CD changer CHRYSLER CARAVAN 2003 Owner's Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2003, Model line: CARAVAN, Model: CHRYSLER CARAVAN 2003Pages: 2177, PDF Size: 59.81 MB
Page 1628 of 2177
SPECIFICATIONS - 41TE TRANSAXLE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Transaxle TypeFully adaptive, electronically controlled, four speed
automatic with torque converter and integral differential
Cooling Method Air-to-oil heat exchanger
Lubrication Pump (internal-external gear-type
GEAR RATIOS
DESCRIPTION SPECIFICATION
First Gear 2.84
Second Gear 1.57
Direct Gear 1.00
Overdrive Gear 0.69
Reverse Gear 2.21
BEARING SETTINGS (END PLAY & TURNING TORQUE)
DESCRIPTION METRIC STANDARD
Differential Assembly 0.6-2 N´m 5-18 in. lbs.
Output Hub 0.3-2 N´m 3-8 in. lbs.
Transfer Shaft (End Play) 0.051-0.102 mm 0.002-0.004 in.
Overall Drag At Output Hub 0.3-1.9 N´m 3-16 in. lbs.
CLUTCH CLEARANCES
DESCRIPTION METRIC STANDARD
Low/Rev Clutch (Select Reaction
Plate)0.89-1.47 mm 0.035-0.058 in.
Two/Four Clutch (No Selection) 0.76-2.64 mm 0.030-0.104 in.
Reverse Clutch (Select Snap Ring) 0.89-1.37 mm 0.035-0.054 in.
Overdrive Clutch (No Selection) 1.07-3.25 mm 0.042-0.128 in.
Underdrive Clutch (Select Pressure
Plate)0.94-1.50 mm 0.037-0.059 in.
OIL PUMP CLEARANCES
DESCRIPTION METRIC STANDARD
Outer Gear-to-Crescent 0.060-0.298 mm 0.0023-0.0117 in.
Inner Gear-to-Crescent 0.093-0.385 mm 0.0036-0.0151 in.
Outer Gear-to-Pocket 0.089-0.202 mm 0.0035-0.0079 in.
Outer Gear Side Clearance 0.020-0.046 mm 0.0008-0.0018 in.
Inner Gear Side Clearance 0.020-0.046 mm 0.0008-0.0018 in.
RS41TE AUTOMATIC TRANSAXLE21 - 181
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com
Page 1722 of 2177
CAUTION: Never attempt to train more than one
vehicle at a time. System is capable of reading tire
pressure sensor transmissions from other near-by
vehicles.
Each time a wheel rotation or tire pressure sensor
replacement occurs the tire pressure sensors must be
retrained. This is necessary to inform the Electronic
Vehicle Information Center (EVIC) that a sensor
change was made and where. Retraining is accom-
plished through the EVIC used in conjunction with a
Re-learn Magnet, Special Tool 8821.
NOTE: Use the following procedure to retrain all
four (4) road wheel tire pressure sensors. No
attempt should be made to retrain individual sen-
sors.
(1) Retrieve Re-learn Magnet, Special Tool 8821.
(2) Press MENU Button on EVIC until9RETRAIN
TIRE SENSORS - NO9is displayed.
(3) Press STEP button to select9YES9.
NOTE: There is a 60 second timer for training the
first sensor and a 60 second timer between training
the remaining sensors. If any of these timers expire,
the EVIC will abort the training procedure.
NOTE: If at any time the EVIC display reads(TRAIN-
ING ABORTED(, move the vehicle ahead at least
one foot and repeat the entire retraining procedure.
(4) Press MENU button to start retraining. Dis-
play will read9TRAIN LEFT FRONT TIRE9
NOTE: The order for retraining all four sensors is:
²Left Front
²Right Front
²Right Rear
²Left Rear
(5) Starting at left front tire, place Re-learn Mag-
net over valve stem (Fig. 17). Within approximately 5
seconds, vehicle horn will chirp indicating training
complete at that particular sensor. Remove the mag-
net.
(6) Repeat step (5) on remaining sensors as indi-
cated by EVIC until all four TPM sensors positions
are trained.
(7) Once EVIC displays9TRAINING COMPLETE9,
pressing either STEP, C/T, RESET or MENU button
will exit training routine.
REMOVAL
(1) Remove tire and wheel assembly from vehicle.
(Refer to 22 - TIRES/WHEELS - REMOVAL)
CAUTION: The cap used on this valve stem con-
tains an O-ring seal to prevent contamination and
moisture from entering the valve stem. Retain this
valve stem cap for reuse. Do not substitute a regu-
lar valve stem cap in its place.
CAUTION: The valve stem used on this vehicle is
made of aluminum and the core is nickel plated
brass. The original valve stem core must be rein-
stalled and not substituted with a valve stem core
made of a different material. This is required to pre-
vent corrosion in the valve stem caused by the dif-
ferent metals.
(2) Dismount tire from wheel following tire
changer manufacturers instructions while paying
special attention to the following to avoid damaging
the pressure sensor:
(a) When breaking the tire bead loose from the
wheel rim, avoid using the Bead Breaker in the
area of the sensor. That includes both front and
rear beads of the tire.
(b) When preparing to dismount the tire from
the wheel, carefully insert the mounting/dimount-
ing tool at the valve stem 10É (Fig. 18), then pro-
ceed to dismount the tire from the wheel. Use this
process on both the upper and lower tire beads.
(3) Using a thin wall socket, remove special nut
retaining sensor to wheel (Fig. 19).
(4) Remove sensor from wheel (Fig. 19).
Fig. 17 Magnet Placement Over Valve Stem
1 - RE-LEARN MAGNET
2 - VALVE STEM
RSTIRES/WHEELS22-11
SENSOR - TPM (Continued)
ProCarManuals.com
Page 1723 of 2177
INSTALLATION
NOTE: Before reinstalling a tire pressure sensor,
replace sealing grommet at base of valve stem.
