open gas tank CHRYSLER VOYAGER 2005 Service Manual

letter ªGº. Chassis lubricant is identified by the letter
ªLº. The letter following the usage letter indicates
the quality of the lubricant. The following symbols
indicate the highest quality.
SPECIALIZED LUBRICANTS AND OILS
Some maintenance or repair procedures may
require the use of specialized lubricants or oils. Con-
sult the appropriate sections in this manual for the
correct application of these lubricants.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less boiling protection.
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to theradiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769), or the equiva-
lent ethylene glycol base coolant with hybrid organic
corrosion inhibitors (called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% Ethylene Glycol and 50% distilled
water to obtain a freeze point of -37ÉC (-35ÉF). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu-
tion.
The green coolantMUST NOT BE MIXEDwith
the orange or magenta coolants. When replacing cool-
ant the complete system flush must be performed
before using the replacement coolant.
CAUTION: MoparTAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Doing so
will reduce the corrosion protection and may result
in premature water pump seal failure. If non-HOAT
coolant is introduced into the cooling system in an
emergency, it should be replaced with the specified
coolant as soon as possible.
DESCRIPTION - FLEXIBLE FUEL ENGINE OIL
The information in this section is for Flexible Fuel
Vehicles (FFV) only. These vehicles can be identified
by the unique Fuel Filler Door Label that states
Ethanol (E-85) or Unleaded Gasoline Only. This sec-
tion only covers those subjects that are unique to
these vehicles. Please refer to the other sections of
this manual for information on features that are
common between Flexible Fuel and gasoline only
powered vehicles.
ETHANOL FUEL (E-85)
E-85 is a mixture of approximately 85% fuel etha-
nol and 15% unleaded gasoline.
WARNING: Ethanol vapors are extremely flammable
and could cause serious personal injury. Never
have any smoking materials lit in or near the vehi-
cle when removing the fuel filler tube cap (gas cap)
or filling the tank. Do not use E-85 as a cleaning
agent and never use it near an open flame.
FUEL REQUIREMENTS
The vehicle will operate on both unleaded gasoline
with an octane rating of 87, or E-85 fuel, or any mix-
ture of these two.
Fig. 4 NLGI SYMBOL
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
RSLUBRICATION & MAINTENANCE0-3
FLUID TYPES (Continued)

DIAGNOSIS AND TESTING - COOLING SYSTEM
AERATION
Low coolant level in a cross flow radiator will
equalize in both tanks with engine off. With engine
at running and at operating temperature, the high
pressure inlet tank runs full and the low pressure
outlet tank drops, resulting in cooling system aera-
tion. Aeration will draw air into the water pump
resulting in the following:
²High reading shown on the temperature gauge.
²Loss of coolant flow through the heater core.
²Corrosion in the cooling system.
²Water pump seal may run dry, increasing the
risk of premature seal failure.
²Combustion gas leaks into the coolant can also
cause the above problems.
DIAGNOSIS AND TESTING - COOLING SYSTEM
DEAERATION
Air can only be removed from the system by gath-
ering under the pressure cap. On the next heat up it
will be pushed past the pressure cap into the coolant
recovery bottle by thermal expansion of the coolant.
It then escapes to the atmosphere in the coolant
recovery bottle and is replaced with coolant on cool
down.
To effectively deaerate the system, multiple ther-
mal cycles of the system may be required.
NOTE: Deaeration does not occur at engine idleÐ
higher engine speeds are required. Normal driving
will deaerate cooling system.
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLING SYSTEM
DRAINING
WARNING: DO NOT REMOVE OR LOOSEN THE
COOLANT PRESSURE CAP, CYLINDER BLOCK
DRAIN PLUGS, OR THE DRAINCOCK WHEN THE
SYSTEM IS HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
(1)Without removing radiator pressure cap
and with system not under pressure, using a
screwdriver, open the draincock. The draincock is
located on the lower left side of radiator.
(2) After the coolant recovery/reserve container is
empty, then remove coolant pressure cap (Fig. 5).
(3) Remove the cylinder block drain plug(s).
STANDARD PROCEDURE - COOLING SYSTEM
FILLING
Remove radiator pressure cap (Fig. 5) and fill sys-
tem, using a 50/50 mix of MopartAntifreeze/Coolant,
5 Year/100,000 Mile Formula and distilled water.
Continue filling system until full.Be careful not
to spill coolant on drive belts or the generator.
For cooling system capacity, (Refer to LUBRICATION
& MAINTENANCE/FLUID CAPACITIES - SPECIFI-
CATIONS).
Fill coolant recovery/reserve container (Fig. 5) to at
least the MAX mark with 50/50 solution. It may be
necessary to add coolant to the recovery/reserve con-
tainer after three or four warm up/cool down cycles
to maintain coolant level between the MAX and MIN
mark. This will allow trapped air to be removed from
the system.
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The radiator cap should not be removed.
When additional coolant is needed to maintain this
level, it should be added to the coolant recovery/re-
serve container (Fig. 5). Use only 50/50 mix of ethyl-
ene glycol type antifreeze and distilled water. For the
recommeded antifreeze/coolant type (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended. For the
recommeded antifreeze/coolant type (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
STANDARD PROCEDURE - COOLANT LEVEL
CHECK
NOTE: Do not remove radiator cap for routine cool-
ant level inspections.
The coolant reserve system provides a quick visual
method for determining the coolant level without
removing the radiator cap.With the engine cold
and not running,simply observe the level of the
coolant in the recovery/reserve container (Fig. 5). The
coolant level should be between the MIN and MAX
marks.
