
(2) Make certain oil holes in block line up with oil
holes in bearings. Bearing tabs must seat in the
block tab slots.
CAUTION: Do not get oil on the bedplate mating
surface. It will may effect the sealer ability to seal
the bedplate to cylinder block.
(3) Oil the bearings and journals and install
crankshaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine. Ensure that both cylinder block and bed-
plate surfaces are clean.
(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead
of anaerobic sealer MopartBed Plate Sealant to cyl-
inder block as shown in (Fig. 48).(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots.
(6) Position the main bearing/bedplate onto the
engine block.
(7) Before installing bolts, lubricate the threads
with clean engine oil, wipe off any excess oil.
(8) Install main bearing bedplate to engine block
bolts 11, 17 and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block.
(9) To ensure correct thrust bearing alignment,
perform the following steps:
²Step 1: Rotate crankshaft until number 4 piston
is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to limits
of travel.
²Step 4: Wedge an appropriate tool between the
rear of the cylinder block(NOT BED PLATE)and
the rear crankshaft counterweight. This will hold the
crankshaft in it's furthest forward position.
²Step 5: Install and tighten bolts (1±10) in
sequence shown in (Fig. 49) to 41 N´m (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(10) Tighten bolts (1±10) again to 41 N´m (30 ft.
lbs.)PLUS1/4 turn in sequence shown in (Fig. 49).
(11) Install main bearing bedplate to engine block
bolts (11±20), and torque each bolt to 28 N´m (20 ft.
lbs.) in sequence shown in (Fig. 49).
(12) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
Fig. 47 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLES
Fig. 48 Main Bearing Caps/Bedplate Sealing
Fig. 49 Main Bearing Caps/Bedplate Tightening
Sequence
9s - 36 ENGINEKJ
CRANKSHAFT MAIN BEARINGS (Continued)

(4) Install flex plate. Apply MopartLock & Seal
Adhesive to bolt threads and tighten bolts to 95 N´m
(70 ft. lbs.).
(5) Install the transmission.
PISTON & CONNECTING ROD
DESCRIPTION
The pistons are made of a cast aluminum alloy.
The pistons have pressed-in pins attached to forged
powdered metal connecting rods. The pistons pin is
offset 1 mm (0.0394 in.) towards the thrust side of
the piston. The connecting rods are a cracked cap
design and are not repairable. Hex head cap screws
are used to provide alignment and durability in the
assembly. The pistons and connecting rods are ser-
viced as an assembly.
OPERATION
The piston and connecting rod is the link between
the combustion force to the crankshaft.
REMOVAL
NOTE: Cylinder Head must be removed before Pis-
tons and Rods. Refer to Cylinder Head Removal in
this section.
(1) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block.Be sure to keep tops of pistons
covered during this operation. Mark piston with
matching cylinder number (Fig. 60).
(2) Remove oil pan. Scribe the cylinder number on
the side of the rod and cap (Fig. 61) for identification.
(3) Pistons have a directional stamping in the
front half of the piston facing towards thefrontof
engine.
(4) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(5) Remove Balance Shaft Assembly. Refer to Bal-
ance Shaft Removal in this section.
(6) Remove connecting rod cap bolts. Push each
piston and rod assembly out of cylinder bore.
NOTE: Be careful not to nick crankshaft journals.
(7) After removal, install bearing cap on the mat-
ing rod.
(8) Piston and Rods are serviced as an assembly.
Fig. 59 Rear Crankshaft SealÐInstallation
1 - SPECIAL TOOL 6926±2 INSTALLER
Fig. 60 Piston Markings
1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA
9s - 40 ENGINEKJ
CRANKSHAFT OIL SEAL - REAR (Continued)

INSTALLATION
(1) Before installing pistons and connecting rod
assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 62). As viewed
from top.
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
(Fig. 63).Be sure position of rings does not
change during this operation.
(4) The directional stamp on the piston should face
toward the front of the engine.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston assembly into cylinder bore and guide
rod over the crankshaft journal.(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
NOTE: The connecting rod cap bolts should not be
reused.
(7) Before installing theNEWbolts the threads
should be coated with clean engine oil.
(8) Install each bolt finger tight than alternately
torque each bolt to assemble the cap properly.
CAUTION: Do not use a torque wrench for second
part of last step.
(9) Tighten the bolts to 54 N´m PLUS 1/4 turn (40
ft. lbs. PLUS 1/4 turn).
(10) Using a feeler gauge, check connecting rod
side clearance (Fig. 64).
Fig. 61 Identify Connecting Rod to Cylinder
Fig. 62 Piston Ring End Gap Position
1 - GAP OF LOWER SIDE RAIL
2 - NO. 1 RING GAP
3 - GAP OF UPPER SIDE RAIL
4 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 63 PistonÐInstallation
Fig. 64 Checking Connecting Rod Side Clearance
KJENGINE9s-41
PISTON & CONNECTING ROD (Continued)

PISTON RINGS
STANDARD PROCEDURE
PISTON RING - FITTING
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 inch) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 65).
Refer to Engine Specifications.
(2) Check piston ring to groove side clearance (Fig.
66). Refer to Engine Specifications.
PISTON RINGS - INSTALLATION
(1) Install rings with manufacturers I.D. mark fac-
ing up, to the top of the piston (Fig. 67).
CAUTION: Install piston rings in the following
order:
a. Oil ring expander.
b. Upper oil ring side rail.
c. Lower oil ring side rail.
d. No. 2 Intermediate piston ring.
e. No. 1 Upper piston ring.
(2) Install the side rail by placing one end
between the piston ring groove and the expander.
Hold end firmly and press down the portion to be
installed until side rail is in position.Do not use a
piston ring expander(Fig. 68).
(3) Install upper side rail first and then the lower
side rail.
(4) Install No. 2 piston ring and then No. 1 piston
ring.
(5) Position piston ring end gaps as shown in (Fig.
69).
(6) Position oil ring expander gap at least 45É
from the side rail gaps butnoton the piston pin cen-
ter or on the thrust direction. Staggering ring gap is
important for oil control.