(1) Wipe area clean where sensor sealing grommet
contacts wheel. Make sure surface of wheel is not
damaged.
(2) Install sensor in wheel as shown (Fig. 19). Do
not attempt to mount sensor otherwise, damage may
occur.
(3) Using a thin wall socket, install special sensor
nut (Fig. 19). Tighten nut to 4 N´m (35 in. lbs.)
torque.
CAUTION: Over-torquing the sensor nut by as little
as 12 N´m (106 in. lbs.) may result in sensor sepa-
ration from the valve stem. Under this condition,
the sensor may still function, however, the condi-
tion should be corrected immediately.
(4) Mount tire on wheel following tire changer
manufacturers instructions, paying special attention
to the following to avoid damaging tire pressure sen-
sor:
(a) Rotating Wheel Tire Changers - Once the
wheel is mounted to the changer, position the sen-
sor valve stem approximately 210É from the head
of the changer in a clockwise direction before rotat-
ing the wheel (also in a clockwise direction) to
mount the tire (Fig. 20). Use this procedure on
both the upper and lower tire beads.
(b) Rotating Tool Tire Changers - Position the
wheel on the changer so that the sensor valve stem
is approximately 210É from the head of the changer
in a clockwise direction from the mounting end of
the tool (Fig. 21) Make sure the sensor is clear of
the lower bead breaker area to avoid damaging the
sensor when the breaker rises (Fig. 21). Rotate the
tool in a counterclockwise direction to mount the
tire. Use this procedure on both the upper and
lower tire beads.
(5) Install wheel and tire assembly on vehicle.
(Refer to 22 - TIRES/WHEELS - INSTALLATION)
(6) Retrain tire pressure sensors. (Refer to 22 -
TIRES/WHEELS/TIRE PRESSURE MONITORING/
SENSOR - STANDARD PROCEDURE)
Fig. 18 Start Mount/Dismount Tool Within 10
Degrees Of Valve Stem
Fig. 19 Sensor Mounting To Wheel
1 - TIRE PRESSURE SENSOR
2 - WHEEL
3 - NUT
22 - 12 TIRES/WHEELSRS
SENSOR - TPM (Continued)
ProCarManuals.com
Page 1724 of 2177
TIRES
DESCRIPTION
DESCRIPTION - TIRE
Tires are designed and engineered for each specific
vehicle. They provide the best overall performance
for normal operation. The ride and handling charac-
teristics match the vehicle's requirements. With
proper care they will give excellent reliability, trac-
tion, skid resistance, and tread life.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain, in most
cases, much greater mileage than severe use or care-
less drivers. A few of the driving habits which will
shorten the life of any tire are:
²Rapid acceleration
²Severe application of brakes
²High-speed driving
²Taking turns at excessive speeds
²Striking curbs and other obstacles
²Operating vehicle with over or under inflated
tire pressures
Radial ply tires are more prone to irregular tread
wear. It is important to follow the tire rotation inter-
val shown in the section on Tire Rotation. This will
help to achieve a greater tread-life potential.
TIRE IDENTIFICATION
Tire type, size, load index and speed rating are
encoded in the letters and numbers imprinted on the
side wall of the tire. Refer to the Tire Identification
chart to decipher the code. For example purposes, the
tire size P225/60 R 16 97 T is used in the chart. An
All Season type tire will also have eitherM+S,M&
SorM-S(indicating mud and snow traction)
imprinted on the side wall. An Extra or Light Load
marking ªXLº or ªLLº may also be listed on the side-
wall. The absence of an ªXLº or ªLLº marking infers
a standard load tire.
TIRE IDENTIFICATION
PTIRE TYPE (Not
present on all tires)P - Passenger
T - Temporary
C - Commercial
LT - Light Truck
225SECTIONAL WIDTHSHOWN IN
MILLIMETERS
60ASPECT RATIOSECTIONAL HEIGHT
÷ SECTIONAL WIDTH
(Refer to Aspect Ratio
Figure 22 )
Fig. 20 Mounting Tire Using Rotating Wheel
Machine
1 - HEAD OF CHANGER LOCATED HERE
2 - VALVE STEM
Fig. 21 Mounting Tire Using Rotating Tool Machine
1 - VALVE STEM
2 - MOUNTING END OF TOOL
3 - BEAD BREAKER (KEEP CLEAR OF SENSOR)
RSTIRES/WHEELS22-13
SENSOR - TPM (Continued)
ProCarManuals.com
Page 2063 of 2177
(16) Reconnect the battery negative cable.
(17) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(18) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
INSTALLATION - COMPRESSOR MOUNTING
BRACKET - 2.4L ENGINE
(1) Position the compressor mounting bracket onto
the engine.
(2) Install and tighten the four screws that secure
the compressor mounting bracket to the engine.
Tighten the screws to 54 N´m (40 ft. lbs.).
(3) Reinstall the compressor onto the mounting
bracket. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/COMPRESSOR - INSTALLA-
TION).
CONDENSER
DESCRIPTION
The condenser is integral to a cooling module
which includes the radiator, the electric cooling fan,
the fan shroud, air seals and an automatic transmis-
sion oil cooler. The cooling module is located in the
air flow in the front of the engine compartment
behind the radiator grille. The condenser cannot be
repaired or adjusted and, if faulty or damaged, it
must be replaced. The condenser may be removed
from the cooling module for service without removing
the cooling module from the vehicle.
OPERATION
The condenser is a heat exchanger that allows the
high-pressure refrigerant gas being discharged by the
compressor to give up its heat to the air passing over
the condenser fins. When the refrigerant gas gives up
its heat, it condenses. When the refrigerant leaves
the condenser, it has become a high-pressure liquid
refrigerant. The volume of air flowing over the con-
denser fins is critical to the proper cooling perfor-
mance of the air conditioning system. Therefore, it is
important that there are no objects placed in front of
the radiator grille openings in the front of the vehicle
or foreign material on the condenser fins that might
obstruct air flow. Also, any factory-installed air seals
or shrouds must be properly reinstalled following
radiator or condenser service.