7 - 4 COOLINGRS
COOLING (Continued)

ENGINE
DIAGNOSIS AND TESTING - ENGINE COOLING
SYSTEM
Establish what driving condition caused the cooling
system complaint. The problem may be caused by an
abnormal load on the system such as the following:
prolonged idle, very high ambient temperature, slight
tail wind at idle, slow traffic speed, traffic jam, high
speed, steep grade.
DRIVING TECHNIQUES
To avoid overheating the cooling system:
(1) Idle with A/C off when temperature gauge is at
end of normal range.
(2) Do not increase engine speed for more air flow
and coolant flow because the electric motor fan sys-
tems are not responsive to engine RPM. The added
cooling from higher coolant flow rate is more than
offset by increased heat rejection (engine heat added
to coolant).
TRAILER TOWING
Consult the owner's manual under Trailer Towing
and do not exceed specified limits.
VISUAL INSPECTION
If the cooling system problem is not caused by a
driving condition, perform a visual inspection to
determine if there was a recent service or accident
repair, including the following:
²Loose/damaged water pump drive belt
²Incorrect cooling system refilling (trapped air or
low level)
²Brakes possibly dragging
²Damaged hoses
²Loose/damaged hose clamps
²Damaged/incorrect engine thermostat
²Damaged cooling fan motor, fan blade and fan
shroud
²Damaged head gasket
²Damaged water pump
²Damaged radiator
²Damaged coolant recovery system
²Damaged heater core
²Open/shorted electrical circuits
If the visual inspection reveals none of the above
as cause for a cooling system complaint, refer to the
following diagnostic charts.
COOLING SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT.
TEMPERATURE GAUGE READING
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK.1. Pressure relief valve in radiator
cap is defective, or was not
properly seated.1. Check condition of radiator cap
and cap seal. (Refer to 7 -
COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING) Replace cap as
necessary.
2. Incorrect cap was installed. 2. Replace cap as necessary.
3. Incorrect coolant mixture. 3. Check concentration level of the
coolant. (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS
AND TESTING) Adjust the ethylene
glycol-to-water ratio as required.
COOLANT LOSS TO THE
GROUND WITHOUT PRESSURE
CAP BLOWOFF. GAUGE IS
READING HIGH OR HOT.1. Coolant leaks in radiator, cooling
system hoses, water pump or
engine.1. Pressure test and repair as
necessary. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING)
7 - 14 ENGINERS

INSTALLATION
(1)Be sure the air seal is in position before
radiator is installed.Slide radiator down into posi-
tion. Seat the radiator with the rubber isolators into
the mounting holes provided, with a 10 lbs. force.
(2) Position air conditioning condenser onto the
radiator lower mounts and ingage upper mounting
tabs. (Fig. 15).
(3) Install the radiator upper and lower hoses (Fig.
13) or (Fig. 14).
(4) Connect the coolant reserve/recovery hose.
(5) Connect the vapor purge solenoid to the mount-
ing bracket.
(6) Install the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION)
(7) Install the radiator upper crossmember sup-
port. (Refer to 23 - BODY/EXTERIOR/GRILLE
OPENING REINFORCEMENT - INSTALLATION)
(8) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
(9) Connect negative cable to battery.
RADIATOR DRAINCOCK
REMOVAL
NOTE: It is not necessary to remove draincock dur-
ing a routine coolant drain.
(1) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Using a screwdriver, open the draincock by
turning it counterclockwise until it stops.
(3) Pull the draincock from the radiator tank.
INSTALLATION
(1) Align draincock stem to radiator tank opening.
(2) Push draincock into the radiator tank opening.
CAUTION: Do not overtighten. The head of the
draincock may break off.
(3) Using a screwdriver, tighten the draincock by
turning clockwise until it stops.
(4) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
RADIATOR PRESSURE CAP
DESCRIPTION
The cooling system pressure cap is located on the
radiator. The cap construction includes; stainless
steel swivel top, rubber seals, and retainer, main
spring, and a spring loaded valve (Fig. 16).
OPERATION
The cooling system is equipped with a pressure cap
that releases excessive pressure; maintaining a range
of 97-124 kPa (14-18 psi).
The cooling system will operate at higher than
atmospheric pressure. The higher pressure raises the
coolant boiling point thus, allowing increased radia-
tor cooling capacity.
There is also a vent valve in the center of the cap.
This valve also opens when coolant is cooling and
contracting, allowing the coolant to return to cooling
system from coolant reserve system tank by vacuum
through a connecting hose.If valve is stuck shut,
or the coolant recovery hose is pinched, the
radiator hoses will be collapsed on cool down.
Clean the vent valve (Fig. 16) and inspect cool-
ant recovery hose routing, to ensure proper
sealing when boiling point is reached.
The gasket in the cap seals the filler neck, so that
vacuum can be maintained, allowing coolant to be
drawn back into the radiator from the reserve tank.
If the gasket is dirty or damaged, a vacuum
may not be achieved, resulting is loss of coolant
and eventual overheating due to low coolant
level in radiator and engine.
Fig. 16 Cooling System Pressure Cap Filler Neck
1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - RADIATOR
8 - FILLER NECK
RSENGINE7-27
RADIATOR (Continued)

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM
PRESSURE CAP TESTING
Dip the pressure cap in water. Clean any deposits
off the vent valve or its seat and apply cap to end of
the Pressure Cap Test Adaptor that is included with
the Cooling System Tester 7700 (Fig. 17). Working
the plunger, bring the pressure to 104 kPa (15 psi) on
the gauge. If the pressure cap fails to hold pressure
of at least 97 kPa (14 psi), replace the pressure cap.