Fig. 65 Piston Ring Gap
1 - FEELER GAUGE
Fig. 66 Piston Ring Side Clearance
1 - FEELER GAUGE
Fig. 67 Piston Ring Installation
1 - NO. 1 PISTON RING
2 - NO. 2 PISTON RING
3 - SIDE RAIL
4 - OIL RING
5 - SPACER EXPANDER
9s - 42 ENGINEKJ

VIBRATION DAMPER
REMOVAL
(1) Remove accesory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(2) Remove crankshaft damper bolt.
(3) Remove damper using Special Tool 3-Jaw
Puller 1026 and Insert 6827±A (Fig. 70).
INSTALLATION
(1) Install crankshaft vibration damper using M12
1.75 x 150 mm bolt, washer, thrust bearing and nut
from Special Tool 6792 (Fig. 71).
(2) Install crankshaft vibration damper bolt and
tighten to 142 N´m (105 ft. lbs.).
(3) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
Fig. 68 Installing Side Rail - Typical
1 - SIDE RAIL END
Fig. 69 Piston
1 - GAP OF LOWER SIDE RAIL
2 - NO. 1 RING GAP
3 - GAP OF UPPER SIDE RAIL
4 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 70 Crankshaft Vibration Damper - Removal -
Typical
1 - SPECIAL TOOL 1026 3-JAW PULLER
2 - SPECIAL TOOL 6827±A INSERT
Fig. 71 Crankshaft Vibration Damper - Installation -
Typical
1 - M12±1.75 ý 150 MM BOLT, WASHER AND THRUST BEARING
FROM SPECIAL TOOL 6792
KJENGINE9s-43
PISTON RINGS (Continued)

COMPASS CALIBRATION - STANDARD
PROCEDURE.........................8M-2
COMPASS DEMAGNETIZING -
STANDARD PROCEDURE...............8M-2
COMPASS MINI-TRIP COMPUTER -
DIAGNOSIS AND TESTING..............8M-6
COMPASS MINI-TRIP ILLUMINATION
BULB - INSTALLATION................8L-75
COMPASS MINI-TRIP ILLUMINATION
BULB - REMOVAL....................8L-74
COMPASS VARIATION ADJUSTMENT -
STANDARD PROCEDURE...............8M-3
COMPASS/MINI-TRIP COMPUTER -
DESCRIPTION........................8M-4
COMPASS/MINI-TRIP COMPUTER -
INSTALLATION.......................8M-8
COMPASS/MINI-TRIP COMPUTER -
OPERATION.........................8M-5
COMPASS/MINI-TRIP COMPUTER -
REMOVAL...........................8M-7
COMPRESSION PRESSURE - DIAGNOSIS
AND TESTING, CYLINDER................9-8
COMPRESSOR CLUTCH - INSPECTION,
A/C................................24-14
COMPRESSOR CLUTCH - INSTALLATION,
A/C................................24-14
COMPRESSOR CLUTCH - REMOVAL, A/C . . 24-13
COMPRESSOR CLUTCH BREAK-IN -
STANDARD PROCEDURE, A/C...........24-12
COMPRESSOR CLUTCH COIL -
DIAGNOSIS AND TESTING, A/C..........24-12
COMPRESSOR CLUTCH RELAY -
DESCRIPTION, A/C...................24-15
COMPRESSOR CLUTCH RELAY -
DIAGNOSIS AND TESTING.............24-15
COMPRESSOR CLUTCH RELAY -
INSTALLATION, A/C...................24-16
COMPRESSOR CLUTCH RELAY -
OPERATION, A/C.....................24-15
COMPRESSOR CLUTCH RELAY -
REMOVAL, A/C......................24-16
COMPRESSOR NOISE - DIAGNOSIS AND
TESTING, A/C.......................24-42
COMPUTER - DESCRIPTION, COMPASS/
MINI-TRIP..........................8M-4
COMPUTER - DIAGNOSIS AND TESTING,
COMPASS MINI-TRIP..................8M-6
COMPUTER - INSTALLATION, COMPASS/
MINI-TRIP..........................8M-8
COMPUTER - OPERATION, COMPASS/
MINI-TRIP..........................8M-5
COMPUTER - REMOVAL, COMPASS/
MINI-TRIP..........................8M-7
CONDENSER - DESCRIPTION, A/C.......24-45
CONDENSER - INSTALLATION, A/C.......24-46
CONDENSER - OPERATION, A/C.........24-45
CONDENSER - REMOVAL, A/C..........24-45
CONDITIONER - DESCRIPTION, HEATER
AND AIR ............................24-1
CONDITIONER - OPERATION, HEATER
AND AIR ............................24-2
CONDITIONS - DIAGNOSIS AND
TESTING, SPARK PLUG................8I-13
CONNECT FITTING - DESCRIPTION,
QUICK.............................14-10
CONNECTING ROD - DESCRIPTION,
PISTON.............................9-49
CONNECTING ROD BEARING - FITTING -
STANDARD PROCEDURE................9-40
CONNECTING ROD BEARING, FITTING.....9-49
CONNECTOR - DESCRIPTION, DATA LINK . 8E-10
CONNECTOR - INSTALLATION
.......8W-01-11
CONNECTOR - INSTALLATION, TRAILER
TOW
..............................8L-61
CONNECTOR - OPERATION, DATA LINK
. . . 8E-10
CONNECTOR - REMOVAL
...........8W-01-11
CONNECTOR - REMOVAL, TRAILER TOW
. . 8L-61
CONNECTOR, GROUND AND SPLICE
INFORMATION - DESCRIPTION
........8W-01-7
CONNECTOR/GROUND/SPLICE LOCATION
- DESCRIPTION
....................8W-91-1
CONSOLE - DESCRIPTION, OVERHEAD
....8M-1
CONSOLE - INSTALLATION, FLOOR
.....23-158
CONSOLE - OPERATION, OVERHEAD
......8M-2
CONSOLE - REMOVAL, FLOOR
.........23-158
CONSOLE DUCT - INSTALLATION, FLOOR
. 24-31
CONSOLE DUCT - REMOVAL, FLOOR