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
NOTE: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These air seals are used to direct air through
the condenser and radiator. The air seals must be
reinstalled in their proper locations in order for the
air conditioning and engine cooling systems to per-
form as designed.
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Remove the two large screws that secure the
front fascia and the outboard ends of the radiator
sight shield to the radiator closure panel crossmem-
ber (Fig. 4).
(3) Remove the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
(4) Remove the radiator sight shield from the radi-
ator closure panel crossmember.
(5) Remove the two screws that secure the hood
latch unit to the front of the radiator closure panel
Fig. 4 Radiator Sight Shield
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
24 - 66 PLUMBING - FRONTRS
A/C COMPRESSOR (Continued)
ProCarManuals.com
Page 2071 of 2177
(9) Install plugs in, or tape over the opened liquid
line fitting and the filter-drier outlet port.
(10) Remove the nut that secures the suction line
and liquid line fittings to the stud on the expansion
valve.
(11) Disconnect the suction line and liquid line fit-
tings from the expansion valve and move the lines
out of the way.
(12) Remove the seals from the suction line and
liquid line fittings and discard.
(13) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(14) Remove the two screws that secure the expan-
sion valve to the evaporator tube tapping plate.
(15) Disconnect the HVAC wire harness connector
for the evaporator temperature sensor from the sen-
sor on the top of the expansion valve.
(16) Remove the expansion valve from the evapo-
rator inlet and outlet tube fittings.
(17) Remove the seals from the evaporator inlet
and outlet tube fittings and discard.
(18) Install plugs in, or tape over the opened evap-
orator inlet and outlet tube fittings and both expan-
sion valve ports.
INSTALLATION
(1) Remove the tape or plugs from the evaporator
inlet and outlet tube fittings and both ports on the
back of the expansion valve.
(2) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the evaporator
inlet and outlet tube fittings.
(3) Position the expansion valve onto the evapora-
tor inlet and outlet tube fittings.
(4) Install and tighten the two screws that secure
the expansion valve to the evaporator tube tapping
plate plate. Tighten the screws to 11 N´m (97 in.
lbs.).
(5) Reconnect the HVAC wire harness connector
for the evaporator temperature sensor to the sensor
connector receptacle on the top of the expansion
valve.
(6) Remove the tape or plugs from the front liquid
line rear section and suction line fittings for the
expansion valve and both ports on the front of the
expansion valve.
(7) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the front liquid
line rear section and suction line fittings for the
expansion valve.
(8) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(9) Install and tighten the nut that secures the
suction line and liquid line fittings to the stud on theexpansion valve. Tighten the nut to 23 N´m (17 ft.
lbs.).
(10) Remove the tape or plugs from the liquid line
rear section fitting for the filter-drier and the filter-
drier outlet port.
(11) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(12) Reconnect the liquid line fitting to the filter-
drier outlet port on the top of the filter-drier.
(13) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 11 N´m (100 in. lbs.).
(14) Reconnect the headlamp and dash wire har-
ness connector for the A/C pressure transducer to the
transducer on the front liquid line rear section.
(15) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(16) Reinstall the air cleaner housing into the
right side of the engine compartment.
(17) Reconnect the battery negative cable.
(18) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(19) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
HEATER CORE
DESCRIPTION
The heater core is located in the distribution hous-
ing of the heater-A/C unit, under the instrument
panel. It is a heat exchanger made of rows of tubes
and fins. One end of the core is fitted with a molded
plastic tank that includes integral heater core inlet
and outlet ports. The removable heater core tubes
are held in place these ports by a sealing plate
secured with a screw to the heater core tank. This
removable heater core tube arrangement allows the
heater core to be serviced without removing the heat-
er-A/C unit housing from the vehicle. The heater core
cannot be repaired and, if faulty or damaged, it must
be replaced.
OPERATION
Engine coolant is circulated through heater hoses
to the heater core at all times. As the coolant flows
through the heater core, heat removed from the
engine is transferred to the heater core fins and
tubes. Air directed through the heater core picks up
the heat from the heater core fins. The blend air door
allows control of the heater output air temperature
by controlling how much of the air flowing through
24 - 74 PLUMBING - FRONTRS
EXPANSION VALVE (Continued)
ProCarManuals.com
Page 2095 of 2177
INSTALLATION
(1) Remove the tape or plugs from the evaporator
tube fittings and both expansion valve ports.
(2) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the evaporator
tube fittings.
(3) Position the expansion valve onto the evapora-
tor tubes.
(4) Install and tighten the two screws that secure
the expansion valve to the evaporator tube sealing
plate. Tighten the screws to 11 N´m (97 in. lbs.).
(5) Reinstall the rear evaporator line extension
onto the expansion valve. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - REAR/EVAPO-
RATOR - INSTALLATION - EVAPORATOR LINE
EXTENSION).
(6) Install the foam insulator wrap over the rear
expansion valve.
(7) Reinstall the rear heater-A/C unit housing into
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/REAR HEATER-
A/C HOUSING - INSTALLATION).
(8) Run the HVAC Cooldown Test to verify proper
operation.
HEATER CORE
DESCRIPTION
The rear heater core is located near the front of
the rear heater-A/C unit housing, behind the right
rear wheel house. It is a heat exchanger made of
rows of tubes and fins. One end of the core is fitted
with a molded plastic tank that includes integral
heater core inlet and outlet nipples. The heater core
can be serviced without removing the rear heater-A/C
unit housing from the vehicle. The heater core cannot
be repaired and, if faulty or damaged, it must be
replaced.
