engine CHRYSLER VOYAGER 2004 Service Manual

DIAGNOSIS AND TESTING - VEHICLE DOES
NOT FILL
CONDITION POSSIBLE CAUSES CORRECTION
Pre-Mature Nozzle Shut-Off Defective fuel tank assembly
components.Fill tube improperly installed
(sump)
Fill tube hose pinched.
Check valve stuck shut.
Control valve stuck shut.
Defective vapor/vent components. Vent line from control valve to
canister pinched.
Vent line from canister to vent
filter pinched.
Canister vent valve failure
(requires double failure,
plugged to NVLD and
atmosphere).
Leak detection pump failed
closed.
Leak detection pump filter
plugged.
On-Board diagnostics evaporative
system leak test just conducted.Canister vent valve vent
plugged to atmosphere.
engine still running when
attempting to fill (System
designed not to fill).
Defective fill nozzle. Try another nozzle.
Fuel Spits Out Of Filler
Tube.During fill. See Pre-Mature Shut-Off.
At conclusion of fill. Defective fuel handling
component. (Check valve stuck
open).
Defective vapor/vent handling
component.
Defective fill nozzle.
PCV VALVE
DESCRIPTION
The PCV valve contains a spring loaded plunger.
The plunger meters the amount of crankcase vapors
routed into the combustion chamber based on intake
manifold vacuum (Fig. 10) or (Fig. 11).
OPERATION
When the engine is not operating or during an
engine backfire, the spring forces the plunger back
against the seat. This prevents vapors from flowing
through the valve (Fig. 12).When the engine is at idle or cruising, high mani-
fold vacuum is present. At these times manifold vac-
uum is able to completely compress the spring and
pull the plunger to the top of the valve (Fig. 13). In
this position there is minimal vapor flow through the
valve.
During periods of moderate intake manifold vac-
uum the plunger is only pulled part way back from
the inlet. This results in maximum vapor flow
through the valve (Fig. 14).
25 - 16 EVAPORATIVE EMISSIONSRS
ORVR (Continued)

DIAGNOSIS AND TESTING - PCV SYSTEM
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE PERFORMING ANY TEST
OR ADJUSTMENT WITH THE ENGINE OPERATING.
(1) With engine idling, remove the hose from the
PCV valve. If the valve is not plugged, a hissing
noise will be heard as air passes through the valve. A
strong vacuum should also be felt when a finger is
placed over the valve inlet.
(2) Install hose on PCV valve. Remove the
make-up air hose from the air plenum at the rear of
the engine. Hold a piece of stiff paper (parts tag)
loosely over the end of the make-up air hose.
(3) After allowing approximately one minute for
crankcase pressure to reduce, the paper should draw
up against the hose with noticeable force. If the
engine does not draw the paper against the grommet
after installing a new valve, replace the PCV valve
hose.
(4) Turn the engine off. Remove the PCV valve
from intake manifold. The valve should rattle when
shaken.
(5) Replace the PCV valve and retest the system if
it does not operate as described in the preceding
tests.Do not attempt to clean the old PCV valve.
If the valve rattles, apply a light coating of Loctitet
Pipe Sealant With Teflon to the threads. Thread the
PCV valve into the manifold plenum and tighten to 7
N´m (60 in. lbs.) torque.
Fig. 10 PCV VALVE 2.4L
1 - PCV Valve
Fig. 11 PCV VALVE 3.3/3.8L
Fig. 12 Engine Off or Engine Backfire No Vapor
Flow
Fig. 13 High Intake Manifold Vacuum Minimal Vapor
Flow
Fig. 14 Moderate Intake Manifold Vacuum Maximum
Vapor Flow
RSEVAPORATIVE EMISSIONS25-17
PCV VALVE (Continued)

VAPOR CANISTER
DESCRIPTION
There are 2 EVAP canisters on the vehicle. The
vacuum and vapor tubes connect to the top of the
canister. It is a charcoal canister (Fig. 15) or (Fig.
16).
OPERATION
All vehicles use a maintenance free, evaporative
(EVAP) canister. Fuel tank vapors vent into the can-
ister. The canister temporarily holds the fuel vapors
until intake manifold vacuum draws them into the
combustion chamber. The Powertrain Control Module
(PCM) purges the canister through the proportional
purge solenoid. The PCM purges the canister at pre-
determined intervals and engine conditions.
Purge Free Cells
Purge-free memory cells are used to identify the
fuel vapor content of the evaporative canister. Since
the evaporative canister is not purged 100% of the
time, the PCM stores information about the evapora-
tive canister's vapor content in a memory cell.
The purge-free cells are constructed similar to cer-
tain purge-normal cells. The purge-free cells can be
monitored by the DRB IIItScan Tool. The only dif-
ference between the purge-free cells and normal
adaptive cells is that in purge-free, the purge is com-
pletely turned off. This gives the PCM the ability to
compare purge and purge-free operation.
REMOVAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the 2 hoses (Fig. 15).
(3) Remove bolt.
(4) Pull canister rearward to remove.
Fig. 15 FRONT EVAP CANISTER
1 - Front EVAP Canister
2 - Vent Valve
Fig. 16 REAR EVAP CANISTER
1 - Rear EVAP Canister
2 - Front EVAP Canister
3 - Vent Valve
25 - 18 EVAPORATIVE EMISSIONSRS

VA LV E
DESCRIPTION
The EGR system consists of:
²EGR tube (connects a passage in the intake
manifold to the exhaust port in the cylinder head)
²EGR valve
²Electronic EGR Transducer
²Connecting hoses
OPERATION
Refer to Monitored Systems - EGR Monitor in this
group for more information.