.....24-31CONSOLE LID LATCH - INSTALLATION,
FLOOR............................23-158
CONSOLE LID LATCH - REMOVAL,
FLOOR............................23-158
CONSOLE, REMOVAL - OVERHEAD.......8M-4
CONTAINER - DESCRIPTION, COOLANT
RECOVERY PRESS....................7-19
CONTAINER - OPERATION, COOLANT
RECOVERY PRESS....................7-19
CONTAMINATION - DIAGNOSIS AND
TESTING, BRAKE FLUID................5-26
CONTAMINATION - DIAGNOSIS AND
TESTING, FLUID....................21-125
CONTINUITY - STANDARD PROCEDURE,
TESTING.........................8W-01-9
CONTROL - DESCRIPTION, A/C HEATER . . . 24-16
CONTROL - DESCRIPTION, IGNITION......8I-1
CONTROL - DESCRIPTION, SPEED........8P-1
CONTROL - INSTALLATION, A/C HEATER . . 24-17
CONTROL - OPERATION, IGNITION........8I-1
CONTROL - OPERATION, SPEED..........8P-1
CONTROL - REMOVAL, A/C HEATER......24-17
CONTROL - TORQUE, SPEED............8P-2
CONTROL ARM - DESCRIPTION, LOWER . . . 2-21
CONTROL ARM - INSTALLATION, LOWER . . 2-10,
2-21
CONTROL ARM - INSTALLATION, UPPER . . . 2-21
CONTROL ARM - OPERATION, LOWER.....2-21
CONTROL ARM - REMOVAL, LOWER . . 2-10,2-21
CONTROL ARM - REMOVAL, UPPER......2-20
CONTROL ASSEMBLY WINDOW
DEFOGGER FUNCTION - DIAGNOSIS
AND TESTING, REAR HVAC.............8G-9
CONTROL CABLE - INSTALLATION,
THROTTLE..........................14-46
CONTROL CABLE - REMOVAL,
THROTTLE..........................14-45
CONTROL ILLUMINATION BULB -
INSTALLATION, HEATER-A/C............8L-78
CONTROL ILLUMINATION BULB -
REMOVAL, HEATER-A/C...............8L-78
CONTROL INFORMATION (VECI) LABEL -
DESCRIPTION, VEHICLE EMISSION.....Intro.-8
CONTROL MODULE - DESCRIPTION,
AIRBAG.............................8O-9
CONTROL MODULE - DESCRIPTION,
BODY...............................8E-2
CONTROL MODULE - DESCRIPTION,
SIDE IMPACT AIRBAG.................8O-43
CONTROL MODULE - DESCRIPTION,
TRANSMISSION......................8E-18
CONTROL MODULE - DIAGNOSIS AND
TESTING, BODY.......................8E-7
CONTROL MODULE - INSTALLATION....23-183
CONTROL MODULE - INSTALLATION,
AIRBAG............................8O-12
CONTROL MODULE - INSTALLATION,
BODY...............................8E-7
CONTROL MODULE - INSTALLATION,
SIDE IMPACT AIRBAG.................8O-45
CONTROL MODULE - OPERATION,
AIRBAG............................8O-10
CONTROL MODULE - OPERATION, BODY . . . 8E-5
CONTROL MODULE - OPERATION, SIDE
IMPACT AIRBAG.....................8O-43
CONTROL MODULE - OPERATION,
TRANSMISSION......................8E-18
CONTROL MODULE - REMOVAL........23-183
CONTROL MODULE - REMOVAL, AIRBAG . 8O-11
CONTROL MODULE - REMOVAL, BODY....8E-7
CONTROL MODULE - REMOVAL, SIDE
IMPACT AIRBAG.....................8O-44
CONTROL MOTOR - DESCRIPTION, IDLE
AIR ...............................14-35
CONTROL MOTOR - INSTALLATION, IDLE
AIR ...............................14-36
CONTROL MOTOR - OPERATION, IDLE
AIR ...............................14-35
CONTROL MOTOR - REMOVAL, IDLE AIR . . 14-36
CONTROL RELAY - DESCRIPTION,
TRANSMISSION.....................21-168
CONTROL RELAY - OPERATION,
TRANSMISSION
.....................21-168
CONTROL SWITCH - DESCRIPTION
.....23-184
CONTROL SWITCH - DIAGNOSIS AND
TESTING
..........................23-184
CONTROL SWITCH - INSTALLATION
.....23-184
CONTROL SWITCH - OPERATION
.......23-184CONTROL SWITCH - REMOVAL........23-184
CONTROL SYSTEM - DESCRIPTION,
EMISSION...........................25-1
CONTROL SYSTEM - DESCRIPTION,
EVAPORATION.......................25-24
CONTROLLER ANTILOCK BRAKE -
INSTALLATION.......................8E-10
CONTROLLER ANTILOCK BRAKE -
REMOVAL..........................8E-10
CONVERTER - DESCRIPTION, CATALYTIC . . . 11-2
CONVERTER - DESCRIPTION, TORQUE . . . 21-162
CONVERTER - INSPECTION, CATALYTIC....11-3
CONVERTER - INSTALLATION, CATALYTIC . . 11-3
CONVERTER - INSTALLATION, TORQUE . . 21-167
CONVERTER - OPERATION, TORQUE....21-166
CONVERTER - REMOVAL, CATALYTIC......11-2
CONVERTER - REMOVAL, TORQUE......21-167
CONVERTER HOUSING FLUID LEAK -
DIAGNOSIS AND TESTING.............21-80
COOLANT - DESCRIPTION, ENGINE........0-3
COOLANT LOW INDICATOR -
DESCRIPTION.......................8J-15
COOLANT LOW INDICATOR - OPERATION . 8J-16
COOLANT RECOVERY PRESS
CONTAINER - DESCRIPTION.............7-19
COOLANT RECOVERY PRESS
CONTAINER - OPERATION...............7-19
COOLANT TEMPERATURE SENSOR -
DESCRIPTION, ENGINE.................7-19
COOLANT TEMPERATURE SENSOR -
INSTALLATION, ENGINE................7-21
COOLANT TEMPERATURE SENSOR -
