to the OFF posi ti on to
unl ock the steeri ng wheel .
(7) Secure steeri ng wheel i n strai ght ahead posi -
ti on wi th a cl amp devi ce desi gned for towi ng.
(8) Pl ace transmi ssi on i n park.
FOUR-WHEEL-DRIVE VEHICLE TOWING
Dai ml erChrysl er Corporati on recommends that a
4WD vehi cl e be transported on a fl at-bed devi ce. A
Wheel -l i ft devi ce can be used provi ded the trailing
wheels are off the ground and positioned in
tow dollies.
Fig. 6 Tow Vehicles With Approved Equipment
KJ LUBRICATION & MAINTENANCE 0 - 7
TOWING (Continued)
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION.
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
FOUR WHEEL DRIVE TOWING—REAR END LIFTED
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
FACE OR THE WHEELS ARE BLOCKED TO PRE-
VENT VEHICLE FROM ROLLING.
(1) Attach wheel l i ft devi ce to front wheel s.
(2) Pl ace the transmi ssi on i n neutral .
(3) Rai se the front of the vehi cl e off the ground
and i nstal l tow dol l i es under front wheel s.
(4) Attach wheel l i ft devi ce to rear wheel s and
rai se vehi cl e to towi ng posi ti on.
(5) Attach safety chai ns. Route chai ns so not to
i nterfere wi th tai l pi pe when vehi cl e i s l i fted.
(6) Turn the i gni ti on swi tch to the OFF posi ti on to
unl ock the steeri ng wheel .
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
(7) Secure steeri ng wheel i n strai ght ahead posi -
ti on wi th a cl amp devi ce desi gned for towi ng.
(8) Pl ace transmi ssi on i n park.
FOUR WHEEL DRIVE TOWING—FRONT END
LIFTED
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
FACE OR THE WHEELS ARE BLOCKED TO PRE-
VENT VEHICLE FROM ROLLING.
(1) Attach wheel l i ft devi ce to rear wheel s.
(2) Pl ace the transmi ssi on i n neutral .
(3) Rai se the rear of the vehi cl e off the ground and
i nstal l tow dol l i es under rear wheel s.
(4) Attach wheel l i ft devi ce to front wheel s and
rai se vehi cl e to towi ng posi ti on.
(5) Attach the safety chai ns.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
(6) Turn the i gni ti on swi tch to the OFF posi ti on to
unl ock the steeri ng wheel .
(7) Secure steeri ng wheel i n strai ght ahead posi -
ti on wi th a cl amp devi ce desi gned for towi ng.
(8) Pl ace transmi ssi on i n park.
0 - 8 LUBRICATION & MAINTENANCE KJ
TOWING (Continued)
SUSPENSION
TABLE OF CONTENTS
page page
FRONT
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 1
BUSHINGS
REMOVAL
REMOVAL - LOWER CONTROL ARM
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVAL - CLEVIS BRACKET BUSHING . . . . 2
REMOVAL - UPPER CONTROL ARM
BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION
INSTALLATION - LOWER CONTROL ARM
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION - CLEVIS BRACKET
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION - UPPER CONTROL ARM
BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LOWER BALL JOINT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REAR
SPECIAL TOOLS
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . 6
UPPER BALL JOINT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BUSHINGS
REMOVAL
REMOVAL - LOWER SUSPENSION ARM
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL - UPPER SUSPENSION ARM
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION
INSTALLATION - LOWER SUSPENSION
ARM BUSHING . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION - UPPER SUSPENSION ARM
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FRONT
SPECIAL TOOLS
FRONT SUSPENSION
BALL JOINT PRESS - C-4212F
Remover C-4150A
REMOVER / INSTALLER FRONT LOWER BALL
JOINT - 8859
KJ SUSPENSION 2s - 1
BUSHINGS
REMOVAL
REMOVAL - LOWER CONTROL ARM BUSHING
(1) Remove the l ower control arm (Refer to 2 -
SUSPENSI ON/FRONT/LOWER CONTROL ARM -
REMOVAL).
(2) Secure the control arm i n a vi se.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(3) Press the bushi ng out usi ng speci al tool s
8858-5 (Recei ver), 8858-6 (Dri ver) and 8839 wi th the
threaded rod and the beari ng as shown (Fi g. 1)
REMOVAL - CLEVIS BRACKET BUSHING
(1) Remove the cl evi s bracket from the shock
(Refer to 2 - SUSPENSI ON/FRONT/CLEVI S
BRACKET - REMOVAL).
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
FRONT LOWER CONTROL ARM & CLEVIS
BUSHING REMOVER/INSTALLER - 8858
REAR LOWER CONTROL ARM BUSHING
REMOVER/INSTALLER - 8862
FRONT LOWER CONTROL BUSHING REMOVER/
INSTALLER - 8830
Fig. 1 LOWER CONTROL ARM BUSHING -
REMOVAL
1 - 8858-5 RECEIVER
2 - 8858-6 DRIVER
3 - 8839 THREADED ROD
2s - 2 SUSPENSION KJ
FRONT (Continued)
(2) Press the bushi ng out usi ng speci al tool s
8858-1 (recei ver), 8858-3 (dri ver) and 8839 wi th the
threaded rod 8839 and the beari ng as shown (Fi g. 2)
REMOVAL - UPPER CONTROL ARM BUSHINGS
(1) Remove the upper control arm (Refer to 2 -
SUSPENSI ON/FRONT/UPPER CONTROL ARM -
REMOVAL).
(2) Secure the control arm i n a vi se.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(3) I nstal l bushi ng remover tool s 8830-3, 8830-2
and 8830–4 wi th the threaded rod 8838 and the bear-
i ng as shown (Fi g. 3)
(4) Press out the bushi ng.
INSTALLATION
INSTALLATION - LOWER CONTROL ARM
BUSHING
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(1) I nstal l the new l ower control arm bushi ngs i nto
the l ower control arm usi ng tool s 8858-5 (dri ver),
8858-6 (recei ver) and the beari ng wi th the threaded
rod 8839 (Fi g. 4) maki ng sure to properl y ori ent the
bushi ng i n the control .
Fig. 2 CLEVIS BRACKET BUSHING
1 - 8839 THREADED ROD
2 - 8858-1 RECEIVER
3 - 8858-3 DRIVER
Fig. 3 UPPER CONTROL ARM BUSHING REMOVAL
1 - 8830-3
2 - 8830-2
3 - 8830-4
4 - 8838
Fig. 4 LOWER CONTROL ARM BUSHING -
INSTALLATION
1 - 8858-5 DRIVER
2 - 8858-6 RECEIVER
3 - 8839 THREADED ROD
KJ SUSPENSION 2s - 3
BUSHINGS (Continued)
(2) Remove the control arm from the vi se.
(3) I nstal l the l ower control arm (Refer to 2 - SUS-
PENSI ON/FRONT/LOWER CONTROL ARM -
I NSTALLATI ON).
(4) Reset the vehi cl e ri de hei ght (Refer to 2 - SUS-
PENSI ON/WHEEL ALI GNMENT - STANDARD
PROCEDURE).
(5) Perform a wheel al i gnment (Refer to 2 - SUS-
PENSI ON/WHEEL ALI GNMENT - STANDARD
PROCEDURE).
INSTALLATION - CLEVIS BRACKET BUSHING
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(1) I nstal l the new cl evi s bracket bushi ng i nto the
l ower control arm usi ng tool s 8858-2 (dri ver), 8858-1
(recei ver) and the beari ng wi th the threaded rod
8839 (Fi g. 5) maki ng sure to properl y ori ent the
bushi ng i n the control .
(2) I nstal l the cl evi s bracket (Refer to 2 - SUS-
PENSI ON/FRONT/CLEVI S BRACKET - I NSTALLA-
TI ON).
INSTALLATION - UPPER CONTROL ARM
BUSHINGS
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(1) I nstal l the new upper control arm bushi ngs
i nto the upper control arm usi ng tool s 8830-3, 8830-1
and 8830-2 the beari ng wi th the threaded rod 8838
(Fi g. 6) maki ng sure to properl y ori ent the bushi ng i n
the control arm.
(2) Remove the control arm from the vi se.
(3) I nstal l the upper control arm (Refer to 2 - SUS-
PENSI ON/FRONT/UPPER CONTROL ARM -
I NSTALLATI ON).
(4) Reset the vehi cl e ri de hei ght (Refer to 2 - SUS-
PENSI ON/WHEEL ALI GNMENT - STANDARD
PROCEDURE).
(5) Perform a wheel al i gnment (Refer to 2 - SUS-
PENSI ON/WHEEL ALI GNMENT - STANDARD
PROCEDURE).
Fig. 5 CLEVIS BRACKET BUSHING
1 - 8858-2 DRIVER
2 - 8858-1 RECEIVER
3 - 8839 THREADED ROD
Fig. 6 UPPER CONTROL ARM BUSHING -
INSTALLATION
1 - 8830-3
2 - 8830-1
3 - BUSHING
4 - 8830-2
5 - 8838
2s - 4 SUSPENSION KJ
BUSHINGS (Continued)
LOWER BALL J OINT
REMOVAL
(1) Remove the ti re and wheel assembl y.
(2) Remove the brake cal i per and rotor (Refer to 5
- BRAKES/HYDRAULI C/MECHANI CAL/ROTORS -
REMOVAL).
(3) Di sconnect the ti e rod from the steeri ng
knuckl e (Refer to 19 - STEERI NG/LI NKAGE/TI E
ROD END - REMOVAL).
(4) Remove the steeri ng knuckl e (Refer to 2 - SUS-
PENSI ON/FRONT/KNUCKLE - REMOVAL).
(5) Move the hal fshaft to the si de and support the
hal fshaft out of the way (I f Equi pped).
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(6) Secure the steeri ng knuckl e i n a vi se.
(7) Press the bal l joi nt from the steeri ng knuckl e
usi ng speci al tool s C-4212–F (PRESS), 8859-2
(RECEI VER) and 8859-1 (DRI VER) (Fi g. 7).
INSTALLATION
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(1) I nstal l the bal l joi nt i nto the steeri ng knuckl e
and press i n usi ng speci al tool s C-4212–F (press),
8859-3 (dri ver) and 6761 (recei ver) (Fi g. 8).
(2) I nstal l the bal l joi nt boot.
(3) Remove the support for the hal fshaft and
i nstal l i nto posi ti on (I f Equi pped).
(4) I nstal l the steeri ng knuckl e (Refer to 2 - SUS-
PENSI ON/FRONT/KNUCKLE - I NSTALLATI ON).
(5) I nstal l the ti e rod end i nto the steeri ng knuckl e
(Refer to 19 - STEERI NG/LI NKAGE/TI E ROD END -
I NSTALLATI ON).
(6) I nstal l and ti ghten the hal fshaft nut to 136
N·m (100 ft. l bs.).
(7) I nstal l the brake cal i per and rotor (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/ROTORS -
I NSTALLATI ON).
(8) I nstal l the ti re and wheel assembl y (Refer to 22
- TI RES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(9) Check the vehi cl e ri de hei ght (Refer to 2 - SUS-
PENSI ON/WHEEL ALI GNMENT - STANDARD
PROCEDURE).
(10) Perform a wheel al i gnment (Refer to 2 - SUS-
PENSI ON/WHEEL ALI GNMENT - STANDARD
PROCEDURE).
Fig. 7 LOWER BALL JOINT
1 - 8859-1 DRIVER
2 - C-4212F PRESS
3 - 8859-2 RECEIVER
Fig. 8 LOWER BALL JOINT
1 - 6761 RECEIVER
2 - 8859-3 DRIVER
3 - C-4212F PRESS
KJ SUSPENSION 2s - 5
REAR
SPECIAL TOOLS
REAR SUSPENSION
UPPER BALL J OINT
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Support the rear axl e wi th a hydraul i c jack.
(3) Remove the bal l joi nt pi nch bol t from the top of
the axl e. (Fi g. 9)
(4) Separate the bal l joi nt arm assembl y from the
di fferenti al housi ng by pryi ng upwards.
(5) Remove the upper suspensi on arm from the
vehi cl e (Refer to 2 - SUSPENSI ON/REAR/UPPER
CONTROL ARM - REMOVAL).
(6) Secure the suspensi on arm i n a vi se.
(7) I nstal l speci al tool s C-4212F (press), 8861-3
(dri ver) and 8861-2 (recei ver) (Fi g. 10)
(8) Press out the ol d bal l joi nt.
INSTALLATION
(1) I nstal l speci al tool s C-4212F (press), 8861-1
(recei ver) and 8861-2 (dri ver) wi th the bal l joi nt i n
pl ace (Fi g. 11).
BALL JOINT PRESS - C-4212F
REMOVER / INSTALLER REAR UPPER BALL JOINT
- 8861
REMOVAL / INSTALLATION REAR UPPER
CONTROL ARM BUSHINGS - 8860
Fig. 9 BALL JOINT PINCH BOLT
1 - UPPER BALL JOINT
2 - PINCH BOLT
Fig. 10 UPPER BALL JOINT - REMOVAL
1 - C-4212F PRESS
2 - 8861-3 DRIVER
3 - 8861-2 RECEIVER
2s - 6 SUSPENSION KJ
(2) Press the bal l joi nt i n the upper suspensi on
arm.
(3) Remove the upper suspensi on arm from the
vi se.
(4) Rei nstal l the upper suspensi on arm (Refer to 2
- SUSPENSI ON/REAR/UPPER CONTROL ARM -
I NSTALLATI ON).
(5) Rai se the rear axl e wi th a hydraul i c jack to
al i gn the bal l joi nt wi th the di fferenti al housi ng
bracket.
(6) I nsert the bal l joi nt i nto the di fferenti al hous-
i ng bracket.
(7) I nstal l the bal l joi nt pi nch bol t and ti ghten to
95 N·m (70 ft. l bs.). (Fi g. 9).
(8) Remove the supports and l ower the vehi cl e.
BUSHINGS
REMOVAL
REMOVAL - LOWER SUSPENSION ARM
BUSHING
(1) Remove the l ower suspensi on arm (Refer to 2 -
SUSPENSI ON/REAR/LOWER CONTROL ARM -
REMOVAL).
(2) Secure the suspensi on arm i n a vi se.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(3) I nstal l speci al tool s 8862-4 (recei ver), 8862-5
(spacer) and 8862-1 or 8862- 2 (dri ver) wi th the
threaded rod 8839 and the beari ng as shown (Fi g. 12)
(4) Press out the bushi ng.
REMOVAL - UPPER SUSPENSION ARM
BUSHING
(1) Remove the upper suspensi on arm (Refer to 2 -
SUSPENSI ON/REAR/UPPER CONTROL ARM -
REMOVAL).
(2) Secure the suspensi on arm i n a vi se.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(3) I nstal l speci al tool s 8853-3 (dri ver), 8860-1
(recei ver) and wi th the threaded rod 8838 and the
beari ng as shown (Fi g. 13)
(4) Press out the bushi ng.
Fig. 11 UPPER BALL JOINT - INSTALLATION
1 - C-4212F PRESS
2 - 8861-1 RECEIVER
3 - 8861-2 DRIVER
Fig. 12 LOWER SUSPENSION ARM BUSHING
REMOVAL
1 - 8839 THREADED ROD
2 - 8862-4 RECEIVER
3 - 8862-5 SPACER
4 - 8862-1 OR 8862-2 DRIVERS
KJ SUSPENSION 2s - 7
UPPER BALL J OINT (Continued)
INSTALLATION
INSTALLATION - LOWER SUSPENSION ARM
BUSHING
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(1) I nstal l the new l ower suspensi on arm bushi ngs
i nto the l ower suspensi on arm usi ng tool s 8862-3
(dri ver), 8862-4 (recei ver), 8862-5 (spacer) and the
beari ng wi th the threaded rod 8839 (Fi g. 14) maki ng
sure to properl y ori ent the bushi ng i n the suspensi on
arm.
(2) Remove the suspensi on arm from the vi se.
(3) I nstal l the l ower suspensi on arm (Refer to 2 -
SUSPENSI ON/REAR/LOWER CONTROL ARM -
I NSTALLATI ON).
INSTALLATION - UPPER SUSPENSION ARM
BUSHING
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(1) I nstal l the new upper suspensi on arm bushi ngs
i nto the upper suspensi on arm usi ng tool s 8835-3
(recei ver), 8860-2 (dri ver) and the beari ng wi th the
threaded rod 8838 (Fi g. 15) maki ng sure to properl y
ori ent the bushi ng i n the suspensi on arm.
(2) Remove the suspensi on arm from the vi se.
(3) I nstal l the upper suspensi on arm (Refer to 2 -
SUSPENSI ON/REAR/UPPER CONTROL ARM -
I NSTALLATI ON).
Fig. 13 UPPER SUSPENSION ARM BUSHING -
REMOVAL
1 - 8853-3 DRIVER
2 - 8860-1 RECEIVER
3 - 8838 THREADED ROD
Fig. 14 LOWER SUSPENSION ARM BUSHING
INSTALLATION
1 - 8862-3 DRIVER
2 - 8862-5 SPACER
3 - 8862-4 RECEIVER
4 - 8839 THREADED ROD
Fig. 15 UPPER SUSPENSION ARM BUSHING -
INSTALLATION
1 - 8838 THREADED ROD
2 - 8835-3 RECEIVER
3 - 8860-2 DRIVER
2s - 8 SUSPENSION KJ
BUSHINGS (Continued)
DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page page
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 1
HALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FRONT AXLE - 186FIA . . . . . . . . . . . . . . . . . . . . 19
REAR AXLE - 198RBI . . . . . . . . . . . . . . . . . . . . . 49
REAR AXLE - 8 1/4 . . . . . . . . . . . . . . . . . . . . . . . 86
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT
DIAGNOSIS AND TESTING - PROPELLER
SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURES - PROPELLER
SHAFT ANGLE . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 6
PROPELLER SHAFT - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PROPELLER SHAFT - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SINGLE CARDAN UNIVERSAL JOINTS
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PROPELLER SHAFT
DIAGNOSIS AND TESTING - PROPELLER
SHAFT
VIBRATION
Ti res that are out-of-round, or wheel s that are
unbal anced, wi l l cause a l ow frequency vi brati on.
Brake rotors that are unbal anced wi l l cause a
harsh, l ow frequency vi brati on.
Dri vel i ne vi brati on can al so resul t from l oose or
damaged engi ne mounts.
Propel l er shaft vi brati on i ncreases as the vehi cl e
speed i s i ncreased. A vi brati on that occurs wi thi n a
speci fi c speed range i s not usual l y caused by a pro-
pel l er shaft bei ng unbal anced. Defecti ve joi nts or an
i ncorrect propel l er shaft angl e, are usual l y the cause
of such a vi brati on.
KJ DIFFERENTIAL & DRIVELINE 3 - 1
DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1. Undercoating or other foreign
material on shaft.
1. Clean exterior of shaft and wash
with solvent.
2. Loose U-joint clamp screws. 2. Install new clamps and screws
and tighten to proper torque.
3. Loose or bent U-joint yoke or
excessive runout.
3. Install new yoke.
4. Incorrect driveline angularity. 4. Measure and correct driveline
angles.
5. Worn joint. 5. Install new joint.
6. Propeller shaft damaged or out
of balance.
6. Installl new propeller shaft.
7. Broken rear spring. 7. Install new rear spring.
8. Excessive runout or unbalanced
condition.
8. Re-index propeller shaft, test, and
evaluate.
9. Excessive drive pinion gear shaft
runout.
9. Re-index propeller shaft and
evaluate.
10. Excessive axle yoke deflection. 10. Inspect and replace yoke if
necessary.
11. Excessive transfer case runout. 11. Inspect and repair as necessary.
Joint Noise 1. Loose U-joint clamp screws. 1. Install new clamps and screws
and tighten to proper torque.
2. Lack of lubrication. 2. Replace joints as necessary.
BALANCE
NOTE: Removing and re-indexing the propeller
shaft 180° relative to the yoke may eliminate some
vibrations.
I f propel l er shaft i s suspected of bei ng unbal anced,
i t can be veri fi ed wi th the fol l owi ng procedure:
(1) Rai se the vehi cl e.
(2) Cl ean al l the forei gn materi al from the propel -
l er shaft and the uni versal joi nts.
(3) I nspect the propel l er shaft for mi ssi ng bal ance
wei ghts, broken wel ds, and bent areas. If the pro-
peller shaft is bent, it must be replaced.
(4) I nspect the uni versal joi nts to ensure that they
are not worn, are properl y i nstal l ed, and are cor-
rectl y al i gned wi th the shaft.
(5) Check the uni versal joi nt cl amp screws torque.
(6) Remove the wheel s and ti res. I nstal l the wheel
l ug nuts to retai n the brake drums or rotors.
(7) Mark and number the shaft si x i nches from the
yoke end at four posi ti ons 90° apart.
(8) Run and accel erate the vehi cl e unti l vi brati on
occurs. Note the i ntensi ty and speed the vi brati on
occurred. Stop the engi ne.
(9) I nstal l a screw cl amp at posi ti on 1 (Fi g. 1).
Fig. 1 CLAMP AT POSITION 1
1 - CLAMP
2 - SCREWDRIVER
3 - 2 PROPELLER SHAFT KJ
PROPELLER SHAFT (Continued)
(10) Start the engi ne and re-check for vi brati on. I f
there i s l i ttl e or no change i n vi brati on, move the
cl amp to one of the other three posi ti ons. Repeat the
vi brati on test.
(11) I f there i s no di fference i n vi brati on at the
other posi ti ons, the source of the vi brati on may not
be propel l er shaft.
(12) I f the vi brati on decreased, i nstal l a second
cl amp (Fi g. 2) and repeat the test.
(13) I f the addi ti onal cl amp causes an addi ti onal
vi brati on, separate the cl amps (1/4 i nch above and
bel ow the mark). Repeat the vi brati on test (Fi g. 3).
(14) I ncrease di stance between the cl amp screws
and repeat the test unti l the amount of vi brati on i s
at the l owest l evel . Bend the sl ack end of the cl amps
so the screws wi l l not l oosen.
(15) I f the vi brati on remai ns unacceptabl e, appl y
the same steps to the front end of the propel l er shaft.
(16) I nstal l the wheel and ti res. Lower the vehi cl e.
RUNOUT
(1) Remove di rt, rust, pai nt and undercoati ng from
the propel l er shaft surface where the di al i ndi cator
wi l l contact the shaft.
(2) The di al i ndi cator must be i nstal l ed perpendi c-
ul ar to the shaft surface.
(3) Measure runout at the center and ends of the
shaft suffi ci entl y far away from wel d areas to ensure
that the effects of the wel d process wi l l not enter i nto
the measurements.
(4) Refer to Runout Speci fi cati ons chart.
(5) I f the propel l er shaft runout i s out of speci fi ca-
ti on, remove the propel l er shaft, i ndex the shaft 180°,
and re-i nstal l the propel l er shaft. Measure shaft
runout agai n.
(6) I f the propel l er shaft runout i s now wi thi n
speci fi cati ons, mark the shaft and yokes for proper
ori entati on.
(7) I f the propel l er shaft runout i s not wi thi n spec-
i fi cati ons, veri fy that the runout of the transmi ssi on/
transfer case and axl e are wi thi n speci fi cati ons.
Correct as necessary and re-measure propel l er shaft
runout.
(8) Repl ace the propel l er shaft i f the runout sti l l
exceeds the l i mi ts.
RUNOUT SPECIFICATIONS
Front of Shaft 0.020 in. (0.50 mm)
Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
note:
Measure front/rear runout approximately 3 inches (76
mm) from the weld seam at each end of the shaft
tube for tube lengths over 30 inches. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.
STANDARD PROCEDURES - PROPELLER
SHAFT ANGLE
The procedure appl i es to both the front propel l er
shafts and the rear propel l er shaft. To obtai n the
front (output) angl e on the C/V front propel l er shaft,
the i ncl i nometer i s pl aced on the machi ned ri ng of
the pi ni on fl ange. To obtai n the propel l er shaft angl e
measurement on the C/V front propel l er shaft, the
i ncl i nometer i s pl aced on the propel l er shaft tube.
(1) Rai se and support the vehi cl e at the axl es as
l evel as possi bl e. Al l ow the wheel s and propel l er
shaft to turn.
(2) Remove any external beari ng snap ri ngs from
uni versal joi nt i f equi pped, so the i ncl i nometer base
wi l l si ts fl at.
Fig. 2 TWO CLAMPS AT SAME POSITION
Fig. 3 CLAMPS SEPARATED
1 - ½ INCH
KJ PROPELLER SHAFT 3 - 3
PROPELLER SHAFT (Continued)
(3) Rotate the shaft unti l transmi ssi on/transfer
case output yoke beari ng cap i s faci ng downward, i f
necessary.
NOTE: Always make measurements from front to
rear.
(4) Pl ace I ncl i nometer on yoke beari ng cap, or the
pi ni on fl ange ri ng, (A) paral l el to the shaft (Fi g. 4).
Center bubbl e i n si ght gl ass and record measure-
ment.
NOTE: This measurement will give you the trans-
mission or Output Yoke Angle (A).
(5) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on yoke beari ng cap, or propel l er shaft
tube on C/V propel l er shaft, paral l el to the shaft (Fi g.
5). Center bubbl e i n si ght gl ass and record measure-
ment. Thi s measurement can al so be taken at the
rear end of the shaft.
NOTE: This measurement will give you the propeller
shaft angle (C).
(6) Subtract smal l er fi gure from l arger (C mi nus
A) to obtai n transmi ssi on output operati ng angl e.
(7) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on pi ni on yoke beari ng cap paral l el to
the shaft (Fi g. 6). Center bubbl e i n si ght gl ass and
record measurement.
NOTE: This measurement will give you the pinion
shaft or input yoke angle (B).
Fig. 4 OUTPUT YOKE ANGLE (A)
1 - SLIP YOKE BEARING CAP
2 - INCLINOMETER
Fig. 5 PROPELLER SHAFT ANGLE (C)
1 - SHAFT YOKE BEARING CAP
2 - INCLINOMETER
Fig. 6 INPUT YOKE ANGLE (B)
1 - PINION YOKE BEARING CAP
2 - INCLINOMETER
3 - 4 PROPELLER SHAFT KJ
PROPELLER SHAFT (Continued)
(8) Subtract smal l er fi gure from l arger (C mi nus
B) to obtai n axl e I nput Operati ng Angl e.
Refer to rul es gi ven bel ow and the exampl e i n (Fi g.
7) for addi ti onal i nformati on.
• Good cancel l ati on of U-joi nt operati ng angl es
(wi thi n 1°).
• Operati ng angl es l ess than 3°.
• Operati ng angl es l ess than 10° for doubl e cardan
U-joi nt.
• At l east 1/2 of one degree conti nuous operati ng
(propel l er shaft) angl e.
Fig. 7 U-JOINT ANGLE EXAMPLE
1 - 4.9°Angle (C)
2 - 3.2°Angle (B)
3 - Input Yoke
4 - 3.0°Angle (A)
5 - Output Yoke
KJ PROPELLER SHAFT 3 - 5
PROPELLER SHAFT (Continued)
SPECIFICATIONS
PROPELLER SHAFT
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Front Shaft - Companion
Flange Bolts
30 22 -
Rear Shaft - Yoke Nuts 18 13 -
SPECIAL TOOLS
PROPELLER SHAFT - FRONT
REMOVAL
(1) Shi ft transmi ssi on and transfer case i nto Neu-
tral .
(2) Rai se and support the vehi cl e.
(3) Mark compani on fl anges and C/V joi nts at the
front and rear of the propel l er shaft for i nstal l ati on
reference.
(4) Remove bol ts from the front and rear C/V
joi nts.
(5) Push propel l er shaft forward to cl ear transfer
case compani on fl ange (Fi g. 8).
(6) Remove the shaft from the front axl e compan-
i on fl ange.
(7) Ti l t the front of the shaft down and pul l shaft
forward and remove from the vehi cl e.
INSTALLATION
(1) I nstal l propel l er shaft between compani on
fl anges.
(2) Al i gn marks on the compani on fl anges wi th the
marks on the C/V joi nts.
(3) I nstal l front C/V joi nt bol ts and ti ghten to 30
N·m (22 ft. l bs.).
(4) I nstal l rear C/V joi nt bol ts and ti ghten to 30
N·m (22 ft. l bs.).
(5) Lower vehi cl e.
Inclinometer 7663
Fig. 8 TRANSFER CASE COMPANION FLANGE
1 - FLANGE BOLT
2 - COMPANION FLANGE
3 - 6 PROPELLER SHAFT KJ
PROPELLER SHAFT (Continued)
PROPELLER SHAFT - REAR
REMOVAL
(1) Shi ft the transmi ssi on/transfer case i nto Neu-
tral .
(2) Rai se and support vehi cl e.
(3) Mark a reference l i ne across the pi ni on yoke
and propel l er shaft for i nstal l ati on.
(4) Remove U-joi nt strap bol ts at the pi ni on shaft
yoke.
(5) Pry open cl amp hol di ng the dust boot to propel -
l er shaft yoke (Fi g. 9), i f equi pped.
(6) Sl i de sl i p yoke off of the transmi ssi on/transfer
case output shaft and remove the propel l er shaft
(Fi g. 10).
INSTALLATION
(1) Sl i de sl i p yoke on the transmi ssi on/transfer
case output shaft.
(2) Al i gn reference marks on the pi ni on yoke and
propel l er shaft.
(3) I nstal l U-joi nt straps and ti ghten strap bol ts to
18 N·m (13 ft. l bs.).
(4) Ti ghten dust boot cl amp i f equi pped wi th
Cl amp C-4975A (Fi g. 11).
(5) Remove support and l ower the vehi cl e.
Fig. 9 DUST BOOT CLAMP
1 - SLINGER
2 - BOOT
3 - AWL
4 - TRANSFER CASE
Fig. 10 REAR PROPELLER SHAFT
1 - CLAMP
2 - YOKE
3 - PROPELLER SHAFT
4 - AXLE YOKE
5 - CLAMP
6 - OUTPUT SHAFT
7 - BOOT
Fig. 11 CRIMPING BOOT CLAMP
1 - CLAMP TOOL
2 - SLINGER
3 - BOOT
4 - CLAMPS
KJ PROPELLER SHAFT 3 - 7
SINGLE CARDAN UNIVERSAL
J OINTS
DISASSEMBLY
NOTE: Individual components of cardan universal
joints are not serviceable. If worn or leaking, they
must be replaced as an assembly.
(1) Remove the propel l er shaft.
(2) Tap the outsi de of the beari ng cap assembl y
wi th a dri ft to l oosen snap ri ng.
(3) Remove snap ri ngs from both si des of yoke
(Fi g. 12).
(4) Set the yoke i n an arbor press or vi se wi th a
socket whose i nsi de di ameter i s l arge enough to
recei ve the beari ng cap posi ti oned beneath the yoke.
(5) Posi ti on the yoke wi th the grease fi tti ng, i f
equi pped, poi nti ng up.
(6) Pl ace a socket wi th an outsi de di ameter
smal l er than the upper beari ng cap on the upper
beari ng cap and press the cap through the yoke to
rel ease the l ower beari ng cap (Fi g. 13).
(7) I f the beari ng cap wi l l not pul l out of the yoke
by hand after pressi ng, tap the yoke ear near the
beari ng cap to di sl odge the cap.
(8) To remove the opposi te beari ng cap, turn the
yoke over and strai ghten the cross i n the open hol e.
Then, careful l y press the end of the cross unti l the
remai ni ng beari ng cap can be removed (Fi g. 14).
CAUTION: If the cross or bearing cap are not straight
during installation, the bearing cap will score the walls
of the yoke bore and damage can occur.
Fig. 12 REMOVE SNAP RING
1 - SNAP RING
Fig. 13 PRESS OUT BEARING
1 - PRESS
2 - SOCKET
Fig. 14 PRESS OUT REMAINING BEARING
1 - CROSS
2 - BEARING CAP
3 - 8 PROPELLER SHAFT KJ
ASSEMBLY
(1) Appl y extreme pressure (EP) N.L.G.I . Grade 1
or 2 grease to i nsi de of yoke bores.
(2) Posi ti on the cross i n the yoke wi th i ts l ube fi t-
ti ng, i f equi pped, poi nti ng up (Fi g. 15).
(3) Pl ace a beari ng cap over the trunni on and
al i gn the cap wi th the yoke bore (Fi g. 16). Keep the
needl e beari ngs upri ght i n the beari ng cap.
(4) Press the beari ng cap i nto the yoke bore
enough to cl ear snap ri ng groove.
(5) I nstal l a snap ri ng.
(6) Repeat Step 3 and Step 4 to i nstal l the oppo-
si te beari ng cap.
NOTE: If the joint is stiff or binding, strike the yoke
with a soft hammer to seat the needle bearings.
(7) Add grease to l ube fi tti ng, i f equi pped.
(8) I nstal l the propel l er shaft.
Fig. 15 CROSS IN YOKE
1 - CROSS
2 - YOKE
Fig. 16 INSTALL BEARING ON TRUNNION
1 - BEARING CAP
2 - TRUNNION
KJ PROPELLER SHAFT 3 - 9
SINGLE CARDAN UNIVERSAL J OINTS (Continued)
HALF SHAFT
TABLE OF CONTENTS
page page
HALF SHAFT
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING - HALF SHAFT . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIFICATIONS
HALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 12
CV JOINT/BOOT-OUTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
CV JOINT/BOOT-INNER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
HALF SHAFT
CAUTION
CAUTION:: Never grasp half shaft assembly by the
boots. This may cause the boot to pucker or crease
and reduce the service life of the boot.
Avoid over angulating or stroking the C/V joints
when handling the half shaft.
Half shafts exposed to battery acid, transmission
fluid, brake fluid, differential fluid or gasoline may
cause the boots to deteriorate.
DIAGNOSIS AND TESTING - HALF SHAFT
Check for grease at the i nboard and outboard C/V
joi nt. Thi s i s a si gn of boot or boot cl amp damage.
NOISE AND/OR VIBRATION IN TURNS
A cl i cki ng noi se or a vi brati on i n turns coul d be
caused by a damaged outer C/V or i nner tri pod joi nt
seal boot or seal boot cl amps. Thi s wi l l resul t i n the
l oss/contami nati on of the joi nt grease, resul ti ng i n
i nadequate l ubri cati on of the joi nt. Noi se coul d al so
be caused by another component of the vehi cl e com-
i ng i n contact wi th the hal f shafts.
CLUNKING NOISE DURING ACCELERATION
Thi s noi se may be a resul t of a damaged or worn
C/V joi nt. A torn boot or l oose/mi ssi ng cl amp on the
i nner/outer joi nt whi ch has al l owed the grease to be
l ost wi l l damage the C/V joi nt.
SHUDDER OR VIBRATION DURING ACCELERATION
Thi s probl em coul d be a resul t of a worn/damaged
i nner tri pod joi nt or a sti cki ng tri pod joi nt. I mproper
wheel al i gnment may al so cause a shudder or vi brati on.
VIBRATION AT HIGHWAY SPEEDS
Thi s probl em coul d be a resul t of out of bal ance
front ti res or ti re/wheel runout. Forei gn materi al
(mud, etc.) packed on the backsi de of the wheel (s)
wi l l al so cause a vi brati on.
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove wheel and ti re assembl y.
(3) Remove hal f shaft hub nut.
(4) Remove stabi l i zer l i nk (Fi g. 1).
Fig. 1 STABILIZER BAR LINK
1 - STABILIZER BAR
2 - STABILIZER BAR LINK
3 - 10 HALF SHAFT KJ
(5) Remove l ower cl evi s bol t (Fi g. 2).
(6) Seperate l ower bal l joi nt from the l ower control
arm (Fi g. 3).
(7) Pul l out on the steeri ng knuckl e and push the
hal f shaft out of the knuckl e.
(8) Wi th a pry bar remove the hal f shaft from the
axl e.
NOTE: The right side has a splined axle shaft that
will stay in the axle.
INSTALLATION
(1) Appl y a l i ght coat of wheel beari ng grease on
the femal e spl i nes of the i nner C/V joi nt.
(2) I nstal l hal f shaft on the axl e shaft spl i ne and
push fi rml y to engage the snap ri ng. Pul l on the hal f
shaft to veri fy snap has engaged.
(3) Cl ean hub beari ng bore and appl y a l i ght coat
of wheel beari ng grease.