The engines use Exhaust Gas Recirculation (EGR)
systems. The EGR system reduces oxides of nitrogen
(NOx) in engine exhaust and helps prevent detona-
tion (engine knock). Under normal operating condi-
tions, engine cylinder temperature can reach more
than 3000ÉF. Formation of NOx increases proportion-
ally with combustion temperature. To reduce the
emission of these oxides, the cylinder temperature
must be lowered. The system allows a predetermined
amount of hot exhaust gas to recirculate and dilute
the incoming air/fuel mixture. The diluted air/fuel
mixture reduces peak flame temperature during com-
bustion.
The electric EGR transducer contains an electri-
cally operated solenoid and a back-pressure trans-
ducer (Fig. 2). The Powertrain Control Module (PCM)
operates the solenoid. The PCM determines when toenergize the solenoid. Exhaust system back-pressure
controls the transducer.
When the PCM energizes the solenoid, vacuum
does not reach the transducer. Vacuum flows to the
transducer when the PCM de-energizes the solenoid.
When exhaust system back-pressure becomes high
enough, it fully closes a bleed valve in the trans-
ducer. When the PCM de-energizes the solenoid and
back-pressure closes the transducer bleed valve, vac-
uum flows through the transducer to operate the
EGR valve.
Fig. 1 EGR VALVE AND TUBE 2.4L
1 - EGR Tube
2 - EGR Valve
Fig. 2 EGR Valve and Transducer - Typical
1 - DIAPHRAGM
2 - PISTON
3 - SPRING
4 - EGR VALVE ASSEMBLY
5 - VACUUM MOTOR
6 - VACUUM MOTOR FITTING
7 - VACUUM OUTLET FITTING TO EGR VALVE
8 - EGR VALVE CONTROL ASSEMBLY
9 - ELECTRIC SOLENOID PORTION OF VALVE CONTROL
10 - VACUUM INLET FITTING FROM ENGINE
11 - BACK-PRESSURE HOSE
12 - TRANSDUCER PORTION OF VALVE CONTROL
13 - ELECTRICAL CONNECTION POINT
14 - EGR VALVE BACK-PRESSURE FITTING
15 - EXHAUST GAS INLET
16 - STEM PROTECTOR AND BUSHING
17 - BASE
18 - MOVEMENT INDICATOR
19 - POPPET VALVE
20 - SEAT
21 - EXHAUST GAS OUTLET
25 - 22 EXHAUST GAS RECIRCULATIONRS

De-energizing the solenoid, but not fully closing the
transducer bleed hole (because of low back-pressure),
varies the strength of vacuum applied to the EGR
valve. Varying the strength of the vacuum changes
the amount of EGR supplied to the engine. This pro-
vides the correct amount of exhaust gas recirculation
for different operating conditions.
This system does not allow EGR at idle.
A failed or malfunctioning EGR system can cause
engine spark knock, sags or hesitation, rough idle,
engine stalling and increased emissions.
REMOVAL - 2.4L
The EGR valve and Electrical EGR Transducer are
serviced as an assembly (Fig. 1).
(1) Disconnect vacuum tube from electric EGR
transducer. Inspect vacuum tube for damage.
(2) Remove electrical connector from solenoid.
(3) Remove EGR tube bolts from EGR valve.
(4) Remove EGR valve from cylinder head adaptor.
(5) Clean gasket surface and discard old gasket.
Check for any signs of leakage or cracked surfaces.
Repair or replace as necessary.
INSTALLATION - 2.4L
The EGR valve and Electrical EGR Transducer are
serviced as an assembly (Fig. 1).
(1) Assemble EGR valve with new gasket onto the
cylinder head adaptor.
(2) Loose assemble the bolts from EGR valve to
EGR tube.
(3) Loose assemble the bolts from EGR valve to
cylinder head.
(4) Tighten bolts from EGR valve to cylinder head
to 22.8 N´m (200  25 in. lbs.) torque.
(5) Tighten bolts from EGR valve to EGR tube to
11.9 N´m (105  20 in. lbs.) torque.
(6) Reconnect vacuum hose and electrical connec-
tor to electrical EGR transducer.
RSEXHAUST GAS RECIRCULATION25-23
VALVE (Continued)

The Task Manager Screen shows both a Requested
MIL state and an Actual MIL state. When the MIL is
illuminated upon completion of a test for a good trip,
the Requested MIL state changes to OFF. However,
the MIL remains illuminated until the next key
cycle. (On some vehicles, the MIL will actually turn
OFF during the thirdgood trip) During the key cycle
for the third good trip, the Requested MIL state is
OFF, while the Actual MIL state is ON. After the
next key cycle, the MIL is not illuminated and both
MIL states read OFF.
Diagnostic Trouble Codes (DTCs)
With OBD II, different DTC faults have different
priorities according to regulations. As a result, the
priorities determine MIL illumination and DTC era-
sure. DTCs are entered according to individual prior-
ity. DTCs with a higher priority overwrite lower
priority DTCs.
Priorities
²Priority 0 ÐNon-emissions related trouble codes.
²Priority 1 Ð One trip failure of a two trip fault
for non-fuel system and non-misfire. (MIL Off)
²Priority 2 Ð One trip failure of a two trip fault
for fuel system (rich/lean) or misfire. (MIL Off)
²Priority3ÐTwotrip failure for a non-fuel sys-
tem and non-misfire or matured one trip comprehen-
sive component fault. (MIL On)
²Priority4ÐTwotrip failure or matured fault
for fuel system (rich/lean) and misfire or one trip cat-
alyst damaging misfire. Catalyst damage misfire is a
2 trip MIL. The MIL flashes on the first trip when
catalyst damage misfire levels are present. (MIL On)
Non-emissions related failures have no priority.
One trip failures of two trip faults have low priority.
Two trip failures or matured faults have higher pri-
ority. One and two trip failures of fuel system and
misfire monitor take precedence over non-fuel system
and non-misfire failures.
DTC Self Erasure
With one trip components or systems, the MIL is
illuminated upon test failure and DTCs are stored.
