ipm CHRYSLER VOYAGER 2005 Service Manual

(4) Raise the liquid line (discharge) pressure to
about 1793 kPa (260 psi) by placing a piece of card-
board over part of the front side of the condenser. To
place the cardboard properly, remove the upper radi-
ator sight shield from the front fascia. Cover only
enough of the condenser to raise and maintain the
liquid line pressure at the specified level.
(5) Observe the liquid line (discharge) pressure
and liquid line temperature. Using the Charge Deter-
mination Chart (Fig. 1), determine whether the
refrigerant system is operating within the Proper
Charge Range.
(a) If the refrigerant system is operating in the
Undercharged area of the chart, add 0.057 kilo-
gram (0.125 pound or 2 ounces) of refrigerant to
the system.
(b) If the refrigerant system is operating in the
Overcharged area of the chart, reclaim 0.057 kilo-
gram (0.125 pound or 2 ounces) of refrigerant from
the system.
(6) Recheck the system charge level following each
refrigerant adjustment. Continue this process until
the system readings are in the Proper Charge Range
area on the Charge Determination Chart.
STANDARD PROCEDURE
HANDLING TUBING AND FITTINGS
CAUTION: The system must be completely empty
before opening any fitting or connection in the
refrigeration system. Open fittings with caution
even after the system has been emptied. If any
pressure is noticed as a fitting is loosened,
retighten fitting and evacuate the system again.
A good rule for the flexible hose lines is to keep the
radius of all bends at least 10 times the diameter of
the hose. Sharper bends will reduce the flow of
refrigerant. The flexible hose lines should be routed
so they are at least 3 inches (80 mm) from the
exhaust manifold. Inspect all flexible hose lines to
make sure they are in good condition and properly
routed.
The use of correct wrenches when making connec-
tions is very important. Improper wrenches or
improper use of wrenches can damage the fittings.
The internal parts of the A/C system will remain sta-
ble as long as moisture-free refrigerant and refrig-
erant oil is used. Abnormal amounts of dirt,
moisture or air can upset the chemical stability.
This may cause operational troubles or even seri-
ous damage if present in more than very small
quantities. Before disconnecting a component,
clean the outside of the fittings thoroughly to pre-
vent contamination from entering the refrigerant
system.When opening a refrigeration system, have every-
thing you will need to repair the system ready. This
will minimize the amount of time the system must
be opened. Cap or plug all lines and fittings as
soon as they are opened. This will help prevent the
entrance of dirt and moisture. All new lines and
components should be capped or sealed until they
are ready to be used. Before connecting a compo-
nent, clean the outside of the fittings thoroughly to
prevent contamination from entering the refrigerant
system.
All tools, including the refrigerant dispensing mani-
fold, the manifold gauge set, and test hoses should
be kept clean and dry.
Kinks in the refrigerant tubing or sharp bends in
the refrigerant hose lines will greatly reduce the
capacity of the entire system. High pressures are pro-
duced in the system when it is operating. Extreme
care must be exercised to make sure that all connec-
tions are pressure tight. Dirt and moisture can enter
the system when it is opened for repair or replace-
ment of lines or components. The refrigerant oil will
absorb moisture readily out of the air. This moisture
will convert into acids within a closed system.
REFRIGERANT SYSTEM SERVICE EQUIPMENT
WARNING: EYE PROTECTION MUST BE WORN
WHEN SERVICING AN AIR CONDITIONING REFRIG-
ERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE)
ALL VALVES ON THE EQUIPMENT BEING USED
BEFORE CONNECTING TO, OR DISCONNECTING
FROM THE REFRIGERANT SYSTEM. FAILURE TO
OBSERVE THESE WARNINGS MAY RESULT IN PER-
SONAL INJURY.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
RECOVERY/RECYCLING STATION
When servicing the air conditioning system, a
R-134a refrigerant recovery/recycling/charging sta-
tion that meets SEA Standard J2210 must be used
(Fig. 2). Contact an automotive service equipment
supplier for refrigerant recovery/recycling/charging
equipment. See the operating instructions supplied
by the equipment manufacturer for proper care and
use of this equipment.
RSPLUMBING - FRONT24-69
PLUMBING - FRONT (Continued)

MANIFOLD GAUGE SET
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
A manifold gauge set may be needed with some
recovery/recycling/charging equipment (Fig. 3). The
service hoses on the gauge set being used should
have manual (turn wheel), or automatic back-flow
valves at the service port connector ends. This will
prevent refrigerant from being released into the
atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
²LOW PRESSURE GAUGE HOSE- The low
pressure hose (Blue with Black stripe) attaches to
the low side service port. This service port is located
on the suction line near the A/C compressor.
²HIGH PRESSURE GAUGE HOSE- The high
pressure hose (Red with Black stripe) attaches to the
high side service port. This service port is located on
the liquid line fitting at the reciever/drier.
²RECOVERY/RECYCLING/EVACUATION/
CHARGING HOSE- The center manifold hose (Yel-
low, or White, with Black stripe) is used to recover,
evacuate, and charge the refrigerant system. When
the low or high pressure valves on the manifold
gauge set are opened, the refrigerant in the system
will escape through this hose.
REFRIGERANT SYSTEM RECOVERY
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).
A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to recover the refrigerant from an R-134a refrig-
erant system. Refer to the operating instructions sup-
plied by the equipment manufacturer for the proper
care and use of this equipment.
REFRIGERANT SYSTEM EVACUATE
NOTE: Special effort must be used to prevent mois-
ture from entering the A/C system oil. Moisture in
the oil is very difficult to remove and will cause a
reliability problem with the compressor.