(4) Pul l out on the steeri ng knuckl e and push the
hal f shaft through the knuckl e.
(5) I nstal l l ower bal l joi nt i nto the l ower control
arm and ti ghten pi nch bol t.
(6) Al i gn cl evi s wi th knuckl e. I nstal l and ti ghten
l ower cl evi s bol t.
(7) I nstal l stabi l i zer l i nk.
(8) I nstal l hal f shaft hub nut.
(9) I nstal l wheel and ti re assembl y.
(10) Remove support and l ower vehi cl e.
SPECIFICATIONS
HALF SHAFT
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Half Shaft Nut 136 100 -
Fig. 3 LOWER CONTROL ARM
1 - FRONT CAM BOLT
2 - OUTER TIE ROD END
3 - LOWER BALL JOINT NUT
4 - LOWER CONTROL ARM
5 - REAR CAM BOLT
Fig. 2 CLEVIS BRACKET
1 - UPPER BOLT
2 - CLEVIS BRACKET
3 - LOWER BOLT
KJ HALF SHAFT 3 - 11
HALF SHAFT (Continued)
SPECIAL TOOLS
CV J OINT/BOOT-OUTER
REMOVAL
(1) Cl amp shaft i n a vi se (wi th soft jaws) and sup-
port C/V joi nt.
(2) Remove cl amps wi th a cut-off wheel or gri nder
(Fi g. 4).
CAUTION: Do not damage C/V housing or half shaft.
(3) Sl i de the boot down the shaft.
(4) Remove l ubri cant to expose the C/V joi nt snap
ri ng.
(5) Spread snap ri ng and sl i de the joi nt off the
shaft (Fi g. 5).
(6) Sl i de boot off the shaft and di scard ol d boot.
(7) Mark al i gnment marks on the i nner race/hub,
beari ng cage and housi ng wi th dabs of pai nt (Fi g. 6).
(8) Cl amp C/V joi nt i n a verti cal posi ti on i n a i n
soft jawed vi se.
(9) Press down one si de of the beari ng cage to gai n
access to the bal l at the opposi te.
NOTE: If joint is tight, use a hammer and brass drift
to loosen the bearing hub. Do not contact the bear-
ing cage with the drift.
CLAMP INSTALLER C-4975A
Fig. 4 BOOT CLAMP LOCATIONS
1 - C/V HOUSING
2 - CLAMP
3 - HALF SHAFT
4 - CLAMP
5 - C/V BOOT
Fig. 5 OUTER C/V JOINT
1 - SNAP RING
2 - SNAP RING GROVE
3 - SNAP RING PLIERS
Fig. 6 BEARING ACCESS
1 - ALIGNMENT MARKS
2 - BEARING HUB
3 - BEARING CAGE
4 - HOUSING
3 - 12 HALF SHAFT KJ
HALF SHAFT (Continued)
(10) Remove bal l from the beari ng cage (Fi g. 7).
(11) Repeat step above unti l al l si x bal l s are
removed from the beari ng cage.
(12) Li ft cage and i nner race upward and out from
the housi ng (Fi g. 8).
(13) Turn i nner race 90° i n the cage and rotate the
i nner race/hub out of the cage (Fi g. 9).
INSTALLATION
NOTE: If C/V joint is worn, replace entire C/V joint
and boot.
(1) Appl y a l i ght coat of grease to the C/V joi nt
components before assembl i ng them.
(2) Al i gn the i nner race, cage and housi ng accord-
i ng to the al i gnment reference marks.
(3) I nsert the i nner race i nto the cage (Fi g. 10) and
rotate race i nto the cage.
Fig. 7 BEARING
1 - HOUSING
2 - INNER RACE/HUB
3 - BEARING CAGE
4 - BALL
Fig. 8 CAGE AND INNER RACE/HUB
1 - HOUSING
2 - INNER RACE
3 - CAGE WINDOW
Fig. 9 INNER RACE/HUB
Fig. 10 INNER RACE/HUB
1 - INNER RACE/HUB
2 - BEARING CAGE
KJ HALF SHAFT 3 - 13
CV J OINT/BOOT-OUTER (Continued)
(4) Rotate the i nner race/hub i n the cage (Fi g. 11).
(5) I nsert cage i nto the housi ng (Fi g. 12). Rotate
the cage 90° i nto the housi ng (Fi g. 13).
(6) Appl y the l ubri cant i ncl uded wi th the repl ace-
ment boot to the bal l races. Spread the l ubri cant
equal l y between al l the races.
(7) Ti l t i nner race/hub and cage and i nstal l the
bal l s (Fi g. 14).
Fig. 11 CAGE AND INNER RACE/HUB
1 - CAGE WINDOWS
2 - SNAP RING
Fig. 12 BEARING CAGE AND HOUSING
1 - OUTER RACE
2 - BEARING CAGE WINDOW
3 - CV JOINT HOUSING
Fig. 13 CAGE AND INNER RACE/HUB
1 - C/V HOUSING
2 - BEARING HUB LARGE COUNTERBORE OUTWARD
3 - BOOT RETAINING SHOULDER
4 - BEARING HUB SMALL COUNTERBORE INWARD
5 - SLINGER
Fig. 14 BALL BEARING
1 - C/V HOUSING
2 - INNER RACE/HUB
3 - BEARING CAGE
4 - BEARING
3 - 14 HALF SHAFT KJ
CV J OINT/BOOT-OUTER (Continued)
(8) Pl ace new cl amps onto new boot and sl i de boot
onto the shaft to i t’s ori gi nal posi ti on.
(9) Appl y the rest of l ubri cant to the C/V joi nt and
boot.
(10) I nstal l the joi nt onto the shaft. Push the joi nt
onto the shaft unti l the snap ri ng seats i n the groove
(Fi g. 15). Pul l on the joi nt to veri fy the span ri ng has
engaged.
(11) Posi ti on the boot on the joi nt i n i t’s ori gi nal
posi ti on. Ensure that the boot i s not twi sted and
remove any excess ai r.
(12) Secure both boot cl amps (Fi g. 16) wi th Cl amp
I nstal l er C-4975A. Pl ace tool on cl amp bri dge and
ti ghten tool unti l the jaws of the tol l are cl osed.
CV J OINT/BOOT-INNER
REMOVAL
(1) Cl amp shaft i n a vi se (wi th soft jaws) and sup-
port C/V joi nt.
(2) Remove cl amps wi th a cut-off wheel or gri nder.
CAUTION: Do not damage C/V housing or half
shaft.
(3) Sl i de the boot down the shaft (Fi g. 17).
Fig. 15 OUTER C/V JOINT
1 - SNAP RING
2 - SHAFT TAPER
3 - SNAP RING GROVE
4 - BEARING HUB
Fig. 16 BOOT CLAMP LOCATIONS
1 - C/V HOUSING
2 - CLAMP
3 - HALF SHAFT
4 - CLAMP
5 - C/V BOOT
Fig. 17 INNER C/V BOOT
1 - HOUSING
2 - BOOT
3 - HOUSING SNAP RING
KJ HALF SHAFT 3 - 15
CV J OINT/BOOT-OUTER (Continued)
(4) Remove l ubri cant to expose the C/V housi ng
snap ri ng and remove snap ri ng (Fi g. 18).
(5) Remove beari ngs from the cage (Fi g. 19).
(6) Rotate cage 30° and sl i de cage off the i nner
race and down the shaft.
(7) Remove spread i nner race snap ri ng (Fi g. 20)
and remove race from the shaft.
(8) Remove boot from the shaft and di scard.
(9) Cl ean and i nspect al l components for wear or
damage (Fi g. 21).
Fig. 18 HOUSING SNAP RING
1 - HOUSING
2 - SNAP RING
3 - CAGE/INNER RACE
Fig. 19 C/V BEARINGS
1 - CAGE
2 - INNER RACE
3 - SHAFT
4 - BEARING
Fig. 20 INNER RACE
1 - INNER RACE
2 - PLIERS
3 - SHAFT
4 - SNAP RING ACCESS
Fig. 21 INNER C/V JOINT
1 - HOUSING
2 - CAGE
3 - BEARINGS
4 - HOUSING SNAP RING
5 - INNER RACE SNAP RING
6 - INNER RACE
3 - 16 HALF SHAFT KJ
CV J OINT/BOOT-INNER (Continued)
INSTALLATION
(1) Appl y a coat of grease suppl i ed wi th the joi nt/
boot to the C/V joi nt components before assembl i ng
them.
(2) Pl ace new cl amps on the new boot and sl i de
boot down the shaft.
(3) Sl i de cage onto the shaft (Fi g. 22) wi th the
smal l di ameter end towards the boot.
(4) I nstal l the i nner race onto the shaft (Fi g. 23).
Pul l on the race to veri fy snap ri ng has engaged.
(5) Al i gn cage wi th the i nner race and sl i de over
the race.
(6) Turn the cage 30° to al i gn the cage wi ndows
wi th the race (Fi g. 24).
(7) Appl y grease to the i nner race and beari ngs
and i nstal l the beari ngs.
Fig. 22 BEARING CAGE
1 - SHAFT
2 - CAGE
3 - SMALL DIAMETER
4 - SNAP RING GROOVE
Fig. 23 INNER RACE
1 - INNER RACE
2 - CAGE
3 - SHAFT
Fig. 24 CAGE/INNER RACE
1 - CAGE
2 - INNER RACE
3 - SHAFT
4 - CAGE WINDOW
KJ HALF SHAFT 3 - 17
CV J OINT/BOOT-INNER (Continued)
(8) Appl y grease to the housi ng bore (Fi g. 25) then
i nstal l the beari ng assmbl y i nto the housi ng.
(9) I nstal l the housi ng snap ri ng and veri fy i t i s
seated i n the groove.
(10) Fi l l the housi ng and boot wi th the remai ni ng
grease.
(11) Sl i de the boot onto the C/V housi ng i nto i t’s
ori gi nal posi ti on. Ensure boot i s not twi sted and
remove any excess ai r.
(12) Secure both boot cl amps wi th Cl amp I nstal l er
C-4975A. Pl ace tool on cl amp bri dge and ti ghten tool
unti l the jaws of the tool are cl osed.
Fig. 25 C/V COMPONENTS
1 - HOUSING
2 - BEARING ASSEMBLY
3 - HOUSING SNAP RING
4 - HOUSING BORE
3 - 18 HALF SHAFT KJ
CV J OINT/BOOT-INNER (Continued)
FRONT AXLE - 186FIA
TABLE OF CONTENTS
page page
FRONT AXLE - 186FIA
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - AXLE . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 25
SPECIFICATIONS - FRONT AXLE . . . . . . . . . . . 33
SPECIAL TOOLS
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . 34
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 41
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
PINION GEAR/RING GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
FRONT AXLE - 186FIA
DESCRIPTION
The 186FI A (Model 30) axl e consi sts of an al umu-
num center secti on wi th an axl e tube extendi ng from
one si de. The tube i s pressed i nto the di fferenti al
housi ng. The i ntegral type housi ng, hypoi d gear
desi gn has the centerl i ne of the pi ni on set bel ow the
centerl i ne of the ri ng gear.
The di fferenti al case i s a one-pi ece desi gn. The di ffer-
enti al pi ni on mate shaft i s retai ned wi th a rol l -pi n. Di f-
ferenti al beari ng prel oad and ri ng gear backl ash i s
adjusted by the use of shi ms (sel ect thi ckness). The
shi ms are l ocated between the di fferenti al beari ng cups
and the axl e housi ng. Pi ni on beari ng prel oad i s set and
mai ntai ned by the use of a col l apsi bl e spacer.
The power i s transferred from the axl e through two
constant vel oci ty (C/V) dri ve shafts to the wheel hubs.
The di fferenti al cover provi des a means for i nspec-
ti on and servi ce wi thout removi ng the axl e from the
vehi cl e. The cover has a vent tube used to rel i eve
i nternal pressure caused by vapori zati on and i nter-
nal expansi on.
OPERATION
The axl e recei ves power from the transfer case through
the front propel l er shaft. The front propel l er shaft i s con-
nected to the pi ni on gear whi ch rotates the di fferenti al
through the gear mesh wi th the ri ng gear bol ted to the
di fferenti al case. The engi ne power i s transmi tted to the
axl e shafts through the pi ni on mate and si de gears. The
si de gears are spl i ned to the axl e shafts.
Duri ng strai ght-ahead dri vi ng, the di fferenti al pi n-
i on gears do not rotate on the pi ni on mate shaft. Thi s
occurs because i nput torque appl i ed to the gears i s
di vi ded and di stri buted equal l y between the two si de
gears. As a resul t, the pi ni on gears revol ve wi th the
pi ni on mate shaft but do not rotate around i t (Fi g. 1).
Fig. 1 DIFFERENTIAL-STRAIGHT AHEAD DRIVING
1 - STRAIGHT AHEAD DRIVING
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
KJ FRONT AXLE - 186FIA 3 - 19
When turni ng corners, the outsi de wheel must
travel a greater di stance than the i nsi de wheel to
compl ete a turn. The di fference must be compensated
for to prevent the ti res from scuffi ng and ski ddi ng
through turns. To accompl i sh thi s, the di fferenti al
al l ows the axl e shafts to turn at unequal speeds (Fi g.
2). I n thi s i nstance, the i nput torque appl i ed to the
pi ni on gears i s not di vi ded equal l y. The pi ni on gears
now rotate around the pi ni on mate shaft i n opposi te
di recti ons. Thi s al l ows the si de gear and axl e shaft
attached to the outsi de wheel to rotate at a faster
speed.
DIAGNOSIS AND TESTING - AXLE
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, tooth contact, worn/damaged
gears or the carri er housi ng not havi ng the proper
offset and squareness.
Gear noi se usual l y happens at a speci fi c speed
range. The noi se can al so occur duri ng a speci fi c type
of dri vi ng condi ti on. These condi ti ons are accel era-
ti on, decel erati on, coast, or constant l oad.
When road testi ng, fi rst warm-up the axl e fl ui d by
dri vi ng the vehi cl e at l east 5 mi l es and then accel er-
ate the vehi cl e to the speed range where the noi se i s
the greatest. Shi ft out-of-gear and coast through the
peak-noi se range. I f the noi se stops or changes
greatl y:
• Check for i nsuffi ci ent l ubri cant.
• I ncorrect ri ng gear backl ash.
• Gear damage.
Di fferenti al si de gears and pi ni ons can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ght-ahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on mate shaft can al so cause a
snappi ng or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on beari ngs can
al l produce noi se when worn or damaged. Beari ng
noi se can be ei ther a whi ni ng, or a growl i ng sound.
Pi ni on beari ngs have a constant-pi tch noi se. Thi s
noi se changes onl y wi th vehi cl e speed. Pi ni on beari ng
noi se wi l l be hi gher pi tched because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
U-joi nt or by worn si de-gear thrust washers. A worn
pi ni on shaft bore wi l l al so cause l ow speed knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by:
• Damaged dri ve shaft.
• Mi ssi ng dri ve shaft bal ance wei ght(s).
• Worn or out of bal ance wheel s.
• Loose wheel l ug nuts.
• Worn U-joi nt(s).
• Loose/broken spri ngs.
• Damaged axl e shaft beari ng(s).
• Loose pi ni on gear nut.
• Excessi ve pi ni on yoke run out.
• Bent axl e shaft(s).
Check for l oose or damaged front end components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rear end
vi brati on. Do not overl ook engi ne accessori es, brack-
ets and dri ve bel ts.
Al l dri vel i ne components shoul d be exami ned
before starti ng any repai r.
Fig. 2 DIFFERENTIAL-ON TURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
3 - 20 FRONT AXLE - 186FIA KJ
FRONT AXLE - 186FIA (Continued)
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged) can be caused by:
• Hi gh engi ne i dl e speed.
• Transmi ssi on shi ft operati on.
• Loose engi ne/transmi ssi on/transfer case mounts.
• Worn U-joi nts.
• Loose spri ng mounts.
• Loose pi ni on gear nut and yoke.
• Excessi ve ri ng gear backl ash.
• Excessi ve si de gear to case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.
4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.
5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.
7. Inspect and replace as
necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
KJ FRONT AXLE - 186FIA 3 - 21
FRONT AXLE - 186FIA (Continued)
Condition Possible Causes Correction
Differential Cracked 1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
3 - 22 FRONT AXLE - 186FIA KJ
FRONT AXLE - 186FIA (Continued)
Condition Possible Causes Correction
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion
contact pattern.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
KJ FRONT AXLE - 186FIA 3 - 23
FRONT AXLE - 186FIA (Continued)
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove wheel and ti re assembl i es.
(3) Remove hal f shaft hub nuts.
(4) Remove l ower control arms. Refer to 2 suspen-
si on for procedure.
(5) Remove hal f shafts.
(6) Remove ski d pl ate.
(7) Remove di fferenti al drai n pl ug (Fi g. 3) and
drai n fl ui d.
(8) Remove di fferenti al vent hose (Fi g. 4) from
cover.
(9) Remove propel l er shaft from pi ni on fl ange.
(10) Support axl e wi th a l i ft/jack.
(11) Remove bol t from l eft front axl e bracket frame
mount (Fi g. 5).
(12) Remove bol ts from ri ght axl e bracket frame
mounts (Fi g. 6).
(13) Remove bol t from l eft rear axl e bracket frame
mount (Fi g. 7).
(14) Lower axl e from vehi cl e.
(15) Remove brackets from axl e i f necessary.
INSTALLATION
(1) I nstal l l eft rear bracket to axl e and ti ghten to
61 N·m (45 ft. l bs.).
(2) I nstal l ri ght bracket to axl e and ti ghten to 88
N·m (65 ft. l bs.).
(3) I nstal l l eft front bracket to axl e and ti ghten to
61 N·m (45 ft. l bs.).
(4) Rai se axl e up and al i gn brackets wi th frame
mounts.
(5) I nstal l frame mount bol ts and ti ghten to 88
N·m (65 ft. l bs.).
(6) I nstal l propel l er shaft.
(7) I nstal l hal f shafts.
Fig. 3 DRAIN PLUG
1 - LEFT FRONT AXLE BRACKET
2 - DRAIN PLUG
3 - DIFFERENTIAL HOUSING
Fig. 4 DIFFERENTIAL COVER
1 - COVER
2 - VENT TUBE
Fig. 5 LEFT FRONT AXLE BRACKET
1 - LEFT FRONT AXLE BRACKET
2 - BRACKET BOLT
3 - 24 FRONT AXLE - 186FIA KJ
FRONT AXLE - 186FIA (Continued)
(8) I nstal l l ower control arms, refer to 2 Suspen-
si on for procedures.
(9) I nstal l new hal f shaft hub nuts and ti ghten to
136 N·m (100 ft. l bs.).
(10) I nstal l axl e vent hose.
(11) Fi l l di fferenti al wi th gear l ubri cant.
(12) I nstal l ski d pl ate.
(13) I nstal l wheel and ti re assembl i es.
(14) Remove support and l ower vehi cl e.
(15) Check vehi cl e al i gnment.
ADJUSTMENTS
Ri ng and pi ni on gears are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng and
pi ni on gear are etched onto each gear (Fi g. 8). A pl us
(+) number, mi nus (–) number or zero (0) i s etched
i nto the face of the pi ni on gear. Thi s number i s the
amount (i n thousandths of an i nch) the depth vari es
from the standard depth setti ng of a pi ni on etched
wi th a (0). The standard setti ng from the center l i ne
of the ri ng gear to the back face of the pi ni on i s 92.1
mm (3.625 i n.). The standard depth provi des the best
gear tooth contact pattern. Refer to Backl ash and
Contact Pattern Anal ysi s paragraph i n thi s secti on
for addi ti onal i nformati on.
Fig. 6 RIGHT AXLE BRACKET
1 - RIGHT AXLE BRACKET
2 - FRONT BRACKET BOLT
3 - REAR BRACKET BOLT
Fig. 7 LEFT REAR AXLE BRACKET
1 - LEFT REAR AXLE BRACKET
2 - BRACKET BOLT
Fig. 8 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - DRIVE PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
KJ FRONT AXLE - 186FIA 3 - 25
FRONT AXLE - 186FIA (Continued)
Compensati on for pi ni on depth vari ance i s
achi eved wi th a sel ect shi m/oi l sl i nger. The shi ms are
pl aced between the rear pi ni on beari ng and the pi n-
i on gear head (Fi g. 9).
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance etched i nto both the ori gi nal and repl ace-
ment pi ni on. Add or subtract thi s number from the
thi ckness of the ori gi nal depth shi m/oi l sl i nger to
compensate for the di fference i n the depth vari ances.
Refer to the Pi ni on Gear Depth Vari ance chart.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. I ntersecti ng fi gure represents pl us or
mi nus the amount needed.
Note the etched number on the face of the pi ni on
gear head (–1, –2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi ms. I f the number
i s posi ti ve, subtract that val ue from the thi ckness of
the depth shi m. I f the number i s 0 no change i s nec-
essary.
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
Ϫ4 Ϫ3 Ϫ2 Ϫ1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003
0 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004
Ϫ1 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005
Ϫ2 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006
Ϫ3 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006 Ϫ0.007
Ϫ4 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006 Ϫ0.007 Ϫ0.008
Fig. 9 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM/OIL SLINGER
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
3 - 26 FRONT AXLE - 186FIA KJ
FRONT AXLE - 186FIA (Continued)
PINION DEPTH MEASUREMENT
Measurements are taken wi th pi ni on beari ng cups
and pi ni on beari ngs i nstal l ed i n the housi ng. Take
measurements wi th Pi ni on Gauge Set and Di al I ndi -
cator C-3339 (Fi g. 10).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 8804 and rear pi ni on beari ng onto Screw 6741
(Fi g. 10).
(2) I nsert hei ght gauge components i nto the hous-
i ng through pi ni on beari ng cups.
(3) I nstal l front pi ni on beari ng and hand ti ght
Cone-nut 6740 onto the screw.
(4) Posi ti on Arbor Di sc 6732 and Arbor D-115-3
i nto the housi ng beari ng cradl es. I nstal l di fferenti al
beari ng caps on Arbor Di scs and ti ghten bol ts to 41
N·m (30 ft. l bs.) (Fi g. 11).
NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(6) Posi ti on Scooter Bl ock/Di al I ndi cator fl ush on
the pi ni on hei ght bl ock. Hol d the scooter bl ock and
zero the di al i ndi cator.
(7) Sl owl y sl i de the scooter bl ock across the pi ni on
hei ght bl ock over to the arbor (Fi g. 12). Move the
scooter bl ock ti l l the di al i ndi cator probe crests the
arbor and record the hi ghest readi ng.
(8) Sel ect a shi m/oi l sl i nger equal to the di al i ndi -
cator readi ng pl us the pi ni on depth vari ance number
etched i n the face of the pi ni on (Fi g. 8). For exampl e,
i f the depth vari ance i s –2, add +0.002 i n. to the di al
i ndi cator readi ng.
DIFFERENTIAL
Di fferenti al beari ng prel oad and gear backl ash i s
adjusted by the use of sel ecti ve shi ms. The shi ms are
l ocated between the di fferenti al beari ng cups and the
di fferenti al housi ng. The proper shi m thi ckness can
be determi ned usi ng sl i p-fi t Dummy Beari ngs D-348
i n pl ace of the di fferenti al si de beari ngs and a Di al
I ndi cator C-3339. Before proceedi ng wi th the di ffer-
enti al beari ng prel oad and gear backl ash measure-
ments, measure the pi ni on gear depth and prepare
the pi ni on for i nstal l ati on. Establ i shi ng proper pi ni on
gear depth i s essenti al to establ i shi ng gear backl ash
and tooth contact patterns. After the overal l shi m
thi ckness to take up di fferenti al si de pl ay i s mea-
sured, the pi ni on i s i nstal l ed, and the gear backl ash
Fig. 10 PINION GEAR DEPTH TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 11 DEPTH TOOLS IN HOUSING
1 - PINION HEIGHT BLOCK
2 - ARBOR DISC
3 - ARBOR
4 - PINION BLOCK
KJ FRONT AXLE - 186FIA 3 - 27
FRONT AXLE - 186FIA (Continued)
shi m thi ckness i s measured. The overal l shi m thi ck-
ness i s the total of the di al i ndi cator readi ng and the
prel oad speci fi cati on added together. The gear back-
l ash measurement determi nes the thi ckness of the
shi m used on the ri ng gear si de of the di fferenti al
case. Subtract the gear backl ash shi m thi ckness from
the total overal l shi m thi ckness and sel ect that
amount for the pi ni on gear si de of the di fferenti al
(Fi g. 13). Di fferenti al shi m measurements are per-
formed wi th spreader W-129-B removed.
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove di fferenti al si de beari ngs from di ffer-
enti al case.
(2) I nstal l ri ng gear on di fferenti al case and
ti ghten bol ts to speci fi cati on.
(3) I nstal l Dummy Beari ngs D-348 on di fferenti al
case.
(4) I nstal l di fferenti al case i n the housi ng.
(5) Record the thi ckness of Dummy Shi ms 8107.
I nsert the shi ms between the dummy beari ngs and
the di fferenti al housi ng (Fi g. 14).
Fig. 12 PINION DEPTH MEASUREMENT
1 - SCOOTER BLOCK
2 - ARBOR
3 - DIAL INDICATOR
Fig. 13 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM/OIL SLINGER
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
Fig. 14 DUMMY SHIMS
1 - DUMMY SHIM
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS
3 - 28 FRONT AXLE - 186FIA KJ
FRONT AXLE - 186FIA (Continued)
(6) I nstal l the beari ng caps i n thei r correct posi -
ti ons and snug the bol ts (Fi g. 15).
(7) Wi th a dead-bl ow hammer, seat the di fferenti al
dummy beari ngs to each si de of the axl e housi ng
(Fi g. 16) and (Fi g. 17).
(8) Thread Pi l ot Stud C-3288-B i nto rear cover bol t
hol e bel ow ri ng gear.
(9) Attach a Di al I ndi cator C-3339 to the Pi l ot
Stud. Posi ti on the di al i ndi cator pl unger on fl at sur-
face between the ri ng gear bol ts.
(10) Push and hol d di fferenti al case to pi ni on gear
si de of the housi ng and zero di al i ndi cator (Fi g. 18).
Fig. 15 BEARING CAP BOLTS
Fig. 16 SEAT DUMMY BEARINGS PINION SIDE
1 - HAMMER
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL
Fig. 17 SEAT DUMMY BEARING RING GEAR SIDE
1 - DIFFERENTAIL HOUSING
2 - HAMMER
3 - RING GEAR
Fig. 18 DIFFERENTIAL PINION GEAR SIDE
1 - PINION SIDE
2 - PILOT STUD
3 - DIAL INDICATOR
KJ FRONT AXLE - 186FIA 3 - 29
FRONT AXLE - 186FIA (Continued)
(11) Push and hol d di fferenti al case to ri ng gear
si de of the housi ng and record di al i ndi cator readi ng
(Fi g. 19).
(12) Add 0.152 mm (0.006 i n.) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms to compress or prel oad the new beari ngs when
the di fferenti al i s i nstal l ed.
(13) Rotate di al i ndi cator out of the way on the
pi l ot stud.
(14) Remove di fferenti al case and dummy beari ngs
from the housi ng.
(15) I nstal l the pi ni on gear i n the housi ng. I nstal l
the pi ni on yoke and establ i sh the correct pi ni on
rotati ng torque.
(16) I nstal l di fferenti al case and Dummy Beari ngs
D-348 i n the housi ng.
(17) I nstal l a si ngl e dummy shi m i n the ri ng gear
si de. I nstal l beari ng caps and ti ghten bol ts snug.
(18) Seat ri ng gear si de dummy beari ng (Fi g. 17).
(19) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads.
(20) Push and hol d di fferenti al case toward pi ni on
gear and zero di al i ndi cator (Fi g. 20).
(21) Push and hol d di fferenti al case to ri ng gear
si de of the housi ng and record di al i ndi cator readi ng
(Fi g. 21). Add dummy shi m thi ckness to thi s readi ng.
Thi s wi l l be the total shi m thi ckness to achi eve zero
backl ash.
(22) Subtract 0.076 mm (0.003 i n.) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Thi s total i s the thi ckness
shi m requi red to achi eve proper backl ash.
(23) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
axl e housi ng.
(24) Rotate di al i ndi cator out of the way on pi l ot
stud.
(25) Remove di fferenti al case and dummy beari ngs
from the housi ng.
(26) I nstal l si de beari ngs and cups on di fferenti al
case.
(27) I nstal l spreader W-129-B wi th Adapter Set
6987 on the housi ng and spread axl e openi ng enough
to recei ve di fferenti al case.
CAUTION: Never spread the differential housing
over 0.34 mm (0.013 in.). If the housing is over-
spread, it could be distorted or damaged.
Fig. 19 DIFFERENTIAL RING GEAR SIDE
1 - DIAL INDICATOR
2 - DIFFERENTIAL HOUSING
Fig. 20 DIFFERENTIAL PINION GEAR SIDE
1 - DIAL INDICATOR
2 - PINION GEAR
3 - RING GEAR
Fig. 21 DIFFERENTIAL RING GEAR SIDE
1 - DIAL INDICATOR
2 - PINION GEAR
3 - RING GEAR
3 - 30 FRONT AXLE - 186FIA KJ
FRONT AXLE - 186FIA (Continued)
(28) Pl ace the beari ng prel oad shi ms i n the axl e
housi ng, agai nst the axl e tubes.
(29) I nstal l di fferenti al case i nto the housi ng.
(30) Remove spreader from the housi ng.
(31) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(32) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 22).
(33) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(34) Zero di al i ndi cator face to poi nter.
(35) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm (0.005 i n.) and
0.20 mm (0.008 i n.). I f backl ash i s not wi thi n speci fi -
cati ons transfer the necessary amount of shi m thi ck-
ness from one si de of the housi ng to the other (Fi g.
23).
(36) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at ei ght
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform
Gear Contact Pattern Anal ysi s procedure.
GEAR CONTACT PATTERN
The ri ng gear and pi ni on teeth contact patterns
wi l l show i f the pi ni on depth i s correct i n the hous-
i ng. I t wi l l al so show i f the ri ng gear backl ash has
been adjusted correctl y. The backl ash can be adjusted
wi thi n speci fi cati ons to achi eve desi red tooth contact
patterns.
(1) Appl y a thi n coat of hydrated ferri c oxi de or
equi val ent to the dri ve and coast si de of the ri ng gear
teeth.
(2) Wrap, twi st and hol d a shop towel around the
pi ni on yoke to i ncrease the turni ng resi stance of the
pi ni on. Thi s wi l l provi de a more di sti nct contact pat-
tern.
(3) Wi th a boxed end wrench on a ri ng gear bol t,
rotate the di fferenti al case one compl ete revol uti on i n
both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on teeth wi l l squee-
gee the compound to the areas wi th the l east amount
of contact. Note and compare patterns on the ri ng
gear teeth to Gear Tooth Contact Patterns chart (Fi g.
24)and adjust pi ni on depth and gear backl ash as nec-
essary.
Fig. 22 RING GEAR BACKLASH
1 - DIAL INDICATOR
2 - RING GEAR
Fig. 23 BACKLASH SHIMS
KJ FRONT AXLE - 186FIA 3 - 31
FRONT AXLE - 186FIA (Continued)
Fig. 24 GEAR TOOTH CONTACT PATTERNS
3 - 32 FRONT AXLE - 186FIA KJ
FRONT AXLE - 186FIA (Continued)
DIFFERENTIAL BEARING PRELOAD CHECK
The fi nal check on the di fferenti al assembl y before
i nstal l i ng the axl es, i s torque to rotate pi ni on and
di fferenti al combi ned. Thi s wi l l veri fy the correct di f-
ferenti al beari ng prel oad.
Torque to rotate the di fferenti al and pi ni on i s the
torque to rotate the pi ni on pl us:
Gear Rati o 3.73 . . . . 0.45-0.75 N·m (3.9-6.6 i n. l bs.)
Gear Rati o 3.91 . . . . 0.43-0.72 N·m (3.8-6.4 i n. l bs.)
Gear Rati o 4.10 . . . . 0.41-0.69 N·m (3.6-6.0 i n. l bs.)
SPECIFICATIONS - FRONT AXLE
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.73, 3.92, 4.10
Ring Gear Diameter 186 mm (7.33 in.)
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Gear Standard Depth 92.1 mm (3.625 in.)
Pinion Bearing Preload 1.69-2.82 N·m (15-25 in. lbs.)
Differential Bearing Preload
Added To Pinion Torque To Rotate
Gear Ratio 3.73 0.45-0.75 N·m (3.9-6.6 in. lbs.)
Gear Ratio 3.92 0.43-0.72 N·m (3.8-6.4 in. lbs.)
Gear Ratio 4.10 0.41-0.69 N·m (3.6-6.0 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Ring Gear Bolts 95-122 70-90 -
Differential Bearing Cap
Bolts
54-67 39-50 -
Differential Cover Bolts 19-26 14-19 -
Pinion Nut 217-352 160-260 -
Left Axle Bracket Bolts 61 45 -
Front Axle Bracket Bolts 61 45 -
Right Axle Bracket Bolts 88 65 -
Axle Brackets To Frame
Bolts
88 65 -
KJ FRONT AXLE - 186FIA 3 - 33
FRONT AXLE - 186FIA (Continued)
SPECIAL TOOLS
FRONT AXLE
PULLER C-293-PA
PLUG SP-3289
ADAPTER C-293-39
PULLER C-452
DIAL INDICATOR C-3339
INSTALLER C-3716-A
HANDLE C-4171
INSTALLER D-146
REMOVER D-149
INSTALLER W-162-D
3 - 34 FRONT AXLE - 186FIA KJ
FRONT AXLE - 186FIA (Continued)
CUP 8109
PINION DEPTH SET 6774
PINION BLOCK 8804
SPANNER WRENCH 6958
SPREADER W-129-B
ADAPTER KIT 6987B
PILOT STUD C-3288-B
REMOVER C-4307
INSTALLER C-4308
INSTALLER 6448
KJ FRONT AXLE - 186FIA 3 - 35
FRONT AXLE - 186FIA (Continued)
ADAPTER C-293-42
INSTALLER 8805
INSTALLER 8806
REMOVER 8420A
REMOVER 7794-A
3 - 36 FRONT AXLE - 186FIA KJ
FRONT AXLE - 186FIA (Continued)
AXLE SHAFTS
REMOVAL
(1) Pl ace the transmi ssi on i n Neutral .
(2) Rai se and support vehi cl e.
(3) Remove ri ght wheel and ti re and assembl y.
(4) Remove ri ght hal f shaft from vehi cl e.
(5) Remove snap ri ng from axl e shaft.
(6) Assembl e Remover 8420A onto the shaft (Fi g.
25). Thread sl i d hammer i nto remover and remove
shaft.
(7) Sl i de axl e shaft out of the axl e tube.
NOTE: Use care to prevent damage to axle shaft
bearing and seal, which will remain in axle shaft
tube.
INSTALLATION
(1) Lubri cate beari ng bore and seal l i p wi th gear
l ubri cant. I nsert axl e shaft through seal , beari ng
(Fi g. 26) and engage i t i nto si de gear spl i nes.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal.
(2) Push on the axl e shaft unti l the axl e shaft
snap-ri ng passes through the si de gear.
(3) I nstal l ri ght hal f shaft.
(4) I nstal l ri ght wheel and ti re assembl y.
(5) Check di fferenti al fl ui d l evel .
(6) Lower vehi cl e.
AXLE SHAFT SEALS
REMOVAL
(1) Remove hal f shaft.
(2) Remove axl e shaft for ri ght si de seal removal .
(3) Remove shaft seal wi th Remover 7794-A and a
sl i de hammer (Fi g. 27).
Fig. 25 AXLE SHAFT PULLER
1 - SNAP RING GROVE
2 - SLID HAMMER THREADS
3 - REMOVER BLOCKS
4 - REMOVER COLLAR
Fig. 26 AXLE SHAFT SEAL
1 - BEARING
2 - SEAL
Fig. 27 SHAFT SEAL REMOVER
1 - SHAFT SEAL
2 - REMOVER
KJ FRONT AXLE - 186FIA 3 - 37
INSTALLATION
(1) Appl y a l i ght coat of l ubri cant on the l i p of the
shaft seal .