Two trip monitors are components requiring failure
in two consecutive trips for MIL illumination. Upon
failure of the first test, the Task Manager enters a
maturing code. If the component fails the test for a
second time the code matures and a DTC is set.
After three good trips the MIL is extinguished and
the Task Manager automatically switches the trip
counter to a warm-up cycle counter. DTCs are auto-
matically erased following 40 warm-up cycles if the
component does not fail again.
For misfire and fuel system monitors, the compo-
nent must pass the test under a Similar Conditions
Window in order to record a good trip. A Similar Con-ditions Window is when engine RPM is within  375
RPM and load is within  20% of when the fault
occurred.
NOTE: It is important to understand that a compo-
nent does not have to fail under a similar window of
operation to mature. It must pass the test under a
Similar Conditions Window when it failed to record
a Good Trip for DTC erasure for misfire and fuel
system monitors.
DTCs can be erased anytime with a DRBIIIt.
Erasing the DTC with the DRBIIIterases all OBD II
information. The DRBIIItautomatically displays a
warning that erasing the DTC will also erase all
OBD II monitor data. This includes all counter infor-
mation for warm-up cycles, trips and Freeze Frame.
Trip Indicator
TheTripis essential for running monitors and
extinguishing the MIL. In OBD II terms, a trip is a
set of vehicle operating conditions that must be met
for a specific monitor to run. All trips begin with a
key cycle.
Good Trip
The Good Trip counters are as follows:
²Global Good Trip
²Fuel System Good Trip
²Misfire Good Trip
²Alternate Good Trip (appears as a Global Good
Trip on DRBIIIt)
²Comprehensive Components
²Major Monitor
²Warm-Up Cycles
Global Good Trip
To increment a Global Good Trip, the Oxygen sen-
sor and Catalyst efficiency monitors must have run
and passed, and 2 minutes of engine run time.
Fuel System Good Trip
To count a good trip (three required) and turn off
the MIL, the following conditions must occur:
²Engine in closed loop
²Operating in Similar Conditions Window
²Short Term multiplied by Long Term less than
threshold
²Less than threshold for a predetermined time
If all of the previous criteria are met, the PCM will
count a good trip (three required) and turn off the
MIL.
Misfire Good Trip
If the following conditions are met the PCM will
count one good trip (three required) in order to turn
off the MIL:
²Operating in Similar Condition Window
²1000 engine revolutions with no misfire
RSON-BOARD DIAGNOSTICS25-25
TASK MANAGER (Continued)

Alternate Good Trip
Alternate Good Trips are used in place of Global
Good Trips for Comprehensive Components and
Major Monitors. If the Task Manager cannot run a
Global Good Trip because a component fault is stop-
ping the monitor from running, it will attempt to
count an Alternate Good Trip.
The Task Manager counts an Alternate Good Trip
for Comprehensive components when the following
conditions are met:
²Two minutes of engine run time, idle or driving
²No other faults occur
The Task Manager counts an Alternate Good Trip
for a Major Monitor when the monitor runs and
passes. Only the Major Monitor that failed needs to
pass to count an Alternate Good Trip.
Warm-Up Cycles
Once the MIL has been extinguished by the Good
Trip Counter, the PCM automatically switches to a
Warm-Up Cycle Counter that can be viewed on the
DRBIIIt. Warm-Up Cycles are used to erase DTCs
and Freeze Frames. Forty Warm-Up cycles must
occur in order for the PCM to self-erase a DTC and
Freeze Frame. A Warm-Up Cycle is defined as fol-
lows:
²Engine coolant temperature must start below
and rise above 160É F
²Engine coolant temperature must rise by 40É F
²No further faults occur
Freeze Frame Data Storage
Once a failure occurs, the Task Manager records
several engine operating conditions and stores it in a
Freeze Frame. The Freeze Frame is considered one
frame of information taken by an on-board data
recorder. When a fault occurs, the PCM stores the
input data from various sensors so that technicians
can determine under what vehicle operating condi-
tions the failure occurred.
The data stored in Freeze Frame is usually
recorded when a system fails the first time for two
trip faults. Freeze Frame data will only be overwrit-
ten by a different fault with a higher priority.
CAUTION: Erasing DTCs, either with the DRBIIIT;or
by disconnecting the battery, also clears all Freeze
Frame data.
Similar Conditions Window
The Similar Conditions Window displays informa-
tion about engine operation during a monitor. Abso-
lute MAP (engine load) and Engine RPM are stored
in this window when a failure occurs. There are two
different Similar conditions Windows: Fuel System
and Misfire.FUEL SYSTEM
²Fuel System Similar Conditions WindowÐ
An indicator that 'Absolute MAP When Fuel Sys Fail'
and 'RPM When Fuel Sys Failed' are all in the same
range when the failure occurred. Indicated by switch-
ing from 'NO' to 'YES'.
²Absolute MAP When Fuel Sys FailÐ The
stored MAP reading at the time of failure. Informs
the user at what engine load the failure occurred.
²Absolute MAPÐ A live reading of engine load
to aid the user in accessing the Similar Conditions
Window.
²RPM When Fuel Sys FailÐ The stored RPM
reading at the time of failure. Informs the user at
what engine RPM the failure occurred.
²Engine RPMÐ A live reading of engine RPM
to aid the user in accessing the Similar Conditions
Window.
²Adaptive Memory FactorÐ The PCM utilizes
both Short Term Compensation and Long Term Adap-
tive to calculate the Adaptive Memory Factor for
total fuel correction.
²Upstream O2S VoltsÐ A live reading of the
Oxygen Sensor to indicate its performance. For
example, stuck lean, stuck rich, etc.
²SCW Time in Window (Similar Conditions
Window Time in Window)Ð A timer used by the
PCM that indicates that, after all Similar Conditions
have been met, if there has been enough good engine
running time in the SCW without failure detected.
This timer is used to increment a Good Trip.