Fig. 2 Refrigerant Recovery/Recycling Station -
Typical
1 - R-134a REFRIGERANT STATION
Fig. 3 Manifold Gauge Set - Typical
1 - HIGH PRESSURE GAUGE
2 - VALVE
3 - VACUUM/REFRIGERANT HOSE (YELLOW W/BLACK STRIPE)
4 - HIGH PRESSURE HOSE (RED W/BLACK STRIPE)
5 - LOW PRESSURE HOSE (BLUE W/BLACK STRIPE)
6 - VALVE
7 - LOW PRESSURE GAUGE
24 - 70 PLUMBING - FRONTRS
PLUMBING - FRONT (Continued)

If a compressor designed to use R-134a refrigerant
is left open to the atmosphere for an extended period
of time. It is recommended that the refrigerant oil be
drained and replaced with new oil or a new compres-
sor be used. This will eliminate the possibility of con-
taminating the refrigerant system.
If the refrigerant system has been open to the
atmosphere, it must be evacuated before the system
can be filled. Moisture and air mixed with the refrig-
erant will raise the compressor head pressure above
acceptable operating levels. This will reduce the per-
formance of the air conditioner and damage the com-
pressor. Moisture will boil at near room temperature
when exposed to vacuum. A R-134a refrigerant recov-
ery/recycling/charging station that meets SAE Stan-
dard J2210 must be used to evacuate the refrigerant
system. See the operating instructions supplied by
the equipment manufacturer for proper care and use
of this equipment. To evacuate the refrigerant sys-
tem, use the following procedure:
NOTE: When connecting the service equipment
couplings to the refrigerant system service ports,
be certain that the valve of each coupling is fully
closed. This will reduce the amount of effort
required to make the connection.
(1) Recover the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
(2) Connect a suitable charging station, refrigerant
recovery machine or a manifold gauge set with vac-
uum pump and refrigerant recovery equipment.
(3) Open the suction and discharge valves and
start the vacuum pump. The vacuum pump should
run a minimum of 45 minutes prior to charge to
eliminate all moisture in system. When the suction
gauge reads -88 kPa (-26 in. Hg) vacuum or greater
for 30 minutes, close all valves and turn off vacuum
pump. If the system fails to reach specified vacuum,
the refrigerant system likely has a leak that must be
corrected. If the refrigerant system maintains speci-
fied vacuum for at least 30 minutes, start the vac-
uum pump, open the suction and discharge valves.
Then allow the system to evacuate an additional 10
minutes.
(4) Close all valves. Turn off and disconnect the
vacuum pump.
(5) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).REFRIGERANT SYSTEM CHARGE
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).
After all refrigerant system leaks have been
repaired and the refrigerant system has been evacu-
ated, a refrigerant charge can be injected into the
system. For the proper amount of the refrigerant
charge, refer to REFRIGERANT CHARGE CAPAC-
ITY. A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to charge the refrigerant system with R-134a
refrigerant. See the operating instructions supplied
by the equipment manufacturer for proper care and
use of this equipment.
REFRIGERANT CHARGE CAPACITY
NOTE: Always refer to the underhood HVAC Speci-
fication Label for the refrigerant fill specification of
the vehicle being serviced.
CHARGING PROCEDURE
CAUTION: A small amount of refrigerant oil is
removed from the A/C system each time the refrig-
erant system is recovered and evacuated. Before
charging the A/C system, you MUST replenish any
oil lost during the recovery process. Refer the
equipment manufacturer instructions for more infor-
mation.
(1) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(2) A manifold gauge set and a R-134a refrigerant
recovery/recycling/charging station that meets SAE
Standard J2210 should still be connected to the
refrigerant system.
(3) Measure the proper amount of refrigerant and
heat it to 52É C (125É F) with the charging station.
See the operating instructions supplied by the equip-
ment manufacturer for proper use of this equipment.
RSPLUMBING - FRONT24-71
PLUMBING - FRONT (Continued)

rest of the system must be drained from the replace-
ment A/C compressor. The oil capacity of the system,
minus the amount of oil still in the remaining com-
ponents (refer to the oil capacity chart below) can be
measured and poured into the suction port of the A/C
compressor. When a line or component has ruptured
and oil has escaped, the receiver/drier must be
replaced along with the ruptured component.
Example: On this A/C system the front A/C evapo-
rator retains 50 ml. (1.7 oz.). The A/C condenser
retains 50 ml. (1.7 oz.) of oil, and front A/C system oil
capacity is 180 ml. (6.1 oz.).
180 ml. ± 100 ml. = 80 ml. (2.7 oz.).
A/C COMPONENT REFRIGERANT OIL
CAPACITIES
Front A/C Front & Rear
A/C
COMPONENT ml fl oz ml fl oz
Total System Fill 180 6.1 230 7.8
Receiver/Drier 25 0.8 25 0.8
A/C Condenser 50 1.7 50 1.7
Front Evaporator 50 1.7 50 1.7
Rear Evap. (including
underbody lines)N/A N/A 50 1.7
A/C Compressor Drain and measure the oil
from the old A/C compressor
- See text above.
VERIFY REFRIGERANT LUBRICANT LEVEL
(1) Recover the refrigerant from the system.
(2) Disconnect the refrigerant lines from the A/C
compressor. Cap open lines to prevent moisture from
entering the system.
(3) Remove A/C compressor from the vehicle.
(4) From the suction and discharge ports on the
A/C compressor, drain the lubricant from the com-
pressor.