(2) I nstal l new shaft seal wi th I nstal l er 8806 and
Handl e C-4171 (Fi g. 28).
(3) I nstal l ri ght axl e shaft i f removed.
(4) I nstal l hal f shaft.
AXLE BEARINGS
REMOVAL
(1) Remove hal f shaft.
(2) Remove axl e shaft for ri ght si de seal removal .
(3) Remove shaft seal wi th Remover 7794-A and a
sl i de hammer.
(4) Remove shaft beari ng wi th Remover 7794-A
and a sl i de hammer (Fi g. 29).
INSTALLATION
(1) I nstal l new shaft beari ng wi th I nstal l er 8805
and Handl e C-4171.
(2) Appl y a l i ght coat of l ubri cant on the l i p of the
shaft seal .
(3) I nstal l new shaft seal wi th an appropri ate
i nstal l er.
(4) I nstal l ri ght axl e shaft i f removed.
(5) I nstal l hal f shaft.
PINION SEAL
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove wheel and ti re assembl i es.
(3) Remove brake cal i pers and rotors, refer to 5
Brakes for procedures.
(4) Mark propel l er shaft and pi ni on compani on
fl ange for i nstal l ati on reference.
(5) Remove propel l er shaft from the pi ni on com-
pani on fl ange.
(6) Rotate pi ni on gear a mi ni mum of ten ti mes and
veri fy the pi ni on rotates smoothl y.
(7) Record the torque to rotate the pi ni on gear
(Fi g. 30) wi th a i nch pound torque wrench.
Fig. 28 SEAL INSTALLER
1 - SEAL BORE
2 - INSTALLER
Fig. 29 SHAFT BEARING REMOVER
1 - SHAFT BEARING
2 - REMOVER
Fig. 30 PINION ROTATING TORQUE
1 - PINION COMPANION FLANGE
2 - TORQUE WRENCH
3 - 38 FRONT AXLE - 186FIA KJ
AXLE SHAFT SEALS (Continued)
(8) Usi ng a short pi ece of pi pe and Spanner
Wrench 6958 to hol d the pi ni on compani on fl ange
(Fi g. 31) and remove the pi ni on nut.
(9) Remove pi ni on compani on fl ange (Fi g. 32) wi th
Remover C-452 and Spanner Wrench 6958.
(10) Remove pi ni on seal wi th Remover 7794-A and
a sl i de hammer (Fi g. 33).
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th an appropri ate
i nstal l er (Fi g. 34).
(2) I nstal l pi ni on compani on fl ange on the pi ni on
gear wi th I nstal l er W-162-D, Cup 8109 and Wrench
6958.
CAUTION: Do not exceed the minimum tightening
torque 216 N·m (160 ft. lbs.) while installing pinion
nut at this point. Damage to collapsible spacer or
bearings may result.
(3) I nstal l a new nut on the pi ni on gear. Tighten
the nut only enough to remove the shaft end
play.
CAUTION: Never loosen pinion nut to decrease pin-
ion rotating torque and never exceed specified pre-
load torque. If preload torque or rotating torque is
exceeded a new collapsible spacer must be
installed.
Fig. 31 PINION FLANGE NUT
1 - SPANNER WRENCH
2 - PINION COMPANION FLANGE
Fig. 32 PINION FLANGE REMOVER
1 - SPANNER WRENCH
2 - REMOVER
Fig. 33 PINION SEAL
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 34 PINION SEAL INSTALLATION
1 - HANDLE
2 - INSTALLER
KJ FRONT AXLE - 186FIA 3 - 39
PINION SEAL (Continued)
(4) Rotate pi ni on a mi ni mum of ten ti me and ver-
i fy pi ni on rotates smoothl y. Rotate the pi ni on shaft
wi th an i nch pound torque wrench. Rotati ng torque
shoul d be equal to the readi ng recorded duri ng
removal pl us 0.56 N·m (5 i n. l bs.) (Fi g. 35).
(5) I f the rotati ng torque i s l ow, use Spanner
Wrench 6958 to hol d the pi ni on compani on fl ange
and ti ghten the pi ni on shaft nut i n 6.8 N·m (5 ft.
l bs.) i ncrements unti l proper rotati ng torque i s
achi eved.
CAUTION: If maximum tightening torque is reached
prior to reaching the required rotating torque, the
collapsible spacer may have been damaged.
Replace the collapsible spacer.
(6) I nstal l propel l er shaft wi th i nstal l ati on refer-
ence marks al i gned.
(7) Fi l l di fferenti al wi th gear l ubri cant.
(8) I nstal l brake rotors and cal i pers.
(9) I nstal l wheel and ti re assembl i es.
(10) Lower the vehi cl e.
DIFFERENTIAL
REMOVAL
(1) Remove axl e from the vehi cl e.
(2) Remove di fferenti al housi ng cover (Fi g. 36).
(3) Push ri ght axl e shaft out of si de gear (Fi g. 37)
and remove the shaft.
(4) Mark di fferenti al beari ng caps for i nstal l ati on
reference.
(5) Loosen the beari ng cap bol ts.
Fig. 35 PINION ROTATING TORQUE
1 - PINION COMPANION FLANGE
2 - TORQUE WRENCH
Fig. 36 DIFFERENTIAL COVER
1 - COVER
2 - VENT TUBE
Fig. 37 RIGHT SHAFT IN SIDE GEAR
1 - AXLE SHAFT
2 - SCREWDRIVER
3 - SIDE GEAR
3 - 40 FRONT AXLE - 186FIA KJ
PINION SEAL (Continued)
(6) Posi ti on Spreader W-129-B onto the di fferenti al
l ocati ng hol es and i nstal l the safety hol ddown cl amps
(Fi g. 38). Ti ghten the tool turnbuckl e fi nger-ti ght.
(7) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load i ndi cator pl unger agai nst the
opposi te si de of the housi ng and zero the i ndi cator.
(8) Spread the housi ng to remove the di fferenti al
case from the housi ng. Measure the di stance wi th the
di al i ndi cator (Fi g. 39).
CAUTION: Never spread the differential housing
over 0.34 mm (0.013 in). If housing is over-spread, it
could be distorted or damaged.
(9) Remove the di al i ndi cator.
(10) Hol di ng the di fferenti al case i n posi ti on, and
remove beari ng cap bol ts and caps.
(11) Remove the di fferenti al from the housi ng (Fi g.
40). Ensure di fferenti al beari ng cups and shi ms
remai n i n posi ti on on the di fferenti al beari ngs.
(12) Tag di fferenti al beari ng cups and shi ms to
i ndi cate thei r l ocati on.
(13) Remove spreader from housi ng.
DISASSEMBLY
(1) Remove ri ng gear.
(2) Remove rol l -pi n hol di ng mate shaft i n housi ng.
(3) Remove pi ni on gear mate shaft.
(4) Rotate di fferenti al si de gears and remove the
pi ni on mate gears and thrust washers (Fi g. 41).
(5) Remove di fferenti al si de gears and thrust
washers.
ASSEMBLY
(1) I nstal l di fferenti al si de gears and thrust wash-
ers.
(2) I nstal l pi ni on mate gears and thrust washers.
(3) I nstal l pi ni on gear mate shaft.
(4) Al i gn hol e i n the pi ni on gear mate shaft wi th
the hol e i n the di fferenti al case.
Fig. 38 DIFFERENTIAL SPREADER
1 - DIFFERENTIAL HOUSING
2 - SAFETY CLAMPS
3 - SPREADER
4 - TURNBUCKLE
Fig. 39 SPREAD DIFFERENTIAL CASE
1 - PILOT STUD
2 - DIAL INDICATOR
3 - SPREADER
KJ FRONT AXLE - 186FIA 3 - 41
DIFFERENTIAL (Continued)
(5) I nstal l the rol l -pi n i n the di fferenti al case wi th
a hammer and punch (Fi g. 42). Peen the edge of the
rol l -pi n hol e i n the di fferenti al case i n two pl aces
180° apart.
(6) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
(7) I nstal l ri ng gear.
INSTALLATION
NOTE: If differential bearings or differential case are
replaced, Refer to adjustments fore Differential
Bearing Preload and Gear Backlash procedures.
(1) Posi ti on Spreader W-129-B on di fferenti al l oca-
ti on hol es and i nstal l safety hol ddown cl amps.
Ti ghten the tool turnbuckl e fi nger-ti ght.
(2) I nstal l Pi l ot Stud C-3288-B to the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load the i ndi cator pl unger agai nst the
opposi te si de of the housi ng and zero the i ndi cator.
(3) Spread the housi ng to i nstal l the di fferenti al
case and prel oad shi ms i n the housi ng. Measure the
di stance wi th the di al i ndi cator.
CAUTION: Never spread the differential housing
over 0.34 mm (0.013 in). If housing is over-spread, it
could be distorted or damaged.
Fig. 40 DIFFERENTIAL CASE
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - DIFFERENTIAL BEARINGS
Fig. 41 PINION MATE GEAR
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
Fig. 42 PINION MATE SHAFT ROLL-PIN
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
3 - 42 FRONT AXLE - 186FIA KJ
DIFFERENTIAL (Continued)
(4) Remove the di al i ndi cator.
(5) I nstal l di fferenti al case i n the housi ng. Ensure
di fferenti al beari ng cups remai n on the beari ngs and
prel oad shi ms are seated i n the housi ng. Tap di ffer-
enti al case to ensure beari ngs cups are seated i n the
housi ng.
(6) I nstal l beari ng caps to thei r ori gi nal l ocati ons
and l oosel y i nstal l cap bol ts.
(7) Remove di fferenti al housi ng spreader (Fi g. 43).
(8) Ti ghten the beari ng cap bol ts i n a cri ss-cross
pattern to 54-68 N·m (39-50 ft. l bs.).
(9) I nstal l the ri ght axl e shaft.
(10) Appl y a 6.38mm (1/4 i n.) bead of red Mopar
Si l i cone Seal er or equi val ent to the housi ng cover.
CAUTION: If cover is not installed within 3 to 5 min-
utes, the cover must be cleaned and new RTV
applied or adhesion quality will be compromised.
(11) I nstal l di fferenti al housi ng cover and ti ghten
bol ts i n a cri ss-cross pattern to 19-26 N·m (14-19 ft.
l bs.).
(12) I nstal l axl e assembl y i n vehi cl e.
(13) Fi l l di fferenti al wi th l ubri cant and i nstal l fi l l
pl ug.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove di fferenti al from the housi ng.
(2) Remove beari ngs from the di fferenti al case
wi th Pul l er/Press C-293-PA, Adapters C-293-39 and
Pl ug SP-3289 (Fi g. 44).
Fig. 43 DIFFERENTIAL SPREADER
1 - DIFFERENTIAL HOUSING
2 - SAFETY CLAMPS
3 - SPREADER
4 - TURNBUCKLE
Fig. 44 DIFFERENTIAL BEARING PULLER
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
KJ FRONT AXLE - 186FIA 3 - 43
DIFFERENTIAL (Continued)
INSTALLATION
(1) I nstal l di fferenti al case beari ngs wi th I nstal l er
C-3716-A and Handl e C-4171 (Fi g. 45).
(2) I nstal l di fferenti al i nto the housi ng.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring gear and pinion are serviced as a
matched set. Never replace ring gear without
replacing the matched pinion gear.
(1) Rai se and support vehi cl e
(2) Mark pi ni on compani on fl ange and propel l er
shaft for i nstal l ati on al i gnment.
(3) Remove propel l er shaft from pi ni on compani on
fl ange and ti e propel l er shaft to underbody.
(4) Remove axl e assembl y from the vehi cl e.
(5) Remove di fferenti al from axl e housi ng.
(6) Pl ace di fferenti al case i n a vi se wi th soft metal
jaw (Fi g. 46).
(7) Remove bol ts hol di ng ri ng gear to di fferenti al
case.
(8) Dri ver ri ng gear off the di fferenti al case wi th a
rawhi de hammer (Fi g. 46).
(9) Wi th Spanner Wrench 6958 and a short l ength
of 1 i n. pi pe, hol d pi ni on compani on fl ange and
remove pi ni on nut (Fi g. 47).
Fig. 45 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 46 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 47 PINION COMPANION FLANGE
1 - SPANNER WRENCH
2 - PINION COMPANION FLANGE
3 - 44 FRONT AXLE - 186FIA KJ
DIFFERENTIAL CASE BEARINGS (Continued)
(10) Remove pi ni on compani on fl ange from pi ni on
shaft wi th Remover C-452 and Fl ange Wrench
C-3281 (Fi g. 48).
(11) Remove pi ni on gear and col l apsi bl e spacer
from housi ng (Fi g. 49).
(12) Remove front pi ni on beari ng cup, beari ng, oi l
sl i nger and pi ni on seal wi th Remover C-149 and
Handl e C-4171 (Fi g. 50).
(13) Remove rear pi ni on beari ng cup (Fi g. 51) wi th
Remover C-4307 and Handl e C-4171.
Fig. 48 PINION FLANGE REMOVER
1 - SPANNER WRENCH
2 - REMOVER
Fig. 49 PINION GEAR
1 - RAWHIDE HAMMER
Fig. 50 FRONT BPINION BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 51 REAR PINION BEARING CUP
1 - REMOVER
2 - HANDLE
KJ FRONT AXLE - 186FIA 3 - 45
PINION GEAR/RING GEAR (Continued)
(14) Remove col l apsi bl e prel oad spacer from pi ni on
gear (Fi g. 52).
(15) Remove rear pi ni on beari ng from the pi ni on
wi th Pul l er/Press C-293-PA and Adapters C-293-39
(Fi g. 53). Remove oi l sl i nger/pi ni on depth shi m from
the pi ni on shaft and record thi ckness.
INSTALLATION
NOTE: Pinion depth shims are placed between the
rear pinion bearing and the pinion gear head to
achieve proper ring and pinion gear mesh. If ring
and pinion gears are reused, the pinion oil slinger/
depth shim should not require replacement. Refer
to Adujstments (Pinion Gear Depth) to select the
proper thickness shim before installing pinion gear.
(1) Appl y Mopar Door Ease or equi val ent l ubri cant
to outsi de surface of pi ni on beari ng cups.
(2) I nstal l rear beari ng cup wi th I nstal l er C-4308
and Handl e C-4171 and veri fy cup i s seated.
(3) I nstal l front beari ng cup wi th I nstal l er D-146
and Handl e C-4171 (Fi g. 54) and veri fy cup i s seated.
(4) I nstal l front pi ni on beari ng, and oi l sl i nger i f
equi pped.
Fig. 52 COLLAPSIBLE PRELOAD SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING
Fig. 53 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
Fig. 54 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
3 - 46 FRONT AXLE - 186FIA KJ
PINION GEAR/RING GEAR (Continued)
(5) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal and i ntal l seal wi th an appropri ate
i nstal l er (Fi g. 55).
(6) I nstal l rear pi ni on beari ng and oi l sl i nger/depth
shi m onto the pi ni on shaft wi th I nstal l er 6448 and a
press (Fi g. 56).
(7) I nstal l a new col l apsi bl e spacer on pi ni on shaft
and i nstal l the pi ni on i nto the housi ng (Fi g. 57).
(8) I nstal l pi ni on compani on fl ange, wi th I nstal l er
W-162-D, Cup 8109 and Spanner Wrench 6958.
(9) I nstal l pi ni on a new nut onto the pi ni on gear
and ti ghten the nut to 216 N·m (160 ft. l bs.). Do not
over-tighten.
CAUTION: Never loosen pinion gear nut to decrease
pinion rotating torque and never exceed specified
preload torque. If preload torque is exceeded a new
collapsible spacer must be installed.
Fig. 55 PINION SEAL
1 - HANDLE
2 - INSTALLER
Fig. 56 REAR PINION BEARING
1 - INSTALLER
2 - OIL SLINGER
3 - PINION GEAR
4 - REAR PINION BEARING
5 - PRESS
Fig. 57 COLLAPSIBLE PRELOAD SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING
KJ FRONT AXLE - 186FIA 3 - 47
PINION GEAR/RING GEAR (Continued)
(10) Use Fl ange Wrench 6958, a l ength of 1 i n.
pi pe and a torque wrench set at 678 N·m (500 ft. l bs.)
and crush col l apsi bl e spacer unti l beari ng end pl ay i s
taken up (Fi g. 58).
(11) Sl owl y ti ghten the nut i n 6.8 N·m (5 ft. l b.)
i ncrements unti l the requi red rotati ng torque i s
achi eved. Measure the rotati ng torque frequentl y to
avoi d over crushi ng the col l apsi bl e spacer (Fi g. 59).
(12) Rotate the pi ni on a mi ni mum of ten ti mes.
Veri fy pi ni on rotates smoothl y and check rotati ng
torque wi th an i nch pound torque wrench (Fi g. 59).
Pi ni on gear rotati ng torque i s:
• Ori gi nal Beari ngs: 1 to 2.25 N·m (10 to 20 i n.
l bs.).
• New Beari ngs: 1.69 to 2.82 N·m (15 to 25 i n.
l bs.).
(13) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
(14) I nvert the di fferenti al case i n the vi se. I nstal l
new ri ng gear bol ts and al ternatel y ti ghten to 108
N·m (80 ft. l bs.) (Fi g. 60).
CAUTION: Never reuse the ring gear bolts. The
bolts can fracture causing extensive damage.
(15) I nstal l di fferenti al i n housi ng and veri fy di f-
ferenti al beari ng prel oad, gear mesh and contact pat-
tern. Refer to Adjustment for procedure.
(16) I nstal l di fferenti al cover and fi l l wi th gear
l ubri cant.
(17) I nstal l propel l er shaft wi th reference marks
al i gned.
(18) Remove supports and l ower vehi cl e.
Fig. 58 PINION FLANGE NUT
1 - SPANNER WRENCH
2 - PINION COMPANION FLANGE
Fig. 59 PINION ROTATING TORQUE
1 - PINION COMPANION FLANGE
2 - TORQUE WRENCH
Fig. 60 RING GEAR BOLTS
1 - TORQUE WRENCH
2 - RING GEAR BOLTS
3 - RING GEAR
4 - DIFFERENTIAL CASE
3 - 48 FRONT AXLE - 186FIA KJ
PINION GEAR/RING GEAR (Continued)
REAR AXLE - 198RBI
TABLE OF CONTENTS
page page
REAR AXLE - 198RBI
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 49
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
DIAGNOSIS AND TESTING - AXLE . . . . . . . . . . 51
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 55
SPECIFICATIONS - REAR AXLE . . . . . . . . . . . . 62
SPECIAL TOOLS
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 63
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 65
AXLE BEARING/SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68
COLLAPSIBLE SPACER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKா . . . . . 74
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 75
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 77
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79
PINION GEAR/RING GEAR/TONE RING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 82
REAR AXLE - 198RBI
DESCRIPTION
The Rear Beam-desi gn I ron (RBI ) axl e housi ng has
an i ron center casti ng (di fferenti al housi ng) wi th axl e
shaft tubes extendi ng from ei ther si de. The tubes are
pressed i nto and wel ded to the di fferenti al housi ng to
form a one-pi ece axl e housi ng. The axl es are
equi pped wi th semi –fl oati ng axl e shafts, meani ng
that l oads are supported by the axl e shaft and bear-
i ngs. The axl e shafts are retai ned by the uni t bear-
i ng, retai ner pl ate and bol ts.
The i ntegral type, hypoi d gear desi gn, housi ng has
the centerl i ne of the pi ni on set bel ow the centerl i ne
of the ri ng gear. The di fferenti al case i s a one-pi ece
desi gn. The di fferenti al pi ni on mate shaft i s retai ned
wi th a threaded screw. Di fferenti al beari ng prel oad
and ri ng gear backl ash i s adjusted by the use of
sel ecti ve spacer shi ms. Pi ni on beari ng prel oad i s set
and mai ntai ned by the use of a col l apsi bl e spacer
(Fi g. 1).
The cover provi des a means for servi ci ng the di ffer-
enti al wi thout removi ng the axl e. The axl e has a vent
hose to rel i eve i nternal pressure caused by l ubri cant
vapori zati on and i nternal expansi on.
Axl es equi pped wi th a Trac-Lok௡ di fferenti al are
opti onal . A Trac-Lok௡ di fferenti al has a one-pi ece di f-
ferenti al case, and the same i nternal components as
a standard di fferenti al , pl us two cl utch di sc packs.
OPERATION
The axl e recei ves power from the transmi ssi on/
transfer case through the rear propel l er shaft. The
Fig. 1 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
5 - COLLAPSIBLE SPACER
KJ REAR AXLE - 198RBI 3 - 49
rear propel l er shaft i s connected to the pi ni on gear
whi ch rotates the di fferenti al through the gear mesh
wi th the ri ng gear bol ted to the di fferenti al case. The
engi ne power i s transmi tted to the axl e shafts
through the pi ni on mate and si de gears. The si de
gears are spl i ned to the axl e shafts.
STANDARD DIFFERENTIAL
Duri ng strai ght-ahead dri vi ng, the di fferenti al pi n-
i on gears do not rotate on the pi ni on mate shaft. Thi s
occurs because i nput torque appl i ed to the gears i s
di vi ded and di stri buted equal l y between the two si de
gears. As a resul t, the pi ni on gears revol ve wi th the
pi ni on mate shaft but do not rotate around i t (Fi g. 2).
When turni ng corners, the outsi de wheel must
travel a greater di stance than the i nsi de wheel to
compl ete a turn. The di fference must be compensated
for to prevent the ti res from scuffi ng and ski ddi ng
through turns. To accompl i sh thi s, the di fferenti al
al l ows the axl e shafts to turn at unequal speeds (Fi g.
3). I n thi s i nstance, the i nput torque appl i ed to the
pi ni on gears i s not di vi ded equal l y. The pi ni on gears
now rotate around the pi ni on mate shaft i n opposi te
di recti ons. Thi s al l ows the si de gear and axl e shaft
attached to the outsi de wheel to rotate at a faster
speed.
TRAC-LOK™ DIFFERENTIAL
The Trac-l ok™ cl utches are engaged by two concur-
rent forces. The fi rst bei ng the prel oad force exerted
through Bel l evi l l e spri ng washers wi thi n the cl utch
packs. The second i s the separati ng forces generated
by the si de gears as torque i s appl i ed through the
ri ng gear (Fi g. 4).
Fig. 2 DIFFERENTIAL-STRAIGHT AHEAD DRIVING
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
Fig. 3 DIFFERENTIAL-ON TURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
Fig. 4 TRAC-LOK DIFFERENTIAL
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
3 - 50 REAR AXLE - 198RBI KJ
REAR AXLE - 198RBI (Continued)
The Trac-l ok™ desi gn provi des the di fferenti al
acti on needed for turni ng corners and for dri vi ng
strai ght ahead duri ng peri ods of unequal tracti on.
When one wheel l ooses tracti on, the cl utch packs
transfer addi ti onal torque to the wheel havi ng the
most tracti on. Trac-l ok™ di fferenti al s resi st wheel
spi n on bumpy roads and provi de more pul l i ng power
when one wheel l ooses tracti on. Pul l i ng power i s pro-
vi ded conti nuousl y unti l both wheel s l oose tracti on. I f
both wheel s sl i p due to unequal tracti on, Trac-l ok™
operati on i s normal . I n extreme cases of di fferences
of tracti on, the wheel wi th the l east tracti on may
spi n.
DIAGNOSIS AND TESTING - AXLE
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, i ncorrect pi ni on depth, tooth
contact, worn/damaged gears, or the carri er housi ng
not havi ng the proper offset and squareness.
Gear noi se usual l y happens at a speci fi c speed
range. The noi se can al so occur duri ng a speci fi c type
of dri vi ng condi ti on. These condi ti ons are accel era-
ti on, decel erati on, coast, or constant l oad.
When road testi ng, fi rst warm-up the axl e fl ui d by
dri vi ng the vehi cl e at l east 5 mi l es and then accel er-
ate the vehi cl e to the speed range where the noi se i s
the greatest. Shi ft out-of-gear and coast through the
peak-noi se range. I f the noi se stops or changes
greatl y:
• Check for i nsuffi ci ent l ubri cant.
• I ncorrect ri ng gear backl ash.
• Gear damage.
Di fferenti al si de gears and pi ni ons can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ght-ahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on shaft can al so cause a snap-
pi ng or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on beari ngs can
al l produce noi se when worn or damaged. Beari ng
noi se can be ei ther a whi ni ng, or a growl i ng sound.
Pi ni on beari ngs have a constant-pi tch noi se. Thi s
noi se changes onl y wi th vehi cl e speed. Pi ni on beari ng
noi se wi l l be hi gher pi tched because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
U-joi nt or by worn si de–gear thrust washers. A worn
pi ni on shaft bore wi l l al so cause l ow speed knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by a:
• Damaged dri ve shaft.
• Mi ssi ng dri ve shaft bal ance wei ght(s).
• Worn or out-of-bal ance wheel s.
• Loose wheel l ug nuts.
• Worn U-joi nt(s).
• Loose/broken spri ngs.
• Damaged axl e shaft beari ng(s).
• Loose pi ni on gear nut.
• Excessi ve pi ni on yoke run out.
• Bent axl e shaft(s).
Check for l oose or damaged front-end components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rearend vi bra-
ti on. Do not overl ook engi ne accessori es, brackets
and dri ve bel ts.
NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged), can be caused by:
• Hi gh engi ne i dl e speed.
• Transmi ssi on shi ft operati on.
• Loose engi ne/transmi ssi on/transfer case mounts.
• Worn U-joi nts.
• Loose spri ng mounts.
• Loose pi ni on gear nut and yoke.
• Excessi ve ri ng gear backl ash.
• Excessi ve si de gear to case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
KJ REAR AXLE - 198RBI 3 - 51
REAR AXLE - 198RBI (Continued)
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
3 - 52 REAR AXLE - 198RBI KJ
REAR AXLE - 198RBI (Continued)
Condition Possible Causes Correction
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion
contact pattern. Adjust backlash or
pinion depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
KJ REAR AXLE - 198RBI 3 - 53
REAR AXLE - 198RBI (Continued)
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Posi ti on a l i ft/jack under the axl e and secure
axl e to devi ce.
(3) Remove wheel s and ti res.
(4) Mark propel l er shaft and pi ni on yoke for
i nstal l ati on reference.
(5) Remove propel l er shaft and suspend under the
vehi cl e.
(6) Remove brake drums, parki ng brake cabl es and
speed sensor from the axl e.
(7) Di sconnect the brake hose at the body juncti on
bl ock.
(8) Remove brakes and backi ng pl ates.
(9) Remove vent hose from the axl e shaft tube.
(10) Remove the stabi l i zer bar (Fi g. 5).
(11) Remove upper control arm bal l joi nt pi nch
bol t from bracket (Fi g. 6).
(12) Remove shock absorbers from axl e brackets
(Fi g. 7).
(13) Loosen al l l ower control arms mounti ng bol ts
(Fi g. 8).
(14) Lower axl e enough to remove coi l spri ngs and
spri ng i nsul ators.
(15) Remove l ower control arm bol ts from the axl e
brackets.
(16) Lower and remove the axl e.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before the lower control arms
are tightened. This must be done to maintain vehi-
cle ride height and prevent premature bushing fail-
ure.
(1) Rai se the axl e under the vehi cl e.
(2) I nstal l l ower control arms onto the axl e brack-
ets and l oosel y i nstal l the mounti ng bol ts.
(3) I nstal l coi l spri ng i sol ators and spri ng.
(4) Rai se axl e up unti l spri ngs are seated.
(5) I nstal l upper control arm bal l joi nt i nto axl e
bracket and ti ghten pi nch bol t to torque speci fi cati on.
(6) I nstal l shock absorbers and ti ghten nuts to
torque speci fi cati on.
(7) I nstal l stabi l i zer bar and ti ghten nuts to torque
speci fi cati on.
(8) I nstal l brake backi ng pl ates, parki ng brake
cabl es, brake drums and speed sensor.
(9) I nstal l brake hose to the body juncti on bl ock
and bl eed the brakes.
Fig. 5 STABILIZER BAR MOUNTS
1 - STABILIZER BAR MOUNTING BOLTS
2 - LOWER SUSPENSION ARM
Fig. 6 BALL JOINT PINCH BOLT
1 - UPPER BALL JOINT
2 - PINCH BOLT
Fig. 7 SHOCK ABSORBER
1 - UPPER MOUNTING BOLT
2 - LOWER MOUNTING BOLT
3 - 54 REAR AXLE - 198RBI KJ
REAR AXLE - 198RBI (Continued)
(10) I nstal l axl e vent hose.
(11) I nstal l propel l er shaft wi th reference marks.
(12) I nstal l the wheel s and ti res.
(13) Add gear l ubri cant to speci fi cati ons, i f neces-
sary.
(14) Remove l i fti ng devi ce from axl e and l ower the
vehi cl e.
(15) Ti ghten the l ower control arm bol ts to torque
speci fi cati on.
ADJ USTMENTS
ADJUSTMENT
Ri ng and pi ni on gears are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng and
pi ni on gear are etched i nto the face of each gear (Fi g.
9). A pl us (+) number, mi nus (–) number or zero (0) i s
etched i nto the face of the pi ni on gear. Thi s number
i s the amount (i n thousandths of an i nch) the depth
vari es from the standard depth setti ng of a pi ni on
etched wi th a (0). The standard setti ng from the cen-
ter l i ne of the ri ng gear to the back face of the pi ni on
i s 96.850 mm (3.813 i n.). The standard depth pro-
vi des the best teeth contact pattern. Refer to Back-
l ash and Contact Pattern Anal ysi s Paragraph i n thi s
secti on for addi ti onal i nformati on.
Compensati on for pi ni on depth vari ance i s
achi eved wi th sel ect shi ms. The shi ms are pl aced
under the i nner pi ni on beari ng cone (Fi g. 10).
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance etched i nto both the ori gi nal and repl ace-
ment pi ni on gear. Add or subtract the thi ckness of
the ori gi nal depth shi ms to compensate for the di ffer-
ence i n the depth vari ances. Refer to the Depth Vari -
ance charts.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. I ntersecti ng fi gure represents pl us or
mi nus amount needed.
Note the etched number on the face of the dri ve
pi ni on gear (–1, –2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi m(s). I f the num-
ber i s posi ti ve, subtract that val ue from the thi ckness
of the depth shi m(s). I f the number i s 0 no change i s
necessary. Refer to the Pi ni on Gear Depth Vari ance
Chart.
Fig. 8 LOWER SUSPENSION ARM
1 - AXLE BRACKET BOLT
2 - LOWER CONTROL ARM
3 - BODY BRACKET BOLT
Fig. 9 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 10 Shim Locations
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
KJ REAR AXLE - 198RBI 3 - 55
REAR AXLE - 198RBI (Continued)
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
Ϫ4 Ϫ3 Ϫ2 Ϫ1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003
0 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004
Ϫ1 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005
Ϫ2 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006
Ϫ3 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006 Ϫ0.007
Ϫ4 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006 Ϫ0.007 Ϫ0.008
PINION DEPTH MEASUREMENT
Measurements are taken wi th pi ni on cups and pi n-
i on beari ngs i nstal l ed i n the housi ng. Take measure-
ments wi th a Pi ni on Gauge Set, Pi ni on Bl ock 6735,
Arbor Di scs 6732 and Di al I ndi cator C-3339 (Fi g. 11).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 6735 and rear pi ni on beari ng onto Screw 6741
(Fi g. 11).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto the housi ng through pi n-
i on beari ng cups (Fi g. 12).
(3) I nstal l front pi ni on beari ng and Cone 6740
hand ti ght.
(4) Pl ace Arbor Di sc 6732 on Arbor D-115-3 i n posi -
ti on i n the housi ng si de beari ng cradl es (Fi g. 13).
I nstal l di fferenti al beari ng caps on Arbor Di scs and
ti ghten cap bol ts. Refer to the Torque Speci fi cati ons.
NOTE: Arbor Discs 6732 have different step diame-
ters to fit other axle sizes. Pick correct size step for
axle being serviced.
Fig. 11 PINION DEPTH TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 12 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 56 REAR AXLE - 198RBI KJ
REAR AXLE - 198RBI (Continued)
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(6) Posi ti on Scooter Bl ock/Di al I ndi cator fl ush on
the pi ni on hei ght bl ock. Hol d scooter bl ock and zero
the di al i ndi cator.
(7) Sl owl y sl i de the scooter bl ock across the pi ni on
hei ght bl ock over to the arbor (Fi g. 14). Move the
scooter bl ock ti l l the di al i ndi cator probe crests the
arbor bar and record the hi ghest readi ng. I f the di al
i ndi cator can not achi eve the zero readi ng, the rear
beari ng cup or the pi ni on depth gauge set i s not
i nstal l ed correctl y.
(8) Sel ect a shi m equal to the di al i ndi cator read-
i ng pl us the dri ve pi ni on gear depth vari ance number
etched i n the face of the pi ni on gear (Fi g. 9) usi ng
the opposi te si gn on the vari ance number. For exam-
pl e, i f the depth vari ance i s –2, add +0.002 i n. to the
di al i ndi cator readi ng.
(9) Remove the pi ni on depth gauge components
from the housi ng
DIFFERENTIAL BEARING PRELOAD
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms i nserted between the
beari ng cup and the housi ng. The proper shi m thi ck-
ness can be determi ned usi ng sl i p-fi t Dummy Bear-
i ngs D-348 i n pl ace of the di fferenti al si de beari ngs
and a Di al I ndi cator C-3339. Before proceedi ng wi th
the di fferenti al beari ng prel oad and gear backl ash
measurements, measure the pi ni on gear depth and
prepare the pi ni on gear for i nstal l ati on. Establ i shi ng
proper pi ni on gear depth i s essenti al to establ i shi ng
gear backl ash and tooth contact patterns. After the
overal l shi m thi ckness to take up di fferenti al si de
pl ay i s measured, the pi ni on gear i s i nstal l ed and the
gear backl ash shi m thi ckness i s measured. The over-
al l shi m thi ckness i s the total of the di al i ndi cator
readi ng, starti ng poi nt shi m thi ckness and the pre-
l oad speci fi cati on added together. The gear backl ash
measurement determi nes the thi ckness of the shi m
used on the ri ng gear si de of the di fferenti al case.
Subtract the gear backl ash shi m thi ckness from the
total overal l shi m thi ckness and sel ect that amount
for the pi ni on gear si de of the di fferenti al (Fi g. 15).
Fig. 13 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 14 Pinion Gear Depth Measurement
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 15 Shim Locations
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
KJ REAR AXLE - 198RBI 3 - 57
REAR AXLE - 198RBI (Continued)
PRELOAD SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove si de beari ngs from di fferenti al case.
(2) I nstal l ri ng gear, i f necessary, on di fferenti al
case and ti ghten bol ts to speci fi cati on.
(3) I nstal l Dummy Beari ngs D-348 on di fferenti al
case.
(4) I nstal l di fferenti al case i n the housi ng.
(5) I nsert Dummy Shi ms 8107 (0.118 i n. /3.0 mm)
starti ng poi nt shi ms between the dummy beari ng
and the housi ng (Fi g. 16).
(6) I nstal l beari ng caps i n thei r correct posi ti ons
and snug the bol ts.
(7) Use a dead-bl ow hammer to seat the di fferen-
ti al dummy beari ngs to each si de of the housi ng (Fi g.
17) and (Fi g. 18).
Fig. 16 DUMMY SHIMS
1 - DUMMY SHIM
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS
Fig. 17 SEAT DUMMY BEARING PINION GEAR SIDE
Fig. 18 SEAT DUMMY BEARING RING GEAR SIDE
1 - DIFFERENTIAL HOUSING
2 - DEAD-BLOW HAMMER
3 - DIFFERENTIAL CASE
3 - 58 REAR AXLE - 198RBI KJ
REAR AXLE - 198RBI (Continued)
(8) Thread Pi l ot Stud C-3288-B i nto rear cover bol t
hol e bel ow ri ng gear (Fi g. 19).
(9) Attach Di al I ndi cator C-3339 to the pi l ot stud
and posi ti on i ndi cator pl unger on a fl at surface of the
ri ng gear bol t head (Fi g. 19).
(10) Push the di fferenti al case fi rml y to the pi ni on
gear si de of the housi ng (Fi g. 20) and zero di al i ndi -
cator.