OPERATION, ENGINE...................7-20
COOLANT TEMPERATURE SENSOR -
REMOVAL, ENGINE....................7-20
COOLANT THERMOSTAT - OPERATION,
ENGINE.............................7-21
COOLER - DESCRIPTION, FLUID.........19-20
COOLER - DESCRIPTION, TRANS.........7-32
COOLER - INSTALLATION, FLUID........19-20
COOLER - OPERATION, FLUID..........19-20
COOLER - REMOVAL, FLUID............19-20
COOLING, SPECIAL TOOLS..............7-14
COOLING SYSTEM - OPERATION..........7-2
COOLING SYSTEM - REVERSE
FLUSHING - STANDARD PROCEDURE.....7-12
COOLING SYSTEM 3.7L ENGINE -
DESCRIPTION.........................7-1
COOLING SYSTEM 3.7L ENGINE -
STANDARD PROCEDURE, DRAINING......7-12
COOLING SYSTEM 3.7L ENGINE -
STANDARD PROCEDURE, REFILLING......7-12
COOLING SYSTEM DIAGNOSIS CHART -
DIAGNOSIS AND TESTING...............7-6
COOLING SYSTEM LEAKS - DIAGNOSIS
AND TESTING.........................7-4
COOLING SYSTEM REQUIREMENTS -
DESCRIPTION........................24-1
COOLING SYSTEM ROUTING 3.7L
ENGINE - DESCRIPTION.................7-2
CORE - DESCRIPTION, HEATER.........24-52
CORE - INSTALLATION, HEATER.........24-53
CORE - OPERATION, HEATER...........24-52
CORE - REMOVAL, HEATER............24-52
CORE AND OIL GALLERY PLUGS -
STANDARD PROCEDURE, ENGINE........9-10
COURTESY LAMP BULB - INSTALLATION . . 8L-76
COURTESY LAMP BULB - REMOVAL.....8L-75
COURTESY LAMP REPLACEMENT -
STANDARD PROCEDURE...............8M-2
COURTESY LAMP UNIT - INSTALLATION . . 8L-77
COURTESY LAMP UNIT - REMOVAL......8L-76
COVER - DESCRIPTION, STRUCTURAL.....9-55
COVER - FRONT - INSTALLATION, SEAT
BACK.............................23-167
COVER - FRONT - INSTALLATION, SEAT
CUSHION..........................23-167
COVER - FRONT - REMOVAL, SEAT BACK . 23-166
COVER - FRONT - REMOVAL, SEAT
CUSHION..........................23-167
COVER - INSTALLATION, COWL TRIM . . . 23-157
COVER - INSTALLATION, INSTRUMENT
PANEL TOP
........................23-153
COVER - INSTALLATION, STRUCTURAL
....9-55
COVER - OPERATION, STRUCTURAL
......9-55
COVER - REAR - INSTALLATION, SEAT
BACK
.............................23-169
COVER - REAR - REMOVAL, SEAT BACK
. 23-169
6 INDEXKJ
Description Group-Page Description Group-Page Description Group-Page

ENGINE - DESCRIPTION, COOLING
SYSTEM 3.7L.........................7-1
ENGINE - DESCRIPTION, COOLING
SYSTEM ROUTING 3.7L.................7-2
ENGINE - INSTALLATION, 3.7L . . . 7-17,7-18,7-22
ENGINE - REMOVAL, 3.7L...........7-17,7-21
ENGINE - STANDARD PROCEDURE,
DRAINING COOLING SYSTEM 3.7L........7-12
ENGINE - STANDARD PROCEDURE,
REFILLING COOLING SYSTEM 3.7L.......7-12
ENGINE BLOCK - CLEANING.............9-39
ENGINE BLOCK - DESCRIPTION..........9-39
ENGINE BLOCK - INSPECTION...........9-40
ENGINE COOLANT - DESCRIPTION.........0-3
ENGINE COOLANT TEMPERATURE
SENSOR - DESCRIPTION...............7-19
ENGINE COOLANT TEMPERATURE
SENSOR - INSTALLATION...............7-21
ENGINE COOLANT TEMPERATURE
SENSOR - OPERATION.................7-20
ENGINE COOLANT TEMPERATURE
SENSOR - REMOVAL...................7-20
ENGINE COOLANT THERMOSTAT -
OPERATION..........................7-21
ENGINE CORE AND OIL GALLERY PLUGS
- STANDARD PROCEDURE..............9-10
ENGINE CRADLE CROSSMEMBER -
INSTALLATION........................13-6
ENGINE CRADLE CROSSMEMBER -
REMOVAL...........................13-6
ENGINE DIAGNOSIS - INTRODUCTION -
DIAGNOSIS AND TESTING.................9-4
ENGINE DIAGNOSIS - LUBRICATION -
DIAGNOSIS AND TESTING...............9-7
ENGINE DIAGNOSIS - MECHANICAL -
DIAGNOSIS AND TESTING...............9-6
ENGINE DIAGNOSIS - PERFORMANCE -
DIAGNOSIS AND TESTING...............9-4
ENGINE FIRING ORDER, 2.4L 4-
CYLINDER...........................8I-2
ENGINE FIRING ORDER, 3.7L V-6.........8I-2
ENGINE GASKET SURFACE
PREPARATION - STANDARD
PROCEDURE..........................9-9
ENGINE OIL - STANDARD PROCEDURE....9-61
ENGINE OIL LEAK - DIAGNOSIS AND
TESTING............................9-60
ENGINE OIL PRESSURE - DIAGNOSIS
AND TESTING........................9-60
ENGINE, SPECIAL TOOLS - 3.7L..........9-15
ENGINE, SPECIFICATIONS - 3.7L.........9-12
ENGINE TEMPERATURE GAUGE -
DESCRIPTION.......................8J-18
ENGINE TEMPERATURE GAUGE -
OPERATION.........................8J-18
ENGINES - GENERATOR RATINGS, GAS . . . 8F-23
ENTRY MODULE - DESCRIPTION,
REMOTE KEYLESS....................8N-7
ENTRY MODULE - DIAGNOSIS AND
TESTING, REMOTE KEYLESS............8N-7
ENTRY MODULE - INSTALLATION,