(5) Add the system capacity minus the capacity of
the components that have not been replaced. Refer to
the A/C Component Refrigerant Oil Capacities chart.
Add lubricant through the suction and discharge
ports on the A/C compressor.
(6) Install the A/C compressor and connect the
refrigerant lines. Then evacuate and charge refriger-
ant system.
(7) Most reclaim/recycling equipment will measure
the lubricant being removed. This amount of lubri-
cant should be added back to the system. If a new
A/C compressor is being installed, drain the lubricant
from the used compressor, measure the amount
drained and discard the used lubricant. Drain the
lubricant from the new A/C compressor into a cleancontainer. Return the amount of lubricant measured
from the used compressor, plus the amount reclaimed
from the system back into the new A/C compressor.
Refer to the reclaim/recycling equipment manufactur-
ers instructions.
SERVICE PORT VALVE CORE
DESCRIPTION
A/C SERVICE PORT VALVE CORES
The low side valve is located on the suction line
near the A/C compressor. The low side A/C service
port valve core is a serviceable item. The high side
A/C service port valve core is located on the liquid
line fitting attached to the top of the receiver/drier.
The high side A/C service port valve core is not a sep-
arate serviceable item. If the high side service port
valve core is faulty or damaged, the front section of
the liquid line will require replacement.
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).
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Using a standard Schrader-type valve core tool,
remove the valve core from the low side A/C service
port located on the suction line.
(3) Install a plug in or tape over the opened low
side A/C service port.
INSTALLATION
(1) Lubricate the low side A/C service port valve
core with clean refrigerant oil prior to installation.
Use only refrigerant oil of the type recommended for
the compressor in the vehicle.
(2) Remove the tape or plug from the A/C service
port located on the suction line near the A/C com-
pressor.
(3) Using a standard Schrader-type valve core tool,
install and tighten the replacement valve core into
the low side A/C service port.
RSPLUMBING - FRONT24-95
REFRIGERANT OIL (Continued)

DIAGNOSIS AND TESTING
REAR A/C EXPANSION VALVE
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: The expansion valve should only be tested
following testing of the compressor.
NOTE: Liquid CO
2is required to test the expansion
valve. This material is available from most welding
supply facilities. Liquid CO
2is also available from
companies which service and sell fire extinguish-
ers.
When testing the expansion valve, the work area
and the vehicle temperature must be 21É to 27É C
(70É to 85É F). To test the expansion valve:
(1) Connect a charging station or manifold gauge
set to the refrigerant system service ports. Verify the
refrigerant charge level.
(2) Close all doors, windows and vents to the pas-
senger compartment.
(3) Set the heater-air conditioner controls so that
the compressor is operating, the temperature control
is in the highest temperature position, the mode door
is directing the output to the floor outlets, and the
blower is operating at the highest speed setting.
(4) Start the engine and allow it to idle at 1000
rpm. After the engine has reached normal operating
temperature, allow the passenger compartment to
heat up. This will create the need for maximum
refrigerant flow into the evaporator.
(5) If the refrigerant charge is sufficient, the dis-
charge (high pressure) gauge should read 965 to 1655
kPa (140 to 240 psi). The suction (low pressure)
gauge should read 140 kPa to 207 kPa (20 psi to 30
psi). If OK, go to Step 6. If not OK, replace the faulty
expansion valve.
WARNING: PROTECT THE SKIN AND EYES FROM
EXPOSURE TO LIQUID CO
2. PERSONAL INJURY
CAN RESULT.
(6)
If the suction (low pressure) gauge reads within
the specified range, freeze the expansion valve control
head for 30 seconds using liquid CO
2or another suit-
able super-cold material.Do not spray R-134a or
R-12 refrigerant on the expansion valve controlhead for this test.
The suction (low pressure) gauge
reading should drop by 10 psi. If OK, go to Step 7 If
not OK, replace the faulty expansion valve.
(7) Allow the expansion valve control head to thaw.
The suction (low pressure) gauge reading should sta-
bilize at 140 kPa to 240 kPa (20 psi to 30 psi). If not
OK, replace the faulty expansion valve.
(8) When expansion valve testing is complete, test
the overall air conditioner performance (Refer to 24 -
HEATING & AIR CONDITIONING - DIAGNOSIS
AND TESTING - A/C PERFORMANCE TEST).
Remove all test equipment before returning the vehi-
cle to 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), (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - CAUTION - A/C PLUMBING), and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - WARNING - HEATER PLUMBING).
(1) Remove the rear HVAC housing from the vehi-
cle (Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).
(2) Carefully remove the foam insulator wrap from
the rear expansion valve.
(3) Remove the rear evaporator line extension from
the expansion valve (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - REAR/EVAPORA-
TOR - REMOVAL - EVAPORATOR LINE EXTEN-
SION).
(4) Remove the two screws that secure the expan-
sion valve to the evaporator tube sealing plate.
(5) Remove the expansion valve from the evapora-
tor tubes.
(6) Remove the seals from the evaporator tube fit-
tings and discard.
(7) Install plugs in, or tape over the opened evap-
orator tube fittings and both expansion valve ports.
INSTALLATION
(1) Remove the tape or plugs from the rear A/C
evaporator tube fittings and both expansion valve
ports.
(2) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the rear evapora-
tor tube fittings.
(3) Position the expansion valve onto the evapora-
tor tubes.
(4) Install the two screws that secure the rear A/C
expansion valve to the evaporator tube sealing plate.
Tighten the screws to 11 N´m (97 in. lbs.).