CAUTION: The Cooling System Tester Tool is very
sensitive to small air leaks that will not cause cool-
ing system problems. A pressure cap that does not
have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to the tool. Turn tool
upside down and recheck pressure cap to confirm
that cap is bad.
If the pressure cap tests properly while positioned
on Cooling System Tester (Fig. 17), but will not hold
pressure or vacuum when positioned on the filler
neck. Inspect the filler neck and cap top gasket for
irregularities that may prevent the cap from sealing
properly.
DIAGNOSIS AND TESTING - RADIATOR CAP
TO FILLER NECK SEAL
The pressure cap upper gasket (seal) pressure
relief can be checked by removing the overflow hose
at the radiator filler neck nipple (Fig. 18). Attach the
Radiator Pressure Tool to the filler neck nipple and
pump air into the radiator. Pressure cap upper gas-
ket should relieve at 69-124 kPa (10-18 psi) and hold
pressure at 55 kPa (8 psi) minimum.WARNING: THE WARNING WORDS ªDO NOT OPEN
HOTº ON THE RADIATOR PRESSURE CAP IS A
SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT OR UNDER PRESSURE.
There is no need to remove the radiator cap at any
timeexceptfor the following purposes:
(1) Check and adjust coolant freeze point.
(2) Refill system with new coolant.
(3) Conducting service procedures.
(4) Checking for vacuum leaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT 15 MINUTES BEFORE REMOVING CAP. THEN
PLACE A SHOP TOWEL OVER THE CAP AND WITH-
OUT PUSHING DOWN ROTATE COUNTERCLOCK-
WISE TO THE FIRST STOP. ALLOW FLUIDS TO
ESCAPE THROUGH THE OVERFLOW TUBE AND
WHEN THE SYSTEM STOPS PUSHING COOLANT
AND STEAM INTO THE CRS TANK AND PRESSURE
DROPS PUSH DOWN AND REMOVE THE CAP COM-
PLETELY. SQUEEZING THE RADIATOR INLET HOSE
WITH A SHOP TOWEL (TO CHECK PRESSURE)
BEFORE AND AFTER TURNING TO THE FIRST
STOP IS RECOMMENDED.
CLEANING
Use only a mild soap to clean the pressure cap.
Fig. 17 Testing Cooling System Pressure Cap
1 - PRESSURE CAP
2 - PRESSURE TESTER
Fig. 18 Radiator Pressure Cap Filler Neck
1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - RADIATOR
8 - FILLER NECK
7 - 28 ENGINERS
RADIATOR PRESSURE CAP (Continued)

(6) Open fuel fill door and remove screws mount-
ing fuel filler tube assembly to body. Do not discon-
nect rubber fuel fill or vent hoses from tank at this
time.
(7) Place a transmission jack under center of fuel
tank. Apply a slight amount of pressure to fuel tank
with transmission jack.
(8) Remove fuel tank mounting straps.
(9)Lower the tank just enough so that the
filler tube fitting is the highest point of the fuel
tank.
(10) Remove filler tube from fuel tank. Tank will
be drained through this fitting.
NOTE: WRAP SHOP TOWELS AROUND HOSES TO
CATCH ANY GASOLINE SPILLAGE.
(11) Drain fuel tank into holding tank or a prop-
erly labeledGasolinesafety container.
WARNING: GASOLINE OR GASOLINE VAPORS ARE
HIGHLY FLAMMABLE. A FIRE COULD OCCUR IF AN
IGNITION SOURCE IS PRESENT. NEVER DRAIN OR
STORE GASOLINE OR DIESEL FUEL IN AN OPEN
CONTAINER, DUE TO THE POSSIBILITY OF FIRE
OR EXPLOSION. THIS MAY RESULT IN PERSONAL
INJURY OR DEATH.
(12) If fuel pump module removal is necessary,
refer to Fuel Pump Module Removal/Installation in
this section.
STANDARD PROCEDURE - FUEL PRESSURE
GAUGE
This gauge package (special tool #8974) (Fig. 1)is
designed to check the injectors or fuel pump for leak
down conditions and fuel system pressures. Refer to
the Powertrain Diagnostic Manual for more informa-
tion on the operation of this tool.
(1) Preform the fuel pressure release procedure,
refer to the Fuel Pressure release procedure in this
section.(2) Find a fuel line quick connect fitting that is
accessible and install special tool #8974.
(3) Refer to the Powertrain Diagnostic Manual for
the proper operation of this gauge package.
(4) Preform the fuel pressure release procedure,
refer to the Fuel Pressure release procedure in this
section.
(5) Remove gauge from fuel system and reconnect
fuel lines.