²Fuel System Good Trip CounterÐATrip
Counter used to turn OFF the MIL for Fuel System
DTCs. To increment a Fuel System Good Trip, the
engine must be in the Similar Conditions Window,
Adaptive Memory Factor must be less than cali-
brated threshold and the Adaptive Memory Factor
must stay below that threshold for a calibrated
amount of time.
²Test Done This TripÐ Indicates that the
monitor has already been run and completed during
the current trip.
MISFIRE
²Same Misfire Warm-Up StateÐ Indicates if
the misfire occurred when the engine was warmed up
(above 160É F).
²In Similar Misfire WindowÐ An indicator
that 'Absolute MAP When Misfire Occurred' and
'RPM When Misfire Occurred' are all in the same
range when the failure occurred. Indicated by switch-
ing from 'NO' to 'YES'.
²Absolute MAP When Misfire OccurredÐ
The stored MAP reading at the time of failure.
Informs the user at what engine load the failure
occurred.
25 - 26 ON-BOARD DIAGNOSTICSRS
TASK MANAGER (Continued)

²Absolute MAPÐ A live reading of engine load
to aid the user in accessing the Similar Conditions
Window.
²RPM When Misfire OccurredÐ The stored
RPM reading at the time of failure. Informs the user
at what engine RPM the failure occurred.
²Engine RPMÐ A live reading of engine RPM
to aid the user in accessing the Similar Conditions
Window.
²Adaptive Memory FactorÐ The PCM utilizes
both Short Term Compensation and Long Term Adap-tive to calculate the Adaptive Memory Factor for
total fuel correction.
²200 Rev CounterÐ Counts 0±100 720 degree
cycles.
²SCW Cat 200 Rev CounterÐ Counts when in
similar conditions.
²SCW FTP 1000 Rev CounterÐ Counts 0±4
when in similar conditions.
²Misfire Good Trip CounterÐ Counts up to
three to turn OFF the MIL.
RSON-BOARD DIAGNOSTICS25-27
TASK MANAGER (Continued)

INDEX
ABS FASTENER TORQUE,
SPECIFICATIONS......................5-79
ABSORBER - DESCRIPTION, SHOCK.......2-37
ABSORBER - INSTALLATION, SHOCK......2-38
ABSORBER - OPERATION, SHOCK........2-37
ABSORBER - REMOVAL, SHOCK..........2-37
ABSORBER (UPPER BUSHING) -
ASSEMBLY, SHOCK....................2-38
ABSORBER (UPPER BUSHING) -
DISASSEMBLY, SHOCK.................2-37
A/C COMPRESSOR - DESCRIPTION......24-73
A/C COMPRESSOR - OPERATION........24-73
A/C COMPRESSOR CLUTCH COIL -
DIAGNOSIS AND TESTING.............24-15
A/C COMPRESSOR CLUTCH RELAY -
DESCRIPTION.......................24-19
A/C COMPRESSOR CLUTCH RELAY -
INSTALLATION.......................24-20
A/C COMPRESSOR CLUTCH RELAY -
OPERATION.........................24-19
A/C COMPRESSOR CLUTCH RELAY -
REMOVAL..........................24-20
A/C COMPRESSOR CLUTCH/COIL -
DESCRIPTION.......................24-15
A/C COMPRESSOR CLUTCH/COIL -
INSPECTION........................24-17
A/C COMPRESSOR CLUTCH/COIL -
INSTALLATION.......................24-17
A/C COMPRESSOR CLUTCH/COIL -
OPERATION.........................24-15
A/C COMPRESSOR CLUTCH/COIL -
REMOVAL..........................24-16
A/C COMPRESSOR MOUNTING BRACKET
- 2.4L ENGINE - INSTALLATION.........24-76
A/C COMPRESSOR MOUNTING BRACKET
- 2.4L ENGINE - REMOVAL.............24-75
A/C CONDENSER - DESCRIPTION........24-76
A/C CONDENSER - INSTALLATION.......24-78
A/C CONDENSER - OPERATION..........24-76
A/C CONDENSER - REMOVAL...........24-77
A/C COOL DOWN TEST - DIAGNOSIS
AND TESTING........................24-6
A/C DISCHARGE LINE - INSTALLATION . . . 24-80
A/C DISCHARGE LINE - REMOVAL.......24-79
A/C EVAPORATOR - DESCRIPTION . . 24-80,24-97
A/C EVAPORATOR - INSTALLATION......24-80
A/C EVAPORATOR - INSTALLATION,
REAR..............................24-99
A/C EVAPORATOR - OPERATION....24-80,24-97
A/C EVAPORATOR - REMOVAL..........24-80
A/C EVAPORATOR - REMOVAL, REAR.....24-97
A/C EVAPORATOR LINE EXTENSION -
INSTALLATION, REAR.................24-99
A/C EVAPORATOR LINE EXTENSION -
REMOVAL..........................24-98
A/C EXPANSION VALVE - DESCRIPTION . . . 24-99
A/C EXPANSION VALVE - DIAGNOSIS
AND TESTING.......................24-81
A/C EXPANSION VALVE - INSTALLATION . 24-100
A/C EXPANSION VALVE - OPERATION.....24-99
A/C EXPANSION VALVE - REMOVAL.....24-100
A/C HEATER CONTROL - DESCRIPTION . . . 24-20
A/C HEATER CONTROL - INSTALLATION . . . 24-21
