service CHRYSLER VOYAGER 2004 Service Manual

(9) Use absorbent toweling to clean up any engine
coolant spills from the preceding operation.
(10) Release the four latch tabs that secure the
heater core into the rear HVAC housing.
(11) Carefully pull the heater core straight out of
the rear HVAC housing.
(12) Use absorbent toweling to clean up any
engine coolant spills from the preceding operation.
INSTALLATION
NOTE: If the rear heater core or the rear HVAC
housing have been removed from the vehicle for
service, the rear heater core may be pre-filled with
the proper engine coolant mixture prior to recon-
necting the heater hoses to the heater core hose fit-
tings (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - REAR/HEATER CORE - STANDARD
PROCEDURE - HEATER CORE FILLING).
(1) Carefully slide the heater core into the rear
HVAC housing.
(2) Using hand pressure, press firmly and evenly
on the heater core end plate until the four latch tabs
that secure the heater core in the rear HVAC housing
are fully engaged.
(3) Remove the plugs or tape from the heater core
fittings and both heater hoses.
(4) Reconnect the heater hoses to the rear heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).
(5) Install the screw that secures the front of the
rear HVAC housing to the right quarter inner panel.
Tighten the screw to 11 N´m (97 in. lbs.).
(6) Install the screw that secures the back of the
rear HVAC housing to the right D-pillar. Tighten the
screw to 11 N´m (97 in. lbs.).
(7) Install the rear heater distribution duct (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION - REAR/REAR HEATER DISTRIBUTION
DUCT - INSTALLATION).
(8) Install the right quarter trim panel and right
D-pillar trim panel (Refer to 23 - BODY/INTERIOR/
QUARTER TRIM PANEL - INSTALLATION).
(9) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
HEATER HOSES
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 -
WARNING).
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Using spring tension clamp pliers, compress
and slide the clamps off of each end of the hose being
removed.
CAUTION:
DO NOT apply excessive pressure on heater tubes
or connections when removing heater hoses.
Excessive pressure may damage or deform the
tubes, causing an engine coolant leak.
(3) Disconnect the front underbody heater inlet
and return hose by carefully twisting the hoses back
and forth on the underbody tubes, while gently pull-
ing them away from the end of the tubes (Fig. 6).
(4) If necessary, carefully cut the hose ends and
peel the hoses off of the tubes.
NOTE:
Replacement of the heater hoses will be required if
the hose ends are cut for removal.
Fig. 6 Underbody Heater Hose Connections - Front
1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - RETAINER STRAP (3)
4 - HEATER TUBES
5 - UNDERBODY LINES
RSPLUMBING - REAR24 - 103
HEATER CORE (Continued)

(18) Install plugs in, or tape over the opened suc-
tion line fittings.
(19) Lower the vehicle.
(20) Remove the suction line from the engine com-
partment.
INSTALLATION
(1) Position the suction line into the engine com-
partment.
(2) Remove the tape or plugs from the suction line
and liquid line fittings and both expansion valve
ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the suction line
and liquid line fittings.
(4) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(5) Install the nut that secures the suction line
and liquid line fittings to the front expansion valve.
Tighten the nut to 23 N´m (17 ft. lbs.).
(6) Engage the retainer that secures the suction
line routing clip to the receiver/drier mounting
bracket on the side of the right front strut tower in
the engine compartment.
(7) Remove the tape or plugs from the compressor
suction port and the suction line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the suction line fit-
ting.
(9) Reconnect the suction line fitting to the com-
pressor suction port.
(10) Install the nut that secures the suction line
fitting to the A/C compressor. Tighten the nut to 23
N´m (17 ft. lbs.).
(11) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(12) Reinstall the air cleaner top cover and snorkel
onto the air cleaner housing located on the right side
of the engine compartment.
(13) Reconnect the battery negative cable.
(14) Raise and support the vehicle.
(15) Remove the tape or plugs from the suction
line extension fitting and the underbody suction line
fitting.(16) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody suction
line fitting.
(17) Reconnect the suction line extension fitting to
the underbody suction line fitting. Tighten the fitting
to 23 N´m (17 ft. lbs.).
(18) Install a new tie strap just forward of the con-
nections between the underbody plumbing and the
engine compartment plumbing for the rear heater
and air conditioner.
(19) Lower the vehicle.
(20) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(21) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
UNDERBODY LINES
DESCRIPTION
The underbody heater-A/C plumbing is used only
on models with the optional rear heater-A/C system
(Fig. 11). The underbody suction line, liquid line, and
heater tubes can each be serviced separately.
OPERATION
The rear heater and A/C lines are all serviced as
individual pieces. When disconnecting any line or
block ensure that the area around it is clean of any
contaminations that can get in to the system (Fig.
12), (Fig. 13), (Fig. 15), (Fig. 14) and (Fig. 16).
Any kinks or sharp bends in the rear heater-A/C
unit plumbing will reduce the capacity of the entire
heating and air conditioning system. Kinks and
sharp bends reduce the system flow. High pressures
are produced in the refrigerant system when the air
conditioning compressor is operating. High tempera-
ture coolant is present in the heater plumbing when
the engine is operating. Extreme care must be exer-
cised o make sure that each of the plumbing connec-
tions is pressure-tight and leak free.
RSPLUMBING - REAR24 - 107
SUCTION LINE (Continued)