(6) Use the DRBIIItto pressurize the fuel system
to check for leaks
Fig. 1 FUEL SYSTEM PRESSURE TESTER #8978
1 - GAUGES
2 - HANGER
3 - RELEASE TOOL
4 - DRAIN HOSE
5 - DRAIN HOSE VALVE
6 - SHUT-OFF VALVE
RSFUEL DELIVERY14-3
FUEL DELIVERY (Continued)

FRONT WIPER/WASHER SWITCH -DIAGNOSIS AND TESTING ..............8R-2
FRONT-WHEEL-DRIVE - INSTALLATION ....2-36
FRONT-WHEEL-DRIVE - REMOVAL ........2-36
FUEL CORRECTION OR ADAPTIVE MEMORIES, OPERATION ...............14-24
FUEL DELIVERY SYSTEM - DIAGNOSIS AND TESTING ........................ 14-2
FUEL DOSING PUMP - DESCRIPTION ....24-117
FUEL DOSING PUMP - INSTALLATION . . . 24-117
FUEL DOSING PUMP - OPERATION .....24-117
FUEL DOSING PUMP - REMOVAL .......24-117
FUEL ENGINE OIL - DESCRIPTION, FLEXIBLE .............................0-3
FUEL FILL DOOR - INSTALLATION .......23-52
FUEL FILL DOOR - REMOVAL ...........23-52
FUEL FILL DOOR BLOCKER LATCH - INSTALLATION ....................... 23-53
FUEL FILL DOOR BLOCKER LATCH - REMOVAL .......................... 23-53
FUEL FILL DOOR BLOCKER LATCH STRIKER - INSTALLATION ..............23-53
FUEL FILL DOOR BLOCKER LATCH STRIKER - REMOVAL .................23-53
FUEL FILL DOOR BLOCKER LOCKOUT LINK - INSTALLATION .................23-54
FUEL FILL DOOR BLOCKER LOCKOUT LINK - REMOVAL ..................... 23-54
FUEL FILLER CAP - DESCRIPTION .......25-13
FUEL FILLER CAP - OPERATION .........25-13
FUEL INJECTOR - DESCRIPTION .........14-30
FUEL INJECTOR - OPERATION ..........14-31
FUEL LEVEL SENDING UNIT / SENSOR - DESCRIPTION ........................ 14-5
FUEL LEVEL SENDING UNIT / SENSOR - INSTALLATION ........................ 14-6
FUEL LEVEL SENDING UNIT / SENSOR - OPERATION .......................... 14-5
FUEL LEVEL SENDING UNIT / SENSOR - REMOVAL ........................... 14-5
FUEL LINES/HOSES AND CLAMPS - DESCRIPTION ........................ 14-7
FUEL PRESSURE GAUGE - STANDARD PROCEDURE ......................... 14-3
FUEL PRESSURE REGULATOR - INSTALLATION ........................ 14-7
FUEL PRESSURE REGULATOR - OPERATION .......................... 14-7
FUEL PRESSURE REGULATOR - REMOVAL ........................... 14-7
FUEL PUMP - DESCRIPTION .............14-8
FUEL PUMP - OPERATION ..............14-8
FUEL PUMP MODULE - DESCRIPTION .....14-8
FUEL PUMP MODULE - OPERATION .......14-9
FUEL PUMP RELAY - DESCRIPTION ......14-32
FUEL PUMP RELAY - OPERATION ........14-32
FUEL REQUIREMENTS - DESCRIPTION ......0-4
FUEL REQUIREMENTS - DIESEL ENGINE - DESCRIPTION ........................0-6
FUEL, SPECIAL TOOLS ............14-27,14-4
FUEL SYSTEM PRESSURE RELEASE PROCEDURE - STANDARD
PROCEDURE ......................... 14-2
FUEL SYSTEM PRESSURE, SPECIFICATIONS ...................... 14-4
FUEL TANK - DESCRIPTION ............14-12
FUEL TANK - OPERATION ..............14-12
FUEL TANK - STANDARD PROCEDURE, DRAINING ........................... 14-2
FUEL TANK FILLER TUBE - INSTALLATION ....................... 14-17
FUEL TANK FILLER TUBE - REMOVAL ....14-16
FULL OPEN SWITCH - DESCRIPTION ....8N-11,
8N-52
FUNCTIONS - DESCRIPTION, CIRCUIT . . 8W-01-6
FUSE - DESCRIPTION, IOD ...........8W-97-3
FUSE - OPERATION, IOD .............8W-97-3
FUSES POWERING SEVERAL LOADS - STANDARD PROCEDURE, TESTING
FOR A SHORT TO GROUND ON ......8W-01-10
FWD - FOLD-IN-FLOOR SEATING - INSTALLATION ........................ 2-45
FWD - FOLD-IN-FLOOR SEATING - REMOVAL ........................... 2-45
FWD - INSTALLATION ..................2-45
FWD - INSTALLATION, REAR WHEEL SPEED SENSOR ....................... 5-93
FWD - INSTALLATION, SPRING ...........2-42FWD - REMOVAL
...................... 2-45
FWD - REMOVAL, REAR WHEEL SPEED SENSOR ............................ 5-93
FWD - REMOVAL, SPRING ..............2-40
GALLERY PLUGS - STANDARD PROCEDURE, ENGINE CORE AND OIL . 9-10,9-88
GAP AND FLUSH MEASUREMENTS - SPECIFICATIONS .................... 23-177
GAP, SPECIFICATIONS - WHEEL SPEED SENSOR AIR ......................... 5-91
GAS STRUT - SECOND ROW - FOLD-IN-FLOOR - INSTALLATION, SEAT . . 23-139
GAS STRUT - SECOND ROW - FOLD-IN-FLOOR - REMOVAL, SEAT ......23-138