A/C HEATER CONTROL - REMOVAL......24-21
A/C PERFORMANCE TEST - DIAGNOSIS
AND TESTING........................24-7
A/C PRESSURE TRANSDUCER -
DESCRIPTION.......................24-21
A/C PRESSURE TRANSDUCER -
DIAGNOSIS AND TESTING.............24-22
A/C PRESSURE TRANSDUCER -
INSTALLATION.......................24-22
A/C PRESSURE TRANSDUCER -
OPERATION.........................24-21
A/C PRESSURE TRANSDUCER -
REMOVAL..........................24-22
A/C SYSTEM, CAUTION................24-66
A/C SYSTEM, SPECIFICATIONS..........24-11
A/C SYSTEM, WARNING...............24-65
ACCELERATOR PEDAL - INSTALLATION . . . 14-24
ACCELERATOR PEDAL - REMOVAL
.......14-24
ACCESSORY DRIVE BELT - DIAGNOSIS
AND TESTING
.........................7-7
ACCESSORY DRIVE BELT TENSION,
SPECIFICATIONS
.......................7-5
ACCUMULATOR - DESCRIPTION
.......21-188,
21s-206,21s-94
ACCUMULATOR - OPERATION
....21-189,21s-94A/C-HEATER CONTROL - DESCRIPTION . . . 24-34
A/C-HEATER CONTROL - INSTALLATION . . . 24-35
A/C-HEATER CONTROL - OPERATION.....24-34
A/C-HEATER CONTROL - REMOVAL......24-34
A/C-HEATER CONTROL CALIBRATION -
STANDARD PROCEDURE...............24-20
ACTUATOR - DESCRIPTION, BLEND
DOOR........................24-23,24-35
ACTUATOR - DESCRIPTION, ENGAGE.....8N-10
ACTUATOR - DESCRIPTION, LATCH......8N-14
ACTUATOR - DESCRIPTION, MODE
DOOR.............................24-30
ACTUATOR - DESCRIPTION,
RECIRCULATION DOOR................24-32
ACTUATOR - INSTALLATION, BLEND
DOOR........................24-23,24-36
ACTUATOR - INSTALLATION, ENGAGE....8N-11
ACTUATOR - INSTALLATION, INSIDE
HANDLE............................23-27
ACTUATOR - INSTALLATION, LATCH.....8N-14
ACTUATOR - INSTALLATION, MODE
DOOR.............................24-31
ACTUATOR - INSTALLATION,
RECIRCULATION DOOR................24-33
ACTUATOR - OPERATION, BLEND DOOR . . 24-23,
24-35
ACTUATOR - OPERATION, ENGAGE......8N-11
ACTUATOR - OPERATION, LATCH........8N-14
ACTUATOR - OPERATION, MODE DOOR . . . 24-30
ACTUATOR - OPERATION,
RECIRCULATION DOOR................24-32
ACTUATOR - REAR - DESCRIPTION,
MODE DOOR........................24-39
ACTUATOR - REAR - INSTALLATION,
MODE DOOR........................24-40
ACTUATOR - REAR - OPERATION, MODE
DOOR.............................24-40
ACTUATOR - REAR - REMOVAL, MODE
DOOR.............................24-40
ACTUATOR - REMOVAL, BLEND DOOR . . . 24-23,
24-36
ACTUATOR - REMOVAL, ENGAGE........8N-11
ACTUATOR - REMOVAL, INSIDE HANDLE . . 23-27
ACTUATOR - REMOVAL, LATCH.........8N-14
ACTUATOR - REMOVAL, MODE DOOR....24-30
ACTUATOR - REMOVAL, RECIRCULATION
DOOR.............................24-33
ADAPTER - INSTALLATION, FRONT DISC
BRAKE CALIPER.................5-31,5s-30
ADAPTER - INSTALLATION, OIL FILTER . . . 9-139
ADAPTER - REMOVAL, FRONT DISC
BRAKE CALIPER.................5-31,5s-30
ADAPTER - REMOVAL, OIL FILTER.......9-139
ADAPTIVE MEMORIES, OPERATION -
FUEL CORRECTION OR................14-20
ADDING ADDITIONAL COOLANT -
STANDARD PROCEDURE.................7-5
ADDITIONAL COOLANT - STANDARD
PROCEDURE, ADDING...................7-5
ADHESIVE ATTACHED - INSTALLATION,
EXTERIOR NAME PLATES..............23-51
ADHESIVE ATTACHED - REMOVAL,
EXTERIOR NAME PLATES..............23-51
ADHESIVE LOCATIONS -
SPECIFICATIONS, STRUCTURAL
........23-156
ADJUSTABLE - INSTALLATION, PEDALS
. . . 5s-40
ADJUSTABLE - REMOVAL, PEDALS
.......5s-38
ADJUSTABLE PEDALS SWITCH -
INSTALLATION
.......................5s-10
ADJUSTABLE PEDALS SWITCH -
REMOVAL
..........................5s-10
ADJUSTER-BORC-PILLAR -
INSTALLATION, SEAT BELT HEIGHT
......8O-13
ADJUSTER-BORC-PILLAR -
REMOVAL, SEAT BELT HEIGHT
..........8O-13
ADJUSTER - DIAGNOSIS AND TESTING,
DRUM BRAKE AUTOMATIC
.........5-13,5s-13
ADJUSTER - INSTALLATION, FRONT
SEAT TRACK MANUAL
................23-95
ADJUSTER - INSTALLATION, FRONT
SEAT TRACK POWER
.................23-95
ADJUSTER - REMOVAL, FRONT SEAT
TRACK MANUAL
.....................23-95
ADJUSTER - REMOVAL, FRONT SEAT
TRACK POWER
......................23-95
ADJUSTER KNOB - INSTALLATION, SEAT
BELT HEIGHT
.......................8O-14ADJUSTER KNOB - REMOVAL, SEAT
BELT HEIGHT.......................8O-14
ADJUSTER NOISE DIAGNOSIS -
DIAGNOSIS AND TESTING, HYDRAULIC