(5) Remove the two retaining screws and remove
pipe assembly (Fig. 2).
INSTALLATION
(1) Install the air intake pipe assembly and install
the two retaining screws. Tighten the screws to 7
N´m (62 in. lbs.).
(2) Attach the steel tube to the flexible tube and
position and then tighten the retaining clamp
securely.
(3) Install the flexible tube to the cabin heater air
intake muffler and install and tighten the retaining
clamp securely.
(4) Install the cabin heater tubes to the lower
heater connection and the lower EGR cooler connec-
tion and tighten the retaining clamps.
(5) Lower the vehicle.
(6) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(7) Verify function of the cabin heater.
EXHAUST TUBE
REMOVAL
WARNING: THERE IS A POTENTIAL DANGER OF
SKIN BURNS AS THE SUPPLEMENTAL CABIN
HEATER AND ITS COMPONENTS MAY BE VERY
HOT. MAKE SURE THE CABIN HEATER IS
ALLOWED TO COOL DOWN BEFORE ANY SERVICE
WORK ON THE CABIN HEATER SYSTEM IS
ATTEMPTED.
(1) Raise and support the vehicle. Take note of the
location of the flexible section of the cabin heater
exhaust tube.
(2) Remove the exhaust clamp at the flexible pipe
and steel pipe connection (Fig. 3).
(3) Remove the clamp at the flexible pipe connec-
tion and the cabin heater housing (if required).
(4) Remove the three screws holding the exhaust
pipe to the body.
(5) Remove the steel exhaust pipe from the vehi-
cle.
(6) Remove the flexible exhaust pipe from the
vehicle (if required).
Fig. 1 Cabin Heater Flexible Air Intake Line
1 - CABIN HEATER AND SPLASH SHIELD
2 - DOSING PUMP
3 - DOSING PUMP FUEL LINE
4 - FLEXIBLE INTAKE LINE
5 - CLAMP
6 - STEEL INTAKE PIPE
Fig. 2 Cabin Heater Air Intake And Heater Pipe
Assembly
1 - INTAKE TUBE AIR INTAKE
2 - INTAKE PIPE
3 - RETAINING SCREWS
4 - INTAKE HEATER LINE
5 - RETURN HEATER LINE
24 - 114 CABIN HEATERRS
AIR INTAKE PIPE (Continued)