RSPLUMBING - REAR24 - 101
A/C EXPANSION VALVE (Continued)

ENGINE OIL PRESSURE - DIAGNOSISAND TESTING, CHECKING ...............9-53
ENGINE, SPECIAL TOOLS - 2.4L ..........9-21
ENGINE, SPECIAL TOOLS - 3.3/3.8L .......9-98
ENGINE, SPECIFICATIONS - 3.3/3.8L ......9-93
ENGINE SPEED SENSOR - DESCRIPTION . . 14-30
ENGINE SPEED SENSOR - OPERATION ....14-30
ENGINE, STANDARD PROCEDURE - HYDROSTATIC LOCKED .............9-10,9-87
ENGINES - DESCRIPTION, ENGINE OIL - DIESEL ..............................0-6
ENGINES - EXPORT - DESCRIPTION, DIESEL ............................. 0-21
ENGINES, INSTALLATION - 2.4L/3.3L/ 3.8L ............................... 24-77
ENGINES, INSTALLATION - 2.5L/2.8L DIESEL ............................ 24-78
ENGINES, REMOVAL - 2.4L/3.3L/3.8L .....24-76
ENGINES, REMOVAL - 2.5L/2.8L DIESEL . . 24-77
ENTRY MODULE - DESCRIPTION, SENTRY KEY REMOTE .................8Q-3
ENTRY MODULE - DIAGNOSIS AND TESTING, SENTRY KEY REMOTE .........8Q-5
ENTRY MODULE - INSTALLATION, SENTRY KEY REMOTE .................8Q-6
ENTRY MODULE - OPERATION, SENTRY KEY REMOTE ........................ 8Q-4
ENTRY MODULE - REMOVAL, SENTRY KEY REMOTE ........................ 8Q-6
ENTRY SYSTEM - DIAGNOSIS AND TESTING, SENTRY KEY REMOTE .........8Q-3
ENTRY TRANSMITTER, DIAGNOSIS AND TESTING - KEYLESS .................. 8N-24
ENTRY TRANSMITTER PROGRAMMING - STANDARD PROCEDURE, REMOTE
KEYLESS ........................... 8N-24
EQUIPMENT, STANDARD PROCEDURE - REFRIGERANT SYSTEM SERVICE ........24-69
ERASING TRANSMITTER CODES, STANDARD PROCEDURE ..............8M-12
EVACUATE, STANDARD PROCEDURE - REFRIGERANT SYSTEM ...............24-70
EVAP CANISTER - INSTALLATION, REAR . . 25-21
EVAP CANISTER - REMOVAL, REAR ......25-20
EVAPORATION CONTROL SYSTEM - OPERATION ......................... 25-11
EVAPORATOR - DESCRIPTION, A/C . 24-80,24-98
EVAPORATOR - INSTALLATION, A/C ......24-81
EVAPORATOR - OPERATION, A/C . . . 24-80,24-98
EVAPORATOR - REMOVAL, A/C ..........24-81
EVAPORATOR, INSTALLATION - REAR A/C............................... 24-100
EVAPORATOR LINE EXTENSION, INSTALLATION - REAR A/C ............24-100
EVAPORATOR LINE EXTENSION, REMOVAL - REAR A/C .................24-99
EVAPORATOR, REMOVAL - REAR A/C .....24-98
EVAPORATOR TEMPERATURE SENSOR - DESCRIPTION ....................... 24-26
EVAPORATOR TEMPERATURE SENSOR - OPERATION ......................... 24-27
EVAP/PURGE SOLENOID - DESCRIPTION . . 25-13
EVAP/PURGE SOLENOID - INSTALLATION . 25-13
EVAP/PURGE SOLENOID - OPERATION ....25-13
EVAP/PURGE SOLENOID - REMOVAL .....25-13
EXCESSIVE EXHAUST SYSTEM NOISE - DIAGNOSIS AND TESTING ..............11-2
EXHAUST MANIFOLD - CLEANING ........9-63
EXHAUST MANIFOLD - INSPECTION .......9-63
EXHAUST MANIFOLD - INSTALLATION .....9-63
EXHAUST MANIFOLD - LEFT - CLEANING . . 9-154
EXHAUST MANIFOLD - LEFT - INSPECTION ........................ 9-155
EXHAUST MANIFOLD - LEFT - INSTALLATION ....................... 9-155
EXHAUST MANIFOLD - LEFT - REMOVAL . . 9-154
EXHAUST MANIFOLD - REMOVAL .........9-63
EXHAUST MANIFOLD - RIGHT - CLEANING .......................... 9-153
EXHAUST MANIFOLD - RIGHT - INSPECTION ........................ 9-153
EXHAUST MANIFOLD - RIGHT - INSTALLATION ....................... 9-153
EXHAUST MANIFOLD - RIGHT - REMOVAL .......................... 9-152
EXHAUST SYSTEM - DESCRIPTION .......11-1
EXHAUST SYSTEM NOISE - DIAGNOSIS AND TESTING, EXCESSIVE ..............11-2EXHAUST SYSTEM RESTRICTION CHECK
- DIAGNOSIS AND TESTING .............11-2
EXHAUST SYSTEM, SPECIAL TOOLS ......11-4
EXHAUST TUBE - INSTALLATION .......24-116
EXHAUST TUBE - REMOVAL ...........24-116
EXHAUSTER - DESCRIPTION, REAR QUARTER PANEL/FENDER AIR ..........23-59
EXHAUSTER - INSTALLATION, REAR QUARTER PANEL/FENDER AIR ..........23-60
EXHAUSTER - REMOVAL, REAR QUARTER PANEL/FENDER AIR ..........23-59
EXPANSION VALVE - DESCRIPTION ......24-81
EXPANSION VALVE - DESCRIPTION, A/C . 24-100
EXPANSION VALVE - OPERATION ........24-81
EXPANSION VALVE - OPERATION, A/C . . . 24-100