GASKET - DIAGNOSIS AND TESTING, CYLINDER HEAD ................. 9-102,9-25
GASKET SURFACE PREPARATION - STANDARD PROCEDURE, ENGINE ....9-11,9-87
GASKETS AND SEALERS, STANDARD PROCEDURE - FORM-IN-PLACE ......9-11,9-86
GAUGE - STANDARD PROCEDURE, FUEL PRESSURE .......................... 14-3
GEAR - DESCRIPTION .................19-26
GEAR - INSTALLATION, LHD ............19-31
GEAR - INSTALLATION, RHD ............19-33
GEAR & LINK ROD - DESCRIPTION, LIFT . 8N-16
GEAR & LINK ROD - INSTALLATION, LIFT ............................... 8N-17
GEAR & LINK ROD - OPERATION, LIFT . . . 8N-16
GEAR & LINK ROD - REMOVAL, LIFT .....8N-16
GEAR - OPERATION .................... 19-26
GEAR - REMOVAL, LHD ...............19-26
GEAR - REMOVAL, RHD ...............19-29
GEAR SHIFT CABLE - INSTALLATION ....21-234
GEAR SHIFT CABLE - REMOVAL . . . 21-233,21-84
GEAR, SPECIAL TOOLS - POWER STEERING .......................... 19-34
GEARSHIFT CABLE ADJUSTMENT, ADJUSTMENTS ..................... 21-235
GEARTRAIN - DESCRIPTION, PLANETARY .................. 21-112,21-263
GEARTRAIN - OPERATION, PLANETARY . 21-112, 21-263
GENERAL - WARNINGS .............8W-01-7
GENERAL DIAGNOSIS - DIAGNOSIS AND TESTING, 4XTE TRANSAXLE .......21-149,21-5
GENERATOR - DESCRIPTION ...........8F-24
GENERATOR - OPERATION .............8F-24
GENERATOR DECOUPLER PULLEY - DESCRIPTION ....................... 8F-28
GENERATOR DECOUPLER PULLEY - DIAGNOSIS AND TESTING ..............8F-28
GENERATOR DECOUPLER PULLEY - INSTALLATION ....................... 8F-29
GENERATOR DECOUPLER PULLEY - OPERATION ......................... 8F-28
GENERATOR DECOUPLER PULLEY - REMOVAL .......................... 8F-29
GENERATOR, SPECIFICATIONS ..........8F-23
GLASS - DESCRIPTION, HEATED .........8G-1
GLASS - INSTALLATION, DOOR .........23-17
GLASS - INSTALLATION, LIFTGATE ......23-164
GLASS - INSTALLATION, SLIDING DOOR . 23-163
GLASS - OPERATION, HEATED ...........8G-2
GLASS - REMOVAL, DOOR .............23-16
GLASS - REMOVAL, LIFTGATE .........23-164
GLASS - REMOVAL, SLIDING DOOR .....23-163
GLASS INTEGRAL ANTENNA - EXPORT - DESCRIPTION, QUARTER ..............8A-13
GLASS INTEGRAL ANTENNA - EXPORT - OPERATION, QUARTER ................8A-13
GLASS INTEGRAL ANTENNA, EXPORT - QUARTER .......................... 8A-13
GLASS PANEL - INSTALLATION ........23-173
GLASS PANEL - REMOVAL ............23-173
GLASS PANEL ADJUSTMENT, ADJUSTMENTS - SUNROOF ...........23-173
GLASS RUN WEATHERSTRIP - INSTALLATION, FRONT DOOR ..........23-166
GLASS RUN WEATHERSTRIP - REMOVAL, FRONT DOOR .............23-166
GLASS-OUTSIDE REARVIEW MIRROR - INSTALLATION ....................... 23-61
GLASS-OUTSIDE REARVIEW MIRROR - REMOVAL .......................... 23-61
GLOVE BOX - INSTALLATION ...........23-66
GLOVE BOX - REMOVAL ...............23-66GLOVE BOX LAMP SWITCH -
INSTALLATION ....................... 8L-22
GLOVE BOX LAMP SWITCH - REMOVAL . . 8L-22
GLOVE BOX LATCH - INSTALLATION .....23-66
GLOVE BOX LATCH - REMOVAL .........23-66
GLOVE BOX LATCH STRIKER - INSTALLATION ....................... 23-66
GLOVE BOX LATCH STRIKER - REMOVAL . 23-66
GRID REPAIR PROCEDURE, STANDARD PROCEDURE ......................... 8G-5
GRILLE - DESCRIPTION ...............23-55
GRILLE - INSTALLATION ...............23-55
GRILLE - INSTALLATION, COWL .........23-50
GRILLE - REMOVAL ..................23-55
GRILLE - REMOVAL, COWL ............23-50
GROCERY BAG RETAINER - INSTALLATION, PLASTIC ..............23-149
GROCERY BAG RETAINER - REMOVAL, PLASTIC .......................... 23-149
GROMMET REPLACEMENT, STANDARD PROCEDURE - PUSH-PIN ..............8N-48
GROUND - OPERATION, PCM ...........8E-14
GROUND - STANDARD PROCEDURE, TESTING FOR A SHORT TO ..........8W-01-9
GROUND AND SPLICE INFORMATION - DESCRIPTION, CONNECTOR ..........8W-01-7
GROUND ON FUSES POWERING SEVERAL LOADS - STANDARD
PROCEDURE, TESTING FOR A SHORT
TO.............................8W -01-10
GUIDE - INSTALLATION, UNDER SEAT STORAGE BIN ...................... 23-150
GUIDE - REMOVAL, UNDER SEAT STORAGE BIN ...................... 23-150