(11) Push di fferenti al case fi rml y to the ri ng gear
si de and record di al i ndi cator readi ng (Fi g. 21).
(12) Add the di al i ndi cator readi ng to the starti ng
poi nt shi m thi ckness to determi ne total shi m thi ck-
ness to achi eve zero di fferenti al end pl ay.
(13) Add 0.2 mm (0.008 i n.) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms to compress or prel oad the new beari ngs when
the di fferenti al i s i nstal l ed.
(14) Rotate di al i ndi cator out of the way.
(15) Remove di fferenti al case, dummy beari ngs
and starti ng poi nt shi ms from the housi ng.
(16) I nstal l pi ni on gear i n the housi ng. I nstal l the
yoke and establ i sh the correct pi ni on rotati ng torque.
(17) I nstal l di fferenti al case and dummy beari ngs
i n the housi ng (wi thout shi ms) and ti ghten retai ni ng
cap bol ts.
(18) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads (Fi g. 19).
(19) Push and hol d di fferenti al case toward pi ni on
gear.
(20) Zero di al i ndi cator face to poi nter.
(21) Push and hol d di fferenti al case to ri ng gear
si de of the housi ng and record di al i ndi cator readi ng.
(22) Subtract 0.05 mm (0.002 i n.) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Thi s total i s the thi ckness of
shi m requi red to achi eve proper backl ash.
(23) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
housi ng.
Fig. 19 DIFFERENTIAL SIDE PLAY
1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 20 ZERO DIAL INDICATOR
1 - FORCE CASE TO PINION SIDE
2 - PILOT STUD
3 - DIAL INDICATOR EXTENSION
4 - DIAL INDICATOR
Fig. 21 RECORD DIAL INDICATOR
1 - DIAL INDICATOR
2 - FORCE CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
KJ REAR AXLE - 198RBI 3 - 59
REAR AXLE - 198RBI (Continued)
(24) Rotate di al i ndi cator out of the way on pi l ot
stud.
(25) Remove di fferenti al case and dummy beari ngs
from the housi ng.
(26) I nstal l new si de beari ng cones and cups on
di fferenti al case.
(27) I nstal l spreader W-129-B and some compo-
nents of Adapter Set 6987 on di fferenti al housi ng and
spread axl e openi ng enough to recei ve di fferenti al
case.
(28) Pl ace si de beari ng shi ms i nto the housi ng
agai nst the axl e tubes.
(29) I nstal l di fferenti al case i n the housi ng.
(30) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(31) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 22).
(32) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(33) Zero di al i ndi cator face to poi nter.
(34) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.13-0.20 mm (0.005-0.008
i n.). I f backl ash i s not wi thi n speci fi cati ons transfer
the necessary amount of shi m thi ckness from one
si de of the di fferenti al housi ng to the other (Fi g. 23).
(35) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at ei ght
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform the
Gear Contact Pattern Anal ysi s procedure.
GEAR CONTACT PATTERN
The ri ng gear and pi ni on teeth contact patterns
wi l l show i f the pi ni on depth i s correct i n the hous-
i ng. I t wi l l al so show i f the ri ng gear backl ash has
been adjusted correctl y. The backl ash can be adjusted
wi thi n speci fi cati ons to achi eve desi red tooth contact
patterns.
(1) Appl y a thi n coat of hydrated ferri c oxi de or
equi val ent to the dri ve and coast si de of the ri ng gear
teeth.
(2) Wrap, twi st, and hol d a shop towel around the
pi ni on yoke to i ncrease the turni ng resi stance of the
pi ni on. Thi s wi l l provi de a more di sti nct contact pat-
tern.
(3) Wi th a boxed end wrench on a ri ng gear bol t,
rotate the di fferenti al case one compl ete revol uti on i n
both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on teeth wi l l
squeeze the compound to the areas wi th the l east
amount of contact. Note and compare patterns on the
ri ng gear teeth to Gear Tooth Contact Patterns chart
(Fi g. 24) and adjust pi ni on depth and gear backl ash
as necessary.
Fig. 22 RING GEAR BACKLASH
1 - DIAL INDICATOR
Fig. 23 BACKLASH SHIM
3 - 60 REAR AXLE - 198RBI KJ
REAR AXLE - 198RBI (Continued)
Fig. 24 GEAR TOOTH CONTACT PATTERNS
KJ REAR AXLE - 198RBI 3 - 61
REAR AXLE - 198RBI (Continued)
DIFFERENTIAL BEARING PRELOAD CHECK
The fi nal check on the di fferenti al assembl y before
i nstal l i ng the axl es i s torque to rotate pi ni on and di f-
ferenti al combi ned. Thi s wi l l veri fy the correct di ffer-
enti al beari ng prel oad.
Torque to rotate the di fferenti al and pi ni on i s the
torque to rotate the pi ni on pl us:
Gear Rati o 3.73 . . . . . . . 0.45-0.76 N·m (4-7 i n. l bs.)
Gear Rati o 4.10 . . . . . . 0.41-0.69 N·m (3.6-6 i n. l bs.)
SPECIFICATIONS - REAR AXLE
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.73 4.10
Ring Gear Diameter 198 mm (7.795 in.)
Ring Gear Backlash 0.13-0.20 mm (0.005-0.008 in.)
Pinion Gear Standard Depth 96.85 mm (3.813 in.)
Pinion Bearing Preload - New Bearings 1.69-2.82 N·m (15-25 in. lbs.)
Differential Side Gear Clearance 0-0.15 mm (0-0.006 in.)
Differential Bearing Preload 0.20 mm (0.008 in.)
Differential Bearing Preload Added To Pinion Torque To Rotate
3.73 Gear Ratio 0.45-0.76 N·m (4-7 in. lbs.)
4.10 Gear Ratio 0.41-0.69 N·m (3.6-6 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Ring Gear Bolts 129-142 95-105 -
Differential Bearing Cap
Bolts
64-91 47-67 -
Differential Cover Bolts 38-45 28-33 -
Pinion Nut (Minimum) 271 200 -
Cross Shaft Lock Screw 11-22 8-16 -
3 - 62 REAR AXLE - 198RBI KJ
REAR AXLE - 198RBI (Continued)
SPECIAL TOOLS
REAR AXLE
PULLER C-293-PA
ADAPTER 8352
ADAPTER C-293-39
PLUG SP-3289
PULLER C-452
WRENCH C-3281
SPANNER WRENCH 6958
HANDLE C-4171
INSTALLER C-3716-A
INSTALLER D-130
KJ REAR AXLE - 198RBI 3 - 63
REAR AXLE - 198RBI (Continued)
INSTALLER D-146
REMOVER D-103
REMOVER D-149
INSTALLER W-262
PINION DEPTH 6774
TRAC-LOK TOOLS 6960
FIXTURE 6965
SHIMS DUMMY 8107
SPREADER W-129-B
ADAPTER KIT 6987
3 - 64 REAR AXLE - 198RBI KJ
REAR AXLE - 198RBI (Continued)
AXLE SHAFTS
REMOVAL
(1) Pl ace transmi ssi on i n neutral and rai se and
support vehi cl e.
(2) Remove wheel and ti re assembl y.
(3) Remove brake drum.
(4) Remove axl e retai ner pl ate nuts from the rear
of the axl e fl ange.
(5) Pul l axl e shaft from the axl e wi th Sl i de Ham-
mer 7420 and Adapter 6790. Mount the adapter to
the axl e wi th l ug nuts.
NOTE: It is normal that the axle bearing race is
loose in the axle tube.
INSTALLATION
(1) I nsal l axl e i nto the axl e tube wi th the fl at area
of the retai ner pl ate upward.
(2) I nsert retai ni ng pl ate studs i nto the brake
backi ng pl ate and axl e tube fl ange.
(3) I nstal l retai ner nuts and ti ghten to 47-75 N·m
(35-55 ft. l bs.).
(4) I nstal l the brake drum.
(5) I nstal l wheel and ti re.
(6) Check and fi l l the di fferenti al wi th gear l ubri -
cant.
(7) Lower vehi cl e.
PILOT STUDS C-3288-B
PULLER 6790
DIAL INDICATOR C-3339
INSTALLER C-3718
KJ REAR AXLE - 198RBI 3 - 65
REAR AXLE - 198RBI (Continued)
AXLE BEARING/SEAL
REMOVAL
(1) Remove axl e shaft from vehi cl e.
(2) Dri l l a shal l ow hol e i nto soft steel axl e beari ng
retai ni ng ri ng wi th a 3/8 i n. dri l l bi t (Fi g. 25). Use a
dri l l depth stop to avoi d marki ng the axl e.
(3) Wi th a col d chi sel cut the retai ni ng ri ng across
dri l l ed hol e. (Fi g. 26)
(4) Sl i de retai ni ng ri ng from axl e shaft.
(5) Remove axl e beari ng from the shaft wi th a
press and Spl i tter 1130 pl aced between the seal and
beari ng (Fi g. 27).
(6) Remove seal from axl e.
(7) Remove retai ni ng pl ate from axl e shaft.
Fig. 25 DRILL RETAINING RING
1 - DRILL BIT
2 - AXLE
3 - RETAINING PLATE
4 - RETAINING RING
Fig. 26 CUT RETAINING RING
1 - AXLE
2 - COLD CHISEL
3 - VISE
4 - RETAINING RING
Fig. 27 AXLE BEARING AND SEAL
1 - SPLITTER
2 - AXLE SHAFT
3 - BLOCKS
4 - BLOCKS
3 - 66 REAR AXLE - 198RBI KJ
INSTALLATION
NOTE: Verify axle shaft retaining plate is flat with a
straight edge. If the plate is warped replace the
plate.
(1) I nstal l retai ni ng pl ate on the axl e shaft (Fi g.
28).
(2) Appl y a coat of mul ti -purpose grease on seal i ng
surface of axl e seal .
(3) I nstal l seal on the axl e shaft wi th cavi ty away
from retai ni ng pl ate (Fi g. 28).
(4) Lubri cate beari ng wi th Mopar௡ Wheel Beari ng
Grease or equi val ent. Wi pe excess grease from the
beari ng.
(5) I nstal l beari ng on the axl e shaft wi th I nstal l er
7913 and a press (Fi g. 29).
(6) Press retai ni ng ri ng onto axl e shaft wi th
I nstal l er 7913 and a press (Fi g. 30).
(7) I nstal l axl e i n vehi cl e.
Fig. 29 BEARING ON AXLE
1 - PRESS RAM
2 - INSTALLER - 7913
3 - AXLE BEARING
4 - SEAL
5 - RETAINING PLATE
6 - AXLE
Fig. 30 BEARING RETAINING RING ON AXLE
1 - PRESS
2 - AXLE
3 - AXLE BEARING
4 - INSTALLER
5 - SOFT METAL RETAINING RING
Fig. 28 AXLE BEARING AND SEAL COMPONENTS
1 - RETAINING RING
2 - SEAL
3 - AXLE
4 - RETAINING PLATE
5 - AXLE BEARING
KJ REAR AXLE - 198RBI 3 - 67
AXLE BEARING/SEAL (Continued)
PINION SEAL
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove wheel and ti re assembl i es.
(3) Remove rear brake rotors drums.
(4) Mark propel l er shaft and pi ni on yoke for
i nstal l ati on reference.
(5) Remove the propel l er shaft from the yoke.
(6) Rotate pi ni on gear three or four ti mes and ver-
i fy that pi ni on rotates smoothl y.
(7) Measure and record torque to rotate the pi ni on
gear wi th an i nch pound di al -type torque wrench.
(8) Wi th a short pi ece of pi pe and Spanner Wrench
6958 remove the pi ni on nut and washer (Fi g. 31).
(9) Remove pi ni on compani on fl ange wi th Remover
C-452 and Fl ange Wrench C-3281. (Fi g. 32)
(10) Remove pi ni on seal wi th Remover 7794-A and
a sl i de hammer (Fi g. 33).
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th an appropri ate
seal i nstal l er (Fi g. 34).
(2) I nstal l yoke on the pi ni on gear wi th I nstal l er
C-3718 and Spanner Wrench 6958 (Fi g. 35).
(3) I nstal l a new nut on the pi ni on gear. Tighten
the nut only enough to remove the shaft end
play.
CAUTION: Do not exceed the minimum torque 271
N·m (200 ft. lbs.) when installing the pinion yoke
retaining nut at this point. Damage to collapsible
spacer or bearings may result.
(4) Rotate the pi ni on a mi ni mum of ten ti mes and
veri fy pi ni on rotates smoothl y.
(5) Measure and recore pi ni on torque to rotate
wi th an i nch pound torque wrench. Torque to rotate
shoul d be equal to the readi ng recorded duri ng
removal , pl us 0.56 N·m (5 i n. l bs.) (Fi g. 36).
Fig. 31 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - WRENCH
3 - PIPE
Fig. 32 PINION YOKE REMOVER
1 - WRENCH
2 - YOKE
3 - REMOVER
Fig. 33 PINION SEAL REMOVER
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
3 - 68 REAR AXLE - 198RBI KJ
(6) I f rotati ng torque i s l ow, hol d pi ni on yoke wi th
Wrench 6958 (Fi g. 37) and ti ghten pi ni on shaft nut
i n 6.8 N·m (5 ft. l bs.) i ncrements unti l rotati ng
torque i s achi eved.
CAUTION: If maximum tightening torque is reached
prior to reaching the required rotating torque, the
collapsible spacer may have been damaged.
Replace the collapsible spacer.
(7) Al i gn the i nstal l ati on reference marks on the
propel l er shaft and pi ni on yoke and i nstal l the pro-
pel l er shaft.
Fig. 34 PINION SEAL INSTALLATION
1 - HANDLE
2 - INSTALLER
Fig. 35 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - WRENCH
Fig. 36 PINION GEAR ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 37 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - WRENCH
3 - PIPE
KJ REAR AXLE - 198RBI 3 - 69
PINION SEAL (Continued)
(8) Fi l l di fferenti al wi th gear l ubri cant.
(9) I nstal l the brake drums
(10) I nstal l wheel and ti re assembl i es.
(11) Lower the vehi cl e.
COLLAPSIBLE SPACER
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove wheel and ti re assembl i es.
(3) Remove rear brake drums.
(4) Mark the propel l er shaft and pi ni on yoke for
i nstal l ati on reference.
(5) Remove the propel l er shaft from the yoke.
(6) Rotate the pi ni on gear three or four ti mes.
(7) Measure and record torque to rotate the pi ni on
gear wi th an i nch pound di al -type torque wrench.
(8) Hol d pi ni on yoke wi th Spanner Wrench 6958
and remove pi ni on nut and washer.
(9) Remove the pi ni on yoke wi th Remover C-452
and Fl ange Wrench C-3281 (Fi g. 38).
(10) Remove pi ni on shaft seal wi th a pry tool or a
sl i de hammer mounted screw.
(11) Remove front pi ni on beari ng usi ng a pai r of
pi ck tool s. Pul l the beari ng strai ght off the pi ni on
gear shaft. I f the beari ng becomes bound on the pi n-
i on shaft, l i ghtl y tap the end of the pi ni on gear wi th
a rawhi de/rubber hammer.
(12) Remove the col l apsi bl e spacer.
INSTALLATION
(1) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft.
(2) I nstal l pi ni on front beari ng.
(3) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal and i nstal l a new seal wi th an
appropri ate i nstal l er (Fi g. 39).
(4) I nstal l yoke wi th Screw 8112, Cup 8109 and
Spanner Wrench 6958 (Fi g. 40).
(5) I nstal l yoke washer and new nut on the pi ni on
gear. Ti ghten the nut to 271 N·m (200 ft. l bs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion gear bearing rotating torque and never
exceed specified preload torque. If preload torque
or rotating torque is exceeded a new collapsible
spacer must be installed.
Fig. 38 PINION YOKE
1 - FLANGE WRENCH
2 - YOKE
3 - REMOVER
Fig. 39 PINION SEAL
1 - HANDLE
2 - INSTALLER
Fig. 40 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - WRENCH
3 - 70 REAR AXLE - 198RBI KJ
PINION SEAL (Continued)
(6) Usi ng yoke wi th Spanner Wrench 6958 and a
torque wrench set at 474 N·m (350 ft. l bs.), (Fi g. 41)
sl owl y ti ghten the nut i n 6.8 N·m (5 ft. l bs.) i ncre-
ments unti l the rotati ng torque i s achi eved. Measure
the rotati ng torque frequentl y to avoi d over crushi ng
the col l apsi bl e spacer (Fi g. 42).
NOTE: If more than 474 N·m (350 ft. lbs.) torque is
required to crush the collapsible spacer, the spacer
is defective and must be replaced.
(7) Check rotati ng torque wi th an i nch pound
torque wrench (Fi g. 42). The rotati ng torque of the
pi ni on gear shoul d be, the readi ng recorded duri ng
removal pl us an addi ti onal 0.56 N·m (5 i n. l bs.).
(8) I nstal l propel l er shaft wi th reference marks
al i gned.
(9) I nstal l rear brake drums.
(10) Add gear l ubri cant, i f necessary.
(11) I nstal l wheel and ti re assembl i es.
(12) Remove supports and l ower vehi cl e.
DIFFERENTIAL
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove di fferenti al cover and drai n fl ui d.
(3) Cl ean the housi ng cavi ty wi th fl ushi ng oi l , l i ght
engi ne oi l or l i nt free cl oth.
NOTE: Do not use water, steam, kerosene or gaso-
line for cleaning.
(4) Remove axl e shafts.
(5) Note the reference l etters stamped on the beari ng
caps and housi ng machi ned seal i ng surface (Fi g. 43). Fig. 41 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - WRENCH
3 - PIPE
Fig. 42 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 43 BEARING CAP IDENTIFICATION
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
KJ REAR AXLE - 198RBI 3 - 71
COLLAPSIBLE SPACER (Continued)
(6) Loosen the di fferenti al beari ng cap bol ts.
(7) Wi th Spreader W-129-B and adapters from
Adapter set 6987, posi ti on the adapters i n the di ffer-
enti al hol es (Fi g. 44). I nstal l hol d-down cl amps and
ti ghten the tool turnbuckl e fi nger-ti ght.
(8) I nstal l Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load the i ndi cator pl unger agai nst the
opposi te si de of the housi ng (Fi g. 45) and zero the
i ndi cator.
(9) Spread the housi ng whi l e measuri ng the di s-
tance wi th the di al i ndi cator. Spread the housi ng
enough to remove the di fferenti al case (Fi g. 46).
CAUTION: Do not spread over 0.38 mm (0.015 in). If
housing is over-spread, it could be distorted or
damaged.
(10) Remove the di al i ndi cator and pi l ot stud.
(11) Remove di fferenti al beari ng cap bol ts and caps
whi l e hol di ng the case.
Fig. 44 SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
2 - ADAPTER
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 45 DIAL INDICATOR LOCATION
1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD
Fig. 46 SPREAD DIFFERENTIAL HOUSING
1 - DIAL INDICATOR
2 - SPREADER
3 - 72 REAR AXLE - 198RBI KJ
DIFFERENTIAL (Continued)
(12) Remove di fferenti al from the housi ng. Ensure
that the di fferenti al beari ng cups remai n i n posi ti on
on the di fferenti al beari ngs (Fi g. 47).
(13) Remove beari ng cups from the di fferenti al and
tag them to i ndi cate thei r l ocati on.
(14) Remove di fferenti al case prel oad shi ms from
the housi ng and tag them to i ndi cate thei r l ocati on.
(15) Remove spreader from housi ng.
INSTALLATION
NOTE: If differential bearings or differential case are
replaced, differential bearing preload shim require-
ments may change. Refer Adjustments (Differential
Bearing Preload and Gear Backlash) to determine
the proper shim selection.
(1) Wi th Spreader W-129-B and adapters from
Adapter set 6987, posi ti on the adapters i n the di ffer-
enti al hol es (Fi g. 48). I nstal l the hol d-down cl amps
and ti ghten the tool turnbuckl e fi nger-ti ght.
(2) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load the i ndi cator pl unger agai nst the
opposi te si de of the housi ng and zero the i ndi cator.
(3) Spread the housi ng whi l e measuri ng the di s-
tance wi th the di al i ndi cator. Spread the housi ng
enough to i nstal l the di fferenti al case.
CAUTION: Do not spread over 0.38 mm (0.015 in). If
the housing is over–spread, it could be distorted or
damaged.
(4) Remove the di al i ndi cator.
(5) I nstal l di fferenti al case i n the housi ng (Fi g. 49)
wi th beari ng cups and prel oad shi ms i n thei r ori gi nal
l ocati ons. Tap the di fferenti al case to ensure the
beari ngs cups and shi ms are ful l y seated i n the hous-
i ng.
Fig. 47 DIFFERENTIAL CASE
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
Fig. 48 SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
2 - ADAPTER
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 49 DIFFERENTIAL CASE
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
KJ REAR AXLE - 198RBI 3 - 73
DIFFERENTIAL (Continued)
(6) I nstal l the beari ng caps i n thei r ori gi nal l oca-
ti ons (Fi g. 50).
(7) Loosel y i nstal l di fferenti al beari ng cap bol ts.
(8) Remove axl e housi ng spreader.
(9) Ti ghten the beari ng cap bol ts to 64-91 N·m
(47-67 ft. l bs.).
(10) I nstal l the axl e shafts.
(11) Appl y a 6.35mm (1/4 i n.) bead of red Mopar
Si l i cone Rubber Seal ant or equi val ent to the housi ng
cover (Fi g. 51).
CAUTION: If cover is not installed within 3 to 5 min-
utes, the cover must be cleaned and new RTV
applied or adhesion quality will be compromised.
(12) I nstal l the cover and ti ghten cover bol ts i n a
cri ss-cross pattern to 38-45 N·m (28-33 ft. l bs.).
(13) Refi l l the di fferenti al wi th l ubri cant and
i nstal l fi l l pl ug.
(14) Remove support and l ower the vehi cl e.
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKா
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng the uni t for repai r,
drai n, fl ush and refi l l the axl e wi th the speci fi ed
l ubri cant. A contai ner of Mopar Trac-l ok௡ Lubri cant
(fri cti on modi fi er) shoul d be added after repai r ser-
vi ce or duri ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
DIFFERENTIAL TEST
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 or
equi val ent tool to studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 52).
(6) I f rotati ng torque i s l ess than 41 N·m (56 ft.
l bs.) or more than 271 N·m (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
Fig. 50 BEARING CAP REFERENCE
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 51 DIFFERENTIAL COVER - TYPICAL
1 - SEALING SURFACE
2 - SEALANT BEAD
3 - SEALANT THICKNESS
3 - 74 REAR AXLE - 198RBI KJ
DIFFERENTIAL (Continued)
DISASSEMBLY
(1) Cl amp si de gear Fi xture 6965 i n a vi se and set
di fferenti al case on the fi xture (Fi g. 53).
(2) Remove ri ng gear i f the ri ng gear i s to be
repl aced. The Trac-l ok௡ di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
(3) Remove pi ni on gear mate shaft l ock screw (Fi g.
54).
(4) Remove pi ni on gear mate shaft wi th a dri ft and
hammer.
(5) I nstal l and l ubri cate Step Pl ate 6960-3 (Fi g.
55).
Fig. 52 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 53 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 54 MATE SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION GEAR MATE SHAFT
Fig. 55 Step Plate
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - STEP PLATE
KJ REAR AXLE - 198RBI 3 - 75
DIFFERENTIAL - TRAC-LOK (Continued)
(6) Assembl e Threaded Adapter 6960-1 i nto top
si de gear. Thread Forci ng Screw C-6960-4 i nto
adapter unti l i t becomes centered i n adapter pl ate.
(7) Posi ti on a smal l screw dri ver i n sl ot of
Threaded Adapter Di sc 6960-3 (Fi g. 56) to prevent
adapter from turni ng.
(8) I nstal l Forci ng Screw 6960-4 and ti ghten screw
to 122 N·m (90 ft. l bs.) maxi mum to compress
Bel l evi l l e spri ngs i n cl utch packs (Fi g. 57).
(9) Wi th a feel er gauge remove thrust washers
from behi nd the pi ni on gears (Fi g. 58).
Fig. 56 THREAD ADAPTER DISC
1 - SOCKET
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - STEP PLATE
5 - THREADED ROD
6 - ADAPTER DISC
Fig. 57 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - FORCING SCREW
3 - DIFFERENTIAL CASE
Fig. 58 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
3 - 76 REAR AXLE - 198RBI KJ
DIFFERENTIAL - TRAC-LOK (Continued)
(10) I nsert Turni ng Bar 6960-2 i nto the pi ni on
mate shaft hol e i n the case (Fi g. 59).
(11) Loosen the Forci ng Screw i n smal l i ncrements
unti l the cl utch pack tensi on i s rel i eved and the di f-
ferenti al case can be turned usi ng Turni ng Bar.
(12) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(13) Remove pi ni on gears from di fferenti al case.
(14) Remove Forci ng Screw, Step Pl ate and
Threaded Adapter.
(15) Remove top si de gear, cl utch pack retai ner
and cl utch pack. Keep pl ates i n order duri ng removal
(Fi g. 60).
(16) Remove di fferenti al case from the Hol di ng
Fi xture. Remove si de gear, cl utch pack retai ner and
cl utch pack. Keep pl ates i n order duri ng removal .
CLEANING
Cl ean al l components i n cl eani ng sol vent and dry
components wi th compressed ai r.
INSPECTION
I nspect cl utch pack pl ates for wear, scori ng or dam-
age. Repl ace both cl utch packs i f any one component
i n ei ther pack i s damaged. I nspect si de and pi ni on
gears for cracks chi ps or damage and repl ace as nec-
essary. I nspect di fferenti al case and pi ni on shaft and
repl ace i f worn or damaged.
ASSEMBLY
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
(1) Lubri cate components wi th gear l ubri cant.
(2) Assembl e cl utch di scs i nto packs and secure
di sc packs wi th retai ni ng cl i ps (Fi g. 61).
NOTE: Dished plate is position with the convex side
against the side gear.
Fig. 59 PINION GEARS
1 - PINION GEARS
2 - TURNING BAR
Fig. 60 SIDE GEARS AND CLUTCH DISCS
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
Fig. 61 CLUTCH PACK
1 - DISCS
2 - DISHED PLATE
3 - RETAINER
4 - SIDE GEAR
5 - RETAINER
6 - PLATES
KJ REAR AXLE - 198RBI 3 - 77
DIFFERENTIAL - TRAC-LOK (Continued)
(3) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(4) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 62).Verify
clutch pack retaining clips are in position and
seated in the case pockets.
(5) Posi ti on the di fferenti al case on the Hol di ng
Fi xture 6965.
(6) I nstal l l ubri cated Step Pl ate 6960-3 i n l ower
si de gear (Fi g. 63).
(7) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 63).
(8) Hol d assembl y i n posi ti on. I nsert Threaded
Adapter 6960-1 i nto top si de gear.
(9) I nstal l Forci ng Screw 6960-4 and ti ghten screw
to sl i ghtl y compress cl utch di sc.
(10) Pl ace pi ni on gears i n posi ti on i n si de gears
and veri fy that the pi ni on mate shaft hol e i s al i gned.
(11) Rotate case wi th Turni ng Bar 6960-2 unti l the
pi ni on mate shaft hol es i n pi ni on gears al i gn wi th
hol es i n case. I t may be necessary to sl i ghtl y ti ghten
the forci ng screw i n order to i nstal l the pi ni on gears.
(12) Ti ghten forci ng screw to 122 N·m (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(13) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
(14) Remove Forci ng Screw, Step Pl ate and
Threaded Adapter.
(15) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(16) I nstal l pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
(17) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
Fig. 62 CLUTCH PACK AND LOWER SIDE GEAR
1 - DIFFERENTIAL CASE
2 - SIDE GEAR AND CLUTCH PACK
Fig. 63 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - STEP PLATE
3 - 78 REAR AXLE - 198RBI KJ
DIFFERENTIAL - TRAC-LOK (Continued)
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove di fferenti al case from axl e housi ng.
(2) Remove si de beari ngs from the di fferenti al case
wi th Pul l er/Press C-293-PA, Adapters 8352 and Pl ug
SP-3289 (Fi g. 64).
INSTALLATION
NOTE: If differential side bearings or differential
case are replaced, differential side bearing shim
requirements may change. Refer to Adjustments
(Differential Bearing Preload and Gear Backlash) for
procedures.
(1) I nstal l di fferenti al si de beari ngs wi th I nstal l er
C-3716-A and Handl e C-4171 (Fi g. 65).
(2) I nstal l di fferenti al case i n housi ng.
(3) Remove support and l ower vehi cl e.
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring and pinion gears are serviced as a
matched set. Never replace one gear without the
other gear.
(1) Rai se and support vehi cl e.
(2) Mark pi ni on yoke and propel l er shaft for
i nstal l ati on reference.
(3) Di sconnect propel l er shaft from pi ni on yoke
and ti e shaft to underbody.
(4) Remove di fferenti al from housi ng.
(5) Pl ace di fferenti al case i n a vi se wi th soft metal
jaw.
(6) Remove bol ts hol di ng ri ng gear to di fferenti al
case.
Fig. 64 DIFFERENTIAL CASE BEARING
1 - ADAPTERS
2 - BEARING
3 - DIFFERENTIAL
4 - PLUG
5 - PULLER
Fig. 65 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
KJ REAR AXLE - 198RBI 3 - 79
(7) Dri ve ri ng gear from di fferenti al case wi th a
rawhi de hammer (Fi g. 66).
(8) Hol d pi ni on yoke wi th Spanner Wrench 6958
and remove pi ni on yoke nut and washer (Fi g. 67).
(9) Remove pi ni on yoke from pi ni on shaft wi th
Remover C-452 and Wrench C-3281 (Fi g. 68).
(10) Remove pi ni on gear from housi ng (Fi g. 69).
Fig. 66 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 67 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - WRENCH
3 - PIPE
Fig. 68 PINION YOKE REMOVER
1 - WRENCH
2 - YOKE
3 - REMOVER
Fig. 69 PINION GEAR
1 - RAWHIDE HAMMER
3 - 80 REAR AXLE - 198RBI KJ
PINION GEAR/RING GEAR/TONE RING (Continued)
(11) Remove pi ni on seal wi th Remover 7794-A and
a sl i de hammer (Fi g. 70).
(12) Remove oi l sl i nger, i f equi pped, and front pi n-
i on beari ng.
(13) Remove front pi ni on beari ng cup wi th
Remover D-103 and Handl e C-4171 (Fi g. 71).
(14) Remove rear beari ng cup from housi ng (Fi g.
72) wi th Remover D-149 and Handl e C-4171.
(15) Remove col l apsi bl e prel oad spacer (Fi g. 73).
Fig. 70 PINION SEAL REMOVER
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 71 FRONT PINION BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 72 REAR PINION BEARING CUP
1 - DRIVER
2 - HANDLE
Fig. 73 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - PINION DEPTH SHIM
5 - REAR BEARING
KJ REAR AXLE - 198RBI 3 - 81
PINION GEAR/RING GEAR/TONE RING (Continued)
(16) Remove rear beari ng from the pi ni on wi th
Pul l er/Press C-293-PA and Adapters C-293-39 (Fi g.
74).
(17) Remove depth shi ms from pi ni on gear shaft
and record shi m thi ckness.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If ring gear and pinion are reused, the pinion
depth shim/oil slinger should not require replace-
ment. Refer to Adjustment (Pinion Gear Depth) to
select the proper thickness shim/oil slinger if ring
and pinion gears are replaced.
(1) Appl y Mopar௡ Door Ease or equi val ent l ubri -
cant to outsi de surface of beari ng cup.
(2) I nstal l pi ni on rear beari ng cup wi th I nstal l er
C-146 and Dri ver Handl e C-4171 (Fi g. 75) and veri fy
cup i s seated.
(3) Appl y Mopar௡ Door Ease or equi val ent l ubri -
cant to outsi de surface of beari ng cup.
(4) I nstal l pi ni on front beari ng cup wi th I nstal l er
D-130 and Handl e C-4171 (Fi g. 76) and veri fy cup i s
seated.
(5) I nstal l pi ni on front beari ng and oi l sl i nger, i f
equi pped.
Fig. 74 REAR PINION BEARING PULLER
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
Fig. 75 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 76 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
3 - 82 REAR AXLE - 198RBI KJ
PINION GEAR/RING GEAR/TONE RING (Continued)
(6) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th an appropri ate
i nstal l er (Fi g. 77).
(7) I nstal l pi ni on depth shi m on the pi ni on gear.
(8) I nstal l rear beari ng on the pi ni on gear wi th
I nstal l er W-262 and a press (Fi g. 78).
(9) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft and i nstal l pi ni on gear i n the housi ng (Fi g.
79).
(10) I nstal l yoke wi th I nstal l er C-3718 and Span-
ner Wrench 6958 (Fi g. 80).
Fig. 77 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 78 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - PINION GEAR REAR BEARING
Fig. 79 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - PINION DEPTH SHIM
5 - REAR BEARING
Fig. 80 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - WRENCH
KJ REAR AXLE - 198RBI 3 - 83
PINION GEAR/RING GEAR/TONE RING (Continued)
(11) I nstal l the yoke washer and a new nut on the
pi ni on gear and ti ghten the pi ni on nut unti l there i s
zero beari ng end-pl ay.
(12) Ti ghten the nut to 271 N·m (200 ft. l bs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion gear bearing rotating torque and never
exceed specified preload torque. If preload torque
or rotating torque is exceeded a new collapsible
spacer must be installed.
(13) Usi ng Spanner Wrench 6958 and a torque
wrench set at 474 N·m (350 ft. l bs.), (Fi g. 81) sl owl y
ti ghten the nut i n 6.8 N·m (5 ft. l bs.) i ncrements
unti l the rotati ng torque i s achi eved.
CAUTION: Measure torque to rotate frequently to
avoid over crushing the collapsible spacer.
NOTE: If more than 474 N·m (350 ft. lbs.) torque is
required to crush the collapsible spacer, the spacer
is defective and must be replaced.
(14) Check pi ni on torque to rotate wi th a i nch
pound torque wrench (Fi g. 82). The pi ni on torque to
rotate shoul d be:
• Ori gi nal Beari ngs: 1 to 2.25 N·m (10 to 20 i n.
l bs.).
• New Beari ngs: 1.69 to 2.82 N·m (15 to 25 i n.
l bs.).
Fig. 81 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - WRENCH
3 - PIPE
Fig. 82 PINION GEAR ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
3 - 84 REAR AXLE - 198RBI KJ
PINION GEAR/RING GEAR/TONE RING (Continued)
(15) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
(16) I nvert the di fferenti al case i n the vi se.
(17) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 129-142 N·m (95-105 ft. l bs.) (Fi g. 83).
CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.
(18) I nstal l di fferenti al i n housi ng.
(19) Veri fy di fferenti al beari ng prel oad, gear mesh
and contact pattern. Refer to Ajustments for proce-
dure.
(20) I nstal l di fferenti al cover and fi l l wi th gear
l ubri cant.
(21) I nstal l the propel l er shaft wi th the reference
marks al i gned.
(22) Remove supports and l ower vehi cl e.
Fig. 83 RING GEAR
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
KJ REAR AXLE - 198RBI 3 - 85
PINION GEAR/RING GEAR/TONE RING (Continued)
REAR AXLE - 8 1/4
TABLE OF CONTENTS
page page
REAR AXLE - 8 1/4
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 86
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
DIAGNOSIS AND TESTING - AXLE . . . . . . . . . . 88
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 91
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 92
SPECIFICATIONS
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 98
SPECIAL TOOLS
8 1/4 AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 98
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 101
AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 102
AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 102
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 103
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 105
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 105
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKா . . . . 106
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 107
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 109
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 110
PINION GEAR/RING GEAR/TONE RING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 112
REAR AXLE - 8 1/4
DESCRIPTION
The axl e housi ngs consi st of a cast i ron center sec-
ti on wi th axl e tubes extendi ng from ei ther si de. The
tubes are pressed i nto and wel ded to the di fferenti al
housi ng to form a one-pi ece axl e housi ng. The axl es
are equi pped wi th semi -fl oati ng axl e shafts, meani ng
vehi cl e l oads are supported by the axl e shaft and
beari ngs. The axl e shafts are retai ned by C-l ocks i n
the di fferenti al si de gears.