OPERATION
Engine coolant is circulated through heater hoses
to the heater core at all times. As the coolant flows
through the heater core, heat removed from the
engine is transferred to the heater core fins and
tubes. Air directed through the heater core picks up
the heat from the heater core fins. The blend air door
allows control of the heater output air temperature
by controlling how much of the air flowing through
the rear heater-A/C unit housing is directed through
the heater core.
STANDARD PROCEDURE - HEATER CORE
FILLING
In its final installed position, the rear heater core
is positioned higher than the radiator fill cap. There-fore, when the cooling system is drained and refilled,
gravity will not refill the heater core with coolant to
the proper level. This may result in two problems:1.
Insufficient coolant level in the engine cooling sys-
tem, which may result in engine overheating.2.Air
entrapped within the rear heater core, which may
result in insufficient rear heater performance. There
are two methods that may be employed to prevent
these problems:1.Pre-filling of the rear heater core.
2.Thermal cycling of the engine cooling system. Fol-
lowing are descriptions of both prevention methods,
as well as a method to verify rear heater perfor-
mance.
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
PRE-FILLING
If the rear heater core or the rear heater-A/C hous-
ing have been removed from the vehicle for service,
the rear heater core may be pre-filled with the proper
engine coolant mixture prior to reconnecting the
heater hoses to the heater core hose fittings.
(1) The heater core should be installed in the rear
heater-A/C unit housing, and the rear heater-A/C
unit housing should be installed in the vehicle.
(2) Take the proper precautions to protect the car-
peting below the rear heater core from spilled engine
coolant and have absorbent toweling readily avail-
able to mop up any spills.
(3) Insert the small end of an appropriate funnel
into the upper hose fitting of the heater core (Fig. 4).
Fig. 4 Pre-Filling Heater Core - Typical
1 - REAR HEATER CORE
24 - 98 PLUMBING - REARRS
EXPANSION VALVE (Continued)
ProCarManuals.com
Page 2144 of 2177
BUCKET SEAT BACK - QUAD BUCKET -
INSTALLATION.......................23-97
BUCKET SEAT BACK - QUAD BUCKET -
REMOVAL..........................23-97
BUCKET SEAT RISER - INSTALLATION,
QUAD..............................23-96
BUCKET SEAT RISER - REMOVAL, QUAD . . 23-96
BUCKET SEAT SIDE SHIELD - NO CUP
HOLDER - INSTALLATION, QUAD........23-96
BUCKET SEAT SIDE SHIELD - NO CUP
HOLDER - REMOVAL, QUAD............23-96
BUCKET SEAT SIDE SHIELD/CUP
HOLDER - INSTALLATION, QUAD........23-95
BUCKET SEAT SIDE SHIELD/CUP
HOLDER - REMOVAL, QUAD............23-95
BUCKLE - FIRST ROW - BENCH -
INSTALLATION, SEAT BELT.............8O-12
BUCKLE - FIRST ROW - BENCH -
REMOVAL, SEAT BELT................8O-12
BUCKLE - FIRST ROW INBOARD - QUAD
BUCKET - INSTALLATION, SEAT BELT....8O-11
BUCKLE - FIRST ROW INBOARD - QUAD
BUCKET - REMOVAL, SEAT BELT........8O-11
BUCKLE - FRONT INBOARD -
INSTALLATION, SEAT BELT.............8O-11
BUCKLE - FRONT INBOARD - REMOVAL,
SEAT BELT .........................8O-11
BUCKLE - SECOND ROW - THREE
PASSENGER BENCH - INSTALLATION,
SEAT BELT .........................8O-14
BUCKLE - SECOND ROW - THREE
PASSENGER BENCH - REMOVAL, SEAT
BELT ..............................8O-14
BUCKLE - SECOND ROW INBOARD -
50/50 BENCH - INSTALLATION, SEAT
BELT ..............................8O-12
BUCKLE - SECOND ROW INBOARD -
50/50 BENCH - REMOVAL, SEAT BELT....8O-12
BUMPER - DESCRIPTION, JOUNCE........2-35
BUMPER - INSTALLATION, STOP........23-25
BUMPER - OPERATION, JOUNCE.........2-35
BUMPER - REMOVAL, STOP............23-25
BUMPER BEZEL - INSTALLATION,
SLIDING DOOR STOP.................23-25
BUMPER BEZEL - REMOVAL, SLIDING
DOOR STOP........................23-25
BUMPER REINFORCEMENT -
INSTALLATION, FRONT.................13-2
BUMPER REINFORCEMENT -
INSTALLATION, REAR..................13-3
BUMPER REINFORCEMENT - REMOVAL,
FRONT..............................13-2
BUMPER REINFORCEMENT - REMOVAL,
REAR...............................13-3
BUS COMMUNICATION RECEIVE - PCM
INPUT - OPERATION, DATA.............8E-15
BUS, OPERATION - PROGRAMMABLE
COMMUNICATIONS INTERFACE (PCI).....14-21
BUSHING - INSTALLATION, LEAF SPRING