GUIDE PIN BUSHINGS (CONTINENTAL TEVES BRAKES) - ASSEMBLY, CALIPER ....5-25
GUIDE PIN BUSHINGS (CONTINENTAL TEVES BRAKES) - DISASSEMBLY,
CALIPER ............................ 5-24
GUIDE PINS (TRW BRAKES) - INSTALLATION, DISC BRAKE CALIPER .....5-32
GUIDE PINS (TRW BRAKES) - REMOVAL, DISC BRAKE CALIPER .................. 5-31
HALF SHAFT - DIAGNOSIS AND TESTING . . . 3-1
HALF SHAFT - FRONT - DESCRIPTION ......3-1
HALF SHAFT - FRONT - INSTALLATION .....3-4
HALF SHAFT - FRONT - REMOVAL .........3-2
HALF SHAFT - FRONT - SPECIFICATIONS ....3-6
HANDLE - INSTALLATION, ASSIST .......23-79
HANDLE - INSTALLATION, EXTERIOR ....23-22,
23-40
HANDLE - INSTALLATION, INSIDE LATCH . . 23-34
HANDLE - INSTALLATION, OUTSIDE ......23-36
HANDLE - INSTALLATION, RECLINER ....23-108
HANDLE - REMOVAL, ASSIST ...........23-79
HANDLE - REMOVAL, EXTERIOR . . . 23-21,23-40
HANDLE - REMOVAL, INSIDE LATCH .....23-34
HANDLE - REMOVAL, OUTSIDE .........23-35
HANDLE - REMOVAL, RECLINER .......23-108
HANDLE ACTUATOR - INSTALLATION, INSIDE ............................. 23-27
HANDLE ACTUATOR - REMOVAL, INSIDE . . 23-27
HANDLE CABLE - INSTALLATION, INSIDE . . 23-38
HANDLE CABLE - INSTALLATION, OUTSIDE ........................... 23-37
HANDLE CABLE - REMOVAL, INSIDE .....23-37
HANDLE CABLE - REMOVAL, OUTSIDE ....23-37
HANDLE SWITCH - DESCRIPTION, EXTERIOR .......................... 8N-10
HANDLE SWITCH - INSTALLATION, EXTERIOR .......................... 8N-10
HANDLE SWITCH - OPERATION, EXTERIOR .......................... 8N-10
HANDLE SWITCH - REMOVAL, EXTERIOR . 8N-10
HANDLING AIRBAGS - STANDARD PROCEDURE ......................... 8O-6
HANDLING TUBING AND FITTINGS, STANDARD PROCEDURE ...............24-69
HANDS FREE MODULE - INSTALLATION ....8T-3
HANDS FREE MODULE - REMOVAL .......8T-3
HARNESS - DESCRIPTION, WIRING ......8N-59
HARNESS - DIAGNOSIS AND TESTING, WIRING ..........................8W -01-7
HARNESS - INSTALLATION, WIRING .....8N-59
HARNESS - OPERATION, WIRING ........8N-59
HARNESS - REMOVAL, WIRING .........8N-59
HCU (HYDRAULIC CONTROL UNIT) - DESCRIPTION ....................... 5-100
RS INDEX15
Description Group-Page Description Group-Page Description Group-Page

STORAGE BIN GUIDE - INSTALLATION,UNDER SEAT ....................... 23-150
STORAGE BIN GUIDE - REMOVAL, UNDER SEAT ....................... 23-150
STORAGE BIN LOCK/LATCH - INSTALLATION, UNDER SEAT ..........23-150
STORAGE BIN LOCK/LATCH - REMOVAL, UNDER SEAT ....................... 23-150
STRAP - INSTALLATION, CHECK .........23-15
STRAP - INSTALLATION, FRONT SEAT BACK ASSIST ...................... 23-112
STRAP - REMOVAL, CHECK ............23-15
STRAP - REMOVAL, FRONT SEAT BACK ASSIST ........................... 23-112
STRAP - THIRD ROW - FOLD-IN-FLOOR - INSTALLATION, SEAT BACKSTOW .....23-158
STRAP - THIRD ROW - FOLD-IN-FLOOR - REMOVAL, SEAT BACKSTOW .........23-158
STRIKER - INSTALLATION, CENTER ......23-28
STRIKER - INSTALLATION, FUEL FILL DOOR BLOCKER LATCH ...............23-53
STRIKER - INSTALLATION, GLOVE BOX LATCH ............................. 23-66
STRIKER - INSTALLATION, HOLD OPEN LATCH ............................. 23-26
STRIKER - INSTALLATION, LATCH . . 23-19,23-42, 23-64
STRIKER - INSTALLATION, REAR LATCH . . 23-29
STRIKER - REMOVAL, CENTER ..........23-28
STRIKER - REMOVAL, FUEL FILL DOOR BLOCKER LATCH ..................... 23-53
STRIKER - REMOVAL, GLOVE BOX LATCH ............................. 23-66
STRIKER - REMOVAL, HOLD OPEN LATCH ............................. 23-26
STRIKER - REMOVAL, LATCH . 23-19,23-41,23-64
STRIKER - REMOVAL, REAR LATCH ......23-29
STRIPPED THREAD REPAIR - STANDARD PROCEDURE, MANIFOLD ..............9-147
STRUCTURAL ADHESIVE LOCATIONS - FOLD-IN-FLOOR ONLY -
SPECIFICATIONS .................... 23-228
STRUCTURAL ADHESIVE LOCATIONS - SPECIFICATIONS .................... 23-218
STRUCTURAL COLLAR - INSTALLATION ....9-49
STRUCTURAL COLLAR - REMOVAL .......9-49
STRUT - SECOND ROW - FOLD-IN- FLOOR - INSTALLATION, SEAT GAS .....23-139
STRUT - SECOND ROW - FOLD-IN- FLOOR - REMOVAL, SEAT GAS .........23-138