The di fferenti al case i s a one-pi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a
threaded pi n. Di fferenti al beari ng prel oad and ri ng
gear backl ash are set and mai ntai ned by threaded
adjusters at the outsi de of the di fferenti al housi ng.
Pi ni on beari ng prel oad i s set and mai ntai ned by the
use of a col l apsi bl e spacer.
The di fferenti al cover provi des a means for i nspec-
ti on and servi ce wi thout removi ng the compl ete axl e
from the vehi cl e. A vent hose i s used to rel i eve i nter-
nal pressure caused by l ubri cant vapori zati on and
i nternal expansi on.
Axl es equi pped wi th a Trac-Lok௡ di fferenti al are
opti onal . A di fferenti al has a one-pi ece di fferenti al
case, and the same i nternal components as a stan-
dard di fferenti al , pl us two cl utch di sc packs.
OPERATION
The axl e recei ves power from the transmi ssi on/
transfer case through the rear propel l er shaft. The
rear propel l er shaft i s connected to the pi ni on gear
whi ch rotates the di fferenti al through the gear mesh
wi th the ri ng gear bol ted to the di fferenti al case. The
engi ne power i s transmi tted to the axl e shafts
through the pi ni on mate and si de gears. The si de
gears are spl i ned to the axl e shafts.
3 - 86 REAR AXLE - 8 1/4 KJ
STANDARD DIFFERENTIAL
Duri ng strai ght-ahead dri vi ng, the di fferenti al pi n-
i on gears do not rotate on the pi ni on mate shaft. Thi s
occurs because i nput torque appl i ed to the gears i s
di vi ded and di stri buted equal l y between the two si de
gears. As a resul t, the pi ni on gears revol ve wi th the
pi ni on mate shaft but do not rotate around i t (Fi g. 1).
When turni ng corners, the outsi de wheel must
travel a greater di stance than the i nsi de wheel to
compl ete a turn. The di fference must be compensated
for to prevent the ti res from scuffi ng and ski ddi ng
through turns. To accompl i sh thi s, the di fferenti al
al l ows the axl e shafts to turn at unequal speeds (Fi g.
2). I n thi s i nstance, the i nput torque appl i ed to the
pi ni on gears i s not di vi ded equal l y. The pi ni on gears
now rotate around the pi ni on mate shaft i n opposi te
di recti ons. Thi s al l ows the si de gear and axl e shaft
attached to the outsi de wheel to rotate at a faster
speed.
TRAC-LOKா DIFFERENTIAL
Thi s di fferenti al s cl utches are engaged by two con-
current forces. The fi rst bei ng the prel oad force
exerted through Bel l evi l l e spri ng washers wi thi n the
cl utch packs. The second i s the separati ng forces gen-
erated by the si de gears as torque i s appl i ed through
the ri ng gear (Fi g. 3).
Thi s desi gn provi des the di fferenti al acti on needed
for turni ng corners and for dri vi ng strai ght ahead
duri ng peri ods of unequal tracti on. When one wheel
l ooses tracti on, the cl utch packs transfer addi ti onal
torque to the wheel havi ng the most tracti on. Thi s
di fferenti al resi st wheel spi n on bumpy roads and
provi de more pul l i ng power when one wheel l ooses
Fig. 1 Differential Operation - Straight Ahead Driving
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
Fig. 2 Differential Operation - On Turns
1 - PINION GEARS ROTATE ON PINION SHAFT
Fig. 3 Trac-lokா Limited Slip Differential
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
KJ REAR AXLE - 8 1/4 3 - 87
REAR AXLE - 8 1/4 (Continued)
tracti on. Pul l i ng power i s provi ded conti nuousl y unti l
both wheel s l oose tracti on. I f both wheel s sl i p due to
unequal tracti on, Trac-l ok™ operati on i s normal . I n
extreme cases of di fferences of tracti on, the wheel
wi th the l east tracti on may spi n.
DIAGNOSIS AND TESTING - AXLE
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, i ncorrect pi ni on depth, tooth
contact, worn/damaged gears, or the carri er housi ng
not havi ng the proper offset and squareness.
Gear noi se usual l y happens at a speci fi c speed
range. The noi se can al so occur duri ng a speci fi c type
of dri vi ng condi ti on. These condi ti ons are accel era-
ti on, decel erati on, coast, or constant l oad.
When road testi ng, fi rst warm-up the axl e fl ui d by
dri vi ng the vehi cl e at l east 5 mi l es and then accel er-
ate the vehi cl e to the speed range where the noi se i s
the greatest. Shi ft out-of-gear and coast through the
peak-noi se range. I f the noi se stops or changes
greatl y:
• Check for i nsuffi ci ent l ubri cant.
• I ncorrect ri ng gear backl ash.
• Gear damage.
Di fferenti al si de gears and pi ni ons can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ght-ahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on shaft can al so cause a snap-
pi ng or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on beari ngs can
al l produce noi se when worn or damaged. Beari ng
noi se can be ei ther a whi ni ng, or a growl i ng sound.
Pi ni on beari ngs have a constant-pi tch noi se. Thi s
noi se changes onl y wi th vehi cl e speed. Pi ni on beari ng
noi se wi l l be hi gher pi tched because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
U-joi nt or by worn si de–gear thrust washers. A worn
pi ni on shaft bore wi l l al so cause l ow speed knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by a:
• Damaged dri ve shaft.
• Mi ssi ng dri ve shaft bal ance wei ght(s).
• Worn or out-of-bal ance wheel s.
• Loose wheel l ug nuts.
• Worn U-joi nt(s).
• Loose/broken spri ngs.
• Damaged axl e shaft beari ng(s).
• Loose pi ni on gear nut.
• Excessi ve pi ni on yoke run out.
• Bent axl e shaft(s).
Check for l oose or damaged front-end components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rearend vi bra-
ti on. Do not overl ook engi ne accessori es, brackets
and dri ve bel ts.
NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged), can be caused by:
• Hi gh engi ne i dl e speed.
• Transmi ssi on shi ft operati on.
• Loose engi ne/transmi ssi on/transfer case mounts.
• Worn U-joi nts.
• Loose spri ng mounts.
• Loose pi ni on gear nut and yoke.
• Excessi ve ri ng gear backl ash.
• Excessi ve si de gear to case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
3 - 88 REAR AXLE - 8 1/4 KJ
REAR AXLE - 8 1/4 (Continued)
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
KJ REAR AXLE - 8 1/4 3 - 89
REAR AXLE - 8 1/4 (Continued)
Condition Possible Causes Correction
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion
contact pattern. Adjust backlash or
pinion depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
3 - 90 REAR AXLE - 8 1/4 KJ
REAR AXLE - 8 1/4 (Continued)
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Posi ti on a l i ft/jack under the axl e and secure
axl e to devi ce.
(3) Remove wheel s and ti res.
(4) Mark propel l er shaft and pi ni on yoke for
i nstal l ati on reference.
(5) Remove propel l er shaft and suspend under the
vehi cl e.
(6) Remove brake drums, parki ng brake cabl es and
speed sensor from the axl e.
(7) Di sconnect the brake hose at the body juncti on
bl ock.
(8) Remove brakes and backi ng pl ates.
(9) Remove vent hose from the axl e shaft tube.
(10) Remove the stabi l i zer bar (Fi g. 4).
(11) Remove upper control arm bal l joi nt pi nch
bol t from bracket (Fi g. 5).
(12) Remove shock absorbers from axl e brackets
(Fi g. 6).
(13) Loosen al l l ower control arms mounti ng bol ts
(Fi g. 7).
(14) Lower axl e enough to remove coi l spri ngs and
spri ng i nsul ators.
(15) Remove l ower control arm bol ts from the axl e
brackets.
(16) Lower and remove the axl e.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before the lower control arms
are tightened. This must be done to maintain vehi-
cle ride height and prevent premature bushing fail-
ure.
(1) Rai se the axl e under the vehi cl e.
(2) I nstal l l ower control arms onto the axl e brack-
ets and l oosel y i nstal l the mounti ng bol ts.
(3) I nstal l coi l spri ng i sol ators and spri ng.
(4) Rai se axl e up unti l spri ngs are seated.
(5) I nstal l upper control arm bal l joi nt i nto axl e
bracket and ti ghten pi nch bol t to torque speci fi cati on.
(6) I nstal l shock absorbers and ti ghten nuts to
torque speci fi cati on.
(7) I nstal l stabi l i zer bar and ti ghten nuts to torque
speci fi cati on.
(8) I nstal l brake backi ng pl ates, parki ng brake
cabl es, brake drums and speed sensor.
(9) I nstal l brake hose to the body juncti on bl ock
and bl eed the brakes.
Fig. 4 STABILIZER BAR MOUNTS
1 - STABILIZER BAR MOUNTING BOLTS
2 - LOWER SUSPENSION ARM
Fig. 5 BALL JOINT PINCH BOLT
1 - UPPER BALL JOINT
2 - PINCH BOLT
Fig. 6 SHOCK ABSORBER
1 - UPPER MOUNTING BOLT
2 - LOWER MOUNTING BOLT
KJ REAR AXLE - 8 1/4 3 - 91
REAR AXLE - 8 1/4 (Continued)
(10) I nstal l axl e vent hose.
(11) I nstal l propel l er shaft wi th reference marks.
(12) I nstal l the wheel s and ti res.
(13) Add gear l ubri cant to speci fi cati ons, i f neces-
sary.
(14) Remove l i fti ng devi ce from axl e and l ower the
vehi cl e.
(15) Ti ghten the l ower control arm bol ts to torque
speci fi cati on.
ADJUSTMENTS
Ri ng gears and pi ni ons are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng gear
and pi ni on are etched/marked onto each gear (Fi g. 8).
A pl us (+) number, mi nus (–) number or zero (0) i s
etched/marked on the face or shaft of the pi ni on. Thi s
number i s the amount (i n thousandths of an i nch)
the depth vari es from the standard depth setti ng of a
pi ni on etched wi th a (0). The standard depth pro-
vi des the best gear tooth contact pattern. Refer to
Backl ash and Contact Pattern Anal ysi s paragraph i n
thi s secti on for addi ti onal i nformati on.
Compensati on for pi ni on depth vari ance i s
achi eved wi th sel ect shi ms. The shi ms are pl aced
behi nd the rear pi ni on beari ng (Fi g. 9).
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance etched i nto both the ori gi nal and repl ace-
ment pi ni on. Add or subtract the thi ckness of the
ori gi nal depth shi ms to compensate for the di fference
i n the depth vari ances. Refer to the Depth Vari ance
chart.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. I ntersecti ng fi gure represents pl us or
mi nus the amount needed.
Note the etched number on the face of the pi ni on
gear head (–1, –2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi ms. I f the number
i s posi ti ve, subtract that val ue from the thi ckness of
the depth shi m. I f the number i s 0 no change i s nec-
essary.
Fig. 7 LOWER SUSPENSION ARM
1 - AXLE BRACKET BOLT
2 - LOWER CONTROL ARM
3 - BODY BRACKET BOLT
Fig. 8 Pinion Gear ID Numbers - Typical
1 - PRODUCTION NUMBERS
2 - DRIVE PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER (SAME AS RING GEAR
NUMBER)
Fig. 9 Adjustment Shim Locations
1 - DIFFERENTIAL HOUSING
2 - COLLAPSIBLE SPACER
3 - REAR PINION BEARING
4 - PINION DEPTH SHIM
5 - PINION GEAR
6 - BEARING CUP
3 - 92 REAR AXLE - 8 1/4 KJ
REAR AXLE - 8 1/4 (Continued)
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
Ϫ4 Ϫ3 Ϫ2 Ϫ1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003
0 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004
Ϫ1 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005
Ϫ2 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006
Ϫ3 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006 Ϫ0.007
Ϫ4 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006 Ϫ0.007 Ϫ0.008
PINION DEPTH MEASUREMENT
Measurements are taken wi th pi ni on beari ng cups and
pi ni on beari ngs i nstal l ed i n the housi ng. Take measure-
ments wi th Pi ni on Gauge Set and Di al I ndi cator C-3339.
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 8540 and rear pi ni on beari ng onto Screw 6741
(Fi g. 10).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng, and screw i nto the housi ng through
pi ni on beari ng cups (Fi g. 11).
(3) I nstal l front pi ni on beari ng and Cone-Nut 6740
hand ti ght (Fi g. 10).
(4) Pl ace Arbor Di sc 8541 on Arbor D-115-3 i n posi -
ti on i n the housi ng si de beari ng cradl es (Fi g. 12).
I nstal l di fferenti al beari ng caps on Arbor Di scs and
ti ghten cap bol ts to 41 N·m (30 ft. l bs.).
NOTE: Arbor Discs 8541 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
Fig. 10 Pinion Depth Gauge Tools
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOOK
8 - ARBOR DISC
Fig. 11 Pinion Height Block
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
KJ REAR AXLE - 8 1/4 3 - 93
REAR AXLE - 8 1/4 (Continued)
(6) Posi ti on Scooter Bl ock/Di al I ndi cator fl ush on
the pi ni on hei ght bl ock. Hol d scooter bl ock and zero
the di al i ndi cator.
(7) Sl owl y sl i de the scooter bl ock across the pi ni on
hei ght bl ock over to the arbor (Fi g. 13). Move the
scooter bl ock ti l l the di al i ndi cator probe crests the
arbor, then record the hi ghest readi ng.
(8) Sel ect a shi m equal to the di al i ndi cator read-
i ng pl us the dri ve pi ni on gear depth vari ance number
etched/marked on the pi ni on (Fi g. 8). For exampl e, i f
the depth vari ance i s –2, add +0.002 i n. to the di al
i ndi cator readi ng.
BEARING PRELOAD AND GEAR BACKLASH
The fol l owi ng must be consi dered when adjusti ng
beari ng prel oad and gear backl ash:
• The maxi mum ri ng gear backl ash vari ati on i s
0.076 mm (0.003 i nch).
• Mark the gears so the same teeth are meshed
duri ng al l backl ash measurements.
• Mai ntai n the torque whi l e adjusti ng the beari ng
prel oad and ri ng gear backl ash.
• Excessi ve adjuster torque wi l l i ntroduce a hi gh
beari ng l oad and cause premature beari ng fai l ure.
I nsuffi ci ent adjuster torque can resul t i n excessi ve
di fferenti al case free-pl ay and ri ng gear noi se.
• I nsuffi ci ent adjuster torque wi l l not support the
ri ng gear correctl y and can cause excessi ve di fferen-
ti al case free-pl ay and ri ng gear noi se.
NOTE: The differential bearing cups will not always
immediately follow the threaded adjusters as they
are moved during adjustment. To ensure accurate
bearing cup responses to the adjustments:
• Maintain the gear teeth engaged (meshed) as
marked.
• The bearings must be seated by rapidly rotat-
ing the pinion gear a half turn back and forth.
• Do this five to ten times each time the threaded
adjusters are adjusted.
(1) Adjust each threaded adjuster i nward wi th
Wrench C-4164 unti l the di fferenti al beari ng free-
pl ay i s el i mi nated (Fi g. 14). Al l ow some ri ng gear
backl ash, approxi matel y 0.25 mm (0.01 i n.) between
the ri ng and pi ni on gear. Seat the beari ng cups wi th
the procedure descri bed above.
Fig. 12 Gauge Tools In Housing
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 13 Pinion Gear Depth Measurement
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 14 Threaded Adjuster
1 - AXLE TUBE
2 - BACKING PLATE
3 - ADJUSTER WRENCH
3 - 94 REAR AXLE - 8 1/4 KJ
REAR AXLE - 8 1/4 (Continued)
(2) I nstal l di al i ndi cator and posi ti on the pl unger
agai nst the dri ve si de of a ri ng gear tooth (Fi g. 15).
Measure the backl ash at 4 posi ti ons (90 degrees
apart) around the ri ng gear. Locate and mark the
area of mi ni mum backl ash.
(3) Rotate the ri ng gear to the posi ti on of the l east
backl ash. Mark the gear so that al l future backl ash
measurements wi l l be taken wi th the same gear
teeth meshed.
(4) Loosen the ri ght-si de, ti ghten the l eft-si de
threaded adjuster. Obtai n backl ash of 0.076 to 0.102
mm (0.003 to 0.004 i n.) wi th each adjuster ti ghtened
to 14 N·m (10 ft. l bs.). Seat the beari ng cups wi th the
procedure descri bed above.
(5) Ti ghten the di fferenti al beari ng cap bol ts i n a
cri ss-cross pattern to 95 N·m (70 ft. l bs.).
(6) Ti ghten the ri ght-si de threaded adjuster to 102
N·m (75 ft. l bs.). Seat the beari ng cups wi th the pro-
cedure descri bed above. Conti nue to ti ghten the
ri ght-si de adjuster and seat beari ng cups unti l the
torque remai ns constant at 102 N·m (75 ft. l bs.)
(7) Measure the ri ng gear backl ash. The range of
backl ash i s 0.15 to 0.203 mm (0.006 to 0.008 i n.).
(8) Conti nue i ncreasi ng the torque at the ri ght-
si de threaded adjuster unti l the speci fi ed backl ash i s
obtai ned.
NOTE: The left-side threaded adjuster torque
should have approximately 102 N·m (75 ft. lbs.). If
the torque is considerably less, the complete
adjustment procedure must be repeated.
(9) Ti ghten the l eft-si de threaded adjuster unti l
102 N·m (75 ft. l bs.) torque i s i ndi cated. Seat the
beari ng rol l ers wi th the procedure descri bed above.
Do thi s unti l the torque remai ns constant.
(10) I nstal l the threaded adjuster l ocks and
ti ghten the l ock screws to 10 N·m (90 i n. l bs.).
After the proper backl ash i s achi eved, perform the
Gear Contact Pattern procedure.
GEAR CONTACT PATTERN
The ri ng gear and pi ni on teeth contact patterns
wi l l show i f the pi ni on depth i s correct i n the hous-
i ng. I t wi l l al so show i f the ri ng gear backl ash has
been adjusted correctl y. The backl ash can be adjusted
wi thi n speci fi cati ons to achi eve desi red tooth contact
patterns.
(1) Appl y a thi n coat of hydrated ferri c oxi de or
equi val ent, to the dri ve and coast si de of the ri ng
gear teeth.
(2) Wrap, twi st and hol d a shop towel around the
pi ni on yoke to i ncrease the turni ng resi stance of the
pi ni on. Thi s wi l l provi de a more di sti nct contact pat-
tern.
(3) Wi th a boxed end wrench on a ri ng gear bol t,
rotate the di fferenti al case one compl ete revol uti on i n
both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on teeth wi l l squee-
gee the compound to the areas wi th the l east amount
of contact. Note and compare patterns on the ri ng
gear teeth to Gear Tooth Contact Patterns chart (Fi g.
16) and adjust pi ni on depth and gear backl ash as
necessary.
Fig. 15 Ring Gear Backlash
1 - DIAL INDICATOR
2 - RING GEAR
3 - EXCITER RING
KJ REAR AXLE - 8 1/4 3 - 95
REAR AXLE - 8 1/4 (Continued)
Fig. 16 Gear Tooth Contact Patterns
3 - 96 REAR AXLE - 8 1/4 KJ
REAR AXLE - 8 1/4 (Continued)
SIDE GEAR CLEARANCE
NOTE: When measuring side gear clearance, check
each gear independently. If it necessary to replace a
side gear, replace both gears as a matched set.
(1) I nstal l the axl e shafts, C-l ocks and pi ni on mate
shaft.
(2) Measure each si de gear cl earance. I nsert a
matched pai r of feel er gauge bl ades between the gear
and di fferenti al housi ng on opposi te si des of the hub
(Fi g. 17).
(3) I f si de gear cl earances i s no more than 0.005
i nch. Determi ne i f the axl e shaft i s contacti ng the
pi ni on mate shaft. Do not remove the feeler
gauges, inspect the axle shaft with the feeler
gauge inserted behind the side gear. I f the end of
the axl e shaft i s not contacti ng the pi ni on mate
shaft, the si de gear cl earance i s acceptabl e.
(4) I f cl earance i s more than 0.005 i nch (axl e shaft
not contacti ng mate shaft), record the si de gear cl ear-
ance. Remove the thrust washer and measure i ts
thi ckness wi th a mi crometer. Add the washer thi ck-
ness to the recorded si de gear cl earance. The sum of
gear cl earance and washer thi ckness wi l l determi ne
requi red thi ckness of repl acement thrust washer
(Fi g. 18).
I n some cases, the end of the axl e shaft wi l l move
and contact the mate shaft when the feel er gauge i s
i nserted. The C-l ock i s preventi ng the si de gear from
sl i di ng on the axl e shaft.
(5) I f there i s no si de gear cl earance, remove the
C-l ock from the axl e shaft. Use a mi crometer to mea-
sure the thrust washer thi ckness. Record the thi ck-
ness and re-i nstal l the thrust washer. Assembl e the
di fferenti al case wi thout the C-l ock i nstal l ed and re-
measure the si de gear cl earance.
(6) Compare both cl earance measurements. I f the
di fference i s l ess than 0.012 i nch (0.305 mm), add
cl earance recorded when the C-l ock was i nstal l ed to
thrust washer thi ckness measured. The sum wi l l
determi ne the requi red thi ckness of the repl acement
thrust washer.
(7) I f cl earance i s 0.012 i nch (0.305 mm) or
greater, both si de gears must be repl aced (matched
set) and the cl earance measurements repeated.
(8) I f cl earance (above) conti nues to be 0.012 i nch
(0.305 mm) or greater, the case must be repl aced.
Fig. 17 Side Gear Clearance
1 - FEELER GAUGE BLADES
2 - SIDE GEAR
Fig. 18 Side Gear Calculations
KJ REAR AXLE - 8 1/4 3 - 97
REAR AXLE - 8 1/4 (Continued)
SPECIFICATIONS
REAR AXLE
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.07, 3.55, 4.10
Differential Case Flange Runout 0.076 mm (0.003 in.)
Differential Case Clearance 0.12 mm (0.005 in.)
Ring Gear Diameter 209.5 mm (8.25 in.)
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Ring Gear Runout 0.12 mm (0.005 in.)
Pinion Bearing Preload - Original Bearings 1-2 N·m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings 1-3.4 N·m (10-30 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Differential Cover Bolts 41 30 -
Bearing Cap Bolts 136 100 -
Ring Gear Bolts 95 70 -
Pinion Nut Minimum 285 210 -
Pinion Mate Shaft Screw 16.25 12 -
SPECIAL TOOLS
8 1/4 AXLE
PULLER 6790
REMOVER 6310
INSTALLER C-4198
HANDLE C-4171
3 - 98 REAR AXLE - 8 1/4 KJ
REAR AXLE - 8 1/4 (Continued)
INSTALLER C-4076-B
HANDLE C-4735-1
HOLDER 6719
PULLER C-452
INSTALLER C-3718
ADJUSTMENT WRENCH C-4164
PULLER/PRESS C-293–PA
ADAPTERS C-293-48
ADAPTER PLUG SP-3289
ADAPTERS C-293-47
INSTALLER C-4340
KJ REAR AXLE - 8 1/4 3 - 99
REAR AXLE - 8 1/4 (Continued)
FIXTURE 8138
INSTALLER C-4345
REMOVER C-4307
INSTALLER C-4308
INSTALLER D-130
INSTALLER 6448
TRAC-LOK™ TOOLS 8140
TRAC-LOK™ TOOLS 6960
PINION BLOCK 8540
ARBOR DISCS 8541
PINION GAUGE SET
3 - 100 REAR AXLE - 8 1/4 KJ
REAR AXLE - 8 1/4 (Continued)
AXLE SHAFTS
REMOVAL
(1) Pl ace the transmi ssi on i n NEUTRAL and rai se
and support vehi cl e.
(2) Remove wheel and ti re assembl y.
(3) Remove brake drum.
(4) Remove the housi ng cover and drai n l ubri cant.
(5) Rotate di fferenti al case to access the pi ni on
shaft l ock screw. Remove l ock screw and pi ni on shaft
from di fferenti al case (Fi g. 19).
(6) Push axl e shaft i nward then remove axl e shaft
C-l ock (Fi g. 20).
(7) Remove axl e shaft bei ng careful l not to damage
shaft beari ng and seal .
(8) I nspect axl e shaft seal for l eakage or damage.
(9) I nspect axl e shaft beari ng contact surface for
si gns of bri nel l i ng, gal l i ng and pi tti ng.
INSTALLATION
(1) Lubri cate beari ng bore and seal l i p wi th gear
l ubri cant. I nsert axl e shaft through seal , beari ng and
engage i t i nto si de gear spl i nes.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip.
(2) I nsert C-l ock i n end of axl e shaft. Push axl e
shaft outward to seat C-l ock i n si de gear.
(3) I nsert pi ni on shaft i nto di fferenti al case and
through thrust washers and di fferenti al pi ni ons.
(4) Al i gn hol e i n shaft wi th hol e i n the di fferenti al
case and i nstal l l ock screw wi th Locti te௡ on the
threads. Ti ghten l ock screw to 11 N·m (8 ft. l bs.).
(5) I nstal l cover and fi l l wi th gear l ubri cant to the
bottom of the fi l l pl ug hol e.
(6) I nstal l brake drum.
(7) I nstal l wheel and ti re assembl i es.
(8) Remove support and l ower vehi cl e.
AXLE SHAFT SEALS
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove axl e shaft.
(3) Remove axl e shaft seal from the axl e tube wi th
a smal l pry bar (Fi g. 21).
Fig. 19 Pinion Shaft Lock Screw
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 20 Axle Shaft C-Lock
1 - C-LOCK
2 - AXLE SHAFT
3 - SIDE GEAR
Fig. 21 Axle Seal
1 - AXLE TUBE
2 - AXLE SEAL
3 - PRY BAR
KJ REAR AXLE - 8 1/4 3 - 101
INSTALLATION
(1) Wi pe the axl e tube bore cl ean. Remove any ol d
seal er or burrs from the tube.
(2) I nstal l a new axl e seal wi th I nstal l er C-4076-B
and Handl e C-4735-1. When the tool contacts the
axl e tube, the seal i s i nstal l ed to the correct depth.
(3) Coat the l i p of the seal wi th axl e l ubri cant for
protecti on pri or to i nstal l i ng the axl e shaft.
(4) I nstal l the axl e shaft.
(5) Check and fi l l gear l ubri cant.
(6) I nstal l wheel and ti re assembl y.
(7) Remove support and l ower vehi cl e.
AXLE BEARINGS
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove axl e shaft.
(3) Remove axl e shaft seal from the axl e tube wi th
a smal l pry bar (Fi g. 22).
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
(4) Remove axl e shaft beari ng wi th Beari ng
Removal Tool Set 6310 and Adapter Foot 6310-9 (Fi g.
23).
INSTALLATION
(1) Wi pe the axl e tube bore cl ean. Remove any ol d
seal er or burrs from the tube.
(2) I nstal l axl e shaft beari ng wi th I nstal l er C-4198
and Handl e C-4171.
NOTE: Install bearing with part number against the
installer.
(3) I nstal l a new axl e seal wi th I nstal l er C-4198
and Handl e C-4171. When the tool contacts the axl e
tube, the seal i s i nstal l ed to the correct depth.
(4) Coat the l i p of the seal wi th axl e l ubri cant for
protecti on pri or to i nstal l i ng the axl e shaft.
(5) I nstal l the axl e shaft.
(6) Check and fi l l gear l ubri cant.
(7) I nstal l wheel and ti re assembl y.
(8) Remove support and l ower vehi cl e.
PINION SEAL
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Mark the uni versal joi nt, pi ni on yoke and pi n-
i on shaft for i nstal l ati on reference.
(3) Remove propel l er shaft from pi ni on yoke.
(4) Remove the wheel and ti re assembl i es.
(5) Remove the brake drums.
(6) Rotate the pi ni on yoke three or four ti mes.
Fig. 22 Axle Seal
1 - AXLE TUBE
2 - AXLE SEAL
3 - PRY BAR
Fig. 23 Axle Shaft Bearing
1 - NUT
2 - GUIDE PLATE
3 - GUIDE
4 - THREADED ROD
5 - ADAPTER
6 - FOOT
7 - AXLE TUBE
3 - 102 REAR AXLE - 8 1/4 KJ
AXLE SHAFT SEALS (Continued)
(7) Measure rotati ng torque of the pi ni on gear
wi th an i nch pound torque wrench and record the
readi ng for i nstal l ati on reference.
(8) Hol d the pi ni on yoke wi th Hol der 6719 and
remove the pi ni on nut and washer.
(9) Remove yoke wi th Remover C-452 (Fi g. 24).
(10) Remove pi ni on seal wi th a pry tool or screw
mounted to a sl i de-hammer mounted.
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal .
NOTE: The outer perimeter of the seal is pre-coated
with a special sealant. An additional application of
sealant is not required.
(2) I nstal l the new pi ni on seal (Fi g. 25) wi th
I nstal l er C-4076-A and Handl e C-4735.
(3) I nstal l pi ni on yoke on the shaft wi th the refer-
ence marks al i gned.
(4) Seat yoke on pi ni on shaft wi th I nstal l er C-3718
and Hol der 6719A.
(5) Remove the tool s and i nstal l the pi ni on yoke
washer. The convex si de of the washer must face out-
ward.
(6) Usi ng yoke Hol der 6719A ti ghten shaft nut to
285 N·m (210 ft. l bs.) (Fi g. 26). Rotate the pi ni on sev-
eral revol uti ons to ensure the beari ng rol l ers are
seated.
(7) Rotate the pi ni on usi ng an i nch pound torque
wrench. Rotati ng torque shoul d be equal to the read-
i ng recorded duri ng removal , pl us an addi ti onal 0.56
N·m (5 i n. l bs.) (Fi g. 27).
CAUTION: Never loosen pinion nut to decrease pin-
ion rotating torque and never exceed specified pre-
load torque. If preload torque is exceeded a new
collapsible spacer must be installed.
(8) I f the rotati ng torque i s l ow, use Hol der 6719A
(Fi g. 26) and ti ghten the pi ni on nut i n 6.8 N·m (5 ft.
Fig. 24 Pinion Yoke
1 - PINION YOKE
2 - REMOVER
Fig. 25 Pinion Seal Installer
1 - HANDLE
2 - DIFFERENTIAL HOUSING
3 - INSTALLER
Fig. 26 Tightening Pinion Nut
1 - DIFFERENTIAL HOUSING
2 - YOKE HOLDER
3 - TORQUE WRENCH
KJ REAR AXLE - 8 1/4 3 - 103
PINION SEAL (Continued)
l bs.) i ncrements unti l proper rotati ng torque i s
achi eved.
NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, it indicates a binding
condition.
(9) The seal repl acement i s unacceptabl e i f the
fi nal pi ni on nut torque i s l ess than 285 N·m (210 ft.
l bs.).
(10) I nstal l the propel l er shaft wi th the i nstal l a-
ti on reference marks al i gned.
(11) I nstal l the brake drums.
(12) Check the di fferenti al housi ng l ubri cant l evel .
(13) I nstal l wheel and ti re assembl i es and l ower
the vehi cl e.
DIFFERENTIAL
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove fi l l hol e pl ug from the di fferenti al
housi ng cover.
(3) Remove di fferenti al housi ng cover and drai n
housi ng.
(4) Cl ean the housi ng cavi ty wi th a fl ushi ng oi l ,
l i ght engi ne oi l or l i nt free cl oth. Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove the axl e shafts.
NOTE: Side play resulting from bearing races being
loose on case hubs requires replacement of the dif-
ferential case.
(6) Mark the di fferenti al housi ng and beari ng caps
for i nstal l ati on reference (Fi g. 28).
(7) Remove beari ng threaded adjuster l ocks from
each beari ng cap.
(8) Loosen beari ng cap bol ts, them l oosen the
threaded adjusters wi th Wrench C-4164 (Fi g. 29).
Fig. 27 Pinion Rotation Torque
1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH Fig. 28 Reference Mark
1 - REFERENCE MARKS
2 - REFERENCE MARKS
3 - DIFFERENTIAL HOUSING
4 - BEARING CAP
Fig. 29 Threaded Adjuster
1 - AXLE TUBE
2 - BACKING PLATE
3 - THREAD ADJUSTER WRENCH
3 - 104 REAR AXLE - 8 1/4 KJ
PINION SEAL (Continued)
(9) Hol d the di fferenti al case whi l e removi ng bear-
i ng caps and adjusters.
(10) Remove the di fferenti al case.
NOTE: Tag bearing cups and threaded adjusters
location, for installation reference.
DISASSEMBLY
(1) Remove pi ni on shaft l ock screw (Fi g. 30).
(2) Remove pi ni on shaft.
(3) Rotate di fferenti al si de gears and remove di f-
ferenti al pi ni ons and thrust washers (Fi g. 31).
(4) Remove di fferenti al si de gears and thrust
washers.
ASSEMBLY
(1) I nstal l di fferenti al si de gears and thrust wash-
ers.
(2) I nstal l di fferenti al pi ni on and thrust washers.
(3) I nstal l the pi ni on shaft.
(4) Al i gn the hol e i n the pi ni on shaft wi th the hol e
i n the di fferenti al case and i nstal l the pi ni on shaft
l ock screw.
(5) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
INSTALLATION
(1) Appl y a coati ng of hypoi d gear l ubri cant to the
di fferenti al beari ngs, beari ng cups and threaded
adjusters. A dab of grease can be used to keep the
adjusters i n posi ti on. Careful l y posi ti on the assem-
bl ed di fferenti al case i n the housi ng.
(2) I nstal l di fferenti al beari ng caps i n thei r ori gi -
nal l ocati ons (Fi g. 32).
(3) I nstal l beari ng cap bol ts and ti ghten the upper
bol ts to 14 N·m (10 ft. l bs.). Ti ghten the l ower bol ts
fi nger-ti ght unti l the bol t head i s seated.
(4) Perform the di fferenti al beari ng prel oad and
adjustment procedure.
(5) Ti ghten beari ng cap bol ts i n a cri ss-cross pat-
tern to 95 N·m (70 ft.l bs).
Fig. 30 Pinion Shaft Lock Screw
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 31 Differential Case
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
Fig. 32 Bearing Caps & Bolts
1 - REFERENCE MARKS
2 - REFERENCE MARKS
3 - DIFFERENTIAL HOUSING
4 - BEARING CAP
KJ REAR AXLE - 8 1/4 3 - 105
DIFFERENTIAL (Continued)
(6) I nstal l adjuster l ocks on the beari ng caps.
(7) I nstal l axl e shafts.
(8) Appl y a bead of red Mopar si l i cone rubber axl e
seal ant or equi val ent to the housi ng cover (Fi g. 33).
CAUTION: If cover is not installed within 3 to 5 min-
utes, the cover must be cleaned and new RTV
applied or adhesion quality will be compromised.
(9) I nstal l cover and ti ghten bol ts i n a cri ss-cross
pattern to 41 N·m (30 ft. l bs.).
(10) Fi l l di fferenti al wi th gear l ubri cant to bottom
of the fi l l pl ug hol e.
(11) I nstal l the fi l l hol e pl ug.
(12) I nstal l wheel and ti re assembl i es.
(13) Remove support and l ower vehi cl e.
(14) Trac-l ok௡ di fferenti al equi pped vehi cl es shoul d
be road tested by maki ng 10 to 12 sl ow fi gure-ei ght
turns. Thi s maneuver wi l l pump the l ubri cant
through the cl utch di scs to el i mi nate a possi bl e chat-
ter noi se compl ai nt.
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKா
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng the uni t for repai r,
drai n, fl ush and refi l l the axl e wi th the speci fi ed
l ubri cant. A contai ner of Mopar Trac-l ok௡ Lubri cant
(fri cti on modi fi er) shoul d be added after repai r ser-
vi ce or duri ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
DIFFERENTIAL TEST
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 or
equi val ent tool to studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 34).
(6) I f rotati ng torque i s l ess than 41 N·m (56 ft.
l bs.) or more than 271 N·m (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
Fig. 33 Differential Cover Sealant
1 - SEALANT
2 - DIFFERNTIAL COVER
Fig. 34 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
3 - 106 REAR AXLE - 8 1/4 KJ
DIFFERENTIAL (Continued)
DISASSEMBLY
(1) Cl amp si de gear Fi xture 8138 i n a vi se and set
di fferenti al case on the fi xture (Fi g. 35).