FRONT..............................2-29
BUSHING - REMOVAL, LEAF SPRING
FRONT..............................2-28
BUSHINGS - INSTALLATION, FRONT
CROSSMEMBER MOUNT...............13-12
BUSHINGS - REMOVAL, FRONT
CROSSMEMBER MOUNT...............13-12
BUSHINGS (DISC/DISC BRAKES) -
ASSEMBLY, CALIPER GUIDE PIN.........5-25
BUSHINGS (DISC/DISC BRAKES) -
DISASSEMBLY, CALIPER GUIDE PIN.......5-24
CABLE - CROSSOVER - INSTALLATION,
GEARSHIFT.........................21-76
CABLE - CROSSOVER - REMOVAL,
GEARSHIFT.........................21-73
CABLE - DESCRIPTION.................8P-4
CABLE - DESCRIPTION, ANTENNA BODY . . . 8A-4
CABLE - DESCRIPTION, SPARK PLUG.....8I-10
CABLE - DIAGNOSIS AND TESTING,
ANTENNA BODY......................8A-4
CABLE - DIAGNOSIS AND TESTING,
BATTERY...........................8F-16
CABLE - INSTALLATION................8P-4
CABLE - INSTALLATION, ANTENNA BODY
. . 8A-6
CABLE - INSTALLATION, FRONT
..........5-64
CABLE - INSTALLATION, GEAR SHIFT
....21-205
CABLE - INSTALLATION, HOLD OPEN
LATCH
.............................23-38
CABLE - INSTALLATION, INSIDE HANDLE
. . 23-37CABLE - INSTALLATION, INSTRUMENT
PANEL ANTENNA......................8A-9
CABLE - INSTALLATION, LATCH RELEASE . 23-61
CABLE - INSTALLATION, OUTSIDE
HANDLE............................23-36
CABLE - INSTALLATION, PARKING
BRAKE LEVER AND FRONT..............5-66
CABLE - INSTALLATION, THROTTLE
CONTROL..........................14-35
CABLE - OPERATION...................8P-4
CABLE - OPERATION, ANTENNA BODY.....8A-4
CABLE - REMOVAL....................8P-4
CABLE - REMOVAL, ANTENNA BODY......8A-5
CABLE - REMOVAL, FRONT..............5-64
CABLE - REMOVAL, GEAR SHIFT.......21-204
CABLE - REMOVAL, HOLD OPEN LATCH . . . 23-37
CABLE - REMOVAL, INSIDE HANDLE.....23-37
CABLE - REMOVAL, INSTRUMENT PANEL
ANTENNA...........................8A-8
CABLE - REMOVAL, LATCH RELEASE.....23-60
CABLE - REMOVAL, OUTSIDE HANDLE....23-36
CABLE - REMOVAL, PARKING BRAKE
LEVER AND FRONT....................5-65
CABLE - REMOVAL, THROTTLE
CONTROL..........................14-35
CABLE - SELECTOR - INSTALLATION,
GEARSHIFT.........................21-84
CABLE - SELECTOR - REMOVAL,
GEARSHIFT.........................21-81
CABLE ADJUSTMENT, ADJUSTMENTS -
GEARSHIFT........................21-206
CABLE ADJUSTMENT, INSTALLATION -
SYNCHRONIZING...............23-101,23-87
CABLE (FRONT) - INSTALLATION,
PARKING BRAKE......................5-63
CABLE (FRONT) - REMOVAL, PARKING
BRAKE..............................5-59
CABLE (INTERMEDIATE) -
INSTALLATION, PARKING BRAKE.........5-63
CABLE (INTERMEDIATE) - REMOVAL,
PARKING BRAKE......................5-60
CABLE (LEFT REAR) - INSTALLATION,
PARKING BRAKE......................5-64
CABLE (LEFT REAR) - REMOVAL,
PARKING BRAKE......................5-62
CABLE RESISTANCE, SPECIFICATIONS -
SPARK PLUG.........................8I-2
CABLE (RIGHT REAR) - INSTALLATION,
PARKING BRAKE......................5-63
CABLE (RIGHT REAR) - REMOVAL,
PARKING BRAKE......................5-60
CABLES - ADJUSTMENT, PARKING
BRAKE..............................5-64
CABLES - DESCRIPTION, BATTERY.......8F-16
CABLES - INSTALLATION, BATTERY......8F-18
CABLES - OPERATION, BATTERY........8F-16
CABLES - REMOVAL, BATTERY..........8F-18
CALIBRATION - STANDARD PROCEDURE,
COMPASS...........................8M-3
CALIBRATION - STANDARD PROCEDURE,
HEATER-A/C CONTROL.................24-8
CALIPER - CLEANING..............5-25,5-29
CALIPER - INSPECTION............5-25,5-29
CALIPER - INSTALLATION, REAR DISC
BRAKE..............................5-30
CALIPER - REMOVAL, REAR DISC
BRAKE..............................5-27
CALIPER ADAPTER - INSTALLATION,
FRONT DISC BRAKE...................5-31
CALIPER ADAPTER - REMOVAL, FRONT
DISC BRAKE.........................5-31
CALIPER (DISC/DISC BRAKES) -
INSTALLATION, FRONT DISC BRAKE......5-27
CALIPER (DISC/DISC BRAKES) -
REMOVAL, FRONT DISC BRAKE..........5-24
CALIPER (DISC/DRUM BRAKES) -
INSTALLATION, FRONT DISC BRAKE......5-27
CALIPER (DISC/DRUM BRAKES) -
REMOVAL, FRONT DISC BRAKE
..........5-24
CALIPER GUIDE PIN BUSHINGS
(DISC/DISC BRAKES) - ASSEMBLY
........5-25
CALIPER GUIDE PIN BUSHINGS
(DISC/DISC BRAKES) - DISASSEMBLY
.....5-24
CALIPER GUIDE PINS (DISC/DRUM
BRAKES) - INSTALLATION, DISC
BRAKE
..............................5-31
CALIPER GUIDE PINS (DISC/DRUM
BRAKES) - REMOVAL, DISC BRAKE
.......5-31CALIPER PISTON AND SEAL -