LASH...............................9-34
ADJUSTER TENSION RELEASE -
STANDARD PROCEDURE, PARKING
BRAKE AUTOMATIC...............5-58,5s-61
ADJUSTER TENSION RESET -
STANDARD PROCEDURE, PARKING
BRAKE AUTOMATIC...............5-59,5s-61
ADJUSTERS - INSTALLATION,
HYDRAULIC LASH.....................9-34
ADJUSTERS - REMOVAL, HYDRAULIC
LASH...............................9-34
AERATION - DIAGNOSIS AND TESTING,
COOLING SYSTEM.....................7-3
AFTER AN AIRBAG DEPLOYMENT -
STANDARD PROCEDURE, SERVICE.......8O-3
AIR CLEANER ELEMENT - INSTALLATION . . 9-24,
9-98
AIR CLEANER ELEMENT - REMOVAL . . 9-24,9-98
AIR CLEANER HOUSING - INSTALLATION . . 9-24,
9-99
AIR CLEANER HOUSING - REMOVAL . . 9-24,9-99
AIR CONDITIONER - DESCRIPTION,
HEATER .............................24-1
AIR CONDITIONER - OPERATION,
HEATER .............................24-4
AIR CONTROL MOTOR - DESCRIPTION,
IDLE...............................14-28
AIR CONTROL MOTOR - INSTALLATION,
IDLE...............................14-29
AIR CONTROL MOTOR - OPERATION,
IDLE...............................14-28
AIR CONTROL MOTOR - REMOVAL, IDLE . . 14-29
AIR EXHAUSTER - DESCRIPTION, REAR
QUARTER PANEL/FENDER..............23-57
AIR EXHAUSTER - INSTALLATION, REAR
QUARTER PANEL/FENDER..............23-58
AIR EXHAUSTER - REMOVAL, REAR
QUARTER PANEL/FENDER..............23-57
AIR FILTER - DESCRIPTION............24-43
AIR FILTER - INSTALLATION............24-44
AIR FILTER - REMOVAL...............24-43
AIR GAP, SPECIFICATIONS - WHEEL
SPEED SENSOR.......................5-79
AIR INTAKE PIPE - INSTALLATION......24-114
AIR INTAKE PIPE - REMOVAL..........24-113
AIR OUTLETS - DESCRIPTION.....24-44,24-56
AIR OUTLETS - INSTALLATION..........24-56
AIR OUTLETS - REMOVAL.............24-56
AIR PRESSURE TESTS - DIAGNOSIS
AND TESTING, CLUTCH.........21-122,21s-30
AIR TEMPERATURE SENSOR -
DESCRIPTION, INLET.................14-30
AIRBAG - DESCRIPTION, DRIVER........8O-6
AIRBAG - DESCRIPTION, PASSENGER.....8O-8
AIRBAG - DESCRIPTION, SEAT..........8O-11
AIRBAG - INSTALLATION, DRIVER........8O-7
AIRBAG - INSTALLATION, PASSENGER . . . 8O-10
AIRBAG - OPERATION, DRIVER..........8O-6
AIRBAG - OPERATION, PASSENGER.......8O-9
AIRBAG - OPERATION, SEAT...........8O-11
AIRBAG - REMOVAL, DRIVER
............8O-6
AIRBAG - REMOVAL, PASSENGER
........8O-9
AIRBAG DEPLOYMENT - STANDARD
PROCEDURE, SERVICE AFTER AN
........8O-3
AIRBAG SYSTEM - DIAGNOSIS AND
TESTING
............................8O-2
AIRBAG TRIM COVER - INSTALLATION,
DRIVER
.............................8O-7
AIRBAG TRIM COVER - REMOVAL,
DRIVER
.............................8O-7
AIRBAGS - STANDARD PROCEDURE,
HANDLING
..........................8O-3
AJAR SWITCH - EXPORT -
INSTALLATION, HOOD
.................8Q-3
AJAR SWITCH - EXPORT - REMOVAL,
HOOD
..............................8Q-3
ALIGNMENT - DESCRIPTION, WHEEL
......2-47
ALIGNMENT - EXPORT - STANDARD
PROCEDURE, FRONT FOG LAMP UNIT
.....8L-9
ALIGNMENT - EXPORT - STANDARD
PROCEDURE, HEADLAMP UNIT
.........8L-14
ALIGNMENT - STANDARD PROCEDURE,
FRONT FOG LAMP UNIT
................8L-9
RSINDEX1
Description Group-Page Description Group-Page Description Group-Page

BLEEDING - STANDARD PROCEDURE,
BASE BRAKE......................5-7,5s-7
BLEEDING - STANDARD PROCEDURE,
MASTER CYLINDER...............5-35,5s-34
BLEND DOOR ACTUATOR -
DESCRIPTION..................24-23,24-35
BLEND DOOR ACTUATOR -
INSTALLATION..................24-23,24-36
BLEND DOOR ACTUATOR - OPERATION . . 24-23,
24-35
BLEND DOOR ACTUATOR - REMOVAL....24-23,
24-36
BLOCK - CLEANING, ENGINE.......9-112,9-36
BLOCK - DESCRIPTION, BLOWER
MOTOR RESISTOR...................24-26
BLOCK - DESCRIPTION, ENGINE.....9-112,9-35
BLOCK - DESCRIPTION, NON-ABS
JUNCTION......................5-33,5s-32
BLOCK - DIAGNOSIS AND TESTING,
BLOWER MOTOR RESISTOR............24-26
BLOCK - DIAGNOSIS AND TESTING,
REAR BLOWER MOTOR RESISTOR......24-38
BLOCK - INSPECTION, ENGINE......9-112,9-36
BLOCK - INSTALLATION, BLOWER
MOTOR RESISTOR...................24-27
BLOCK - INSTALLATION, NON-ABS
JUNCTION......................5-33,5s-32
BLOCK - OPERATION, BLOWER MOTOR
RESISTOR..........................24-26
BLOCK - OPERATION, NON-ABS