INSTALLATION
(1) Install the flexible exhaust pipe to the cabin
heater. Tighten the mounting clamp securely.
(2) Position the steel exhaust pipe to the flexible
exhaust. Tighten the mounting clamp securely.
(3) Loosely install the three exhaust pipe screws
and adjust pipe placement as required. Tighten the
screws securely.
(4) Install the clamp that secures the steel exhaust
pipe to the flexible exhaust pipe. Tighten the clamp
securely.
(5) Check exhaust end placement of the exhaust
pipe and make any final adjustments.
(6) Lower the vehicle.
FUEL DOSING PUMP
DESCRIPTION
The dosing pump is a combined delivery, dosing
and shut-off system for the fuel supply to the supple-
mental cabin heater from the vehicle fuel tank.
OPERATION
The dosing pump is an electrically operated pump
that receives its operation instructions from the sup-
plemental cabin heater control module. The pump
supplies diesel fuel from the vehicle fuel tank to the
cabin heater.
REMOVAL
NOTE: The dosing pump is serviceable without
removing the component from the vehicle.
(1) Disconnect the rubber hose at the fuel line to
heater fuel pump. Leave the rubber hose on the fuel
line (Refer to 24 - HEATING & AIR CONDITION-
ING/CABIN HEATER/FUEL LINE - REMOVAL)
(Fig. 4).
(2) Disconnect the fuel line between the dosing
pump and the cabin heater unit.
NOTE: Position and retain the heater fuel line to
prevent fuel leakage while servicing the dosing
pump.
Fig. 3 Cabin Heater Exhaust System
1 - MOUNTING SCREWS (3)
2 - STEEL HEATER EXHAUST PIPE
3 - EXHAUST CLAMP (2)4 - FLEXIBLE HEATER EXHAUST PIPE
5 - CABIN HEATER AND SHIELD
6 - EXHAUST PIPE MOUNTING CLIPS (3) (IF EQUIPPED)
RSCABIN HEATER24 - 115
EXHAUST TUBE (Continued)

INSTALLATION
WARNING: DO NOT OPERATE THE DIESEL SUP-
PLEMENTAL CABIN HEATER IN AN ENCLOSED
AREA SUCH AS A GARAGE THAT DOES NOT HAVE
EXHAUST VENTILATION FACILITIES. ALWAYS VENT
THE CABIN HEATER EXHAUST WHEN OPERATING
THE CABIN HEATER. ALLOW THE DIESEL SUPPLE-
MENTAL CABIN HEATER TO COOL BEFORE PER-
FORMING ANY SERVICE PROCEDURES TO THE
CABIN HEATER. VERIFY THAT ALL DIESEL SUP-
PLEMENTAL CABIN HEATER FUEL LINES ARE
SECURELY FASTENED TO THEIR RESPECTIVE
COMPONENTS BEFORE PERFORMING ANY SER-
VICE PROCEDURES TO THE CABIN HEATER. FAIL-
URE TO FOLLOW THESE INSTRUCTION MAY
RESULT IN PERSONAL INJURY OR DEATH.
NOTE: Verify that there is more than 1/8 of a tank of
fuel in the vehicle's fuel tank before performing this
procedure. Add fuel, if necessary.
(1) Install the cabin heater fuel supply line into
vehicle and fuel line retainers.
(2) Install the fuel line connection at the fuel tank
and tighten the connection securely.
(3) Install the fuel line at the dosing pump and
tighten the connection securely.
(4) Lower the vehicle.
NOTE: Failure to prime the dosing pump after drain-
ing the supplemental cabin fuel line will prevent
cabin heater activation during the first attempt to
start the cabin heater. This will also set a diagnostic
trouble code (DTC) in the cabin heater control's
memory. Do not perform the Dosing Pump Priming
procedure if an attempt was made to start the cabin
heater without priming the dosing pump first. This
will put excess fuel in the cabin heater and cause
smoke to emit from the cabin heater exhaust pipe
when cabin heater activation occurs.
(5) Connect the DRBIIItscan tool to the diagnos-
tic link connector.
(6) Turn the ignition to the ON position.
NOTE: Do not activate the dosing pump prime more
than one time. This will put excess fuel in the sup-
plemental cabin heater and cause smoke to emit
from the cabin heater exhaust pipe when cabin
heater activation occurs.
NOTE: A clicking noise heard coming from the dos-
ing pump indicates that the pump is operational.(7) With the DRBIIItscan tool in Cabin Heater,
select System Tests and Dosing Pump Prime. Allow
the dosing pump to run for the full 45 second cycle
time. When the 45 second cycle is complete, press
Page Back on the DRBIIItscan tool key pad to exit
the Dosing Pump Prime. The Dosing Pump Priming
procedure is now complete.
HEATER UNIT
REMOVAL
WARNING: DO NOT OPERATE THE DIESEL SUP-
PLEMENTAL CABIN HEATER IN AN ENCLOSED
AREA SUCH AS A GARAGE THAT DOES NOT HAVE
EXHAUST VENTILATION FACILITIES. ALWAYS VENT
THE CABIN HEATER EXHAUST WHEN OPERATING
THE CABIN HEATER. ALLOW THE DIESEL SUPPLE-
MENTAL CABIN HEATER TO COOL BEFORE PER-
FORMING ANY SERVICE PROCEDURES TO THE
CABIN HEATER. VERIFY THAT ALL DIESEL SUP-
PLEMENTAL CABIN HEATER FUEL LINES ARE
SECURELY FASTENED TO THEIR RESPECTIVE
COMPONENTS BEFORE PERFORMING ANY SER-
VICE PROCEDURES TO THE CABIN HEATER. FAIL-
URE TO FOLLOW THESE INSTRUCTION MAY
RESULT IN PERSONAL INJURY OR DEATH.
(1) Raise and support the vehicle. Take note of the
location of the flexible section of the cabin heater
exhaust tube.
(2) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(3) Carefully open one hose to the underbody tube
assembly and drain the remaining coolant. A salvage
hose is a good idea to control the residual coolant, as
flow will occur from both the cabin heater and the
hose and tube assemblies.
(4) Remove the second hose from the underbody
hose and tube assembly.
(5) Loosen the hose and tube assembly from the
toe-board crossmember at two locations.
(6) Disconnect the electrical connector from the
body harness near the toe-board crossmember and
rail.
(7) Remove the wiring harness from the toe-board
crossmember (Refer to 24 - HEATING & AIR CON-
DITIONING/CABIN HEATER/HEATER UNIT -
REMOVAL).
(8) Open the fuel filler cap. Disconnect the rubber
fuel hose between the body tube assembly and the
fuel pump nipple at the body tube joint. A minimal
amount of fuel may flow from the open port.
NOTE: Utilize an approved fuel storage container to
catch any residual fuel.
24 - 118 CABIN HEATERRS
FUEL LINE (Continued)