STRUT ASSEMBLY - ASSEMBLY ..........2-23
STRUT ASSEMBLY - DESCRIPTION .......2-19
STRUT ASSEMBLY - DIAGNOSIS AND TESTING ............................ 2-20
STRUT ASSEMBLY - DISASSEMBLY .......2-21
STRUT ASSEMBLY - INSTALLATION .......2-25
STRUT ASSEMBLY - OPERATION .........2-19
STRUT ASSEMBLY - REMOVAL ...........2-20
STUDS - FRONT - INSTALLATION, WHEEL MOUNTING ................... 22-21
STUDS - FRONT - REMOVAL, WHEEL MOUNTING ......................... 22-21
STUDS - REAR - INSTALLATION, WHEEL MOUNTING ......................... 22-22
STUDS - REAR - REMOVAL, WHEEL MOUNTING ......................... 22-22
SUCTION LINE - INSTALLATION . . . 24-107,24-97
SUCTION LINE - REMOVAL .......24-106,24-96
SUN VISOR - INSTALLATION ...........23-99
SUN VISOR - REMOVAL ...............23-99
SUN VISOR SUPPORT - INSTALLATION . . . 23-99
SUN VISOR SUPPORT - REMOVAL .......23-99
SUNROOF - DESCRIPTION ............23-169
SUNROOF ASSEMBLY - INSTALLATION . . 23-173
SUNROOF ASSEMBLY - REMOVAL ......23-173
SUNROOF DIAGNOSIS AND TESTING, DIAGNOSIS AND TESTING ............23-169
SUNROOF GLASS PANEL ADJUSTMENT, ADJUSTMENTS ..................... 23-173
SUNROOF MOTOR - INSTALLATION .....23-174
SUNROOF MOTOR - REMOVAL .........23-174
SUNROOF SWITCH - INSTALLATION .....23-176
SUNROOF SWITCH - REMOVAL ........23-176
SUNSHADE - INSTALLATION ...........23-173
SUNSHADE - REMOVAL ..............23-173
SUPPLEMENTAL CABIN HEATER, DIAGNOSIS AND TESTING ............24-114SUPPLY - PCM OUTPUT - OPERATION, 5
VOLT .............................. 8E-15
SUPPORT - INSTALLATION, LUMBAR ....23-150
SUPPORT - INSTALLATION, SUN VISOR . . . 23-99
SUPPORT - REMOVAL, LUMBAR .......23-150
SUPPORT - REMOVAL, SUN VISOR ......23-99
SUPPORT CYLINDER - INSTALLATION ....23-43
SUPPORT CYLINDER - REMOVAL ........23-42
SUPPORT PLATE - DRUM BRAKE - INSTALLATION ........................ 5-61
SUPPORT PLATE - DRUM BRAKE - REMOVAL ........................... 5-61
SUPPRESSION COMPONENTS - DESCRIPTION, RADIO NOISE ...........8A-15
SUPPRESSION COMPONENTS - OPERATION, RADIO NOISE .............8A-15
SURFACE PREPARATION - STANDARD PROCEDURE, ENGINE GASKET .......9-11,9-87
SUSPENSION - DESCRIPTION, FRONT ......2-2
SUSPENSION - DESCRIPTION, REAR ......2-26
SUSPENSION - OPERATION, FRONT ........2-2
SUSPENSION AND STEERING - DIAGNOSIS AND TESTING ..............2-50
SUSPENSION FASTENER TORQUE, SPECIFICATIONS - FRONT ................2-3
SUSPENSION FASTENER TORQUE, SPECIFICATIONS - REAR ................2-28
SUSPENSION, SPECIAL TOOLS - FRONT ....2-3
SUSPENSION, SPECIAL TOOLS - REAR ....2-28
SWITCH - DESCRIPTION .................8P-5
SWITCH - DESCRIPTION, B-PILLAR ......8N-52
SWITCH - DESCRIPTION, BRAKE FLUID LEVEL .............................. 5-10
SWITCH - DESCRIPTION, BRAKE LAMP ....8L-4
SWITCH - DESCRIPTION, EXTERIOR HANDLE ........................... 8N-10
SWITCH - DESCRIPTION, FULL OPEN ....8N-11,
8N-52
SWITCH - DESCRIPTION, HEATED SEAT . . . 8G-8
SWITCH - DESCRIPTION, HORN ..........8H-4
SWITCH - DESCRIPTION, MEMORY ......8N-36
SWITCH - DESCRIPTION, OIL PRESSURE . 9-144
SWITCH - DESCRIPTION, REAR WINDOW DEFOGGER .................. 8G-4
SWITCH - DESCRIPTION, REAR WIPER/WASHER ..................... 8R-10
SWITCH - DESCRIPTION, SEAT .........8N-34
SWITCH - DIAGNOSIS AND TESTING, BRAKE LAMP ........................ 8L-4
SWITCH - DIAGNOSIS AND TESTING, FAILED PARK ........................ 8R-2
SWITCH - DIAGNOSIS AND TESTING, FRONT WIPER/WASHER ................8R-2
SWITCH - DIAGNOSIS AND TESTING, HEADLAMP ......................... 8L-13
SWITCH - DIAGNOSIS AND TESTING, MULTI-FUNCTION .................... 8L-18
SWITCH - DIAGNOSIS AND TESTING, TRACTION CONTROL ................... 5-94
SWITCH - EXPORT - DESCRIPTION, DOOR CYLINDER LOCK ...............8N-22
SWITCH - EXPORT - DESCRIPTION, POWER FOLDAWAY MIRROR ...........8N-29
SWITCH - EXPORT - INSTALLATION, HOOD AJAR ......................... 8Q-3
SWITCH - EXPORT - INSTALLATION, POWER FOLDAWAY MIRROR ...........8N-30
SWITCH - EXPORT - OPERATION, DOOR CYLINDER LOCK ..................... 8N-22