JUNCTION......................5-33,5s-32
BLOCK - REMOVAL, BLOWER MOTOR
RESISTOR...........................24-26
BLOCK - REMOVAL, NON-ABS JUNCTION . . 5-33,
5s-32
BLOCK HEATER - DESCRIPTION, ENGINE . . . 7-20
BLOCK HEATER - INSTALLATION,
ENGINE.............................7-20
BLOCK HEATER - OPERATION, ENGINE....7-20
BLOCK HEATER - REMOVAL, ENGINE......7-20
BLOCK HEATER TESTING - DIAGNOSIS
AND TESTING, ENGINE.................7-20
BLOCKER LATCH - INSTALLATION, FUEL
FILL DOOR.........................23-53
BLOCKER LATCH - REMOVAL, FUEL FILL
DOOR.............................23-53
BLOCKER LATCH STRIKER -
INSTALLATION, FUEL FILL DOOR........23-53
BLOCKER LATCH STRIKER - REMOVAL,
FUEL FILL DOOR.....................23-53
BLOCKER LOCKOUT LINK -
INSTALLATION, FUEL FILL DOOR........23-54
BLOCKER LOCKOUT LINK - REMOVAL,
FUEL FILL DOOR.....................23-53
BLOWER MOTOR - DESCRIPTION . . 24-46,24-57
BLOWER MOTOR - DESCRIPTION,
POWER MODULE....................24-31
BLOWER MOTOR - DESCRIPTION,
POWER MODULE - REAR..............24-41
BLOWER MOTOR - DIAGNOSIS AND
TESTING...........................24-47
BLOWER MOTOR - DIAGNOSIS AND
TESTING, REAR......................24-58
BLOWER MOTOR - INSTALLATION . . 24-49,24-58
BLOWER MOTOR - INSTALLATION,
POWER MODULE....................24-32
BLOWER MOTOR - INSTALLATION,
POWER MODULE - REAR..............24-42
BLOWER MOTOR - OPERATION....24-46,24-57
BLOWER MOTOR - OPERATION, POWER
MODULE...........................24-31
BLOWER MOTOR - OPERATION, POWER
MODULE - REAR.....................24-41
BLOWER MOTOR - REMOVAL......24-47,24-58
BLOWER MOTOR - REMOVAL, POWER
MODULE...........................24-31
BLOWER MOTOR - REMOVAL, POWER
MODULE - REAR.....................24-41
BLOWER MOTOR RELAY - DESCRIPTION
. 24-24,
24-37
BLOWER MOTOR RELAY -
INSTALLATION
..................24-25,24-38
BLOWER MOTOR RELAY - OPERATION
. . . 24-24,
24-37
BLOWER MOTOR RELAY - REMOVAL
....24-25,
24-38
BLOWER MOTOR RESISTOR -
DESCRIPTION
.......................24-38BLOWER MOTOR RESISTOR -
INSTALLATION.......................24-39
BLOWER MOTOR RESISTOR -
OPERATION.........................24-38
BLOWER MOTOR RESISTOR - REMOVAL . . 24-39
BLOWER MOTOR RESISTOR BLOCK -
DESCRIPTION.......................24-26
BLOWER MOTOR RESISTOR BLOCK -
DIAGNOSIS AND TESTING.............24-26
BLOWER MOTOR RESISTOR BLOCK -
DIAGNOSIS AND TESTING, REAR........24-38
BLOWER MOTOR RESISTOR BLOCK -
INSTALLATION.......................24-27
BLOWER MOTOR RESISTOR BLOCK -
OPERATION.........................24-26
BLOWER MOTOR RESISTOR BLOCK -
REMOVAL..........................24-26
BODY - ASSEMBLY, VALVE.....21-257,21s-159,
21s-212
BODY - DESCRIPTION, THROTTLE.......14-35
BODY - DESCRIPTION, VALVE . . . 21-250,21s-152
BODY - DISASSEMBLY, VALVE . . 21-252,21s-155,
21s-208
BODY - INSTALLATION, THROTTLE.......14-35
BODY - INSTALLATION, VALVE . . 21-262,21s-164,
21s-217
BODY - OPERATION, THROTTLE.........14-35
BODY - OPERATION, VALVE....21-250,21s-152
BODY - REMOVAL, THROTTLE..........14-35
BODY - REMOVAL, VALVE.....21-251,21s-153,
21s-206
BODY AND CABLE - DESCRIPTION,
ANTENNA...........................8A-4
BODY AND CABLE - DIAGNOSIS AND
TESTING, ANTENNA...................8A-4
BODY AND CABLE - INSTALLATION,
ANTENNA...........................8A-6
BODY AND CABLE - OPERATION,
ANTENNA...........................8A-4
BODY AND CABLE - REMOVAL,
ANTENNA...........................8A-5
BODY CODE PLATE - DESCRIPTION.....Intro.-1
BODY CONTROL MODULE -
DESCRIPTION........................8s-1
BODY CONTROL MODULE -
DESCRIPTION........................8E-3
BODY CONTROL MODULE -
INSTALLATION........................8s-3
BODY CONTROL MODULE -
INSTALLATION........................8E-5
BODY CONTROL MODULE - OPERATION . . . 8s-1
BODY CONTROL MODULE - OPERATION . . . 8E-3
BODY CONTROL MODULE - REMOVAL.....8s-3
BODY CONTROL MODULE - REMOVAL.....8E-4
BODY LUBRICATION, SPECIFICATIONS....23-12
BODY OPENING DIMENSIONS -
SPECIFICATIONS....................23-127
BODY PANEL REPAIR - STANDARD
PROCEDURE, PLASTIC.................23-3
BODY SEALING LOCATIONS -
SPECIFICATIONS....................23-130
BODY SIDE MOLDINGS - INSTALLATION . . 23-46
BODY SIDE MOLDINGS - REMOVAL......23-45