(2) Remove ri ng gear i f the ri ng gear i s to be
repl aced. The Trac-l ok௡ di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
(3) Remove pi ni on gear mate shaft l ock screw.
(4) Remove pi ni on gear mate shaft wi th a dri ft and
hammer.
(5) I nstal l Di scs 8140 wi thout threaded hol e i n the
l ower si de gear (Fi g. 36).
(6) I nstal l Di sc 8140 wi th threaded hol e i n the
upper si de gear. Thread Forci ng Screw 6960-4
through the upper di sc unti l i t becomes centered i n
l ower di sc.
(7) I nsert a screw dri ver i n sl ot of upper di sc (Fi g.
37) to prevent di sc from turni ng.
Fig. 36 LOWER DISC
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - DISC
Fig. 37 TRAK-LOCா TOOLS
1 - SOCKET
2 - SLOT IN DISC
3 - SCREWDRIVER
4 - LOWER DISC
5 - THREADED ROD
6 - UPPER DISC
Fig. 35 DIFFERENTIAL CASE FIXTURE
1 - FIXTURE
2 - VISE
3 - DIFFERENTIAL
KJ REAR AXLE - 8 1/4 3 - 107
DIFFERENTIAL - TRAC-LOK (Continued)
(8) Ti ghten forci ng screw to 122 N·m (90 ft. l bs.)
maxi mum to compress Bel l evi l l e spri ngs i n cl utch
packs (Fi g. 38).
(9) Wi th a feel er gauge remove thrust washers
from behi nd the pi ni on gears (Fi g. 39).
(10) I nsert Turni ng Bar 6960-2 i nto the pi ni on
mate shaft hol e i n the case (Fi g. 40).
(11) Loosen the Forci ng Screw i n smal l i ncrements
unti l the cl utch pack tensi on i s rel i eved and the di f-
ferenti al case can be turned usi ng Turni ng Bar.
(12) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(13) Remove pi ni on gears from di fferenti al case.
(14) Remove Forci ng Screw and di scs.
(15) Remove top si de gear, cl utch pack retai ner
and cl utch pack. Keep pl ates i n order duri ng removal
(Fi g. 41).
Fig. 38 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - FORCING SCREW
3 - DIFFERENTIAL CASE
Fig. 39 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
Fig. 40 PINION GEARS
1 - PINION GEARS
2 - TURNING BAR
Fig. 41 SIDE GEARS AND CLUTCH DISCS
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
3 - 108 REAR AXLE - 8 1/4 KJ
DIFFERENTIAL - TRAC-LOK (Continued)
(16) Remove di fferenti al case from the fi xture.
Remove si de gear, cl utch pack retai ner and cl utch
pack. Keep pl ates i n order duri ng removal .
CLEANING
Cl ean al l components i n cl eani ng sol vent and dry
components wi th compressed ai r.
INSPECTION
I nspect cl utch pack pl ates for wear, scori ng or dam-
age. Repl ace both cl utch packs i f any one component
i n ei ther pack i s damaged. I nspect si de and pi ni on
gears for cracks chi ps or damage and repl ace as nec-
essary. I nspect di fferenti al case and pi ni on shaft and
repl ace i f worn or damaged.
ASSEMBLY
Lubri cate each component wi th gear l ubri cant
before assembl y.
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
(1) Assembl e the cl utch di scs i nto packs and
secure di sc packs wi th retai ni ng cl i ps (Fi g. 42).
(2) I nstal l assembl ed cl utch di sc packs on the si de
gear hubs.
(3) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 43).Verify
clutch pack retaining clips are in position and
seated in the case pockets.
(4) Set di fferenti al case on Fi xture 8138.
(5) I nstal l l ubri cated Di sc 8140 wi thout the hol e i n
l ower si de gear (Fi g. 44).
(6) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 44).
(7) Hol d assembl y i n posi ti on. I nsert Di sc 8140
wi th threaded hol e i nto top si de gear.
(8) I nstal l Forci ng Screw 6960-4 and ti ghten screw
to sl i ghtl y compress cl utch di sc.
(9) Pl ace pi ni on gears i n posi ti on i n si de gears and
veri fy that the pi ni on mate shaft hol e i s al i gned.
(10) Rotate case wi th Turni ng Bar 6960-2 unti l the
pi ni on mate shaft hol es i n pi ni on gears al i gn wi th
hol es i n case. I t may be necessary to sl i ghtl y ti ghten
the forci ng screw i n order to i nstal l the pi ni on gears.
(11) Ti ghten forci ng screw to 122 N·m (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(12) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
(13) Remove forci ng screw and di scs.
Fig. 42 CLUTCH DISC PACK
1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
Fig. 43 CLUTCH PACK AND LOWER SIDE GEAR
1 - DIFFERENTIAL CASE
2 - LOWER SIDE GEAR AND CLUTCH PACK
KJ REAR AXLE - 8 1/4 3 - 109
DIFFERENTIAL - TRAC-LOK (Continued)
(14) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(15) I nstal l pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
(16) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove di fferenti al case from axl e.
(2) Remove di fferenti al beari ngs from the case
wi th Pul l er/Press C-293-PA and Adapters C-293-48
and Pl ug SP-3289 (Fi g. 45).
INSTALLATION
(1) I nstal l di fferenti al si de beari ngs wi th I nstal l er
C-4340 and Handl e C-4171 (Fi g. 46).
(2) I nstal l di fferenti al case i n axl e.
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
CAUTION: The ring and pinion gears are serviced in
a matched set. Never replace one gear without
replacing the other matched gear.
(1) Mark pi ni on yoke and propel l er shaft for
i nstal l ati on reference.
(2) Remove propel l er shaft from pi ni on yoke and
ti e propel l er shaft to underbody.
(3) Remove di fferenti al from axl e housi ng.
(4) Pl ace di fferenti al case i n a vi se wi th soft metal
jaw (Fi g. 47).
(5) Remove bol ts hol di ng ri ng gear to di fferenti al
case.
(6) Dri ve ri ng gear from the di fferenti al case wi th
a rawhi de hammer.
Fig. 44 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - LOWER DISC
Fig. 45 Differential Bearing Puller
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
3 - 110 REAR AXLE - 8 1/4 KJ
DIFFERENTIAL - TRAC-LOK (Continued)
(7) Hol d pi ni on yoke wi th Hol der 6719A and
remove pi ni on yoke nut and washer.
(8) Remove pi ni on yoke from pi ni on shaft wi th
Remover C-452 (Fi g. 48).
(9) Remove pi ni on from the housi ng (Fi g. 49).
Fig. 46 Differential Bearing Installer
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 47 Ring Gear
1 - CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 48 Pinion Yoke
1 - PINION YOKE
2 - REMOVER
Fig. 49 Pinion Gear
1 - RAWHIDE HAMMER
KJ REAR AXLE - 8 1/4 3 - 111
PINION GEAR/RING GEAR/TONE RING (Continued)
(10) Remove pi ni on shaft seal wi th a pry tool or
sl i de-hammer mounted screw.
(11) Remove oi l sl i nger, i f equi pped, and front pi n-
i on beari ng.
(12) Remove front pi ni on beari ng cup wi th
Remover C-4345 and Handl e C-4171 (Fi g. 50).
(13) Remove rear beari ng cup from housi ng (Fi g.
51) wi th Remover C-4307 and Handl e C-4171.
(14) Remove col l apsi bl e prel oad spacer (Fi g. 52).
(15) Remove rear beari ng from the pi ni on (Fi g. 53)
wi th Pul l er/Press C-293-PA and Adapters C-293-47.
(16) Remove depth shi ms from the pi ni on shaft
and record the shi ms thi ckness.
INSTALLATION
NOTE: A pinion depth shim/oil baffle is placed
between the rear pinion bearing cone and pinion
gear. If the ring and pinion gears are reused, the
original pinion depth shim/oil baffle can be used.
Refer to Adjustments (Pinion Gear Depth) to select
the proper shim thickness if ring and pinion gear
are replaced.
(1) Appl y Mopar Door Ease or equi val ent l ubri cant
to outsi de surface of pi ni on beari ng cups.
(2) I nstal l rear pi ni on beari ng cup (Fi g. 54) wi th
I nstal l er C-4308 and Handl e C-4171 and veri fy cup i s
seated.
(3) I nstal l front pi ni on beari ng cup (Fi g. 55) wi th
I nstal l er D-130 and Handl e C-4171 and veri fy cup i s
seated.
Fig. 50 Front Pinion Bearing Cup
1 - REMOVER
2 - HANDLE
Fig. 51 Rear Pinion Bearing Cup
1 - DRIVER
2 - HANDLE
Fig. 52 Collapsible Spacer
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION
4 - PINION DEPTH SHIM
5 - REAR BEARING
3 - 112 REAR AXLE - 8 1/4 KJ
PINION GEAR/RING GEAR/TONE RING (Continued)
(4) I nstal l pi ni on front beari ng and oi l sl i nger, i f
equi pped.
(5) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal and i nstal l seal wi th I nstal l er
C-4076-B and Handl e C-4735 (Fi g. 56).
(6) Pl ace proper thi ckness depth shi m on the pi n-
i on.
(7) I nstal l rear beari ng and sl i nger i f equi pped, on
the pi ni on shaft (Fi g. 57) wi th I nstal l er 6448 and a
press.
(8) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft and i nstal l pi ni on i n housi ng (Fi g. 58).
(9) I nstal l pi ni on i n housi ng.
(10) I nstal l yoke wi th I nstal l er C-3718 and Yoke
Hol der 6719A.
Fig. 53 Rear Pinion Bearing Puller
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
Fig. 54 Rear Pinion Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 55 Front Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 56 Pinion Seal
1 - HANDLE
2 - DIFFERENTIAL HOUSING
3 - INSTALLER
KJ REAR AXLE - 8 1/4 3 - 113
PINION GEAR/RING GEAR/TONE RING (Continued)
(11) I nstal l yoke washer and a new nut on the pi n-
i on. The convex si de of the washer must face out-
ward.
(12) Ti ghten the nut to 285 N·m (210 ft. l bs.).
CAUTION: Never loosen pinion nut to decrease pin-
ion rotating torque and never exceed specified pre-
load torque. If preload torque or rotating torque is
exceeded a new collapsible spacer must be
installed.
(13) Hol di ng the yoke wi th Hol der 6719A sl owl y
ti ghten the nut i n 6.8 N·m (5 ft. l bs.) i ncrements
unti l the desi red rotati ng torque i s achi eved. Mea-
sure the rotati ng torque frequentl y to avoi d over
crushi ng the spacer (Fi g. 59).
(14) Check beari ng rotati ng torque wi th an i nch
pound torque wrench (Fi g. 59). The pi ni on gear rotat-
i ng torque shoul d be:
• Ori gi nal Beari ngs: 1 to 2 N·m (10 to 20 i n. l bs.).
• New Beari ngs: 1 to 5 N·m (10 to 30 i n. l bs.).
Fig. 57 Rear Pinion Bearing
1 - PRESS
2 - INSTALLATION
3 - PINION GEAR
4 - REAR PINION BEARING
Fig. 58 Collapsible Preload Spacer
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION
4 - PINION DEPTH SHIM
5 - REAR BEARING
Fig. 59 Pinion Rotating Torque
1 - TORQUE WRENCH
2 - PINION YOKE
3 - 114 REAR AXLE - 8 1/4 KJ
PINION GEAR/RING GEAR/TONE RING (Continued)
(15) I nvert the di fferenti al case.
(16) I nstal l ri ng gear on the di fferenti al case and
start two ri ng gear bol ts. Thi s wi l l provi de case-to-
ri ng gear bol t hol e al i gnment.
(17) I nvert the di fferenti al case i n the vi se.
(18) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 102 N·m (75 ft. l bs.) (Fi g. 60).
CAUTION: Never reuse the ring gear bolts. The
bolts can fracture causing extensive damage.
(19) I nstal l di fferenti al i n axl e housi ng and veri fy
gear mesh refer to Adjustments (Gear Contact Pat-
tern).
(20) I nstal l di fferenti al cover fi l l wi th gear l ubri -
cant.
(21) I nstal l the propel l er shaft wi th reference
marks al i gned.
(22) I nstal l wheel and ti re assembl i es and l ower
the vehi cl e.
Fig. 60 Ring Gear
1 - TORQUE WRENCH
2 - BOLTS
3 - RING GEAR
4 - DIFFERENTIAL CASE
KJ REAR AXLE - 8 1/4 3 - 115
PINION GEAR/RING GEAR/TONE RING (Continued)
BRAKES
TABLE OF CONTENTS
page page
POWER BRAKE BOOSTER
REMOVAL - RHD . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION - RHD . . . . . . . . . . . . . . . . . . . . . 1
POWER BRAKE BOOSTER
REMOVAL - RHD
(1) Remove the ai r box (Refer to 9 - ENGI NE/AI R
I NTAKE SYSTEM/AI R CLEANER ELEMENT -
REMOVAL).
(2) Rel ocate the crui se control servo to gai n access
to the booster for removal .
(3) Remove the brake l i nes from the master cyl i n-
der.
(4) Remove the master cyl i nder (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/MASTER
CYLI NDER - REMOVAL).
(5) Di sconnect vacuum hose from booster check
val ve.
(6) Remove knee bl ocker under the steeri ng col um-
n,(Refer to 23 - BODY/I NSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL).
(7) Remove the brake l i ght swi tch.(Refer to 8 -
ELECTRI CAL/LAMPS/LI GHTI NG - EXTERI OR/
BRAKE LAMP SWI TCH - REMOVAL)
(8) Remove retai ni ng cl i p that secures booster
push rod to brake pedal (Fi g. 1).
(9) Remove nuts attachi ng booster to the dash
panel (Fi g. 2).
(10) I n engi ne compartment, sl i de booster studs
out of dash panel , ti l t booster upward, and remove
booster from engi ne compartment.
INSTALLATION - RHD
(1) Al i gn and posi ti on booster on the dash panel .
(2) I nstal l booster mounti ng nuts. Ti ghten nuts
just enough to hol d booster i n pl ace.
(3) Sl i de booster push rod onto the brake pedal .
Then secure push rod to pedal pi n wi th retai ni ng
cl i p.
NOTE: Lubricate the pedal pin with Mopar multi-
mileage grease before installation.
(4) Ti ghten booster mounti ng nuts to 39 N·m (29
ft. l bs.).
(5) I nstal l the brake l i ght swi tch.
(6) I nstal l the knee bl ocker,(Refer to 23 - BODY/
I NSTRUMENT PANEL/KNEE BLOCKER - I NSTAL-
LATI ON).
(7) I f ori gi nal master cyl i nder i s bei ng i nstal l ed,
check condi ti on of seal at rear of master cyl i nder.
Repl ace seal i f cut, or torn.
(8) Cl ean cyl i nder mounti ng surface of brake
booster. Use shop towel wetted wi th brake cl eaner for
Fig. 1 BOOSTER PUSH ROD
1 - BRAKE PEDAL
2 - BOOSTER ROD
Fig. 2 BOOSTER MOUNTING
1 - BRAKE BOOSTER
KJ BRAKES 5s - 1
thi s purpose. Di rt, grease, or si mi l ar materi al s wi l l
prevent proper cyl i nder seati ng and coul d resul t i n
vacuum l eak.
(9) Al i gn and i nstal l master cyl i nder on the
booster studs. I nstal l mounti ng nuts and ti ghten to
17.5 N·m (155 i n. l bs.).
(10) Connect vacuum hose to booster check val ve.
(11) Remount the crui se control servo to the ori gi -
nal l ocati on. Ti ghten bracket mounti ng nuts to 17.5
N·m (155 i n. l bs.).
(12) Connect and secure the brake l i nes to HCU
and master cyl i nder. Start al l brake l i ne fi tti ngs by
hand to avoi d cross threadi ng.
(13) Connect the wi re to fl ui d reservoi r.
(14) I nstal l the ai r box.
(15) Fi l l and bl eed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
(16) Veri fy proper brake operati on before movi ng
vehi cl e.
5s - 2 BRAKES KJ
POWER BRAKE BOOSTER (Continued)
CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - CLUTCH . . . . . . . . 2
SPECIFICATIONS - CLUTCH . . . . . . . . . . . . . . . 5
CLUTCH DISC
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLUTCH RELEASE BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FLYWHEEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - FLYWHEEL . . . . . . 8
PILOT BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LINKAGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MASTER CYLINDER
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CLUTCH PEDAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLUTCH SWITCH OVERRIDE RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLUTCH PEDAL POSITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - CLUTCH PEDAL
POSITION SWITCH . . . . . . . . . . . . . . . . . . . . 11
CLUTCH
DESCRIPTION
The cl utch mechani sm consi sts of a fl ywheel , dry-
type di sc, di aphragm styl e pressure pl ate and
hydraul i c l i nkage. The fl ywheel i s bol ted to the rear
fl ange of the crankshaft. The cl utch pressure pl ate i s
bol ted to the fl ywheel wi th the cl utch di sc between
these two components. The cl utch system provi des
the mechani cal , l i nk between the engi ne and the
transmi ssi on. The system i s desi gned to transfer the
torque output of the engi ne, to the transmi ssi on
whi l e i sol ati ng the transmi ssi on from the engi ne fi r-
i ng pul ses to mi ni mi ze concerns such as gear rattl e.
OPERATION
The cl utch operates wi th l everage, cl ampi ng force
and fri cti on. The di sc serves as the fri cti on el ement,
the di aphragm spri ng and pressure pl ate provi de the
cl ampi ng force. The cl utch pedal , hydraul i c l i nkage,
rel ease l ever and beari ng provi de the l everage.
The cl utch master cyl i nder push rod i s connected
to the cl utch pedal . When the cl utch pedal i s
depressed, the sl ave cyl i nder i s operated by the
cl utch master cyl i nder mounted on the dash panel .
The rel ease fork i s actuated by the hydraul i c sl ave
cyl i nder mounted on the transmi ssi on housi ng. The
rel ease beari ng i s operated by a rel ease fork pi voti ng
on a bal l stud mounted i n the transmi ssi on housi ng.
The rel ease beari ng then depresses the pressure
pl ate spri ng fi ngers, thereby rel easi ng pressure on
the cl utch di sc and al l owi ng the engi ne crankshaft to
spi n i ndependentl y of the transmi ssi on i nput shaft.
KJ CLUTCH 6 - 1
WARNING
WARNING:: EXERCISE CARE WHEN SERVICING
CLUTCH COMPONENTS. FACTORY INSTALLED
CLUTCH DISCS DO NOT CONTAIN ASBESTOS
FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY
CONTAIN ASBESTOS FIBERS FROM AFTERMAR-
KET COMPONENTS. BREATHING EXCESSIVE CON-
CENTRATIONS OF THESE FIBERS CAN CAUSE
SERIOUS BODILY HARM. WEAR A RESPIRATOR
DURING SERVICE AND NEVER CLEAN CLUTCH
COMPONENTS WITH COMPRESSED AIR OR WITH
A DRY BRUSH. EITHER CLEAN THE COMPONENTS
WITH A WATER DAMPENED RAGS OR USE A VAC-
UUM CLEANER SPECIFICALLY DESIGNED FOR
REMOVING ASBESTOS FIBERS AND DUST. DO NOT
CREATE DUST BY SANDING A CLUTCH DISC.
REPLACE THE DISC IF THE FRICTION MATERIAL IS
DAMAGED OR CONTAMINATED. DISPOSE OF ALL
DUST AND DIRT CONTAINING ASBESTOS FIBERS
IN SEALED BAGS OR CONTAINERS. THIS WILL
HELP MINIMIZE EXPOSURE TO YOURSELF AND TO
OTHERS. FOLLOW ALL RECOMMENDED SAFETY
PRACTICES PRESCRIBED BY THE OCCUPATIONAL
SAFETY AND HEALTH ADMINISTRATION (OSHA)
AND THE ENVIRONMENTAL SAFETY AGENCY
(EPA), FOR THE HANDLING AND DISPOSAL OF
PRODUCTS CONTAINING ASBESTOS.
DIAGNOSIS AND TESTING - CLUTCH
Dri ve the vehi cl e at normal speeds. Shi ft the trans-
mi ssi on through al l gear ranges and observe cl utch
acti on. I f the cl utch chatters, grabs, sl i ps or does not
rel ease properl y, remove and i nspect the cl utch com-
ponents. I f the probl em i s noi se or hard shi fti ng, fur-
ther di agnosi s may be needed as the transmi ssi on or
another dri vel i ne component may be at faul t.
NOTE: Vehicles equipped with a Dual Mass Fly-
wheel may produce a rattle when the engine is shut
off. This noise is considered normal.
CLUTCH CONTAMINATION
Fl ui d contami nati on i s a frequent cause of cl utch
mal functi ons. Oi l , water or cl utch fl ui d on the cl utch
di sc and pressure pl ate surfaces wi l l cause chatter,
sl i p and grab. I nspect components for oi l , hydraul i c
fl ui d or water/road spl ash contami nati on.
Oi l contami nati on i ndi cates a l eak at ei ther the
rear mai n seal or transmi ssi on i nput shaft. Cl utch
fl ui d l eaks are usual l y from damaged sl ave cyl i nder
push rod seal s. Heat bui l dup caused by sl i ppage
between the pressure pl ate, di sc and fl ywheel can
bake the oi l resi due onto the components. The gl aze-
l i ke resi due ranges i n col or from amber to bl ack.
Road spl ash contami nati on i s di rt/water enteri ng
the cl utch housi ng due to l oose bol ts, housi ng cracks.
Dri vi ng through deep water puddl es can force water/
road spl ash i nto the housi ng through such openi ngs.
IMPROPER RELEASE OR CLUTCH ENGAGEMENT
Cl utch rel ease or engagement probl ems are caused
by wear or damage cl utch components. A vi sual
i nspecti on of the rel ease components wi l l usual l y
reveal the probl em part.
Rel ease probl ems can resul t i n hard shi fti ng and
noi se. Look for l eaks at the cl utch cyl i nders and
i nterconnecti ng l i ne and l oose sl ave cyl i nder bol ts.
Al so worn/l oose rel ease fork, pi vot stud, cl utch di sc,
pressure pl ate or rel ease beari ng.
Engagement probl ems can resul t i n sl i p, chatter/
shudder and noi sy operati on. The causes may be
cl utch di sc contami nati on, wear, di storti on or fl y-
wheel damage. Vi sual l y i nspect to determi ne the
actual cause of the probl em.
CLUTCH MISALIGNMENT
Cl utch components must be i n proper al i gnment
wi th the crankshaft and transmi ssi on i nput shaft.
Mi sal i gnment caused by excessi ve runout or warpage
of any cl utch component wi l l cause grab, chatter and
i mproper cl utch rel ease.
PRESSURE PLATE AND DISC RUNOUT
Check the cl utch di sc before i nstal l ati on. Axi al
(face) runout of a new di sc shoul d not exceed 0.50
mm (0.020 i n.). Measure runout about 6 mm (1/4 i n.)
from the outer edge of the di sc faci ng. Obtai n
another di sc i f runout i s excessi ve.
Check condi ti on of the cl utch before i nstal l ati on. A
warped cover or di aphragm spri ng wi l l cause grab
and i ncompl ete rel ease or engagement. Be careful
when handl i ng the cover and di sc. I mpact can di stort
the cover, di aphragm spri ng, rel ease fi ngers and the
hub of the cl utch di sc.
Use an al i gnment tool when posi ti oni ng the di sc on
the fl ywheel . The tool prevents acci dental mi sal i gn-
ment whi ch coul d resul t i n cover di storti on and di sc
damage.
A frequent cause of cl utch cover di storti on (and
consequent mi sal i gnment) i s i mproper bol t ti ghten-
i ng.
FLYWHEEL RUNOUT
Check fl ywheel runout whenever mi sal i gnment i s
suspected. Fl ywheel runout shoul d not exceed 0.08
mm (0.003 i n.). Measure runout at the outer edge of
the fl ywheel face wi th a di al i ndi cator. Mount the
i ndi cator on a stud i nstal l ed i n pl ace of one of the fl y-
wheel bol ts.
6 - 2 CLUTCH KJ
CLUTCH (Continued)
Common causes of runout are:
• heat warpage
• i mproper machi ni ng
• i ncorrect bol t ti ghteni ng
• i mproper seati ng on crankshaft fl ange shoul der
• forei gn materi al on crankshaft fl ange
Fl ywheel machi ni ng i s not recommended. The fl y-
wheel cl utch surface i s machi ned to a uni que contour
and machi ni ng wi l l negate thi s feature. Mi nor fl y-
wheel scori ng can be cl eaned up by hand wi th 180
gri t emery or wi th surface gri ndi ng equi pment.
Remove onl y enough materi al to reduce scori ng
(approxi matel y 0.001 - 0.003 i n.). Heavy stock
removal i s not recommended. Repl ace the fl ywheel
i f scori ng i s severe and deeper than 0.076 mm (0.003
i n.). Excessi ve stock removal can resul t i n fl ywheel
cracki ng or warpage after i nstal l ati on; i t can al so
weaken the fl ywheel and i nterfere wi th proper cl utch
rel ease.
Cl ean the crankshaft fl ange before mounti ng the
fl ywheel . Di rt and grease on the fl ange surface may
cock the fl ywheel causi ng excessi ve runout. Use new
bol ts when remounti ng a fl ywheel and secure the
bol ts wi th Mopar Lock And Seal or equi val ent.
Ti ghten fl ywheel bol ts to speci fi ed torque onl y. Over-
ti ghteni ng can di stort the fl ywheel hub causi ng
runout.
DIAGNOSIS CHART
The di agnosi s charts Di agnosi s Chart descri be
common cl utch probl ems, causes and correcti on. Con-
di ti ons, causes and correcti ve acti on are outl i ned i n
the i ndi cated col umns.
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
2. Driver frequently rides (slips) the
clutch. Results in rapid overheating
and wear.
2. Replace cover and disc.
3. Insufficient clutch cover
diaphragm spring tension.
3. Replace cover and disc.
Clutch disc facing contaminated with
oil, grease, or clutch fluid.
1. Leak at rear main engine seal or
transmission input shaft seal.
1. Replace appropriate seal.
2. Excessive amount of grease
applied to the input shaft splines.
2. Remove grease and apply the
correct amount of grease.
3. Road splash, water entering
housing.
3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.
4. Slave cylinder leaking. 4. Replace hydraulic clutch linkage.
Clutch is running partially
disengaged.
1. Release bearing sticking or
binding and does not return to the
normal running position.
1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.
Flywheel below minimum thickness
specification.
1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.
1. Replace flywheel.
Clutch disc, cover and/or diaphragm
spring warped or distorted.
1. Rough handling. Impact bent
cover, spring, or disc.
1. Replace disc or cover as
necessary.
2. Improper bolt tightening
procedure.
2. Tighten clutch cover using proper
procedure.
KJ CLUTCH 6 - 3
CLUTCH (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
Facing on flywheel side of disc torn,
gouged, or worn.
1. Flywheel surface scored or
nicked.
2. Correct surface condition if
possible. Replace flywheel and disc
as necessary.
2. Clutch disc sticking or binding on
transmission input shaft.
2. Lubricate splines with high
temperature graese.
Clutch disc facing burnt. Flywheel
and cover pressure plate surfaces
heavily glazed.
1. Frequent operation under high
loads or hard acceleration
conditions.
1. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.
2. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
Clutch disc binds on input shaft
splines.
1. Clutch disc hub splines damaged
during installation.
1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Input shaft splines rough,
damaged, or corroded.
2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
Clutch disc rusted to flywheel and/or
pressure plate.
1. Clutch not used for and extended
period of time (e.g. long term
vehicle storage).
1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
Pilot bearing seized, loose, or rollers
are worn.
1. Bearing cocked during
installation.
1. Install and lubricate a new
bearing.
2. Bearing defective. 2. Install and lubricate a new
bearing.
3. Bearing not lubricated. 3. Install and lubricate a new
bearing.
4. Clutch misalignment. 4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
Clutch will not disengage properly. 1. Low clutch fluid level. 1. Replace hydraulic linkage
assembly.
2. Clutch cover loose. 2. Follow proper bolt tightening
procedure.
3. Clutch disc bent or distorted. 3. Replace clutch disc.
4. Clutch cover diaphragm spring
bent or warped.
4. Replace clutch cover.
5. Clutch disc installed backwards. 5. Remove and install clutch disc
correctly.
6. Release fork bent or fork pivot
loose or damaged.
6. Replace fork or pivot as
necessary.
7. Clutch master or slave cylinder
failure.
7. Replace hydraulic linkage
assembly.
6 - 4 CLUTCH KJ
CLUTCH (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.
2. Master cylinder bushing not
lubricated.
2. Lubricate master cylinder
bushing.
3. Pedal bushings worn out or
cracked.
3. Replace and lubricate bushings.
Clutch master or slave cylinder
plunger dragging andør binding
1. Master or slave cylinder
components worn or corroded.
1. Replace clutch hydraulic linkage
assembly.
Release bearing is noisy. 1. Release bearing defective or
damaged.
1. Replace release bearing.
Contact surface of release bearing
damaged.
1. Clutch cover incorrect or release
fingers bent or distorted.
1. Replace clutch cover and release
bearing.
2. Release bearing defective or
damaged.
2. Replace the release bearing.
3. Release bearing misaligned. 3. Check and correct runout of
clutch components. Check front
bearing sleeve for damage/
alignment. Repair as necessary.
Partial engagement of clutch disc.
One side of disc is worn and the
other side is glazed and lightly
worn.
1. Clutch pressure plate position
incorrect.
1. Replace clutch disc and cover.
2. Clutch cover, spring, or release
fingers bent or distorted.
2. Replace clutch disc and cover.
3. Clutch disc damaged or
distorted.
2. Replace clutch disc.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, pressure plate, andør
clutch housing. Correct as
necessary.
SPECIFICATIONS - CLUTCH
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Pressure Plate Bolts -
2.4L
31 23 -
Pressure Plate Bolts -
3.7L
50 37 -
Clutch Cylinder Bolts 23 - 200
Flywheel Bolts - 2.4L 81 60 -
Flywheel Bolts - 3.7L 81 60 -
KJ CLUTCH 6 - 5
CLUTCH (Continued)
CLUTCH DISC
REMOVAL
(1) Remove transmi ssi on.
(2) Mark posi ti on of pressure pl ate on fl ywheel
wi th pai nt or a scri ber for assembl y reference, i f
cl utch i s not bei ng repl aced.
(3) Loosen pressure pl ate bol ts evenl y and i n rota-
ti on to rel i eve spri ng tensi on and avoi d warpi ng the
pl ate.
(4) Remove pressure pl ate bol ts and pressure pl ate
and di sc.
INSTALLATION
(1) Li ghtl y scuff sand fl ywheel face wi th 180 gri t
emery cl oth, then cl ean wi th a wax and grease
remover.
(2) Lubri cate pi l ot beari ng wi th Mopar hi gh tem-
perature beari ng grease or equi val ent.
(3) Check runout and operati on of new cl utch di sc.
NOTE: Disc must slide freely on transmission input
shaft splines.
(4) Wi th the di sc on the i nput shaft, check face
runout wi th di al i ndi cator. Check runout at di sc hub
6 mm (1/4 i n.) from outer edge of faci ng. Obtai n
another cl utch di sc i f runout exceed 0.5 mm (0.020
i n.).
(5) Posi ti on cl utch di sc on fl ywheel wi th si de
marked fl ywheel agai nst the fl ywheel .
NOTE: If not marked, the flat side of disc hub goes
towards the flywheel on the 3.7L engine and
towards the transmission on 2.4L engine.
(6) I nsert cl utch al i gnment tool through the cl utch
di sc and i nto the pi l ot beari ng (Fi g. 1).
(7) Posi ti on cl utch pressure pl ate over di sc and on
the fl ywheel (Fi g. 1).
(8) I nstal l pressure pl ate bol ts fi nger ti ght.
CAUTION: Use only the factory bolts to mount the
pressure plate. The bolts must be the correct size.
If bolts are too short, there isn’t enough thread
engagement, if too long bolts interfere with the Dual
Mass Flywheel.
(9) Ti ghten pressure pl ate bol ts evenl y and i n rota-
ti on a few threads at a ti me.
CAUTION: The bolts must be tightened evenly and
to specified torque to avoid distorting the pressure
plate.
(10) Ti ghten pressure pl ate bol ts to 31 N·m (23 ft.
l bs.) on 2.4L engi nes and 50 N·m (37ft. l bs.) on 3.7L
engi nes.
(11) Appl y l i ght coat of Mopar hi gh temperature
beari ng grease or equi val ent to cl utch di sc hub and
spl i nes of transmi ssi on i nput shaft.
CAUTION: Do not over lubricate shaft splines. This
will result in grease contamination of disc.
(12) I nstal l transmi ssi on.
CLUTCH RELEASE BEARING
REMOVAL
(1) Remove transmi ssi on.
(2) Di sconnect rel ease beari ng from rel ease l ever
and remove the beari ng (Fi g. 2).
(3) I nspect beari ng sl i de surface of transmi ssi on
front beari ng retai ner. Repl ace retai ner i f sl i de sur-
face i s scored, worn, or cracked.
(4) I nspect rel ease fork and fork pi vot. Be sure
pi vot i s secure and i n good condi ti on. Be sure fork i s
not di storted or worn. Repl ace rel ease fork retai ner
spri ng i f bent or damaged.
INSTALLATION
(1) Lubri cate crankshaft pi l ot beari ng wi th Mopar
hi gh temperature beari ng grease or equi val ent. Appl y
grease to end of l ong shank, smal l di ameter fl at
bl ade screwdri ver. Then i nsert tool through cl utch
di sc hub to reach beari ng.
Fig. 1 ALIGNING CLUTCH DISC
1 - FLYWHEEL
2 - PRESSURE PLATE
3 - CLUTCH DISC ALIGNMENT TOOL
6 - 6 CLUTCH KJ
(2) Lubri cate i nput shaft spl i nes, beari ng retai ner
sl i de surface, fork pi vot and rel ease fork pi vot sur-
face.
(3) I nstal l new rel ease beari ng. Be sure beari ng i s
properl y secured to rel ease fork.
(4) I nstal l transmi ssi on.
FLYWHEEL
DESCRIPTION
STANDARD FLYWHEEL
The standard fl ywheel i s used on the 3.7L engi ne.
The fl ywheel (Fi g. 3) i s a heavy pl ate bol ted to the
rear of the crankshaft. The fl ywheel i ncorporates the
ri ng gear around the outer ci rcumference to mesh
wi th the starter to permi t engi ne cranki ng. The rear
face of the fl ywheel serves as the dri vi ng member to
the cl utch di sc.
DUAL MASS FLYWHEEL
The Dual Mass Fl ywheel i s used on the 2.4 l
engi ne (Fi g. 4). The fl ywheel i ncorporates the ri ng
gear around the outer ci rcumference to mesh wi th
the starter to permi t engi ne cranki ng. The pri mary
fl ywheel si de i s bol ted to the crankshaft. The second-
ary fl ywheel face serves as the dri vi ng member to the
cl utch di sc. I nternal spri ngs between the fl ywheel s
are use to dampen energy.
OPERATION
The fl ywheel serves to dampen the engi ne fi ri ng
pul ses. The heavy wei ght of the fl ywheel rel ati ve to
the rotati ng mass of the engi ne components serves to
stabi l i ze the fl ow of power to the remai nder of the
dri vetrai n. The crankshaft has the tendency to
attempt to speed up and sl ow down i n response to
the cyl i nder fi ri ng pul ses. The fl ywheel dampens
these i mpul ses by absorbi ng energy when the crank-
shaft speeds and rel easi ng the energy back i nto the
system when the crankshaft sl ows down.
Fig. 2 CLUTCH RELEASE BEARING
1 - RELEASE BEARING
2 - RELEASE FORK
Fig. 3 FLYWHEEL
1 - CRANKSHAFT
2 - RING GEAR
3 - FLYWHEEL
Fig. 4 DUAL MASS FLYWHEEL
1 - LOCATING STUD
2 - BEARING
3 - SECONDARY FLYWHEEL
4 - DAMPER SPRING
5 - RING GEAR
6 - PRIMARY FLYWHEEL
7 - FRICTION DISC
KJ CLUTCH 6 - 7
CLUTCH RELEASE BEARING (Continued)
On a Dual Mass Fl ywheel the addi ti onal secondary
mass coupl ed to the transmi ssi on l owers the natural
frequency of the transmi ssi on rotati ng el ements. Thi s
decreases the transmi ssi on gear rattl e. The damper
spri ngs between the two fl ywheel masses repl ace the
cl utch di sc damper spri ngs and assi st i n a smooth
transfer of torque to the transmi ssi on.