EXPANSION VALVE, DIAGNOSIS AND TESTING - FRONT A/C .................24-82
EXPANSION VALVE, DIAGNOSIS AND TESTING - REAR A/C .................24-101
EXPORT - ANTENNA MODULE ..........8A-10
EXPORT - BRAKE ROTOR ...............5-60
EXPORT - DESCRIPTION ................5-63
EXPORT - DESCRIPTION ................0-13
EXPORT - DESCRIPTION ................2-10
EXPORT - DESCRIPTION, ANTENNA MODULE ........................... 8A-10
EXPORT - DESCRIPTION, DIESEL ENGINES ............................ 0-21
EXPORT - DESCRIPTION, DOOR CYLINDER LOCK SWITCH ...............8N-22
EXPORT - DESCRIPTION, POWER FOLDAWAY MIRROR SWITCH ..........8N-29
EXPORT - DESCRIPTION, QUARTER GLASS INTEGRAL ANTENNA ............8A-13
EXPORT - DOOR CYLINDER LOCK SWITCH ............................ 8N-22
EXPORT - INSTALLATION ...............5-68
EXPORT - INSTALLATION ...............2-11
EXPORT - INSTALLATION, HEADLAMP UNIT .............................. 8L-17
EXPORT - INSTALLATION, HOOD AJAR SWITCH ............................ 8Q-3
EXPORT - INSTALLATION, POWER FOLDAWAY MIRROR SWITCH ..........8N-30
EXPORT - OPERATION, ANTENNA MODULE ........................... 8A-10
EXPORT - OPERATION, DOOR CYLINDER LOCK SWITCH ....................... 8N-22
EXPORT - OPERATION, POWER FOLDAWAY MIRROR SWITCH ..........8N-29
EXPORT - OPERATION, QUARTER GLASS INTEGRAL ANTENNA .................. 8A-13
EXPORT - QUARTER GLASS INTEGRAL ANTENNA .......................... 8A-13
EXPORT - REMOVAL ................... 5-67
EXPORT - REMOVAL ................... 2-11
EXPORT - REMOVAL, HEADLAMP UNIT . . . 8L-17
EXPORT - REMOVAL, HOOD AJAR SWITCH ............................ 8Q-3
EXPORT - REMOVAL, POWER FOLDAWAY MIRROR SWITCH ..........8N-29
EXPORT - STANDARD PROCEDURE, FRONT FOG LAMP UNIT ALIGNMENT ......8L-9
EXPORT - STANDARD PROCEDURE, HEADLAMP UNIT ALIGNMENT ..........8L-15
EXTENSION, INSTALLATION - REAR A/C EVAPORATOR LINE .................. 24-100
EXTENSION, REMOVAL - REAR A/C EVAPORATOR LINE ................... 24-99
EXTENSION TRIM - INSTALLATION, A-PILLAR LOWER .................... 23-79
EXTENSION TRIM - REMOVAL, A-PILLAR LOWER ............................ 23-79
EXTERIOR - DESCRIPTION, LAMPS/ LIGHTING ........................... 8L-2
EXTERIOR - OPERATION, LAMPS/ LIGHTING ........................... 8L-2
EXTERIOR - WARNING, LAMPS/ LIGHTING ........................... 8L-3
EXTERIOR HANDLE - INSTALLATION .....23-22,
23-40
EXTERIOR HANDLE - REMOVAL ....23-21,23-40
EXTERIOR HANDLE SWITCH - DESCRIPTION ....................... 8N-10
EXTERIOR HANDLE SWITCH - INSTALLATION ...................... 8N-10
EXTERIOR HANDLE SWITCH - OPERATION ......................... 8N-10EXTERIOR HANDLE SWITCH - REMOVAL . . 8N-10
EXTERIOR LAMPS, SPECIFICATIONS
......8L-3
EXTERIOR NAME PLATES - ADHESIVE ATTACHED - INSTALLATION ............23-51
EXTERIOR NAME PLATES - ADHESIVE ATTACHED - REMOVAL ................23-51
EXTERIOR NAME PLATES - TAPE ATTACHED - INSTALLATION ............23-51
EXTERIOR NAME PLATES - TAPE ATTACHED - REMOVAL ................23-51
FACTOR SETTING - STANDARD PROCEDURE, PINION .................8E-15
FAILED PARK SWITCH - DIAGNOSIS AND TESTING ............................ 8R-2
FAN - DESCRIPTION, RADIATOR ..........7-29
FAN - INSTALLATION, RADIATOR .........7-30
FAN - OPERATION, RADIATOR ...........7-29
FAN - REMOVAL, RADIATOR .............7-30
FAN MOTOR - DIAGNOSIS AND TESTING, RADIATOR ................... 7-30
FAN RELAY - DESCRIPTION, RADIATOR ....7-31
FAN RELAY - INSTALLATION, RADIATOR . . . 7-31
FAN RELAY - OPERATION, RADIATOR ......7-31
FAN RELAY - REMOVAL, RADIATOR .......7-31
FASCIA - INSTALLATION, FRONT .........13-1
FASCIA - INSTALLATION, REAR ..........13-4
FASCIA - REMOVAL, FRONT .............13-1
FASCIA - REMOVAL, REAR ..............13-4
FASCIA - SCUFF PAD - INSTALLATION, REAR ............................... 13-5
FASCIA - SCUFF PAD - REMOVAL, REAR . . . 13-5
FASTENER TORQUE, SPECIFICATIONS - ABS ................................ 5-91