REMOTE KEYLESS....................8N-7
ENTRY MODULE - OPERATION, REMOTE
KEYLESS............................8N-7
ENTRY MODULE - REMOVAL, REMOTE
KEYLESS............................8N-7
ENTRY TRANSMITTER - DIAGNOSIS AND
TESTING, REMOTE KEYLESS............8N-8
ENTRY TRANSMITTER -
SPECIFICATIONS, REMOTE KEYLESS......8N-9
EQUIPMENT - STANDARD PROCEDURE,
REFRIGERANT SYSTEM SERVICE........24-40
ERASING TRANSMITTER CODES -
STANDARD PROCEDURE...............8M-8
EVACUATE - STANDARD PROCEDURE,
REFRIGERANT SYSTEM...............24-41
EVAPORATION CONTROL SYSTEM -
DESCRIPTION.......................25-24
EVAPORATOR - DESCRIPTION, A/C.......24-49
EVAPORATOR - INSTALLATION, A/C......24-49
EVAPORATOR - OPERATION, A/C........24-49
EVAPORATOR - REMOVAL, A/C..........24-49
EVAP/PURGE SOLENOID - DESCRIPTION . . 25-27
EVAP/PURGE SOLENOID - INSTALLATION
. 25-27
EVAP/PURGE SOLENOID - OPERATION
....25-27
EVAP/PURGE SOLENOID - REMOVAL
.....25-27
EXCEPT DIESEL - TORQUE
.............8F-23
EXHAUST MANIFOLD - DESCRIPTION
.....9-69EXHAUST MANIFOLD - INSTALLATION.....9-70
EXHAUST MANIFOLD - REMOVAL.........9-69
EXHAUST SYSTEM - DESCRIPTION.......11-1
EXHAUST SYSTEM - DIAGNOSIS AND
TESTING............................11-2
EXTENSION HOUSING BUSHING -
NV3550 - INSTALLATION...............21-74
EXTENSION HOUSING BUSHING -
NV3550 - REMOVAL..................21-73
EXTENSION HOUSING SEAL - NV1500 -
INSTALLATION.......................21-32
EXTENSION HOUSING SEAL - NV1500 -
REMOVAL..........................21-32
EXTENSION HOUSING SEAL - NV3550 -
INSTALLATION.......................21-74
EXTENSION HOUSING SEAL - NV3550 -
REMOVAL..........................21-74
EXTERIOR - DESCRIPTION, LAMPS/
LIGHTING...........................8L-2
EXTERIOR - DIAGNOSIS AND TESTING,
LAMPS/LIGHTING.....................8L-7
EXTERIOR - OPERATION, LAMPS/
LIGHTING...........................8L-5
EXTERIOR - SPECIFICATIONS,
LAMPS/LIGHTING....................8L-15
EXTERIOR HANDLE - INSTALLATION....23-123,
23-130,23-136
EXTERIOR HANDLE - REMOVAL . 23-123,23-130,
23-136
EXTERIOR NAME PLATES -
INSTALLATION......................23-141
EXTERIOR NAME PLATES - REMOVAL . . . 23-140
FAN - ELECTRIC - DESCRIPTION,
RADIATOR...........................7-26
FAN - ELECTRIC - INSTALLATION,
RADIATOR...........................7-27
FAN - ELECTRIC - OPERATION,
RADIATOR...........................7-26
FAN - ELECTRIC - REMOVAL, RADIATOR . . . 7-26
FAN - VISCOUS - CLEANING, RADIATOR . . . 7-29
FAN - VISCOUS - DESCRIPTION,
RADIATOR...........................7-27
FAN - VISCOUS - INSPECTION,
RADIATOR...........................7-29
FAN - VISCOUS - INSTALLATION,
RADIATOR...........................7-29
FAN - VISCOUS - OPERATION,
RADIATOR...........................7-27
FAN - VISCOUS - REMOVAL, RADIATOR....7-28
FAN DRIVE - DIAGNOSIS AND TESTING,
VISCOUS............................7-28
FASCIA - INSTALLATION, FRONT.........13-2
FASCIA - INSTALLATION, REAR..........13-2
FASCIA - REMOVAL, FRONT.............13-1
FASCIA - REMOVAL, REAR..............13-2
FASCIA SUPPORT - INSTALLATION,
REAR...............................13-3
FASCIA SUPPORT - REMOVAL, REAR......13-3
FASTENER IDENTIFICATION -
DESCRIPTION......................Intro.-1
FENDER - INSTALLATION, FRONT.......23-141
FENDER - REMOVAL, FRONT..........23-141
FILL - STANDARD PROCEDURE, FLUID
DRAIN......................21-208,21-246
FILL - STANDARD PROCEDURE,
TRANSMISSION.....................21-128
FILL DOOR/HOUSING - INSTALLATION,
FUEL.............................23-141
FILL DOOR/HOUSING - REMOVAL, FUEL . 23-141
FILL/CHECK LOCATIONS - DESCRIPTION,
FLUID...............................0-4
FILLER CAP - DESCRIPTION, FUEL.......25-27
FILLER CAP - OPERATION, FUEL........25-27
FILTER - DESCRIPTION, FUEL............14-7
FILTER - INSTALLATION, FUEL...........14-8
FILTER - INSTALLATION, INLET..........14-28
FILTER - INSTALLATION, OIL............9-63
FILTER - REMOVAL, FUEL...............14-7
FILTER - REMOVAL, INLET.............14-28
FILTER - REMOVAL, OIL
................9-63
FILTER REPLACEMENT - STANDARD
PROCEDURE, FLUID
.................21-126
FINESSE SANDING/BUFFING &
POLISHING - DESCRIPTION
...........23-163
FINISH - DESCRIPTION, BASE
COAT/CLEAR COAT
..................23-162
FIRING ORDER, 2.4L 4-CYLINDER -
ENGINE
..............................8I-2FIRING ORDER, 3.7L V-6 - ENGINE........8I-2
FITTING - CONNECTING ROD BEARING....9-49
FITTING - DESCRIPTION, QUICK
CONNECT...........................14-10