CAUTION: The Dual Mass Flywheel is serviced as
an assembly only and should never be taken apart.
DIAGNOSIS AND TESTING - FLYWHEEL
Check fl ywheel runout whenever mi sal i gnment i s
suspected. Fl ywheel runout shoul d not exceed 0.08
mm (0.003 i n.). Measure runout at the outer edge of
the fl ywheel face wi th a di al i ndi cator. Mount the
i ndi cator on a stud i nstal l ed i n pl ace of one of the fl y-
wheel bol ts.
Common causes of runout are:
• heat warpage
• i mproper machi ni ng
• i ncorrect bol t ti ghteni ng
• i mproper seati ng on crankshaft fl ange shoul der
• forei gn materi al on crankshaft fl ange
Fl ywheel machi ni ng i s not recommended. The fl y-
wheel cl utch surface i s machi ned to a uni que contour
and machi ni ng wi l l negate thi s feature. Mi nor fl y-
wheel scori ng can be cl eaned up by hand wi th 180
gri t emery or wi th surface gri ndi ng equi pment.
Remove onl y enough materi al to reduce scori ng
(approxi matel y 0.001 - 0.003 i n.). Heavy stock
removal i s not recommended. Repl ace the fl ywheel
i f scori ng i s severe and deeper than 0.076 mm (0.003
i n.). Excessi ve stock removal can resul t i n fl ywheel
cracki ng or warpage after i nstal l ati on; i t can al so
weaken the fl ywheel and i nterfere wi th proper cl utch
rel ease.
Cl ean the crankshaft fl ange before mounti ng the
fl ywheel . Di rt and grease on the fl ange surface may
cock the fl ywheel causi ng excessi ve runout. Use new
bol ts when remounti ng a fl ywheel and secure the
bol ts wi th Mopar Lock And Seal or equi val ent.
Ti ghten fl ywheel bol ts to speci fi ed torque onl y. Over-
ti ghteni ng can di stort the fl ywheel hub causi ng
runout.
PILOT BEARING
REMOVAL
(1) Remove the transmi ssi on.
(2) Remove pressure pl ate and cl utch di sc.
(3) Remove pi l ot beari ng wi th an i nternal (bl i nd
hol e) pul l er.
INSTALLATION
(1) Lubri cate new beari ng wi th Mopar hi gh tem-
perature beari ng grease or equi val ent.
(2) Start new beari ng i nto crankshaft by hand.
Then seat beari ng wi th cl utch al i gnment tool (Fi g. 5).
(3) Li ghtl y scuff sand fl ywheel surface wi th 180
gri t emery cl oth. Then cl ean surface wi th wax and
grease remover.
(4) I nstal l cl utch di sc and pressure pl ate.
(5) I nstal l the transmi ssi on.
LINKAGE
REMOVAL
NOTE: The clutch master cylinder, slave cylinder
and connecting line are serviced as an assembly
only. The linkage components cannot be over-
hauled or serviced separately. The cylinders and
connecting line are sealed units.
(1) Rai se vehi cl e.
(2) Remove fasteners attachi ng sl ave cyl i nder to
cl utch housi ng.
(3) Remove sl ave cyl i nder from cl utch housi ng
(Fi g. 6).
(4) Di sengage cl utch fl ui d l i ne from body cl i ps, i f
appl i cabl e.
(5) Lower vehi cl e.
(6) Veri fy cap on cl utch master cyl i nder reservoi r
i s ti ght to avoi d spi l l i ng fl ui d duri ng removal .
(7) Remove cl utch master cyl i nder attachi ng nuts
(Fi g. 7).
(8) Di sengage captured bushi ng on cl utch master
cyl i nder actuator from pi vot pi n on pedal arm.
Fig. 5 Pilot Bearing Installer
1 - PILOT BEARING
2 - ALIGNMENT TOOL
6 - 8 CLUTCH KJ
FLYWHEEL (Continued)
(9) Sl i de actuator off pi vot pi n.
(10) Di sconnect cl utch i nterl ock safety swi tch
wi res.
(11) Remove cl utch hydraul i c l i nkage through
engi ne compartment.
INSTALLATION
NOTE: The clutch master cylinder, slave cylinder
and connecting line are serviced as an assembly
only. The linkage components cannot be over-
hauled or serviced separately. The cylinders and
connecting line are sealed units.
(1) Be sure reservoi r cover on cl utch master cyl i n-
der i s ti ght to avoi d spi l l s.
(2) Posi ti on cl utch l i nkage components i n vehi cl e.
Work connecti ng l i ne and sl ave cyl i nder downward
past engi ne and adjacent to cl utch housi ng.
(3) Posi ti on cl utch master cyl i nder on dash panel .
(4) Attach cl utch master cyl i nder actuator to pi vot
pi n on cl utch pedal .
(5) I nstal l and ti ghten cl utch master cyl i nder
attachi ng nuts to 38 N·m (28 ft. l bs.).
(6) Rai se vehi cl e.
(7) I nsert sl ave cyl i nder push rod through cl utch
housi ng openi ng and i nto rel ease l ever. Be sure cap
on end of rod i s securel y engaged i n l ever. Check thi s
before i nstal l i ng cyl i nder attachi ng nuts.
(8) I nstal l and ti ghten sl ave cyl i nder attachi ng
nuts to 23 N·m (17 ft. l bs.).
(9) Secure cl utch fl ui d l i ne i n body and transmi s-
si on cl i ps.
(10) Lower vehi cl e.
(11) Connect cl utch i nterl ock safety swi tch wi res.
MASTER CYLINDER
INSPECTION
The cl utch fl ui d reservoi r, master cyl i nder, sl ave
cyl i nder and fl ui d l i nes are pre-fi l l ed wi th fl ui d at
the factory duri ng assembl y operati ons.
The hydraul i c system shoul d not requi re addi ti onal
fl ui d under normal ci rcumstances. The reservoir
fluid level will actually increase as normal
clutch wear occurs. Avoid overfilling or remov-
ing fluid from the reservoir.
Cl utch fl ui d l evel i s checked at the master cyl i nder
reservoi r. An i ndi cator ri ng i s provi ded on the outsi de
of the reservoi r. Wi th the cap and di aphragm
removed, fl ui d l evel shoul d not be above i ndi cator
ri ng.
To avoi d contami nati ng the hydraul i c fl ui d duri ng
i nspecti on, wi pe reservoi r and cover cl ean before
removi ng the cap.
Fig. 6 SLAVE CYLINDER
1 - CLUTCH SLAVE CYLINDER
Fig. 7 CLUTCH PEDAL
1 - CYLINDER
2 - ACTUATOR SHAFT
3 - ACTUATOR EYE
4 - PEDAL PIN
5 - CONNECTOR
KJ CLUTCH 6 - 9
LINKAGE (Continued)
CLUTCH PEDAL
REMOVAL
(1) Remove steeri ng col umn l ower cover and knee
bl ocker for access.
(2) Di sconnect cl utch pedal posi ti on swi tch wi res.
(3) Di sengage captured bushi ng l ock tabs attach-
i ng cl utch master cyl i nder actuator to pedal pi vot.
(4) Remove nuts attachi ng pedal and bracket to
dash panel and upper cowl support (Fi g. 8).
(5) Separate pedal assembl e from vehi cl e.
INSTALLATION
(1) Pl ace cl utch pedal and bracket over studs on
dash panel and cowl support.
(2) I nstal l nuts to attach pedal and bracket to
dash panel and upper cowl support. Ti ghten nuts to
39 N·m (29 ft. l bs.) torque
(3) Engage captured bushi ng and actuator on
brake pedal pi vot.
(4) Connect cl utch pedal posi ti on swi tch wi res.
CLUTCH SWITCH OVERRIDE
RELAY
DESCRIPTION
The cl utch pedal posi ti on swi tch overri de rel ay i s
l ocated i n the Power Di stri buti on Center (PDC).
Refer to PDC cover l abel for l ocati on wi thi n PDC.
OPERATION
Refer to Cl utch Pedal Posi ti on Swi tch Operati on
for i nformati on.
REMOVAL
The Cl utch Swi tch Overri de Rel ay i s l ocated i n the
Power Di stri buti on Center (PDC) (Fi g. 9). Refer to
l abel on PDC cover for rel ay l ocati on.
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
The Cl utch Swi tch Overri de Rel ay i s l ocated i n the
Power Di stri buti on Center (PDC). Refer to l abel on
PDC cover for rel ay l ocati on.
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
Fig. 8 CLUTCH PEDAL
1 - CYLINDER
2 - ACTUATOR SHAFT
3 - ACTUATOR EYE
4 - PEDAL PIN
5 - CONNECTOR
Fig. 9 POWER DISTRIBUTION CENTER (PDC)
1 - BATTERY
2 - PDC
3 - PDC COVER
6 - 10 CLUTCH KJ
CLUTCH PEDAL POSITION
SWITCH
DESCRIPTION
The cl utch pedal posi ti on swi tch i s l ocated under
the i nstrument panel . I t i s attached to the cl utch
master cyl i nder push rod (Fi g. 10). The wi ri ng har-
ness connecti on for the swi tch i s made i n the engi ne
compartment (Fi g. 10).
The cl utch pedal posi ti on swi tch overri de rel ay i s
l ocated i n the Power Di stri buti on Center (PDC).
Refer to PDC cover l abel for l ocati on wi thi n PDC.
OPERATION
The cl utch pedal posi ti on swi tch i s used to prevent
starter motor engagement unl ess the cl utch pedal i s
depressed.
4WD Feature: The cl utch pedal posi ti on swi tch
overri de rel ay wi l l i nhi bi t operati on of the posi ti on
swi tch when the vehi cl e transfer case i s i n the four–
wheel –dri ve (4WD) l ow-range posi ti on (onl y). Thi s
feature wi l l al l ow operati on of the starter motor,
wi thout the need for depressi ng the cl utch pedal , for
certai n off-road appl i cati ons. I f any Di agnosti c Trou-
bl e Codes (DTC’s) for ei ther the overri de rel ay or
transfer case swi tch are stored, the overri de rel ay
feature wi l l be i nhi bi ted.
An i nput from thi s swi tch i s al so used to ei ther
shut down and/or prevent operati on of the speed con-
trol system when the cl utch pedal i s depressed.
DIAGNOSIS AND TESTING - CLUTCH PEDAL
POSITION SWITCH
(1) Locate swi tch 2–wi re el ectri cal connector i n
engi ne compartment (Fi g. 10). Di sconnect wi ri ng at
thi s poi nt.
(2) Check for swi tch conti nui ty wi th an ohmmeter
whi l e operati ng cl utch pedal up and down. Conti nu-
i ty shoul d be broken and reappl i ed each ti me pedal i s
pressed.
(3) I f conti nui ty i s not present, or i s al ways
present at any pedal posi ti on, repl ace swi tch. Swi tch
i s not servi ced separatel y. Repl ace cl utch master
cyl i nder.
Fig. 10 CLUTCH PEDAL POSITION SWITCH
1 - CLUTCH MASTER CYLINDER
2 - CLUTCH PEDAL POSITION SWITCH
3 - CLUTCH PEDAL PIN
4 - MASTER CYLINDER PUSHROD
5 - ELECTRICAL CONNECTION (IN ENGINE COMPARTMENT)
KJ CLUTCH 6 - 11
COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM 3.7L
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - COOLING SYSTEM
ROUTING 3.7L ENGINE. . . . . . . . . . . . . . . . . . 2
DESCRIPTION - HOSE CLAMPS . . . . . . . . . . . 2
OPERATION
OPERATION - COOLING SYSTEM . . . . . . . . . 2
OPERATION - HOSE CLAMPS . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ON-BOARD
DIAGNOSTICS (OBD) . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - COOLING
SYSTEM LEAKS . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - COOLING
SYSTEM DIAGNOSIS CHART . . . . . . . . . . . . . 6
STANDARD PROCEDURE
STANDARD PROCEDURE - DRAINING
COOLING SYSTEM 3.7L ENGINE . . . . . . . . . 12
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 3.7L ENGINE . . . . . . . . . 12
STANDARD PROCEDURE - COOLING
SYSTEM - REVERSE FLUSHING. . . . . . . . . . 12
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIAL TOOLS
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . . 15
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 32
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM 3. 7L
ENGINE
The cool i ng system consi sts of the fol l owi ng i tems:
• El ectri c cool i ng fan - Standard.
• El ectri c cool i ng fan and mechani cal thermal vi s-
cous fan wi th l ow di sengaged - Heavy duty cool i ng
onl y
• Radi ator
• Hot bottl e pressure cap
• Thermostat
• Cool ant reserve/overfl ow system
• Radi ator i n-tank transmi ssi on oi l cool er (i f
equi pped wi th an automati c transmi ssi on)
• Cool ant
• Water pump
• Hoses and hose cl amps
KJ COOLING 7 - 1
DESCRIPTION - COOLING SYSTEM ROUTING
3. 7L ENGINE
For cool i ng system routi ng refer to (Fi g. 1).
DESCRIPTION - HOSE CLAMPS
The cool i ng system uti l i zes spri ng type hose
cl amps. I f a spri ng type cl amp repl acement i s neces-
sary, repl ace wi th the ori gi nal Mopar௡ equi pment
spri ng type cl amp.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 2). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 2).
OPERATION
OPERATION - COOLING SYSTEM
The cool i ng system regul ates engi ne operati ng tem-
perature. I t al l ows the engi ne to reach normal oper-
ati ng temperature as qui ckl y as possi bl e. I t al so
mai ntai ns normal operati ng temperature and pre-
vents overheati ng.
Fig. 1 Engine Cooling System 3.7L Engine
1 - LH CYL. HEAD
2 - AIR BLEED
3 - THERMOSTAT LOCATION
4 - RH CYL. HEAD
5 - RH BANK CYL. BLOCK
6 - LH BANK CYL. BLOCK
7 - COOLANT TEMP. SENSOR
7 - 2 COOLING KJ
COOLING (Continued)
The cool i ng system al so provi des a means of heat-
i ng the passenger compartment and cool i ng the auto-
mati c transmi ssi on fl ui d (i f equi pped). The cool i ng
system i s pressuri zed and uses a centri fugal water
pump to ci rcul ate cool ant throughout the system.
OPERATION - HOSE CLAMPS
The spri ng type hose cl amp appl i es constant ten-
si on on a hose connecti on. To remove a spri ng type
hose cl amp, onl y use constant tensi on cl amp pl i ers
desi gned to compress the hose cl amp.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ON-BOARD
DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The powertrai n control modul e (PCM) has been
programmed to moni tor certai n cool i ng system com-
ponents:
• I f the engi ne has remai ned cool for too l ong a
peri od, such as wi th a stuck open thermostat, a Di ag-
nosti c Troubl e Code (DTC) can be set.
• I f an open or shorted condi ti on has devel oped i n
the rel ay ci rcui t control l i ng the el ectri c radi ator fan,
a Di agnosti c Troubl e Code (DTC) can be set.
I f the probl em i s sensed i n a moni tored ci rcui t
often enough to i ndi cated an actual probl em, a DTC
i s stored. The DTC wi l l be stored i n the PCM mem-
ory for eventual di spl ay to the servi ce techni ci an.
(Refer to 25 - EMI SSI ONS CONTROL - DESCRI P-
TI ON).
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTC’s and to obtai n cool i ng system data,
(Refer to 25 - EMI SSI ONS CONTROL - DESCRI P-
TI ON).
ERASING TROUBLE CODES
After the probl em has been repai red, use the DRB
scan tool to erase a DTC. Refer to the appropri ate
Powertrai n Di agnosti c Procedures servi ce i nforma-
ti on for operati on of the DRB scan tool .
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establ i sh what dri vi ng condi ti ons caused the com-
pl ai nt. Abnormal l oads on the cool i ng system such as
the fol l owi ng may be the cause:
• PROLONGED I DLE
• VERY HI GH AMBI ENT TEMPERATURE
• SLI GHT TAI L WI ND AT I DLE
• SLOW TRAFFI C
• TRAFFI C JAMS
• HI GH SPEED
• STEEP GRADES
Dri vi ng techni ques that avoi d overheati ng are:
• I dl e wi th A/C off when temperature gauge i s at
end of normal range.
(1) TRAI LER TOWI NG:
Consul t Trai l er Towi ng secti on of owners manual .
Do not exceed l i mi ts.
(2) RECENT SERVI CE OR ACCI DENT REPAI R:
Determi ne i f any recent servi ce has been per-
formed on vehi cl e that may effect cool i ng system.
Thi s may be:
• Engi ne adjustments (i ncorrect ti mi ng)
• Sl i ppi ng engi ne accessory dri ve bel t(s)
• Brakes (possi bl y draggi ng)
• Changed parts. I ncorrect water pump, or pump
rotati ng i n wrong di recti on due to bel t not correctl y
routed
• Recondi ti oned radi ator or cool i ng system refi l l -
i ng (possi bl y under fi l l ed or ai r trapped i n system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to following Cooling System Diagnosis
charts.
These charts are to be used as a qui ck-reference
onl y. Refer to the group text for i nformati on.
Fig. 2 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
KJ COOLING 7 - 3
COOLING (Continued)
DIAGNOSIS AND TESTING - COOLING SYSTEM
LEAKS
ULTRAVIOLET LIGHT METHOD
A l eak detecti on addi ti ve i s avai l abl e through the
parts department that can be added to cool i ng sys-
tem. The addi ti ve i s hi ghl y vi si bl e under ul travi ol et
l i ght (bl ack l i ght). Pour one ounce of addi ti ve i nto
cool i ng system. Pl ace heater control uni t i n HEAT
posi ti on. Start and operate engi ne unti l radi ator
upper hose i s warm to touch. Ai m the commerci al l y
avai l abl e bl ack l i ght tool at components to be
checked. I f l eaks are present, bl ack l i ght wi l l cause
addi ti ve to gl ow a bri ght green col or.
The bl ack l i ght can be used i n conjuncti on wi th a
pressure tester to determi ne i f any external l eaks
exi st (Fi g. 3).
PRESSURE TESTER METHOD
The engi ne shoul d be at normal operati ng temper-
ature. Recheck the system col d i f cause of cool ant
l oss i s not l ocated duri ng the warm engi ne exami na-
ti on.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Careful l y remove radi ator pressure cap from pres-
sure bottl e and check cool ant l evel . Push down on
cap to di sengage i t from stop tabs. Wi pe i nsi de of
fi l l er neck and exami ne l ower i nsi de seal i ng seat for
ni cks, cracks, pai nt, and di rt. I nspect radi ator-to-
reserve/overfl ow tank hose for i nternal obstructi ons.
I nsert a wi re through the hose to be sure i t i s not
obstructed.
I nspect cams on outsi de of fi l l er neck. I f cams are
damaged, seati ng of pressure cap val ve and tester
seal wi l l be affected.
Attach pressure tester (7700 or an equi val ent) to
radi ator fi l l er neck (Fi g. 4).
Operate tester pump to appl y 110 kPa (16 psi )
pressure to system. I f hoses enl arge excessi vel y or
bul ges whi l e testi ng, repl ace as necessary. Observe
gauge poi nter and determi ne condi ti on of cool i ng sys-
tem accordi ng to fol l owi ng cri teri a:
Holds Steady: I f poi nter remai ns steady for two
mi nutes, seri ous cool ant l eaks are not present i n sys-
tem. However, there coul d be an i nternal l eak that
does not appear wi th normal system test pressure. I f
i t i s certai n that cool ant i s bei ng l ost and l eaks can-
not be detected, i nspect for i nteri or l eakage or per-
form I nternal Leakage Test.
Drops Slowly: I ndi cates a smal l l eak or seepage
i s occurri ng. Exami ne al l connecti ons for seepage or
sl i ght l eakage wi th a fl ashl i ght. I nspect radi ator,
hoses, gasket edges and heater. Seal smal l l eak hol es
wi th a Seal er Lubri cant (or equi val ent). Repai r l eak
hol es and i nspect system agai n wi th pressure
appl i ed.
Drops Quickly: I ndi cates that seri ous l eakage i s
occurri ng. Exami ne system for external l eakage. I f
l eaks are not vi si bl e, i nspect for i nternal l eakage.
Large radi ator l eak hol es shoul d be repai red by a
reputabl e radi ator repai r shop.
INTERNAL LEAKAGE INSPECTION
Remove engi ne oi l pan drai n pl ug and drai n a
smal l amount of engi ne oi l . I f cool ant i s present i n
Fig. 3 Leak Detection Using Black Light - Typical
1 - TYPICAL BLACK LIGHT TOOL
Fig. 4 Pressure Testing Cooling System - Typical
1 - TYPICAL COOLING SYSTEM PRESSURE TESTER
7 - 4 COOLING KJ
COOLING (Continued)
the pan, i t wi l l drai n fi rst because i t i s heavi er than
oi l . An al ternati ve method i s to operate engi ne for a
short peri od to churn the oi l . After thi s i s done,
remove engi ne di psti ck and i nspect for water gl ob-
ul es. Al so i nspect transmi ssi on di psti ck for water
gl obul es and transmi ssi on fl ui d cool er for l eakage.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 124 KPA (18 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Operate engi ne wi thout pressure cap on radi ator
unti l thermostat opens. Attach a Pressure Tester to
fi l l er neck. I f pressure bui l ds up qui ckl y i t i ndi cates a
combusti on l eak exi sts. Thi s i s usual l y the resul t of a
cyl i nder head gasket l eak or crack i n engi ne. Repai r
as necessary.
I f there i s not an i mmedi ate pressure i ncrease,
pump the Pressure Tester. Do thi s unti l i ndi cated
pressure i s wi thi n system range of 110 kPa (16 psi ).
Fl uctuati on of gauge poi nter i ndi cates compressi on or
combusti on l eakage i nto cool i ng system.
Because the vehi cl e i s equi pped wi th a catal yti c
converter, do not remove spark pl ug cabl es or short
out cyl i nders to i sol ate compressi on l eak.
I f the needl e on di al of pressure tester does not
fl uctuate, race engi ne a few ti mes to check for an
abnormal amount of cool ant or steam. Thi s woul d be
emi tti ng from exhaust pi pe. Cool ant or steam from
exhaust pi pe may i ndi cate a faul ty cyl i nder head gas-
ket, cracked engi ne cyl i nder bl ock or cyl i nder head.
A conveni ent check for exhaust gas l eakage i nto
cool i ng system i s provi ded by a commerci al l y avai l -
abl e Bl ock Leak Check tool . Fol l ow manufacturers
i nstructi ons when usi ng thi s product.
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE reusabl e cool ant. I f sol uti on i s
cl ean, drai n cool ant i nto a cl ean contai ner for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drai n suffi ci ent cool ant to al l ow thermostat
removal . (Refer to 7 - COOLI NG/ENGI NE/ENGI NE
COOLANT THERMOSTAT - REMOVAL). Remove
accessory dri ve bel t (Refer to 7 - COOLI NG/ACCES-
SORY DRI VE/DRI VE BELTS - REMOVAL).
Add cool ant to radi ator to bri ng l evel to wi thi n 6.3
mm (1/4 i n) of top of thermostat housi ng.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engi ne and accel erate rapi dl y three ti mes, to
approxi matel y 3000 rpm whi l e observi ng cool ant. I f
i nternal engi ne combusti on gases are l eaki ng i nto
cool i ng system, bubbl es wi l l appear i n cool ant. I f bub-
bl es do not appear, i nternal combusti on gas l eakage
i s not present.
KJ COOLING 7 - 5
COOLING (Continued)
DIAGNOSIS AND TESTING - COOLING SYSTEM DIAGNOSIS CHART
COOLING SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS
LOW
1. Has a Diagnostic Trouble Code
(DTC) been set indicating a stuck
open thermostat?
1. Refer to (Refer to 25 -
EMISSIONS CONTROL -
DESCRIPTION) for On-Board
Diagnostics and DTC information.
Replace thermostat if necessary.
2. Is the temperature sending unit
connected?
2. Check the temperature sensor
connector. (Refer to 7 - COOLING/
ENGINE/ENGINE COOLANT TEMP
SENSOR - DESCRIPTION). Repair
connector if necessary.
3. Is the temperature gauge
operating OK?
3. Check gauge operation. Repair
as necessary.
4. Coolant level low in cold ambient
temperatures accompanied with
poor heater performance.
4. Check coolant level in the coolant
pressure botttle and the radiator.
Inspect system for leaks. Repair
leaks as necessary.
5. Improper operation of internal
heater doors or heater controls.
5. Inspect heater and repair as
necessary. (Refer to 24 - HEATING
& AIR CONDITIONING -
DIAGNOSIS AND TESTING)
6. Electric fan functioning when not
required.
6. Inspect electric fan for proper
operation. Refer to Electric Cooling
Fan in this section. Refer to group
8W for electric cooling fan and relay
circuit schematic data.
1. Trailer is being towed, a steep
hill is being climbed, vehicle is
operated in slow moving traffic, or
engine is being idled with very high
ambient (outside) temperatures and
the air conditioning is on. Higher
altitudes could aggravate these
conditions.
1. This may be a temporary
condition and repair is not
necessary. Turn off the air
conditioning and attempt to drive the
vehicle without any of the previous
conditions. Observe the temperature
gauge. The gauge should return to
the normal range. If the gauge does
not return to the normal range,
determine the cause for overheating
and repair.
2. Is the temperature gauge reading
correctly?
2. Check gauge. (Refer to Group 8J
- INSTRUMENT CLUSTER). Repair
as necessary.
3. Is the temperature warning
illuminating unnecessarily?
3. Check warning lamp operation.
(Refer to Group 8J - INSTRUMENT
CLUSTER).Repair as necessary.
4. Coolant low in coolant pressure
bottle and radiator?
4. Check for coolant leaks and
repair as necessary. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING).
7 - 6 COOLING KJ
COOLING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
5. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following Step 6.
5. Tighten cap
6. Poor seals at the radiator cap. 6. (a) Check condition of cap and
cap seals. (Refer to 7 - COOLING/
ENGINE/RADIATOR PRESSURE
CAP - DIAGNOSIS AND TESTING).
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
7. Coolant not flowing through
system.
7. (a) Check condition of pressure
bottle cap and cap seals. (Refer to
7 - COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING).
(b) Check condition of radiator vent
nipple. If neck is damaged, replace
radiator.
(c) Check condition of the hose from
the radiator to the coolant tank. It
should fit tight at both ends without
any kinks or tears. Replace hose if
necessary.
(d) Check pressure bottle/overflow
tank and tanks hoses for blockage.
Repair as necessary.
8. Incorrect coolant concentration 8. Check coolant. (Refer to 7 -
COOLING/ENGINE/COOLANT -
DESCRIPTION) for correct
coolant/water mixture ratio.
9. Fan installed backwards on
viscous drive.
9. Mount fan on drive correctly.
10. Radiator or A/C condenser fins
are dirty or clogged.
10. Remove insects and debris.
(Refer to 7 - COOLING/ENGINE/
RADIATOR - CLEANING).
11. Radiator core is corroded or
plugged.
11. Have radiator re-cored or
replaced.
12. Fuel or ignition system
problems.
12. Refer to FUEL and /or
IGNITION CONTROL for diagnosis.
13. Dragging brakes. 13. Check and correct as
necessary. (Refer to 5 - BRAKES -
DIAGNOSIS AND TESTING) for
correct procedures.
14. Bug screen or cardboard is
being used, reducing airflow.
14. Remove bug screen or
cardboard.
KJ COOLING 7 - 7
COOLING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
15. Thermostat partially or
completely shut.
15. Check thermostat operation and
replaces necessary. (Refer to 7 -
COOLING/ENGINE/ENGINE
COOLANT THERMOSTAT -
DIAGNOSIS AND TESTING).
16. Viscous fan drive not operating
properly.
16. Check fan drive operation and
replace as necessary. (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING).
17. Cylinder head gasket leaking. 17. Check for cylinder head gasket
leaks. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING). For
repair, (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
18. Heater core leaking. 18. Check heater core for leaks.
(Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/
HEATER CORE - REMOVAL).
Repair as necessary.
19. Electric fan not functioning. 19. Inspect electric fan for proper
operation. Refer to Electric Cooling
Fan in this section. Refer to Group
8W for electric cooling fan and relay
circuit schematic data.
TEMPERATURE GAUGE READING
IS INCONSISTENT (FLUCTUATES,
CYCLES OR IS ERRATIC)
1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly.
1. A normal condition. No correction
is necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.
2. Check operation of gauge and
repair if necessary. Refer to Group
8J, Instrument cluster.
3. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running)
3. A normal condition. No correction
is necessary. Gauge should return
to normal range after vehicle is
driven.
4. Gauge reading high after
re-starting a warmed up (hot)
engine.
4. A normal condition. No correction
is necessary. The gauge should
return to normal range after a few
minutes of engine operation.
5. Coolant level low in cooling
system (air will build up in the
cooling system causing the
thermostat to open late).
5. Check and correct coolant leaks.
(Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
7 - 8 COOLING KJ
COOLING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a
thermostat to open late.
6. (a) Check for cylinder head
gasket leaks. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING).
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from the exhaust system. Repair as
necessary.
7. Water pump impeller loose on
shaft.
7. Check water pump and replace
as necessary. (Refer to 7 -
COOLING/ENGINE/WATER PUMP -
DIAGNOSIS AND TESTING).
8. Loose accessory drive belt.
(water pump slipping)
8. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS
- DIAGNOSIS AND TESTING).
Check and correct as necessary.
9. Air leak on the suction side of
the water pump allows air to build
up in cooling system causing
thermostat to open late.
9. Locate leak and repair as
necessary.
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT
TO COOLANT TANK.
TEMPERATURE GAUGE READING
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK
1. Pressure relief valve in pressure
bottle cap is defective.
1. Check condition of radiator cap
and cap seals. (Refer to 7 -
COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING). Replace cap as
necessary.
COOLANT LOSS TO THE
GROUND WITHOUT PRESSURE
CAP BLOWOFF. GAUGE READING
HIGH OR HOT
1. Coolant leaks in radiator, cooling
system hoses, water pump or
engine.
1. Pressure test and repair as
necessary. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
DETONATION OR PRE-IGNITION
(NOT CAUSED BY IGNITION
SYSTEM). GAUGE MAY OR MAY
NOT BE READING HIGH
1. Engine overheating. 1. Check reason for overheating
and repair as necessary.
2. Freeze point of coolant not
correct. Mixture is too rich or too
lean.
2. Check coolant concentration.
(Refer to 7 - COOLING/ENGINE/
COOLANT - DESCRIPTION) and
adjust ratio as required.
KJ COOLING 7 - 9
COOLING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
HOSE OR HOSES COLLAPSE
WHILE ENGINE IS RUNNING
1. Vacuum created in cooling
system on engine cool-down is not
being relieved through coolant
reserve/overflow system.
1. (a) Radiator cap relief valve
stuck. (Refer to 7 - COOLING/
ENGINE/RADIATOR PRESSURE
CAP - DIAGNOSIS AND TESTING).
Replace if necessary
(b) Hose between coolant
reserve/overflow tank and radiator is
kinked. Repair as necessary.
(c) Vent at coolant reserve/overflow
tank is plugged. Clean vent and
repair as necessary.
(d) Reserve/overflow tank is
internally blocked or plugged. Check
for blockage and repair as
necessary.
NOISY VISCOUS FAN/DRIVE 1. Fan blades loose - 4.0L. 1. Replace fan blade assembly.
(Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - REMOVAL)
2. Fan blades striking a surrounding
object.
2. Locate point of fan blade contact
and repair as necessary.
3. Air obstructions at radiator or air
conditioning condenser.
3. Remove obstructions and/or
clean debris or insects from radiator
or A/C condenser.
4. Thermal viscous fan drive has
defective bearing - 4.0L
4. Replace fan drive. Bearing is not
serviceable. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN -
REMOVAL).
INADEQUATE HEATER
PERFORMANCE. THERMOSTAT
FAILED IN OPEN POSITION
1. Has a Diagnostic trouble Code
(DTC) been set?
1. (Refer to 25 - EMISSIONS
CONTROL - DESCRIPTION) for
correct procedures and replace
thermostat if necessary
2. Coolant level low 2. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
3. Obstructions in heater hose/
fittings
3. Remove heater hoses at both
ends and check for obstructions
4. Heater hose kinked 4. Locate kinked area and repair as
necessary
5. Water pump is not pumping
water to/through the heater core.
When the engine is fully warmed
up, both heater hoses should be
hot to the touch. If only one of the
hoses is hot, the water pump may
not be operating correctly or the
heater core may be plugged.
Accessory drive belt may be
slipping causing poor water pump
operation.
5. (Refer to 7 - COOLING/ENGINE/
WATER PUMP - DIAGNOSIS AND
TESTING). If a slipping belt is
detected, (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS
- REMOVAL). If heater core
obstruction is detected, (Refer to 7 -
COOLING - STANDARD
PROCEDURE) for cooling system
reverse flushing.
7 - 10 COOLING KJ
COOLING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
STEAM IS COMING FROM THE
FRONT OF VEHICLE NEAR THE
GRILL AREA WHEN WEATHER IS
WET, ENGINE IS WARMED UP
AND RUNNING, AND VEHICLE IS
STATIONARY. TEMPERATURE
GAUGE IS IN NORMAL RANGE
1. During wet weather, moisture
(snow, ice or rain condensation) on
the radiator will evaporate when the
thermostat opens. This opening
allows heated water into the
radiator. When the moisture
contacts the hot radiator or
condensor, steam may be emitted.
This usually occurs in cold weather
with no fan or airflow to blow it
away.
1. Occasional steam emitting from
this area is normal. No repair is
necessary.
COOLANT COLOR 1. Coolant color is not necessarily
an indication of adequate corrosion
or temperature protection. Do not
rely on coolant color for determining
condition of coolant.
1. (Refer to 7 - COOLING/ENGINE/
COOLANT - DESCRIPTION) for
coolant concentration information.
Adjust coolant mixture as
necessary.
COOLANT LEVEL CHANGES IN
COOLANT RESERVE/OVERFLOW
TANK. TEMPERATURE GAUGE IS
IN NORMAL RANGE
1. Level changes are to be
expected as coolant volume
fluctuates with engine temperature.
If the level in the tank was between
the FULL and ADD marks at normal
operating temperature, the level
should return to within that range
after operation at elevated
temperatures.
1. A normal condition. No repair is
necessary.
FAN RUNS ALL THE TIME 1. Fan control sensors inoperative. 1. Check for DTC’s. Verify sensor
readings.
2. Fan control solenoid stuck ЉonЉ. 2. Check fan operation speeds.
Refer to fan speed operation table.
3. Fan control solenoid harness
damaged.
3. Check for DTC 1499. Repair as
required.
4. Transmission temperature too
high.
4. Check for transmission over
temp. DTC.
5. Engine coolant temperature too
high.
5. (a) Check coolant level. Correct
level as required.
(b) Thermostat stuck. Replace
thermostat.
(c) Water pump failed. Replace
water pump.
(d) Coolant flow restricted. Clean
radiator.
(e) Air flow over radiator
obstructed.Remove obstruction.
KJ COOLING 7 - 11
COOLING (Continued)
STANDARD PROCEDURE
STANDARD PROCEDURE - DRAINING COOLING
SYSTEM 3. 7L ENGINE
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS (Fig. 5) OR LOOSEN THE
RADIATOR DRAINCOCK WITH SYSTEM HOT AND
UNDER PRESSURE. SERIOUS BURNS FROM
COOLANT CAN OCCUR.
(1) DO NOT remove radi ator cap fi rst. Wi th engi ne
col d, rai se vehi cl e on a hoi st and l ocate radi ator
drai ncock.
NOTE: Radiator draincock is located on the left/
lower side of radiator facing to rear of vehicle.
(2) Attach one end of a hose to the drai ncock. Put
the other end i nto a cl ean contai ner. Open drai ncock
and drai n cool ant from radi ator. Thi s wi l l empty the
cool ant reserve/overfl ow tank. The cool ant does not
have to be removed from the tank unl ess the system
i s bei ng refi l l ed wi th a fresh mi xture. When tank i s
empty, remove radi ator cap and conti nue drai ni ng
cool i ng system.