FASTENER TORQUE, SPECIFICATIONS - BRAKE ...............................5-9
FASTENER TORQUE, SPECIFICATIONS - COLUMN ........................... 19-17
FASTENER TORQUE, SPECIFICATIONS - FRONT SUSPENSION ...................2-3
FASTENER TORQUE, SPECIFICATIONS - POWER STEERING .................... 19-9
FASTENER TORQUE, SPECIFICATIONS - REAR SUSPENSION ................... 2-28
FEED CIRCUIT RESISTANCE TEST - DIAGNOSIS AND TESTING ..............8F-35
FEED CIRCUIT TEST - DIAGNOSIS AND TESTING ........................... 8F-36
FENDER - INSTALLATION, FRONT ........23-52
FENDER - REMOVAL, FRONT ...........23-51
FFV REPLACEMENT PARTS - DESCRIPTION ........................ 14-2
FILL - DIAGNOSIS AND TESTING, VEHICLE DOES NOT .................. 25-17
FILL DOOR - INSTALLATION, FUEL .......23-52
FILL DOOR - REMOVAL, FUEL ..........23-52
FILL DOOR BLOCKER LATCH - INSTALLATION, FUEL .................23-53
FILL DOOR BLOCKER LATCH - REMOVAL, FUEL ..................... 23-53
FILL DOOR BLOCKER LATCH STRIKER - INSTALLATION, FUEL .................23-53
FILL DOOR BLOCKER LATCH STRIKER - REMOVAL, FUEL ..................... 23-53
FILL DOOR BLOCKER LOCKOUT LINK - INSTALLATION, FUEL .................23-54
FILL DOOR BLOCKER LOCKOUT LINK - REMOVAL, FUEL ..................... 23-54
FILL/CHECK LOCATIONS - DESCRIPTION, FLUID ...............................0-7
FILLER CAP - DESCRIPTION, FUEL .......25-13
FILLER CAP - OPERATION, FUEL ........25-13
FILLER NECK SEAL - DIAGNOSIS AND TESTING, RADIATOR CAP TO ............7-28
FILLER TUBE - INSTALLATION, FUEL TANK .............................. 14-17
FILLER TUBE - REMOVAL, FUEL TANK ....14-16
FILLING - STANDARD PROCEDURE, COOLING SYSTEM .....................7-4
FILLING, STANDARD PROCEDURE - REAR HEATER CORE .................24-102
FILTER - DESCRIPTION, AIR ............24-42
FILTER - DESCRIPTION, OIL .............9-54
FILTER - INSTALLATION, AIR ...........24-43
FILTER - INSTALLATION, INLET ..........14-17
FILTER - INSTALLATION, OIL .......9-141,9-54
FILTER - REMOVAL, AIR ...............24-42
FILTER - REMOVAL, INLET .............14-17
FILTER - REMOVAL, OIL ...........9-141,9-54
12 INDEXRS
Description Group-Page Description Group-Page Description Group-Page

QUAD BUCKET - REMOVAL, BUCKETSEAT BACK ........................ 23-140
QUAD BUCKET - REMOVAL, SEAT BELT BUCKLE - FIRST ROW INBOARD ........8O-35
QUAD BUCKET, 50/50 SPLIT, BENCH - INSTALLATION, SEAT BACK HINGE
COVERS ........................... 23-146
QUAD BUCKET, 50/50 SPLIT, BENCH - INSTALLATION, SEAT CUSHION COVER . . 23-144
QUAD BUCKET, 50/50 SPLIT, BENCH - REMOVAL, SEAT BACK HINGE COVERS . . 23-146
QUAD BUCKET, 50/50 SPLIT, BENCH - REMOVAL, SEAT CUSHION COVER ......23-144
QUAD BUCKET SEAT RISER - INSTALLATION ...................... 23-143
QUAD BUCKET SEAT RISER - REMOVAL . 23-143
QUAD BUCKET SEAT SIDE SHIELD - NO CUP HOLDER - INSTALLATION .........23-143
QUAD BUCKET SEAT SIDE SHIELD - NO CUP HOLDER - REMOVAL .............23-143
QUAD BUCKET SEAT SIDE SHIELD/CUP HOLDER - FLAP AND SPRING
ASSEMBLY - INSTALLATION ...........23-151
QUAD BUCKET SEAT SIDE SHIELD/CUP HOLDER - FLAP AND SPRING
ASSEMBLY - REMOVAL ...............23-151
QUAD BUCKET SEAT SIDE SHIELD/CUP HOLDER - INSTALLATION .............23-142
QUAD BUCKET SEAT SIDE SHIELD/CUP HOLDER - REMOVAL .................23-141
QUAD CHILD SEAT - INSTALLATION .....23-106
QUAD CHILD SEAT - REMOVAL ........23-106
QUAD SEAT CUSHION - INSTALLATION . . 23-141
QUAD SEAT CUSHION - REMOVAL ......23-141
QUARTER GLASS INTEGRAL ANTENNA - EXPORT - DESCRIPTION ...............8A-13
QUARTER GLASS INTEGRAL ANTENNA - EXPORT - OPERATION ................8A-13
QUARTER GLASS INTEGRAL ANTENNA, EXPORT ............................ 8A-13
QUARTER PANEL/FENDER AIR EXHAUSTER - DESCRIPTION, REAR ......23-59
QUARTER PANEL/FENDER AIR EXHAUSTER - INSTALLATION, REAR .....23-60
QUARTER PANEL/FENDER AIR EXHAUSTER - REMOVAL, REAR .........23-59
QUARTER TRIM BOLSTER - INSTALLATION ....................... 23-95
QUARTER TRIM BOLSTER - REMOVAL ....23-95