FITTING - MAIN BEARING...............9-45
FITTING - STANDARD PROCEDURE,
CONNECTING ROD BEARING............9-40
FITTING - STANDARD PROCEDURE,
PISTON.............................9-50
FITTING - STANDARD PROCEDURE,
PISTON RING........................9-52
FITTINGS - STANDARD PROCEDURE,
QUICK-CONNECT.....................14-10
FLARE MOLDINGS - INSTALLATION,
FRONT WHEEL OPENING.............23-145
FLARE MOLDINGS - INSTALLATION,
REAR WHEEL OPENING..............23-145
FLARE MOLDINGS - REMOVAL, FRONT
WHEEL OPENING...................23-145
FLARE MOLDINGS - REMOVAL, REAR
WHEEL OPENING...................23-145
FLARING - STANDARD PROCEDURE,
DOUBLE INVERTED.....................5-8
FLARING - STANDARD PROCEDURE, ISO....5-8
FLASHER - DESCRIPTION, COMBINATION . 8L-19
FLASHER - OPERATION, COMBINATION . . . 8L-19
FLEX PLATE - INSTALLATION............9-49
FLEX PLATE - REMOVAL................9-49
FLIP-UP GLASS - INSTALLATION.......23-136
FLIP-UP GLASS - REMOVAL...........23-136
FLIP-UP GLASS AJAR SWITCH -
DESCRIPTION.......................8L-77
FLIP-UP GLASS AJAR SWITCH -
OPERATION.........................8L-77
FLIP-UP GLASS LATCH - INSTALLATION . 23-136
FLIP-UP GLASS LATCH - REMOVAL.....23-136
FLIP-UP GLASS RELEASE SWITCH -
DIAGNOSIS AND TESTING..............8N-5
FLIP-UP GLASS SUPPORT CYLINDER -
INSTALLATION......................23-139
FLIP-UP GLASS SUPPORT CYLINDER -
REMOVAL.........................23-139
FLOOR - DEFROST DOO - INSTALLATION . . 24-37
FLOOR - DEFROST DOOR - REMOVAL....24-36
FLOOR - DEFROST DOOR ACTUATOR -
INSTALLATION.......................24-25
FLOOR - DEFROST DOOR ACTUATOR -
REMOVAL..........................24-24
FLOOR CONSOLE - INSTALLATION......23-158
FLOOR CONSOLE - REMOVAL..........23-158
FLOOR CONSOLE DUCT - INSTALLATION . . 24-31
FLOOR CONSOLE DUCT - REMOVAL.....24-31
FLOOR CONSOLE LID LATCH -
INSTALLATION......................23-158
FLOOR CONSOLE LID LATCH - REMOVAL . 23-158
FLOOR DUCT - INSTALLATION..........24-32
FLOOR DUCT - REMOVAL..............24-32
FLOOR MATS - INSTALLATION, CARPETS . 23-158
FLOOR MATS - REMOVAL, CARPETS....23-158
FLOOR SHIFT BOOT - INSTALLATION,
4WD .............................23-156
FLOOR SHIFT BOOT - REMOVAL, 4WD . . . 23-156
FLOW AND PRESSURE - DIAGNOSIS
AND TESTING, POWER STEERING........19-3
FLOW MANAGEMENT VALVE -
DESCRIPTION........................14-6
FLOW MANAGEMENT VALVE -
INSTALLATION........................14-7
FLOW MANAGEMENT VALVE -
OPERATION..........................14-6
FLOW MANAGEMENT VALVE - REMOVAL . . . 14-6
FLUID - DESCRIPTION, AUTOMATIC
TRANSMISSION.......................0-2
FLUID - DIAGNOSIS AND TESTING,
CAUSES OF BURNT..................21-125
FLUID - OPERATION, AUTOMATIC
TRANSMISSION.......................0-4
FLUID AND FILTER REPLACEMENT -
STANDARD PROCEDURE..............21-126
FLUID CAPACITIES - SPECIFICATIONS......0-4
FLUID CONTAMINATION - DIAGNOSIS
AND TESTING......................21-125
FLUID CONTAMINATION - DIAGNOSIS
AND TESTING, BRAKE
..................5-26
FLUID COOLER - DESCRIPTION
.........19-20
FLUID COOLER - INSTALLATION
.........19-20
FLUID COOLER - OPERATION
...........19-20
FLUID COOLER - REMOVAL
............19-20
KJINDEX 9
Description Group-Page Description Group-Page Description Group-Page

OPERATION - DESCRIPTION, MODES OF . . 8E-11
OPERATION - DIAGNOSIS AND TESTING,
AIR CHECKING TRANSMISSION
CLUTCH............................21-80
ORDER, 2.4L 4-CYLINDER - ENGINE
FIRING..............................8I-2
ORDER, 3.7L V-6 - ENGINE FIRING........8I-2
ORIFICE TUBE - DESCRIPTION, A/C......24-50
ORIFICE TUBE - INSTALLATION, A/C......24-50
ORIFICE TUBE - OPERATION, A/C........24-50
ORIFICE TUBE - REMOVAL, A/C.........24-50
ORVR - DESCRIPTION.................25-29
ORVR - OPERATION..................25-29
OUT - ADJUSTMENT, LOCK..............5-30
OUTBOARD SEAT BELT & RETRACTOR -
INSTALLATION, REAR.................8O-34
OUTBOARD SEAT BELT & RETRACTOR -
REMOVAL, REAR....................8O-33
OUTER BELT MOLDING - INSTALLATION,
FRONT DOOR......................23-186
OUTER BELT MOLDING - INSTALLATION,
REAR DOOR.......................23-186
OUTER BELT MOLDING - REMOVAL,
FRONT DOOR......................23-186
OUTER BELT MOLDING - REMOVAL,
REAR DOOR.......................23-186
OUTER TIE ROD END REMOVAL TOOL,
SPECIAL TOOLS.....................19-15
OUTLET - DESCRIPTION, CIGAR
LIGHTER.........................8W-97-2
OUTLET - DESCRIPTION, POWER......8W-97-11
OUTLET - DIAGNOSIS AND TESTING,