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 3. 7L ENGINE
(1) Ti ghten the radi ator drai ncock and the cyl i nder
bl ock drai n pl ug(s) (i f removed).
CAUTION: Failure to purge air from the cooling sys-
tem can result in an overheating condition and
severe engine damage.
(2) .Fi l l system usi ng a 50/50 mi xture of ethyl ene-
gl ycol anti freeze and l ow mi neral content water.Fi l l
pressure bottl e to servi ce l i ne.and i nstal l cap.
NOTE: The engine cooling system will push any
remaining air into the coolant bottle within about an
hour of normal driving. As a result, a drop in cool-
ant level in the pressure bottle may occur. If the
engine cooling system overheats and pushes cool-
ant into the overflow side of the coolant bottle, this
coolant will be sucked back into the cooling system
ONLY IF THE PRESSURE CAP IS LEFT ON THE
BOTTLE. Removing the pressure cap breaks the
vacuum path between the two bottle sections and
the coolant will not return to cooling system.
(3) Wi th heater control uni t i n the HEAT posi ti on,
operate engi ne wi th pressure bottl e cap i n pl ace.
(4) Add cool ant to pressure bottl e as necessary.
Only add coolant to the pressure bottle when
the engine is cold. Coolant level in a warm
engine will be higher due to thermal expansion.
NOTE: The coolant bottle has two chambers. Cool-
ant will normally only be in the outboard (larger) of
the two. The inboard chamber is only to recover
coolant in the event of an overheat or after a recent
service fill. The inboard chamber should normally
be empty. If there is coolant in the overflow side of
the coolant bottle (after several warm/cold cycles of
the engine) and coolant level is above cold full
when cold, disconnect the end of the overflow hose
at the fill neck and lower it into a clean container.
Allow coolant to drain into the container until emp-
tied. Reconnect overflow hose to fill neck.
STANDARD PROCEDURE - COOLING SYSTEM -
REVERSE FLUSHING
CAUTION: The cooling system normally operates at
97-to-110 kPa (14-to -16 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Reverse fl ushi ng of the cool i ng system i s the forc-
i ng of water through the cool i ng system. Thi s i s done
usi ng ai r pressure i n the opposi te di recti on of normal
cool ant fl ow. I t i s usual l y onl y necessary wi th very
di rty systems wi th evi dence of parti al pl uggi ng.
CHEMICAL CLEANING
I f vi sual i nspecti on i ndi cates the formati on of
sl udge or scal y deposi ts, use a radi ator cl eaner
Fig. 5 Drain Plug - 3.7L Engine
1 - CYLINDER BLOCK DRAIN PLUG
2 - EXHAUST MANIFOLD AND HEAT SHIELD
7 - 12 COOLING KJ
COOLING (Continued)
(Mopar Radi ator Kl een or equi val ent) before fl ushi ng.
Thi s wi l l soften scal e and other deposi ts and ai d the
fl ushi ng operati on.
CAUTION: Be sure instructions on the container are
followed.
REVERSE FLUSHING RADIATOR
Di sconnect the radi ator hoses from the radi ator fi t-
ti ngs. Attach a secti on of radi ator hose to the radi a-
tor bottom outl et fi tti ng and i nsert the fl ushi ng gun.
Connect a water suppl y hose and ai r suppl y hose to
the fl ushi ng gun.
CAUTION: The cooling system normally operates at
97-to-110 kPa (14- to-16 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Al l ow the radi ator to fi l l wi th water. When radi ator
i s fi l l ed, appl y ai r i n short bl asts al l owi ng radi ator to
refi l l between bl asts. Conti nue thi s reverse fl ushi ng
unti l cl ean water fl ows out through rear of radi ator
cool i ng tube passages. For more i nformati on, refer to
operati ng i nstructi ons suppl i ed wi th fl ushi ng equi p-
ment. Have radi ator cl eaned more extensi vel y by a
radi ator repai r shop.
REVERSE FLUSHING ENGINE
Drai n the cool i ng system (Refer to 7 - COOLI NG -
STANDARD PROCEDURE). Remove the thermostat
housi ng and thermostat. I nstal l the thermostat hous-
i ng. Di sconnect the radi ator upper hose from the
radi ator and attach the fl ushi ng gun to the hose. Di s-
connect the radi ator l ower hose from the water
pump. Attach a l ead away hose to the water pump
i nl et fi tti ng.
CAUTION: Be sure that the heater control valve is
closed (heat off). This is done to prevent coolant
flow with scale and other deposits from entering
the heater core.
Connect the water suppl y hose and ai r suppl y hose
to the fl ushi ng gun. Al l ow the engi ne to fi l l wi th
water. When the engi ne i s fi l l ed, appl y ai r i n short
bl asts, al l owi ng the system to fi l l between ai r bl asts.
Conti nue unti l cl ean water fl ows through the l ead
away hose. For more i nformati on, refer to operati ng
i nstructi ons suppl i ed wi th fl ushi ng equi pment.
Remove the l ead away hose, fl ushi ng gun, water
suppl y hose and ai r suppl y hose. Remove the thermo-
stat housi ng (Refer to 7 - COOLI NG/ENGI NE/EN-
GI NE COOLANT THERMOSTAT - REMOVAL).
I nstal l the thermostat and housi ng wi th a repl ace-
ment gasket (Refer to 7 - COOLI NG/ENGI NE/EN-
GI NE COOLANT THERMOSTAT -
I NSTALLATI ON). Connect the radi ator hoses. Refi l l
the cool i ng system wi th the correct anti freeze/water
mi xture (Refer to 7 - COOLI NG - STANDARD PRO-
CEDURE).
SPECIFICATIONS
TORQUE
DESCRIPTION N·m Ft. In.
Lbs. Lbs.
Automatic Belt Tensioner to
Mounting
Bracket—Bolt
2.4L - — -
4.7L 41 30 —
Automatic Belt Tensioner
Pulley—
Bolt
(3.7L) 61 45 —
Block Heater—Bolt
2.4L - — -
3.7L 2 — 17
Condenser to Radiator Bolts 8 70
Coolant Overflow Bottle to
Plenum mounting bolts - 2.4L
only
8.5 75
Coolant Pressure Bottle to
Plenum mounting bolts -3.7L
only
8.5 75
Electric Fan to Fan Shroud
bolts
5.5 50
Fan Blade Assy. to Viscous
Drive
Bolts 3.7L 23 — 210
Fan Shroud to Radiator
Mounting Bolts
8 — 70
Radiator Upper Isolator to
Crossmember - Bolts 9.5 — 85
Thermostat Housing—Bolts
2.4L - - —
4.7L 13 — 115
Water Pump—Bolts
2.4L — — —
4.7L 54 40 —
KJ COOLING 7 - 13
COOLING (Continued)
SPECIAL TOOLS
COOLING
Pliers 6094
Adapter Pins 8346
Spanner Wrench 6958 with 8346 adapter pins
Pressure Tester 7700–A
Coolant Refractometer 8286
7 - 14 COOLING KJ
COOLING (Continued)
ACCESSORY DRIVE
TABLE OF CONTENTS
page page
ACCESSORY DRIVE
DIAGNOSIS AND TESTING - SERPENTINE
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . 15
BELT TENSIONERS
REMOVAL - 3.7L ENGINE . . . . . . . . . . . . . . . . . 17
INSTALLATION - 3.7L ENGINE . . . . . . . . . . . . . 17
DRIVE BELTS - 3.7L
REMOVAL - 3.7L ENGINE . . . . . . . . . . . . . . . . . 17
INSTALLATION - 3.7L ENGINE . . . . . . . . . . . . . 18
ACCESSORY DRIVE
DIAGNOSIS AND TESTING - SERPENTINE
DRIVE BELT
When di agnosi ng serpenti ne dri ve bel ts, smal l
cracks that run across ri bbed surface of bel t from ri b
to ri b (Fi g. 1), are consi dered normal . These are not a
reason to repl ace bel t. However, cracks runni ng al ong
a ri b (not across) are not normal . Any bel t wi th
cracks runni ng al ong a ri b must be repl aced (Fi g. 1).
Al so repl ace bel t i f i t has excessi ve wear, frayed cords
or severe gl azi ng.
Refer to SERPENTI NE DRI VE BELT DI AGNOSI S
CHART for further bel t di agnosi s.
Fig. 1 Serpentine Accessory Drive Belt Wear
Patterns
1 - NORMAL CRACKS BELT OK
2 - NOT NORMAL CRACKS REPLACE BELT
KJ ACCESSORY DRIVE 7 - 15
SERPENTINE DRIVE BELT DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
RIB CHUNKING (ONE OR MORE
RIBS HAS SEPARATED FROM
BELT BODY)
1. Foreign objects imbedded in pulley
grooves.
1. Remove foreign objects from
pulley grooves. Replace belt.
2. Installation damage. 2. Replace belt.
RIB OR BELT WEAR 1. Pulley(s) misaligned. 1. Align pulley(s).
2. Abrasive environment. 2. Clean pulley(s). Replace belt if
necessary.
3. Rusted pulley(s). 3. Clean rust from pulley(s).
4. Sharp or jagged pulley groove tips. 4. Replace pulley.
5. Rubber deteriorated. 5. Replace belt.
LONGITUDINAL BELT
CRACKING (CRACKS BETWEEN
TWO RIBS)
1. Belt has mistracked from pulley
groove.
1. Replace belt.
2. Pulley groove tip has worn away
rubber to tensile member.
2. Replace belt.
BELT SLIPS 1. Belt slipping because of insufficient
tension.
1. Replace automatic belt tensioner.
2. Belt routed 2. Verify belt routing.
incorrectly
3. Incorrect belt. 3. Replace belt.
4. Belt or pulley subjected to
substance (belt dressing, oil ethylene
glycol) that has reduced friction.
4. Replace belt and clean pulleys.
5. Driven component bearing failure. 5. Replace faulty component
bearing.
6. Belt glazed and hardened from
heat and excessive slippage.
6. Replace belt.
“GROOVE JUMPINGЉ (BELT
DOES NOT MAINTAIN CORRECT
POSITION ON PULLEY)
1. Belt tension either too high or too
low.
1. Replace automatic belt tensioner.
2. Belt routed 2. Verify belt routing.
incorrectly.
3. Incorrect belt. 3. Replace belt.
4. Pulley(s) not within design
tolerance.
4. Replace pulley(s).
5. Foreign object(s) in grooves. 5. Remove foreign objects from
grooves.
6. Pulley misalignment. 6. Check and replace.
7. Belt cord line is broken. 7. Replace belt.
7 - 16 ACCESSORY DRIVE KJ
ACCESSORY DRIVE (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
BELT BROKEN (NOTE: IDENTIFY
AND CORRECT PROBLEM
BEFORE NEW BELT IS
INSTALLED)
1. Excessive tension. 1. Replace belt and automatic belt
tensioner.
2. Incorrect belt. 2. Replace belt.
3. Tensile member damaged during
belt installation.
3. Replace belt.
4. Severe misalignment. 4. Check and replace.
5. Bracket, pulley, or bearing failure. 5. Replace defective component
and belt.
NOISE (OBJECTIONABLE
SQUEAL, SQUEAK, OR RUMBLE
IS HEARD OR FELT WHILE
DRIVE BELT IS IN OPERATION)
1. Belt slippage. 1. Replace belt or automatic belt
tensioner.
2. Bearing noise. 2. Locate and repair.
3. Belt misalignment. 3. Replace belt.
4. Belt-to-pulley mismatch. 4. Install correct belt.
BELT TENSIONERS
REMOVAL - 3. 7L ENGINE
(1) Remove accessory dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(2) Remove tensi oner assembl y from engi ne front
cover (Fi g. 2).
WARNING: BECAUSE OF HIGH SPRING TENSION,
DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC
TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY
(EXCEPT FOR PULLEY ON TENSIONER).
(3) Remove pul l ey bol t. Remove pul l ey from ten-
si oner.
INSTALLATION - 3. 7L ENGINE
(1) I nstal l pul l ey and pul l ey bol t to tensi oner.
Ti ghten bol t to 61 N·m (45 ft. l bs.) torque.
(2) An i ndexi ng sl ot i s l ocated on back of tensi oner.
Al i gn thi s sl ot to the head of the bol t on the front
cover. I nstal l the mounti ng bol t. Ti ghten bol t to 41
N·m (30 ft. l bs.).
(3) I nstal l dri ve bel t (Refer to 7 - COOLI NG/AC-
CESSORY DRI VE/DRI VE BELTS - I NSTALLA-
TI ON).
(4) Check bel t i ndexi ng marks (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS - I NSTAL-
LATI ON).
DRIVE BELTS - 3.7L
REMOVAL - 3. 7L ENGINE
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
Fig. 2 Automatic Belt Tensioner
1 - TIMING CHAIN COVER
2 - BOLT TORQUE TO 41 N·m (30 FT LBS)
3 - AUTOMATIC BELT TENSIONER
KJ ACCESSORY DRIVE 7 - 17
ACCESSORY DRIVE (Continued)
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVERE DAM-
AGE MAY OCCUR TO THE TENSIONER.
Bel t tensi on i s not adjustabl e. Bel t adjustment i s
mai ntai ned by an automati c ( spri ng l oad ) bel t ten-
si oner.
(1) Di sconnect negati ve battery cabl e from battery.
(2) Rotate bel t tensi oner unti l i t contacts i ts stop.
Remove bel t, then sl owl y rotate the tensi oner i nto
the freearm posi ti on. (Fi g. 3).
INSTALLATION - 3. 7L ENGINE
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
Bel t tensi on i s not adjustabl e. Bel t adjustment i s
mai ntai ned by an automati c ( spri ng l oad ) bel t ten-
si oner.
(1) Check condi ti on of al l pul l eys.
CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Fig. 3).
(2) I nstal l new bel t (Fi g. 3). Route the bel t around
al l pul l eys except the i dl er pul l ey. Rotate the ten-
si oner arm unti l i t contacts i ts stop posi ti on. Route
the bel t around the i dl er and sl owl y l et the tensi oner
rotate i nto the bel t. Make sure the bel t i s seated onto
al l pul l eys.
(3) Wi th the dri ve bel t i nstal l ed, i nspect the bel t
wear i ndi cator (Fi g. 4). On 3.7L Engi nes the gap
between the tang and the housi ng stop ( measure-
ment A ) must not exceed 24 mm (.94 i nches).
Fig. 3 Belt Routing - 3.7L
1 - GENERATOR PULLEY
2 - ACCESSORY DRIVE BELT
3 - POWER STEERING PUMP PULLEY
4 - CRANKSHAFT PULLEY
5 - IDLER PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
8 - WATER PUMP PULLEY
Fig. 4 Accessory Drive Belt Wear Indicator
1 - AUTOMATIC TENSIONER ASSEMBLY
7 - 18 ACCESSORY DRIVE KJ
DRIVE BELTS - 3.7L (Continued)
ENGINE
TABLE OF CONTENTS
page page
COOLANT RECOVERY PRESS CONTAINER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE COOLANT TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
ENGINE COOLANT THERMOSTAT
DESCRIPTION - 3.7L ENGINE . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIAGNOSIS AND TESTING - THERMOSTAT . . . 21
REMOVAL - 3.7L ENGINE . . . . . . . . . . . . . . . . . 21
INSTALLATION - 3.7L ENGINE . . . . . . . . . . . . . 22
RADIATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
RADIATOR PRESSURE CAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING - RADIATOR
PRESSURE CAP . . . . . . . . . . . . . . . . . . . . . . 25
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 25
RADIATOR FAN - ELECTRIC
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
RADIATOR - FAN - VISCOUS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING - VISCOUS FAN
DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
WATER PUMP
DESCRIPTION
DESCRIPTION - WATER PUMP . . . . . . . . . . . 29
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION - WATER PUMP . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
COOLANT RECOVERY PRESS
CONTAINER
DESCRIPTION
Thi s system works al ong wi th the radi ator pres-
sure cap. Thi s i s done by usi ng thermal expansi on
and contracti on of the cool ant to keep the cool ant
free of trapped ai r. I t provi des:
• A vol ume for cool ant expansi on and contracti on.
• A conveni ent and safe method for checki ng/ad-
justi ng cool ant l evel at atmospheri c pressure. Thi s i s
done wi thout removi ng the radi ator pressure cap.
• Some reserve cool ant to the radi ator to cover
mi nor l eaks and evaporati on or boi l i ng l osses.
As the engi ne cool s, a vacuum i s formed i n the
cool i ng system of both the radi ator and engi ne. Cool -
ant wi l l then be drawn from the cool ant tank and
returned to a proper l evel i n the radi ator.
The cool ant reservoi r/overfl ow system has a radi a-
tor mounted pressuri zed cap, an overfl ow tube, and a
pl asti c cool ant reservoi r/overfl ow tank, mounted to
the ri ght si de of the cowl . I t i s mounted to the cowl
wi th two nuts on top, and a sl i de bracket on the bot-
tom.
OPERATION
The pressure chamber keeps the cool ant free of
trapped ai r, provi des a vol ume for expansi on and con-
tracti on, and provi des a conveni ent and safe method
for checki ng and adjusti ng cool ant l evel at atmo-
spheri c pressure. I t al so provi des some reserve cool -
ant to cover mi nor l eaks, evaporati on or boi l i ng
l osses. The overfl ow chamber al l ows cool ant recovery
i n case of an overheat.
ENGINE COOLANT
TEMPERATURE SENSOR
DESCRIPTION
The Engi ne Cool ant Temperature (ECT) sensor i s
used to sense engi ne cool ant temperature. The sensor
protrudes i nto an engi ne water jacket.
KJ ENGINE 7 - 19
The ECT sensor i s a two-wi re Negati ve Thermal
Coeffi ci ent (NTC) sensor. Meani ng, as engi ne cool ant
temperature i ncreases, resi stance (vol tage) i n the
sensor decreases. As temperature decreases, resi s-
tance (vol tage) i n the sensor i ncreases.
OPERATION
At key-on, the Powertrai n Control Modul e (PCM)
sends out a regul ated 5 vol t si gnal to the ECT sensor.
The PCM then moni tors the si gnal as i t passes
through the ECT sensor to the sensor ground (sensor
return).
When the engi ne i s col d, the PCM wi l l operate i n
Open Loop cycl e. I t wi l l demand sl i ghtl y ri cher ai r-
fuel mi xtures and hi gher i dl e speeds. Thi s i s done
unti l normal operati ng temperatures are reached.
The PCM uses i nputs from the ECT sensor for the
fol l owi ng cal cul ati ons:
• for engi ne cool ant temperature gauge operati on
through CCD or PCI (J1850) communi cati ons
• I njector pul se-wi dth
• Spark-advance curves
• ASD rel ay shut-down ti mes
• I dl e Ai r Control (I AC) motor key-on steps
• Pul se-wi dth pri me-shot duri ng cranki ng
• O2 sensor cl osed l oop ti mes
• Purge sol enoi d on/off ti mes
• EGR sol enoi d on/off ti mes (i f equi pped)
• Leak Detecti on Pump operati on (i f equi pped)
• Radi ator fan rel ay on/off ti mes (i f equi pped)
• Target i dl e speed
REMOVAL
2. 4L
The Engi ne Cool ant Temperature (ECT) sensor i s
i nstal l ed i nto a water jacket at l eft front of cyl i nder
head (Fi g. 1).
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
(1) Parti al l y drai n cool i ng system.
(2) Di sconnect el ectri cal connector from sensor.
(3) Remove sensor from cyl i nder head.
3. 7L
The Engi ne Cool ant Temperature (ECT) sensor i s
i nstal l ed i nto a water jacket at front of i ntake mani -
fol d near rear of generator (Fi g. 2).
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
(1) Parti al l y drai n cool i ng system.
(2) Di sconnect el ectri cal connector from sensor.
(3) Remove sensor from i ntake mani fol d.
Fig. 1 ECT AND UPPER TIMING BELT COVER/
BOLTS-2.4L
1 - UPPER TIMING BELT COVER
2 - ELECTRICAL CONNECTOR (ECT)
3 - MOUNTING BOLTS (3)
Fig. 2 MAP SENSOR / ECT SENSOR - 3.7L
1 - MOUNTING SCREWS
2 - MAP SENSOR
3 - ECT SENSOR
7 - 20 ENGINE KJ
ENGINE COOLANT TEMPERATURE SENSOR (Continued)
INSTALLATION
(1) Appl y thread seal ant to sensor threads.
(2) I nstal l sensor to engi ne.
(3) Ti ghten sensor to 11 N·m (8 ft. l bs.) torque.
(4) Repl ace any l ost engi ne cool ant.
ENGINE COOLANT
THERMOSTAT
DESCRIPTION - 3. 7L ENGINE
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
A pel l et-type thermostat control s the operati ng
temperature of the engi ne by control l i ng the amount
of cool ant fl ow to the radi ator. On al l engi nes the
thermostat i s cl osed bel ow 195°F (90°C). Above thi s
temperature, cool ant i s al l owed to fl ow to the radi a-
tor. Thi s provi des qui ck engi ne warm up and overal l
temperature control . On the 3.7L engi ne the thermo-
stat i s desi gned to bl ock the fl ow of the cool ant
bypass journal by 50% i nstead of compl etel y bl ocki ng
the fl ow. Thi s desi gn control s cool ant temperature
more accuratel y (Fi g. 3).
The same thermostat i s used for wi nter and sum-
mer seasons. An engi ne shoul d not be operated wi th-
out a thermostat, except for servi ci ng or testi ng.
Operati ng wi thout a thermostat causes other prob-
l ems. These are: l onger engi ne warmup ti me, unrel i -
abl e warmup performance, i ncreased exhaust
emi ssi ons and crankcase condensati on. Thi s conden-
sati on can resul t i n sl udge formati on.
OPERATION
The wax pel l et i s l ocated i n a seal ed contai ner at
the spri ng end of the thermostat. When heated, the
pel l et expands, overcomi ng cl osi ng spri ng tensi on
and water pump pressure to force the val ve to open.
DIAGNOSIS AND TESTING - THERMOSTAT
ON-BOARD DIAGNOSTICS
Al l model s are equi pped wi th On-Board Di agnos-
ti cs for certai n cool i ng system components.I f the pow-
ertrai n control modul e (PCM) detects l ow engi ne
cool ant temperature, i t wi l l record a Di agnosti c Trou-
bl e Code (DTC). For other DTC numbers, (Refer to 25
- EMI SSI ONS CONTROL - DESCRI PTI ON).
The DTC can al so be accessed through the DRB
scan tool .
REMOVAL - 3. 7L ENGINE
WARNING: DO NOT LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND PRESSURIZED.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Do not waste reusabl e cool ant. I f sol uti on i s cl ean,
drai n cool ant i nto a cl ean contai ner for reuse.
I f thermostat i s bei ng repl aced, be sure that
repl acement i s speci fi ed thermostat for vehi cl e model
and engi ne type.
(1) Di sconnect negati ve battery cabl e at battery.
(2) Drai n cool i ng system (Refer to 7 - COOLI NG -
STANDARD PROCEDURE).
(3) Rai se vehi cl e on hoi st.
(4) Remove spl ash shi el d.
(5) Remove l ower radi ator hose cl amp and l ower
radi ator hose at thermostat housi ng.
(6) Remove thermostat housi ng mounti ng bol ts,
thermostat housi ng and thermostat (Fi g. 4).
Fig. 3 Thermostat
1 - FROM HEATER
2 - FROM RADIATOR
3 - TO WATER PUMP
4 - ENGINE BYPASS
5 - THERMOSTAT
KJ ENGINE 7 - 21
ENGINE COOLANT TEMPERATURE SENSOR (Continued)
INSTALLATION - 3. 7L ENGINE
(1) Cl ean mati ng areas of ti mi ng chai n cover and
thermostat housi ng.
(2) I nstal l thermostat (spri ng si de down) i nto
recessed machi ned groove on ti mi ng chai n cover (Fi g. 4).
(3) Posi ti on thermostat housi ng on ti mi ng chai n
cover.
(4) I nstal l two housi ng-to-ti mi ng chai n cover bol ts.
Ti ghten bol ts to 13 N·m (115 i n. l bs.) torque.
CAUTION: Housing must be tightened evenly and
thermostat must be centered into recessed groove
in timimg chain cover. If not, it may result in a
cracked housing, damaged timing chain cover
threads or coolant leaks.
(5) I nstal l l ower radi ator hose on thermostat housi ng.
(6) I nstal l spl ash shi el d.
(7) Lower vehi cl e.
(8) Fi l l cool i ng system (Refer to 7 - COOLI NG -
STANDARD PROCEDURE).
(9) Connect negati ve battery cabl e to battery.
(10) Start and warm the engi ne. Check for l eaks.
RADIATOR
DESCRIPTION
Al l vehi cl es are equi pped wi th a cross fl ow type
radi ator wi th pl asti c si de tanks (Fi g. 5).
Pl asti c tanks, whi l e stronger than brass, are sub-
ject to damage by i mpact, such as from tool s or
wrenches. Handl e radi ator wi th care.
Fig. 4 Thermostat and Thermostat Housing
1 - THERMOSTAT HOUSING
2 - THERMOSTAT LOCATION
3 - THERMOSTAT AND GASKET
4 - TIMING CHAIN COVER
Fig. 5 Cross Flow Radiator - Typical
1 - RADIATOR
7 - 22 ENGINE KJ
ENGINE COOLANT THERMOSTAT (Continued)
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR. REFER TO COOLING SYSTEM DRAIN-
ING.
Do not waste reusabl e cool ant. I f the sol uti on i s
cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 6). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 7). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
CAUTION: When removing the radiator or A/C con-
denser for any reason, note the location of all radi-
ator-to-body and radiator-to-A/C condenser rubber
air seals (Fig. 8). These are used at the top, bottom
and sides of the radiator and A/C condenser. To
prevent overheating, these seals must be installed
to their original positions.
(1) Di sconnect the negati ve battery cabl e at bat-
tery.
(2) Drai n cool ant from radi ator (Refer to 7 -
COOLI NG - STANDARD PROCEDURE).
Fig. 6 Hose Clamp Tool - Typical
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
Fig. 7 Clamp Number/Letter Location - Typical
1 - TYPICAL CONSTANT TENSION HOSE CLAMP
2 - CLAMP NUMBER/LETTER LOCATION
3 - TYPICAL HOSE
Fig. 8 Air Seals - Typical
1 - AIR DAM
2 - RADIATOR
3 - AIR DAM
4 - A/C CONDENSER
5 - AIR SEAL
KJ ENGINE 7 - 23
RADIATOR (Continued)
(3) Remove the front gri l l (Refer to 23 - BODY/EX-
TERI OR/GRI LLE - REMOVAL).
(4) Remove the cool i ng fan from the engi ne, i f
equi pped.
(5) Remove the two radi ator mounti ng bol ts.
(6) Di sconnect both transmi ssi on cool er l i nes from
radi ator.
(7) Di sconnect the connector for the el ectri c fan.
(8) Di sconnect the power steeri ng cool er l i ne from
cool er.
(9) Di sconnect the radi ator upper and l ower hoses.
(10) Di sconnect the overfl ow hose from radi ator.
(11) The l ower part of radi ator i s equi pped wi th
two al i gnment dowel pi ns (Fi g. 9). They are l ocated
on the bottom of radi ator tank and fi t i nto rubber
grommets. These rubber grommets are pressed i nto
the radi ator l ower crossmember.
WARNING: THE AIR CONDITIONING SYSTEM (IF
EQUIPPED) IS UNDER A CONSTANT PRESSURE
EVEN WITH THE ENGINE OFF. REFER TO REFRIG-
ERANT WARNINGS IN, HEATING AND AIR CONDI-
TIONING BEFORE HANDLING ANY AIR
CONDITIONING COMPONENT.
NOTE: The radiator and radiator cooling fan can be
removed as an assembly. It is not necessary to
remove the cooling fan before removing or install-
ing the radiator.
(12) Gentl y l i ft up and remove radi ator from vehi -
cl e. Be careful not to scrape the radi ator fi ns agai nst
any other component. Al so be careful not to di sturb
the ai r condi ti oni ng condenser (i f equi pped).
CLEANING
Cl ean radi ator fi ns Wi th the engi ne col d, appl y col d
water and compressed ai r to the back (engi ne si de) of
the radi ator to fl ush the radi ator and/or A/C con-
denser of debri s.
INSPECTION
The radi ator cool i ng fi ns shoul d be checked for
damage or deteri orati on. I nspect cool i ng fi ns to make
sure they are not bent or crushed, these areas resul t
i n reduced heat exchange causi ng the cool i ng system
to operate at hi gher temperatures. I nspect the pl asti c
end tanks for cracks, damage or l eaks.
I nspect the radi ator neck for damage or di storti on.
INSTALLATION
CAUTION: Before installing the radiator or A/C con-
denser, be sure the radiator-to-body and radiator-to-
A/C condenser rubber air seals are properly
fastened to their original positions. These are used
at the top, bottom and sides of the radiator and A/C
condenser. To prevent overheating, these seals
must be installed to their original positions.
(1) Gentl y l ower the radi ator and fan shroud i nto
the vehi cl e. Gui de the two radi ator al i gnment dowel s
i nto the rubber grommets l ocated i n l ower radi ator
crossmember.
(2) Connect the radi ator upper and l ower hoses
and hose cl amps to radi ator.
CAUTION: The tangs on the hose clamps must be
positioned straight down.
(3) I nstal l cool ant reserve/overfl ow tank hose at
radi ator.
(4) Connect both transmi ssi on cool er l i nes at the
radi ator.
(5) I nstal l both radi ator mounti ng bol ts.
(6) Reconnect the el ectri c cool i ng fan.
(7) I nstal l the gri l l (Refer to 23 - BODY/EXTERI -
OR/GRI LLE - I NSTALLATI ON).
(8) Rei nstal l the cool i ng fan to the engi ne.
(9) Rotate the fan bl ades (by hand) and check for
i nterference at fan shroud.
(10) Refi l l cool i ng system (Refer to 7 - COOLI NG -
STANDARD PROCEDURE).
(11) Connect battery cabl e at battery.
(12) Start and warm engi ne. Check for l eaks.
Fig. 9 Radiator Alignment Dowels - Typical
1 - RADIATOR
2 - ALIGNMENT DOWEL
3 - RADIATOR LOWER ISOLATOR
4 - RADIATOR LOWER CROSSMEMBER
7 - 24 ENGINE KJ
RADIATOR (Continued)
RADIATOR PRESSURE CAP
DESCRIPTION
The cool i ng system cap i s l ocated on the cool ant
pressure bottl e. The cap constructi on i ncl udes; stai n-
l ess steel swi vel top, rubber seal s and retai ner, mai n
spri ng, and a spri ng l oaded val ve (Fi g. 10).
OPERATION
The pressure cap al l ows the cool i ng system to oper-
ate at hi gher than atmospheri c pressure whi ch rai ses
the cool ant boi l i ng poi nt, thus al l owi ng i ncreased
radi ator cool i ng capaci ty. The pressure cap rel eases
pressure at some poi nt wi thi n a range of 110 kPa ±
14 kPa (16 psi ± 2 psi ).
A spri ng-l oaded vent val ve i n the center of the cap
al l ows the system to pressuri ze and depressuri ze
wi thout creati ng a vacuum. I f the val ve i s stuck
open, cool ant wi l l escape to the overfl ow hose. There
i s al so a gasket i n the cap to seal to the top of the
fi l l er neck.
CAUTION: Use only the pressure cap specified for
this vehicle. Use of other pressure caps can lead to
coolant loss and overheating.
DIAGNOSIS AND TESTING - RADIATOR
PRESSURE CAP
Remove cap from radi ator. Be sure that seal i ng
surfaces are cl ean. Moi sten rubber gasket wi th water
and i nstal l the cap on pressure tester (tool 7700 or
an equi val ent) (Fi g. 11).
Operate the tester pump and observe the gauge
poi nter at i ts hi ghest poi nt. The cap rel ease pressure
shoul d be 124 to 145 kPa (18 to 21 psi ). The cap i s
sati sfactory when the pressure hol ds steady. I t i s al so
good i f i t hol ds pressure wi thi n the 124 to 145 kPa
(18 to 21 psi ) range for 30 seconds or more. I f the
poi nter drops qui ckl y, repl ace the cap.
CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks, which will not cause
cooling system problems. A pressure cap that does
not have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap
needs replacement.
CLEANING
Cl ean the radi ator pressure cap usi ng a mi l d soap
and water onl y.
INSPECTION
Vi sual l y i nspect the pressure val ve gasket on the
cap. Repl ace cap i f the gasket i s swol l en, torn or
worn. I nspect the area around radi ator fi l l er neck for
whi te deposi ts that i ndi cate a l eaki ng cap.
Fig. 10 PRESSURE CAP
1 - MAIN SPRING
2 - GASKET RETAINER
3 - STAINLESS STEEL SWIVEL TOP
4 - RUBBER SEALS
5 - SPRING LOADED VALVE
6 - COOLANT PRESSURE BOTTLE
7 - FILLER NECK
8 - OVERFLOW NIPPLE
Fig. 11 Pressure Testing Radiator Pressure Cap -
Typical
1 - PRESSURE CAP
2 - TYPICAL COOLING SYSTEM PRESSURE TESTER
KJ ENGINE 7 - 25
RADIATOR FAN - ELECTRIC
DESCRIPTION
The fan (Fi g. 12) i s el ectri cal l y control l ed by the
powertrai n control modul e (PCM) through the fan
control rel ay. Thi s rel ay i s l ocated on the l eft wheel
house i n the engi ne compartment.
OPERATION
The el ectri c radi ator cool i ng fan i s control l ed by
the Powertrai n Control Modul e (PCM) through the
radi ator cool i ng fan rel ay. The PCM regul ates fan
operati on based on i nput from the engi ne cool ant
temperature sensor, battery temperature sensor,ai r
condi ti oni ng sel ect swi tch and vehi cl e speed.
The fan i s not energi zed duri ng engi ne cranki ng
regardl ess of the el ectri cal i nput from the tempera-
ture sensors and ,ai r condi ti oni ng swi tch. However, i f
engi ne operati on condi ti ons warrant fan engagement,
the fan wi l l run once engi ne starts.
On vehicles NOT equipped with AC: The rel ay
i s energi zed when the cool ant temperature i s above
80° C (176° F), or battery temperature sensor above –
12° C (10° F). I t wi l l then de-energi ze when cool ant
temperature drops bel ow 82° C (180° F), or batter
temperature sensor bel ow – 9° C ( 16° F).
Vehicles Equipped with AC: I n addi ti on to usi ng
cool ant temperature and battery temperature sensor
to control cool i ng fan operati on, the cool i ng fan wi l l
al so be engaged when the ,ai r condi ti oni ng system i s
acti vated. The rel ay i s al so energi zed when, ai r con-
di ti oni ng i s sel ected and cool ant temperature i s
above 95° C ( 203° F), or , ai r condi ti oni ng i s sel ected
and battery temperature sensor i s above 41° C (106°
F). I t wi l l then de-energi ze when , ai r condi ti oni ng i s
sel ected and cool ant temperature i s bel ow 92° C
(198° F), or , ai r condi ti oni ng i s sel ected and battery
temperature i s bel ow 38° C (100° F).
REMOVAL
I f the fan bl ade i s bent, warped, cracked or dam-
aged i n any way, i t must be repl aced only wi th a
repl acement fan bl ade. Do not attempt to repair a
damaged fan blade.
NOTE: For 3.7L Heavy Duty/Max Cool/Trailer Tow
cooling package, the vicous fan cannot be removed
seperate from the shroud. Both fan and shroud
must be removed together.
(1) Di sconnect battery negati ve cabl e.
(2) Usi ng speci al tool 6958 spanner wrench and
8346 adapters, remove the vi cous fan from the water
pump (Fi g. 13).
(3) Gentl y l ay fan i nto shroud.
(4) Di sconnect the el ectri cal connector for the el ec-
tri c fan, then di sconnect connector from shroud.
Fig. 12 Radiator Cooling Fan - Typical
1 - RADIATOR
2 - ELECTRIC COOLING FAN CONNECTOR
3 - FAN SHROUD
4 - ELECTRIC COOLING FAN
Fig. 13 Viscous Fan and Fan Drive 3.7L
1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2 - FAN
7 - 26 ENGINE KJ
(5) Remove the two fan shroud mounti ng bol