ASSEMBLY......................5-26,5-29
CALIPER PISTON AND SEAL -
DISASSEMBLY....................5-24,5-28
CAMSHAFT & BEARINGS (IN BLOCK) -
DESCRIPTION.......................9-115
CAMSHAFT & BEARINGS (IN BLOCK) -
INSPECTION........................9-115
CAMSHAFT & BEARINGS (IN BLOCK) -
INSTALLATION.......................9-115
CAMSHAFT & BEARINGS (IN BLOCK) -
OPERATION.........................9-115
CAMSHAFT & BEARINGS (IN BLOCK) -
REMOVAL..........................9-115
CAMSHAFT END PLAY - STANDARD
PROCEDURE, MEASURING..............9-29
CAMSHAFT OIL SEAL(S) - INSTALLATION . . 9-28
CAMSHAFT OIL SEAL(S) - REMOVAL......9-27
CAMSHAFT POSITION SENSOR -
DESCRIPTION.........................8I-3
CAMSHAFT POSITION SENSOR -
OPERATION..........................8I-3
CAMSHAFT SPROCKET - INSTALLATION,
TIMING CHAIN.......................9-157
CAMSHAFT SPROCKET - REMOVAL,
TIMING CHAIN.......................9-156
CAMSHAFT SPROCKETS - INSTALLATION . . 9-65
CAMSHAFT SPROCKETS - REMOVAL......9-64
CAMSHAFT(S) - CLEANING..............9-29
CAMSHAFT(S) - DESCRIPTION...........9-28
CAMSHAFT(S) - INSPECTION............9-30
CAMSHAFT(S) - INSTALLATION..........9-30
CAMSHAFT(S) - OPERATION.............9-28
CAMSHAFT(S) - REMOVAL..............9-29
CANISTER - DESCRIPTION, VAPOR......25-18
CANISTER - INSTALLATION, REAR EVAP . . 25-20
CANISTER - OPERATION, VAPOR........25-18
CANISTER - REMOVAL, REAR EVAP......25-19
CAP - DESCRIPTION, FUEL FILLER.......25-12
CAP - DESCRIPTION, RADIATOR
PRESSURE..........................7-26
CAP - INSTALLATION, INSTRUMENT
PANEL END.........................23-67
CAP - OPERATION, FUEL FILLER........25-12
CAP - OPERATION, RADIATOR
PRESSURE..........................7-27
CAP - REMOVAL, INSTRUMENT PANEL
END ...............................23-67
CAP TESTING - DIAGNOSIS AND
TESTING, COOLING SYSTEM
PRESSURE..........................7-27
CAP TO FILLER NECK SEAL -
DIAGNOSIS AND TESTING, RADIATOR.....7-27
CAPACITIES - SPECIFICATIONS, FLUID......0-6
CARE - CLEANING, ALUMINUM WHEEL . . . 22-18
CARPETS AND FLOOR MATS -
INSTALLATION.......................23-75
CARPETS AND FLOOR MATS - REMOVAL . 23-74
CARRIER ASSEMBLY - DESCRIPTION,
BALANCE SHAFTS.....................9-69
CARRIER ASSEMBLY - INSTALLATION,
BALANCE SHAFTS.....................9-72
CARRIER ASSEMBLY - OPERATION,
BALANCE SHAFTS.....................9-69
CARRIER ASSEMBLY - REMOVAL,
BALANCE SHAFTS.....................9-69
CARRIER SEAL - INSTALLATION,
DIFFERENTIAL........................21-9
CARRIER SEAL - REMOVAL,
DIFFERENTIAL........................21-9
CATALYTIC CONVERTER - DESCRIPTION . . . 11-4
CATALYTIC CONVERTER - INSPECTION....11-5
CATALYTIC CONVERTER - INSTALLATION . . . 11-6
CATALYTIC CONVERTER - OPERATION.....11-4
CATALYTIC CONVERTER - REMOVAL......11-5
CAUSES - DIAGNOSIS AND TESTING,
COMMON PROBLEM..................21-30
CAUTION - CAUTIONS..................5-78
CAUTION, A/C PLUMBING..............24-61
CAUTION, DESCRIPTION.................5-4
CAUTION, DESCRIPTION...............19-37
CAUTION, SENSOR - TPM..............22-10
CAUTIONS, CAUTION..................5-78
CAUTIONS, WARNING - WARNINGS
. 19-10,19-27
CD CHANGER - DESCRIPTION
...........8A-7
CD CHANGER - INSTALLATION
...........8A-8
CD CHANGER - OPERATION
.............8A-7
CD CHANGER - REMOVAL
..............8A-8
RSINDEX5
Description Group-Page Description Group-Page Description Group-Page
ProCarManuals.com
Page 2145 of 2177
CENTER - DESCRIPTION, ELECTRONIC
VEHICLE INFO.......................8M-6
CENTER - DIAGNOSIS AND TESTING,
ELECTRONIC VEHICLE INFORMATION.....8M-7
CENTER - INSTALLATION, ELECTRONIC
VEHICLE INFO.......................8M-9
CENTER - OPERATION, ELECTRONIC
VEHICLE INFO.......................8M-7
CENTER - REMOVAL, ELECTRONIC
VEHICLE INFO.......................8M-9
CENTER BEZEL - INSTALLATION,
INSTRUMENT PANEL..................23-67
CENTER BEZEL - REMOVAL,
INSTRUMENT PANEL..................23-67
CENTER BEZEL OUTLETS -
INSTALLATION.......................24-42
CENTER BEZEL OUTLETS - REMOVAL....24-40
CENTER CONSOLE LAMP SWITCH -
INSTALLATION.......................8L-26
CENTER CONSOLE LAMP SWITCH -
REMOVAL..........................8L-26
CENTER HIGH MOUNTED STOP LAMP -
INSTALLATION........................8L-6
CENTER HIGH MOUNTED STOP LAMP -
REMOVAL...........................8L-6
CENTER HIGH MOUNTED STOP LAMP