CIGAR LIGHTER...................8W-97-2
OUTLET - DIAGNOSIS AND TESTING,
POWER.........................8W-97-11
OUTLET - INSTALLATION, POWER....8W-97-13
OUTLET - OPERATION, CIGAR LIGHTER . 8W-97-2
OUTLET - OPERATION, POWER......8W-97-11
OUTLET - REMOVAL, POWER........8W-97-12
OUTLET BARRELS - INSTALLATION,
PANEL.............................24-29
OUTLET BARRELS - REMOVAL, PANEL . . . 24-29
OUTLETS - DESCRIPTION, DEMISTER....24-29
OUTPUT - DESCRIPTION, PCM...........8I-4
OUTPUT - OPERATION, PCM............14-33
OUTPUT - OPERATION, PCM.............8I-4
OUTPUT SHAFT SEAL - INSTALLATION,
FRONT......................21-208,21-246
OUTPUT SHAFT SEAL - INSTALLATION,
REAR.............................21-212
OUTPUT SHAFT SEAL - REMOVAL,
FRONT......................21-208,21-246
OUTPUT SHAFT SEAL - REMOVAL, REAR . 21-210
OUTPUT SPEED SENSOR - DESCRIPTION . 21-152
OUTPUT SPEED SENSOR -
INSTALLATION......................21-152
OUTPUT SPEED SENSOR - OPERATION . . 21-152
OUTPUT SPEED SENSOR - REMOVAL . . . 21-152
OVERDRIVE OFF INDICATOR -
DESCRIPTION.......................8J-26
OVERDRIVE OFF INDICATOR -
OPERATION.........................8J-26
OVERDRIVE SWITCH - DESCRIPTION....21-153
OVERDRIVE SWITCH - OPERATION.....21-153
OVERHEAD CONSOLE - DESCRIPTION....8M-1
OVERHEAD CONSOLE - OPERATION......8M-2
OVERHEAD CONSOLE, REMOVAL........8M-4
OVERRIDE RELAY - DESCRIPTION,
CLUTCH SWITCH......................6-10
OVERRIDE RELAY - INSTALLATION,
CLUTCH SWITCH......................6-10
OVERRIDE RELAY - OPERATION,
CLUTCH SWITCH......................6-10
OVERRIDE RELAY - REMOVAL, CLUTCH
SWITCH.............................6-10
OXYGEN SENSOR - DESCRIPTION.......14-40
OXYGEN SENSOR - INSTALLATION.......14-43
OXYGEN SENSOR - OPERATION.........14-40
OXYGEN SENSOR - REMOVAL..........14-41
PADS - INSTALLATION, FRONT BRAKE.....5-11
PADS - REMOVAL, FRONT BRAKE........5-11
PAINT CODE - DESCRIPTION..........23-162
PAINT CODES - SPECIFICATIONS.......23-162
PAINT TOUCH-UP - DESCRIPTION
......23-163
PAN - CLEANING, OIL
..................9-63
PAN - DESCRIPTION, OIL
...............9-63
PAN - INSPECTION, OIL
................9-63
PAN - INSTALLATION, OIL
...............9-64PAN - REMOVAL, OIL..................9-63
PANEL - DESCRIPTION, LATCH - ACCESS . 23-139
PANEL - INSTALLATION, GLASS........23-178
PANEL - INSTALLATION, LATCH -
ACCESS...........................23-139
PANEL - INSTALLATION, QUARTER TRIM . 23-159
PANEL - INSTALLATION, TRIM . . . 23-126,23-132,
23-138
PANEL - REMOVAL, GLASS............23-178
PANEL - REMOVAL, LATCH - ACCESS . . . 23-139
PANEL - REMOVAL, QUARTER TRIM....23-159
PANEL - REMOVAL, TRIM . 23-125,23-132,23-138
PANEL ADJUSTMENT, ADJUSTMENTS -
SUNROOF GLASS...................23-178
PANEL ANTENNA CABLE -
INSTALLATION, INSTRUMENT............8A-8
PANEL ANTENNA CABLE - REMOVAL,
INSTRUMENT........................8A-7
PANEL ASSEMBLY - INSTALLATION,
INSTRUMENT......................23-151
PANEL ASSEMBLY - REMOVAL,
INSTRUMENT......................23-149
PANEL CENTER BEZEL - INSTALLATION,
INSTRUMENT......................23-154
PANEL CENTER BEZEL - REMOVAL,
INSTRUMENT......................23-154
PANEL DOOR - INSTALLATION..........24-36
PANEL DOOR ACTUATOR -
INSTALLATION.......................24-25
PANEL DOOR ACTUATOR - REMOVAL....24-24
PANEL DRIVER SIDE BEZELS -
INSTALLATION, INSTRUMENT..........23-154
PANEL DRIVER SIDE BEZELS -
REMOVAL, INSTRUMENT.............23-153
PANEL END CAP - INSTALLATION,
INSTRUMENT......................23-153
PANEL END CAP - REMOVAL,
INSTRUMENT......................23-153
PANEL OUTLET BARRELS -
INSTALLATION.......................24-29
PANEL OUTLET BARRELS - REMOVAL....24-29
PANEL PASSENGER SIDE BEZEL -
INSTALLATION, INSTRUMENT..........23-154
PANEL PASSENGER SIDE BEZEL -
REMOVAL, INSTRUMENT.............23-154
PANEL SEAL - INSTALLATION, GLASS . . . 23-178
PANEL SEAL - REMOVAL, GLASS.......23-178
PANEL TOP COVER - INSTALLATION,
INSTRUMENT......................23-153
PANEL TOP COVER - REMOVAL,
INSTRUMENT......................23-152
PARK - INTERLOCK CABLE -
INSTALLATION......................21-153
PARK - INTERLOCK CABLE - REMOVAL . . 21-153
PARK LAMP RELAY - DESCRIPTION......8L-54
PARK LAMP RELAY - DIAGNOSIS AND
TESTING...........................8L-55
PARK LAMP RELAY - INSTALLATION.....8L-56
PARK LAMP RELAY - OPERATION.......8L-54
PARK LAMP RELAY - REMOVAL.........8L-55
PARK RAMP - INSTALLATION, WIPER
ARM ..............................8R-43