QUARTER TRIM PANEL - INSTALLATION, LEFT .............................. 23-94
QUARTER TRIM PANEL - INSTALLATION, RIGHT ............................. 23-97
QUARTER TRIM PANEL - REMOVAL, LEFT .............................. 23-94
QUARTER TRIM PANEL - REMOVAL, RIGHT ............................. 23-97
QUARTER WINDOW - INSTALLATION ....23-164
QUARTER WINDOW - REMOVAL ........23-164
QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLY -
STANDARD PROCEDURE,
TRANSMISSION COOLER LINE ...........7-38
QUICK LEARN PROCEDURE - STANDARD PROCEDURE ........................ 8E-15
QUICK-CONNECT FITTINGS - STANDARD PROCEDURE ........................ 14-18
RACK - DESCRIPTION, LOWER DRIVE UNIT TRACK ........................ 8N-57
RACK - INSTALLATION, LOWER DRIVE UNIT TRACK ........................ 8N-58
RACK - OPERATION, LOWER DRIVE UNIT TRACK ............................. 8N-57
RACK - REMOVAL, LOWER DRIVE UNIT TRACK ............................. 8N-57
RACK CROSSBAR - INSTALLATION, LUGGAGE .......................... 23-59
RACK CROSSBAR - REMOVAL, LUGGAGE . 23-58
RACK RISER - INSTALLATION, LUGGAGE . . 23-58
RACK RISER - REMOVAL, LUGGAGE .....23-57
RADIAL-PLY TIRES - DESCRIPTION ......22-13
RADIATOR - INSTALLATION .............7-27
RADIATOR - REMOVAL .................7-26
RADIATOR CAP TO FILLER NECK SEAL - DIAGNOSIS AND TESTING ..............7-28
RADIATOR CROSSMEMBER - INSTALLATION, UPPER ................23-56RADIATOR CROSSMEMBER - REMOVAL,
UPPER ............................. 23-56
RADIATOR DRAINCOCK - INSTALLATION . . . 7-27
RADIATOR DRAINCOCK - REMOVAL .......7-27
RADIATOR FAN - DESCRIPTION ..........7-29
RADIATOR FAN - INSTALLATION ..........7-30
RADIATOR FAN - OPERATION ............7-29
RADIATOR FAN - REMOVAL .............7-30
RADIATOR FAN MOTOR - DIAGNOSIS AND TESTING ........................ 7-30
RADIATOR FAN RELAY - DESCRIPTION ....7-31
RADIATOR FAN RELAY - INSTALLATION ....7-31
RADIATOR FAN RELAY - OPERATION ......7-31
RADIATOR FAN RELAY - REMOVAL .......7-31
RADIATOR PRESSURE CAP - DESCRIPTION ........................ 7-27
RADIATOR PRESSURE CAP - OPERATION . . 7-27
RADIO - DESCRIPTION ................8A-13
RADIO - INSTALLATION, ANTENNA - NAVIGATION ........................ 8A-11
RADIO - OPERATION ..................8A-14
RADIO - REMOVAL, ANTENNA - NAVIGATION ........................ 8A-11
RADIO, DIAGNOSIS AND TESTING .......8A-14
RADIO NOISE SUPPRESSION COMPONENTS - DESCRIPTION ..........8A-15
RADIO NOISE SUPPRESSION COMPONENTS - OPERATION ...........8A-15
RANGE - SPECIFICATIONS, TRANSMITTER ...................... 8N-24
RANGE SENSOR - DESCRIPTION, TRANSMISSION ............... 21-130,21-281
RANGE SENSOR - INSTALLATION, TRANSMISSION ............... 21-131,21-282
RANGE SENSOR - OPERATION, TRANSMISSION ............... 21-131,21-282
RANGE SENSOR - REMOVAL, TRANSMISSION ............... 21-131,21-282
READING LAMP - INSTALLATION ........8L-23
READING LAMP - REMOVAL ............8L-22
RECEIVER / DRIER - DESCRIPTION ......24-92
RECEIVER / DRIER - INSTALLATION ......24-93
RECEIVER / DRIER - OPERATION ........24-92
RECEIVER / DRIER - REMOVAL .........24-92
RECIRCULATION DOOR ACTUATOR - DESCRIPTION ....................... 24-31
RECIRCULATION DOOR ACTUATOR - INSTALLATION ....................... 24-32
RECIRCULATION DOOR ACTUATOR - OPERATION ......................... 24-31
RECIRCULATION DOOR ACTUATOR - REMOVAL .......................... 24-32
RECLINER HANDLE - INSTALLATION ....23-108
RECLINER HANDLE - REMOVAL ........23-108
RECLINER/FOLD FORWARD MECHANISM -THIRD ROW -FOLD-IN-FLOOR -
INSTALLATION, SEAT .................23-160
RECLINER/FOLD FORWARD MECHANISM -THIRD ROW -FOLD-IN-FLOOR -
REMOVAL, SEAT .................... 23-160
RECLINER/FORWARD FOLDING MECHANISM -SECOND ROW
-FOLD-IN-FLOOR - INSTALLATION,
SEAT ............................. 23-137
RECLINER/FORWARD FOLDING MECHANISM -SECOND ROW
-FOLD-IN-FLOOR - REMOVAL, SEAT .....23-137
RECOVERY CONTAINER - DESCRIPTION, COOLANT ............................ 7-20