BODY, SPECIAL TOOLS................23-13
BOLSTER - INSTALLATION, QUARTER
TRIM..............................23-79
BOLSTER - REMOVAL, QUARTER TRIM . . . 23-79
BOOSTER - DESCRIPTION, POWER
BRAKE.........................5-40,5s-43
BOOSTER - DIAGNOSIS AND TESTING,
POWER BRAKE..................5-41,5s-44
BOOSTER - OPERATION, POWER BRAKE . . 5-41,
5s-44
BOOT - INNER - INSTALLATION, CV........3-6
BOOT - INNER - REMOVAL, CV...........3-6
BOOT - INNER/OUTER - INSTALLATION,
CV .................................3-17
BOOT - INNER/OUTER - REMOVAL, CV....3-15
BOOT - INSTALLATION, GEARSHIFT......21-73
BOOT - OUTER - INSTALLATION, CV......3-10
BOOT - OUTER - REMOVAL, CV..........3-10
BOOT - REMOVAL, GEARSHIFT
..........21-72
BORE FITTING - STANDARD
PROCEDURE, PISTON TO CYLINDER
......9-42
BORE HONING - STANDARD
PROCEDURE, CYLINDER
...........9-112,9-35
BOX - INSTALLATION, GLOVE
...........23-64
BOX - REMOVAL, GLOVE
..............23-64BOX LAMP SWITCH - INSTALLATION,
GLOVE.............................8L-22
BOX LAMP SWITCH - REMOVAL, GLOVE . . 8L-22
BOX LATCH - INSTALLATION, GLOVE.....23-64
BOX LATCH - REMOVAL, GLOVE.........23-64
BOX LATCH STRIKER - INSTALLATION,
GLOVE.............................23-64
BOX LATCH STRIKER - REMOVAL,
GLOVE.............................23-64
B-PILLAR - INSTALLATION, A-PILLAR-
HEADER, OR........................23-17
B-PILLAR - REMOVAL, A-PILLAR-
HEADER, OR........................23-17
B-PILLAR LOWER TRIM - INSTALLATION . . 23-75
B-PILLAR LOWER TRIM - REMOVAL.....23-74
B-PILLAR SWITCH - DESCRIPTION, LEFT . 8N-32
B-PILLAR SWITCH - DESCRIPTION,
RIGHT.............................8N-32
B-PILLAR SWITCH - INSTALLATION,
LEFT..............................8N-32
B-PILLAR SWITCH - INSTALLATION,
RIGHT.............................8N-32
B-PILLAR SWITCH - OPERATION, LEFT . . . 8N-32
B-PILLAR SWITCH - OPERATION, RIGHT . . 8N-32
B-PILLAR SWITCH - REMOVAL, LEFT....8N-32
B-PILLAR SWITCH - REMOVAL, RIGHT . . . 8N-32
B-PILLAR UPPER TRIM - INSTALLATION . . 23-75
B-PILLAR UPPER TRIM - REMOVAL......23-75
BRACKET - 2.4L ENGINE -
INSTALLATION, A/C COMPRESSOR
MOUNTING.........................24-76
BRACKET - 2.4L ENGINE - REMOVAL,
A/C COMPRESSOR MOUNTING..........24-75
BRACKET - DESCRIPTION, TRANSVERSE . . 8N-18
BRACKET - INSTALLATION, TRANSVERSE . 8N-18
BRACKET - OPERATION, TRANSVERSE . . . 8N-18
BRACKET - REMOVAL, TRANSVERSE.....8N-18
BRACKET ASSEMBLY - INSTALLATION,
FLOOR CONSOLE TRAY................23-83
BRACKET ASSEMBLY - REMOVAL,
FLOOR CONSOLE TRAY................23-83
BRAKE - DESCRIPTION, CONTROLLER
ANTILOCK...........................8E-5
BRAKE - INSTALLATION, CONTROLLER
ANTILOCK...........................8E-6
BRAKE - INSTALLATION, LEVER -
PARKING.......................5-65,5s-67
BRAKE - INSTALLATION, SHOES -
PARKING.......................5-72,5s-75
BRAKE - INSTALLATION, SUPPORT
PLATE - DRUM..................5-56,5s-58
BRAKE - OPERATION, CONTROLLER
ANTILOCK...........................8E-5
BRAKE - REMOVAL, CONTROLLER
ANTILOCK...........................8E-6
BRAKE - REMOVAL, LEVER - PARKING....5-64,
5s-67
BRAKE - REMOVAL, SHOES - PARKING . . . 5-67,
5s-69
BRAKE - REMOVAL, SUPPORT PLATE -
DRUM
.........................5-56,5s-58
BRAKE AUTOMATIC ADJUSTER -
DIAGNOSIS AND TESTING, DRUM
. . . 5-13,5s-13
BRAKE AUTOMATIC ADJUSTER TENSION
RELEASE - STANDARD PROCEDURE,
PARKING
.......................5-58,5s-61
BRAKE AUTOMATIC ADJUSTER TENSION
RESET - STANDARD PROCEDURE,
PARKING
.......................5-59,5s-61
BRAKE BLEEDING - STANDARD
PROCEDURE, BASE
.................5-7,5s-7
BRAKE BOOSTER - DESCRIPTION,
POWER
........................5-40,5s-43
BRAKE BOOSTER - DIAGNOSIS AND
TESTING, POWER
................5-41,5s-44
BRAKE BOOSTER - OPERATION, POWER
. . 5-41,
5s-44
BRAKE CABLE (FRONT) - INSTALLATION,
PARKING
.......................5-63,5s-65
BRAKE CABLE (FRONT) - REMOVAL,
PARKING
.......................5-59,5s-62
BRAKE CABLE (INTERMEDIATE) -
INSTALLATION, PARKING
..........5-63,5s-66
BRAKE CABLE (INTERMEDIATE) -
REMOVAL, PARKING
..............5-60,5s-62
BRAKE CABLE (LEFT REAR) -
INSTALLATION, PARKING
..........5-64,5s-66
4 INDEXRS
Description Group-Page Description Group-Page Description Group-Page