SWITCH - EXPORT - OPERATION, POWER FOLDAWAY MIRROR ...........8N-29
SWITCH - EXPORT - REMOVAL, HOOD AJAR ............................... 8Q-3
SWITCH - EXPORT - REMOVAL, POWER FOLDAWAY MIRROR .................. 8N-29
SWITCH - INSTALLATION ...............8P-6
SWITCH - INSTALLATION, ADJUSTABLE PEDALS ............................. 5-11
SWITCH - INSTALLATION, B-PILLAR .....8N-52
SWITCH - INSTALLATION, BRAKE FLUID LEVEL .............................. 5-11
SWITCH - INSTALLATION, BRAKE LAMP . . . 8L-5
SWITCH - INSTALLATION, CENTER CONSOLE LAMP ..................... 8L-21
SWITCH - INSTALLATION, EXTERIOR HANDLE ........................... 8N-10
SWITCH - INSTALLATION, FULL OPEN ....8N-11 SWITCH - INSTALLATION, GLOVE BOX
LAMP .............................. 8L-22
SWITCH - INSTALLATION, HEADLAMP ....8L-13
SWITCH - INSTALLATION, IGNITION ......19-19
SWITCH - INSTALLATION, MULTI- FUNCTION .......................... 8L-18
SWITCH - INSTALLATION, OIL PRESSURE ..................... 9-144,9-56
SWITCH - INSTALLATION, SUNROOF ....23-176
SWITCH - INSTALLATION, TRACTION CONTROL ........................... 5-95
SWITCH - INSTALLATION, WASHER FLUID LEVEL ........................ 8R-11
SWITCH - OPERATION .................8P-5
SWITCH - OPERATION, B-PILLAR ........8N-52
SWITCH - OPERATION, BRAKE FLUID LEVEL .............................. 5-10
SWITCH - OPERATION, BRAKE LAMP ......8L-4
SWITCH - OPERATION, EXTERIOR HANDLE ........................... 8N-10
SWITCH - OPERATION, FULL OPEN . 8N-11,8N-52
SWITCH - OPERATION, HEATED SEAT .....8G-9
SWITCH - OPERATION, MEMORY ........8N-36
SWITCH - OPERATION, OIL PRESSURE . . . 9-144
SWITCH - OPERATION, REAR WINDOW DEFOGGER .......................... 8G-4
SWITCH - OPERATION, REAR WIPER/ WASHER ........................... 8R-11
SWITCH - OPERATION, SEAT ...........8N-34
SWITCH - REMOVAL .................... 8P-5
SWITCH - REMOVAL, ADJUSTABLE PEDALS ............................. 5-11
SWITCH - REMOVAL, B-PILLAR .........8N-52
SWITCH - REMOVAL, BRAKE FLUID LEVEL .............................. 5-11
SWITCH - REMOVAL, BRAKE LAMP .......8L-5
SWITCH - REMOVAL, CENTER CONSOLE LAMP .............................. 8L-21
SWITCH - REMOVAL, EXTERIOR HANDLE . 8N-10
SWITCH - REMOVAL, FULL OPEN .......8N-11
SWITCH - REMOVAL, GLOVE BOX LAMP . . 8L-22
SWITCH - REMOVAL, HEADLAMP ........8L-13
SWITCH - REMOVAL, IGNITION .........19-17
SWITCH - REMOVAL, MULTI-FUNCTION . . . 8L-18
SWITCH - REMOVAL, OIL PRESSURE ....9-144,
9-56
SWITCH - REMOVAL, SUNROOF ........23-176
SWITCH - REMOVAL, TRACTION CONTROL ........................... 5-95
SWITCH - REMOVAL, WASHER FLUID LEVEL ............................. 8R-11
SWITCH ASSY - DESCRIPTION, SOLENOID/PRESSURE ..........21-117,21-268
SWITCH ASSY - INSTALLATION, SOLENOID/PRESSURE ..........21-119,21-270
SWITCH ASSY - OPERATION, SOLENOID/ PRESSURE .................. 21-118,21-268
SWITCH ASSY - REMOVAL, SOLENOID/ PRESSURE .................. 21-118,21-269
SWITCH, DIAGNOSIS AND TESTING - DOOR LOCK ........................ 8N-23
SWITCH, DIAGNOSIS AND TESTING - DRIVER HEATED SEAT .................8G-9
SWITCH, DIAGNOSIS AND TESTING - DRIVER SEAT ....................... 8N-34
SWITCH, DIAGNOSIS AND TESTING - MEMORY ........................... 8N-37
SWITCH, DIAGNOSIS AND TESTING - REMOTE ........................... 8N-30
SWITCH, DIAGNOSIS AND TESTING - WINDOW ........................... 8N-63
SWITCH, EXPORT - DOOR CYLINDER LOCK .............................. 8N-22
SWITCHES - DESCRIPTION, REMOTE .....8A-16
SWITCHES - OPERATION, REMOTE ......8A-16
SWITCHES, DIAGNOSIS AND TESTING - REMOTE ........................... 8A-16
SYMBOLS - DESCRIPTION, INTERNATIONAL .......................0-1
SYNCHRONIZING CABLE ADJUSTMENT, INSTALLATION ................ 23-105,23-147
TAIL LAMP - INSTALLATION ............8L-19
TAIL LAMP - REMOVAL ................8L-18
TAIL LAMP UNIT - INSTALLATION .......8L-19
TAIL LAMP UNIT - REMOVAL ...........8L-19
TANK - DESCRIPTION, FUEL ............14-12
TANK - OPERATION, FUEL ..............14-12
RS INDEX31
Description Group-Page Description Group-Page Description Group-Page