RECOVERY CONTAINER - INSTALLATION, COOLANT ............................ 7-20
RECOVERY CONTAINER - OPERATION, COOLANT ............................ 7-20
RECOVERY CONTAINER - REMOVAL, COOLANT ............................ 7-20
RECOVERY, STANDARD PROCEDURE - REFRIGERANT SYSTEM ...............24-70
RECOVERY SYSTEM - DIAGNOSIS AND TESTING, COOLANT ................... 7-20
REFACING VALVES AND VALVE SEATS - STANDARD PROCEDURE ...............9-107
REFRIGERANT - DESCRIPTION ..........24-93
REFRIGERANT - OPERATION ............24-94
REFRIGERANT LINES, INSTALLATION - UNDERBODY ....................... 24-112
REFRIGERANT LINES, REMOVAL - UNDERBODY ....................... 24-110
REFRIGERANT OIL - DESCRIPTION ......24-94 REFRIGERANT OIL - OPERATION
........24-94
REFRIGERANT OIL LEVEL, STANDARD PROCEDURE ........................ 24-94
REFRIGERANT SYSTEM CHARGE, STANDARD PROCEDURE ...............24-71
REFRIGERANT SYSTEM EVACUATE, STANDARD PROCEDURE ...............24-70
REFRIGERANT SYSTEM LEAKS, DIAGNOSIS AND TESTING .............24-67
REFRIGERANT SYSTEM RECOVERY, STANDARD PROCEDURE ...............24-70
REFRIGERANT SYSTEM SERVICE EQUIPMENT, STANDARD PROCEDURE ....24-69
REGULATOR - DESCRIPTION, VOLTAGE . . . 8F-30
REGULATOR - INSTALLATION, FUEL PRESSURE .......................... 14-7
REGULATOR - MANUAL - INSTALLATION, WINDOW ........................... 23-23
REGULATOR - MANUAL - REMOVAL, WINDOW ........................... 23-22
REGULATOR - OPERATION, FUEL PRESSURE .......................... 14-7
REGULATOR - OPERATION, VOLTAGE .....8F-30
REGULATOR - POWER - INSTALLATION, WINDOW ........................... 23-22
REGULATOR - POWER - REMOVAL, WINDOW ........................... 23-22
REGULATOR - REMOVAL, FUEL PRESSURE .......................... 14-7
REINFORCEMENT - INSTALLATION, FRONT BUMPER ...................... 13-3
REINFORCEMENT - INSTALLATION, REAR BUMPER .............................. 13-5
REINFORCEMENT - REMOVAL, FRONT BUMPER ............................ 13-3
REINFORCEMENT - REMOVAL, REAR BUMPER ............................ 13-5
RELAY - DESCRIPTION, A/C COMPRESSOR CLUTCH ...............24-18
RELAY - DESCRIPTION, AUTO SHUT DOWN .............................. 8I-3
RELAY - DESCRIPTION, BLOWER MOTOR ....................... 24-23,24-36
RELAY - DESCRIPTION, FUEL PUMP .....14-32
RELAY - DESCRIPTION, RADIATOR FAN ....7-31
RELAY - DESCRIPTION, REAR WINDOW DEFOGGER .......................... 8G-3
RELAY - DESCRIPTION, TRANSMISSION CONTROL ................... 21-130,21-281
RELAY - INSTALLATION, A/C COMPRESSOR CLUTCH ...............24-19
RELAY - INSTALLATION, BLOWER MOTOR ....................... 24-24,24-37
RELAY - INSTALLATION, RADIATOR FAN . . . 7-31
RELAY - INSTALLATION, REAR WINDOW DEFOGGER .......................... 8G-4
RELAY - OPERATION, A/C COMPRESSOR CLUTCH ............................ 24-18
RELAY - OPERATION, AUTO SHUT DOWN . . . 8I-3
RELAY - OPERATION, BLOWER MOTOR . . 24-23, 24-36
RELAY - OPERATION, FUEL PUMP .......14-32
RELAY - OPERATION, RADIATOR FAN ......7-31
RELAY - OPERATION, REAR WINDOW DEFOGGER .......................... 8G-3
RELAY - OPERATION, TRANSMISSION CONTROL ................... 21-130,21-281
RELAY - REMOVAL, A/C COMPRESSOR CLUTCH ............................ 24-19
RELAY - REMOVAL, BLOWER MOTOR ....24-24,
24-37
RELAY - REMOVAL, RADIATOR FAN .......7-31
RELAY - REMOVAL, REAR WINDOW DEFOGGER .......................... 8G-4
RELEASE - STANDARD PROCEDURE, PARKING BRAKE AUTOMATIC
ADJUSTER TENSION ................... 5-63
RELEASE CABLE - INSTALLATION, LATCH . 23-64
RELEASE CABLE - REMOVAL, LATCH .....23-63
RELEASE PROCEDURE - STANDARD PROCEDURE, FUEL SYSTEM
PRESSURE .......................... 14-2
RELIEF VALVE - INSTALLATION, OIL PRESSURE ......................... 9-144
RELIEF VALVE - REMOVAL, OIL PRESSURE ......................... 9-143
RELIEF VALVE, DESCRIPTION - HIGH PRESSURE ......................... 24-72
RS INDEX25
Description Group-Page Description Group-Page Description Group-Page