UNIT - INSTALLATION..................8L-7
CENTER HIGH MOUNTED STOP LAMP
UNIT - REMOVAL.....................8L-6
CENTER HINGE - INSTALLATION.........23-24
CENTER HINGE - REMOVAL............23-24
CENTER PROGRAMMING - STANDARD
PROCEDURE, ELECTRONIC VEHICLE
INFORMATION.......................8M-7
CENTER STRIKER - INSTALLATION.......23-27
CENTER STRIKER - REMOVAL..........23-27
CENTERING - STANDARD PROCEDURE,
CLOCK SPRING.......................8O-4
CERTIFICATION LABEL - DESCRIPTION,
VEHICLE SAFETY..................Intro.-11
CHAIN AND CAMSHAFT SPROCKET -
INSTALLATION, TIMING................9-157
CHAIN AND CAMSHAFT SPROCKET -
REMOVAL, TIMING...................9-156
CHAIN COVER - INSTALLATION, TIMING . . 9-155
CHAIN COVER - REMOVAL, TIMING......9-153
CHAIN WEAR - STANDARD PROCEDURE,
MEASURING TIMING..................9-153
CHANGE - STANDARD PROCEDURE,
DIFFERENTIAL ASSEMBLY FLUID.........3-40
CHANGE - STANDARD PROCEDURE,
ENGINE OIL AND FILTER...........9-137,9-53
CHANGE - STANDARD PROCEDURE,
OVERRUNNING CLUTCH HOUSING
FLUID..............................3-41
CHANGE - STANDARD PROCEDURE, PTU
FLUID..............................21-5
CHANGER - DESCRIPTION, CD...........8A-7
CHANGER - INSTALLATION, CD..........8A-8
CHANGER - OPERATION, CD.............8A-7
CHANGER - REMOVAL, CD..............8A-8
CHANNEL - INSTALLATION, WATER.....23-118
CHANNEL - REMOVAL, WATER.........23-118
CHARGE - STANDARD PROCEDURE,
REFRIGERANT SYSTEM
...............24-88
CHARGE LEVEL - DIAGNOSIS AND
TESTING, REFRIGERANT SYSTEM
.......24-85
CHARGING - STANDARD PROCEDURE,
CONVENTIONAL BATTERY
..............8F-11
CHARGING - STANDARD PROCEDURE,
SPIRAL PLATE BATTERY
...............8F-10
CHARGING SYSTEM - DESCRIPTION
.....8F-20
CHARGING SYSTEM - OPERATION
.......8F-20
CHARTS - DIAGNOSIS AND TESTING,
STEERING SYSTEM DIAGNOSIS
..........19-3
CHARTS - SPECIFICATIONS, COLOR
CODE
..............................23-83
CHATTER COMPLAINTS - DIAGNOSIS
AND TESTING, CLUTCH
.................6-6
CHECK - DIAGNOSIS AND TESTING,
COOLING SYSTEM FLOW
................7-3
CHECK - DIAGNOSIS AND TESTING,
EXHAUST SYSTEM RESTRICTION
.........11-2
CHECK - STANDARD PROCEDURE,
COOLANT LEVEL
.......................7-5
CHECK - STANDARD PROCEDURE,
ENGINE OIL LEVEL
...................9-137CHECK - STANDARD PROCEDURE, FLUID
LEVEL.............................21-71
CHECK, STANDARD PROCEDURE -
ENGINE OIL LEVEL....................9-53
CHECK, STANDARD PROCEDURE - FLUID
LEVEL AND CONDITION..............21-201
CHECK STRAP - INSTALLATION.........23-15
CHECK STRAP - REMOVAL.............23-15
CHECKING - STANDARD PROCEDURE,
BRAKE FLUID LEVEL...................5-32
CHECKING - STANDARD PROCEDURE,
POWER STEERING FLUID LEVEL........19-44
CHECKING BATTERY ELECTROLYTE
LEVEL - STANDARD PROCEDURE........8F-14
CHECKING ENGINE OIL PRESSURE -
DIAGNOSIS AND TESTING..............9-52
CHECKING POWER STEERING BELT
TENSION - STANDARD PROCEDURE.......7-8
CHILD SEAT - INSTALLATION, QUAD.....23-88
CHILD SEAT - REMOVAL, QUAD.........23-88
CHILD SEAT MODULE, BENCH SEAT -
REMOVAL..........................23-86
CHIME SYSTEM - DIAGNOSIS AND
TESTING............................8B-1
CHIME/BUZZER - DESCRIPTION..........8B-1
CHIME/BUZZER - OPERATION............8B-1
CHIME/BUZZER - WARNING.............8B-1
CHIME/THERMISTOR - DESCRIPTION....8N-10
CHIME/THERMISTOR - INSTALLATION....8N-10
CHIME/THERMISTOR - OPERATION......8N-10
CHIME/THERMISTOR - REMOVAL.......8N-10
CHIRP PREFERENCE - STANDARD
PROCEDURE, HORN..................8N-42
CIRCUIT - DIAGNOSIS AND TESTING,
AMBIENT TEMPERATURE SENSOR......8M-12
CIRCUIT FUNCTIONS - DESCRIPTION . . 8W-01-6
CIRCUIT INFORMATION - DESCRIPTION . 8W-01-5
CIRCUIT RESISTANCE TEST -
DIAGNOSIS AND TESTING, FEED........8F-32
CIRCUIT TEST - DIAGNOSIS AND
TESTING, CONTROL..................8F-30
CIRCUIT TEST - DIAGNOSIS AND
TESTING, FEED......................8F-33
CIRCUITS - OPERATION, NON-
MONITORED.........................25-5
CIRCUITS AND VALVES - OPERATION,
HYDRAULIC..........................5-83
CLAMP - STANDARD PROCEDURE,
HOSES..............................14-6
CLAMPS - DESCRIPTION, FUEL
LINES/HOSES........................14-6
CLAMPS - DESCRIPTION, HOSE...........7-1
CLAMPS - OPERATION, HOSE.............7-2
CLEAN, CLEANING...................21-114
CLEARANCE - STANDARD PROCEDURE,
MEASURING CONNECTING ROD
BEARING...........................9-120