PARK RAMP - REMOVAL, WIPER ARM . . . 8R-43
PARKING BRAKE - DESCRIPTION.........5-29
PARKING BRAKE - OPERATION...........5-29
PARK-INTERLOCK CABLE -
ADJUSTMENTS.....................21-154
PART TIME INDICATOR - DESCRIPTION . . . 8J-29
PART TIME INDICATOR - OPERATION.....8J-29
PASSENGER AIRBAG - DESCRIPTION....8O-27
PASSENGER AIRBAG - INSTALLATION....8O-29
PASSENGER AIRBAG - OPERATION......8O-27
PASSENGER AIRBAG - REMOVAL........8O-28
PASSENGER AIRBAG DOOR -
INSTALLATION......................8O-30
PASSENGER AIRBAG DOOR - REMOVAL . . 8O-29
PASSENGER AIRBAG MOUNTING
BRACKET - INSTALLATION.............8O-31
PASSENGER AIRBAG MOUNTING
BRACKET - REMOVAL
.................8O-31
PASSENGER SEAT HEATER SWITCH -
DESCRIPTION
.......................8G-14
PASSENGER SEAT HEATER SWITCH -
INSTALLATION
......................8G-15
PASSENGER SEAT HEATER SWITCH -
OPERATION
.........................8G-14
PASSENGER SEAT HEATER SWITCH -
REMOVAL
..........................8G-15PASSENGER SIDE BEZEL -
INSTALLATION, INSTRUMENT PANEL....23-154
PASSENGER SIDE BEZEL - REMOVAL,
INSTRUMENT PANEL.................23-154
PATTERNS - DIAGNOSIS AND TESTING,
TIRE WEAR..........................22-8
PCM - DESCRIPTION..................8E-11
PCM - OPERATION...................8E-14
PCM INPUT - OPERATION, ASD SENSE.....8I-4
PCM OUTPUT - DESCRIPTION............8I-4
PCM OUTPUT - OPERATION............14-33
PCM OUTPUT - OPERATION.............8I-4
PCM/SKIM PROGRAMMING - STANDARD
PROCEDURE.........................8E-1
PCV VALVE - DESCRIPTION............25-29
PCV VALVE - DIAGNOSIS AND TESTING . . . 25-31
PCV VALVE - INSTALLATION............25-32
PCV VALVE - OPERATION..............25-31
PCV VALVE - REMOVAL...............25-32
PEDAL - DESCRIPTION.................5-20
PEDAL - INSTALLATION................5-20
PEDAL - INSTALLATION, ACCELERATOR . . . 14-30
PEDAL - INSTALLATION, CLUTCH.........6-10
PEDAL - OPERATION...................5-20
PEDAL - REMOVAL....................5-20
PEDAL - REMOVAL, ACCELERATOR......14-29
PEDAL - REMOVAL, CLUTCH............6-10
PEDAL POSITION SWITCH -
DESCRIPTION, CLUTCH.................6-11
PEDAL POSITION SWITCH - DIAGNOSIS
AND TESTING, CLUTCH.................6-11
PEDAL POSITION SWITCH - OPERATION,
CLUTCH.............................6-11
PERFORMANCE - DIAGNOSIS AND
TESTING, A/C........................24-2
PERFORMANCE - DIAGNOSIS AND
TESTING, ENGINE DIAGNOSIS............9-4
PERFORMANCE - DIAGNOSIS AND
TESTING, HEATER.....................24-6
PILOT BEARING - INSTALLATION..........6-8
PILOT BEARING - REMOVAL..............6-8
PINION GEAR/RING GEAR -
INSTALLATION........................3-46
PINION GEAR/RING GEAR - REMOVAL.....3-44
PINION GEAR/RING GEAR/TONE RING -
INSTALLATION...................3-112,3-82
PINION GEAR/RING GEAR/TONE RING -
REMOVAL......................3-110,3-79
PINION SEAL - INSTALLATION . . 3-103,3-39,3-68
PINION SEAL - REMOVAL......3-102,3-38,3-68
PIPE - INSTALLATION, CROSS-OVER......11-3
PIPE - REMOVAL, CROSS-OVER..........11-3
PISTON & CONNECTING ROD -
DESCRIPTION........................9-49
PISTON FITTING - STANDARD
PROCEDURE.........................9-50
PISTON RING FITTING - STANDARD
PROCEDURE.........................9-52
PISTONS - DESCRIPTION.............21-155
PISTONS - OPERATION...............21-155
PLANETARY GEARTRAIN - ASSEMBLY . . . 21-160
PLANETARY GEARTRAIN - CLEANING....21-159
PLANETARY GEARTRAIN - DESCRIPTION . 21-157
PLANETARY GEARTRAIN -
DISASSEMBLY......................21-159
PLANETARY GEARTRAIN - INSPECTION . . 21-159
PLANETARY GEARTRAIN - OPERATION . . 21-157
PLATE - INSTALLATION, DOOR SILL
SCUFF............................23-157
PLATE - INSTALLATION, FLEX............9-49
PLATE - INSTALLATION, FRONT SKID......13-6
PLATE - INSTALLATION, FUEL TANK
SKID...............................13-9
PLATE - INSTALLATION, REAR DOOR
SCUFF............................23-160
PLATE - INSTALLATION, TRANSFER
CASE SKID..........................13-7
PLATE - REMOVAL, DOOR SILL SCUFF . . . 23-157
PLATE - REMOVAL, FLEX...............9-49
PLATE - REMOVAL, FRONT SKID.........13-6
PLATE - REMOVAL, FUEL TANK SKID
......13-9
PLATE - REMOVAL, REAR DOOR SCUFF
. . 23-160
PLATE - REMOVAL, TRANSFER CASE
SKID
...............................13-7
PLATE LAMP BULB - INSTALLATION,
LICENSE
...........................8L-45
PLATE LAMP BULB - REMOVAL,
LICENSE
...........................8L-44
18 INDEXKJ
Description Group-Page Description Group-Page Description Group-Page