(9) Loosen the two fasteners at the rail. Take care
to notice that the exhaust tube bracket tab is on top
of the heater bracket and that there are two spacer
washers installed between the rubber grommets.
(10) Remove the flexible section of the cabin
heater exhaust tube from the exhaust tube by loos-
ening the clamp. Remove the hose from the exhaust
tube. Removal of the rail tube assembly may aid in
this service operation (Refer to 24 - HEATING & AIR
CONDITIONING/CABIN HEATER/EXHAUST TUBE
- REMOVAL).
(11) Remove seat hex nut at the heater mounting
flange to crossmember.
(12) Loosen the remaining fasteners which mount
the exhaust tube assembly to the vehicle.
(a) Install a suitable support device under the
cabin heater and secure the cabin heater to the
support.
(13) Loosen the remaining three fasteners to the
crossmembers.
(14) Remove the loosened fasteners that support
the cabin heater while supporting the weight of the
heater.
(15) Swing the cabin heater mounting bracket
from between the exhaust bracket and rail mounting
location. Drain any residual coolant from the cabin
heater.
(16) Remove the cabin heater from the vehicle.
INSTALLATION
(1) Install the cabin heater mounting bracket
between the exhaust bracket and the rail mounting
location.
(2) Support the cabin heater and install the fasten-
ers that secure the cabin heater to the mounting
bracket.
(3) Install the three fasteners to the crossmem-
bers. Tighten the M6 fasteners to 7 N´m (62 in. lbs.).
(4) Position the two spacer washers between the
body and the rubber grommets for the two mounting
points on the rail.
(5) Tighten the remaining M6 fasteners to 7 N´m
(62 in. lbs.) and the M8 fasteners to 23 N´m (17 ft.
lbs.) which mount the exhaust tube assembly to the
vehicle.
(6) Install the seat hex nut at the heater mounting
flange to the crossmembers. Tighten the nut to 60
N´m (44 ft. lbs.)
(7) Install the flexible section of the cabin heater
exhaust tube to the exhaust tube. Tighten the M6
bolt of the clamp securley. Install the hose to the
exhaust tube.
(8) Tighten the two M8 fasteners at the rail to 23
N´m (17 ft. lbs.). Taking care so that the exhaust
tube bracket tab is on the top of the heater bracket.(9) Install the wiring harness (Refer to 24 - HEAT-
ING & AIR CONDITIONING/CABIN HEATER/
HEATER UNIT - INSTALLATION).
(10) Tighten the hose and tube assembly to the
toe-board crossmember at two locations.
(11) Install the second hose to the underbody hose
and tube assembly.
(12) Connect the rubber fuel hose between the
body tube assembly and the fuel pump nipple at the
body tube joint. Close the fuel fill cap.
(13) Remove the cabin heater support device from
under the vehicle.
(14) Lower the vehicle.
(15) Fill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(16) Verify function of the cabin heater.
SUPPLEMENTAL DIESEL
HEATER WIRING
REMOVAL
(1) Elevate vehicle on a lift taking note of the
exhaust tube flexible section.
(2) Unplug connector from vehicle wiring harness
to cabin heater harness.
(3) Unplug connector from cabin heater harness to
dosing pump connector.
(4) Unplug two connectors from cabin heater har-
ness to cabin heater controller connectors.
(5) Remove two wiring harness connectors from
underbody.
(6) Remove two wiring harness connectors from
cabin heater shield.
(7) Carefully route the cabin heater harness to the
left side between the cabin heater unit and the cabin
heater shield.
INSTALLATION
(1) Carefully route the cabin heater harness from
the left side of the cabin heater between the cabin
heater unit and the cabin heater shield.
(2) Install the two wiring harness retaining con-
nectors to the cabin heater shield.
(3) Route the wiring harness along the underside
of the vehicle and install the two wiring harness
retaining connectors.
(4) Plug the two connectors from the cabin heater
harness to the cabin heater controller.
(5) Plug the connector to the cabin heater harness
to the dosing pump connector.
(6) Plug the connector from the vehicle wiring har-
ness to the cabin heater harness.
(7) Lower the vehicle.
(8) Verify function of the cabin heater.
RSCABIN HEATER24 - 119
HEATER UNIT (Continued)

SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
PCV VAlve 3.3/3.8L 6.3 55
Fig. 1 ORVR System Schematic
1 - FUEL TANK (PLASTIC)
2 - FUEL FILLER TUBE
3 - FUEL CAP (PRESSURE/RELIEF)
4 - FILL TUBE TO FUEL TANK CONNECTOR (ELASTOMERIC)
5 - TANK VENT/ROLLOVER VALVE(S)
6 - VAPOR RECIRCULATION LINE
7 - TANK VAPOR LINE
8 - VAPOR LINE TO CANISTER
9 - CHECK VALVE (N/C)
10 - CONTROL VALVE
11 - NATURAL VACUUM LEAD DETECTION (NVLD)12 - LIQUID SEPARATOR (IF EQUIPPED)
13 - ENGINE WIRING HARNESS TO NVLD
14 - VAPOR CANISTER
15 - PURGE LINE
16 - PURGE DEVICE
17 - WITHOUT NVLD
18 - BREATHER ELEMENT
19 - FLOW CONTROL ORIFICE
20 - SERVICE PORT
21 - WITH NVLD
RSEVAPORATIVE EMISSIONS25-11
EVAPORATIVE EMISSIONS (Continued)

Fig. 9 ORVR System Schematic
1 - FUEL TANK (PLASTIC)
2 - FUEL FILLER TUBE
3 - FUEL CAP (PRESSURE/RELIEF)
4 - FILL TUBE TO FUEL TANK CONNECTOR (ELASTOMERIC)
5 - TANK VENT/ROLLOVER VALVE(S)
6 - VAPOR RECIRCULATION LINE
7 - TANK VAPOR LINE
8 - VAPOR LINE TO CANISTER
9 - CHECK VALVE (N/C)
10 - CONTROL VALVE
11 - NATURAL VACUUM LEAD DETECTION (NVLD)12 - LIQUID SEPARATOR (IF EQUIPPED)
13 - ENGINE WIRING HARNESS TO NVLD
14 - VAPOR CANISTER
15 - PURGE LINE
16 - PURGE DEVICE
17 - WITHOUT NVLD
18 - BREATHER ELEMENT
19 - FLOW CONTROL ORIFICE
20 - SERVICE PORT
21 - WITH NVLD
RSEVAPORATIVE EMISSIONS25-15
ORVR (Continued)

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)

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