CLEARANCE USING PLASTIGAGE -
STANDARD PROCEDURE, MEASURING
BEARING........................9-12,9-84
CLOCK SPRING - DESCRIPTION..........8O-4
CLOCK SPRING - INSTALLATION.........8O-5
CLOCK SPRING - OPERATION...........8O-4
CLOCK SPRING - REMOVAL.............8O-4
CLOCK SPRING CENTERING -
STANDARD PROCEDURE...............8O-4
CLUSTER - DESCRIPTION, INSTRUMENT . . . 8J-1
CLUSTER - OPERATION, INSTRUMENT.....8J-1
CLUSTER BEZEL - INSTALLATION
........23-62
CLUSTER BEZEL - REMOVAL
...........23-62
CLUSTER DIAGNOSIS - DIAGNOSIS AND
TESTING
............................8J-2
CLUSTER ILLUMINATION LAMPS -
INSTALLATION
.......................8L-26
CLUSTER ILLUMINATION LAMPS -
REMOVAL
..........................8L-26
CLUSTER LENS - INSTALLATION
........8J-10
CLUSTER LENS - REMOVAL
............8J-10
CLUTCH - DESCRIPTION
.................6-1
CLUTCH - DESCRIPTION, BI-
DIRECTIONAL OVERRUNNING
...........3-34
CLUTCH - DESCRIPTION, COMPRESSOR
. . 24-16
CLUTCH - OPERATION, BI-DIRECTIONAL
OVERRUNNING
.......................3-36
CLUTCH - OPERATION, COMPRESSOR
....24-17
CLUTCH AIR GAP - STANDARD
PROCEDURE, COMPRESSOR
...........24-17CLUTCH AIR PRESSURE TESTS -
DIAGNOSIS AND TESTING............21-122
CLUTCH ASSEMBLY - ASSEMBLY, INPUT . 21-216
CLUTCH ASSEMBLY - DISASSEMBLY,
INPUT............................21-208
CLUTCH ASSY - 2.4L GAS -
INSTALLATION, MODULAR..............6-11
CLUTCH ASSY - 2.4L GAS - REMOVAL,
MODULAR...........................6-11
CLUTCH BREAK-IN - STANDARD
PROCEDURE, COMPRESSOR...........24-17
CLUTCH CHATTER COMPLAINTS -
DIAGNOSIS AND TESTING...............6-6
CLUTCH COIL - DIAGNOSIS AND
TESTING, COMPRESSOR...............24-20
CLUTCH COVER AND DISC RUNOUT -
DIAGNOSIS AND TESTING...............6-6
CLUTCH DISC AND PRESSURE PLATE -
2.5L TD - INSTALLATION...............6-12
CLUTCH DISC AND PRESSURE PLATE -
2.5L TD - REMOVAL...................6-11
CLUTCH HOUSING FLUID CHANGE -
STANDARD PROCEDURE,
OVERRUNNING.......................3-41
CLUTCH PEDAL INTERLOCK SWITCH -
INSTALLATION........................6-14
CLUTCH PEDAL INTERLOCK SWITCH -
REMOVAL...........................6-13
CLUTCH PEDAL UPSTOP SWITCH -
INSTALLATION........................6-16
CLUTCH PEDAL UPSTOP SWITCH -
REMOVAL...........................6-15
CLUTCH RELAY - DESCRIPTION,
COMPRESSOR........................24-21
CLUTCH RELAY - DIAGNOSIS AND
TESTING, COMPRESSOR...............24-22
CLUTCH RELAY - INSTALLATION,
COMPRESSOR.......................24-22
CLUTCH RELAY - OPERATION,
COMPRESSOR.......................24-21
CLUTCH RELAY - REMOVAL,
COMPRESSOR.......................24-22
CLUTCH RELEASE LEVER AND BEARING
- INSTALLATION.......................6-7
CLUTCH RELEASE LEVER AND BEARING
- REMOVAL...........................6-6
CLUTCH SYSTEM - DIAGNOSIS AND
TESTING.............................6-3
CLUTCH/COIL - INSPECTION,
COMPRESSOR.......................24-18
CLUTCHES - DESCRIPTION, DRIVING....21-190
CLUTCHES - DESCRIPTION, HOLDING . . . 21-207
CLUTCHES - OPERATION, DRIVING.....21-190
CLUTCHES - OPERATION, HOLDING.....21-207
COAT/CLEARCOAT FINISH -
DESCRIPTION, BASE..................23-84
CODE - DESCRIPTION, PAINT...........23-84
CODE CHARTS - SPECIFICATIONS,
COLOR.............................23-83
CODE PLATE - DESCRIPTION, BODY....Intro.-1
CODES - STANDARD PROCEDURE,
ERASING TRANSMITTER..............8M-11
CODES - STANDARD PROCEDURE,
OBTAINING DIAGNOSTIC TROUBLE......8E-15
CODES - STANDARD PROCEDURE,
SETTING TRANSMITTER..............8M-11
COIL - DESCRIPTION, IGNITION
..........8I-6
COIL - DIAGNOSIS AND TESTING,
COMPRESSOR CLUTCH
...............24-20
COIL - OPERATION, IGNITION
............8I-6
COLLAR - INSTALLATION, STRUCTURAL
. . . 9-48
COLLAR - REMOVAL, STRUCTURAL
.......9-47
COLOR CODE CHARTS -
SPECIFICATIONS
.....................23-83
COLUMN - DESCRIPTION, STEERING
.....19-10
COLUMN - DIAGNOSIS AND TESTING,
STEERING
..........................19-12
COLUMN COVER - INSTALLATION,
LOWER STEERING
...................23-69
COLUMN COVER - INSTALLATION, OVER
STEERING
..........................23-69
COLUMN COVER - REMOVAL, LOWER
STEERING
..........................23-69
COLUMN COVER - REMOVAL, OVER
STEERING
..........................23-69
COLUMN COVER BACKING PLATE -
INSTALLATION, STEERING
.............23-69
6 INDEXRS
Description Group-Page Description Group-Page Description Group-Page
ProCarManuals.com