2003 CHRYSLER CARAVAN manual transmission

CAUTION: Never attempt to train more than one
vehicle at a time. System is capable of reading tire
pressure sensor transmissions from other near-by
vehicles.
Each time a wheel rotation or tire pressure sensor
replacement occurs the tire pressure sensors must be
retrained. This is necessary to inform the Electronic
Vehicle Information Center (EVIC) that a sensor
change was made and where. Retraining is accom-
plished through the EVIC used in conjunction with a
Re-learn Magnet, Special Tool 8821.
NOTE: Use the following procedure to retrain all
four (4) road wheel tire pressure sensors. No
attempt should be made to retrain individual sen-
sors.
(1) Retrieve Re-learn Magnet, Special Tool 8821.
(2) Press MENU Button on EVIC until9RETRAIN
TIRE SENSORS - NO9is displayed.
(3) Press STEP button to select9YES9.
NOTE: There is a 60 second timer for training the
first sensor and a 60 second timer between training
the remaining sensors. If any of these timers expire,
the EVIC will abort the training procedure.
NOTE: If at any time the EVIC display reads(TRAIN-
ING ABORTED(, move the vehicle ahead at least
one foot and repeat the entire retraining procedure.
(4) Press MENU button to start retraining. Dis-
play will read9TRAIN LEFT FRONT TIRE9
NOTE: The order for retraining all four sensors is:
²Left Front
²Right Front
²Right Rear
²Left Rear
(5) Starting at left front tire, place Re-learn Mag-
net over valve stem (Fig. 17). Within approximately 5
seconds, vehicle horn will chirp indicating training
complete at that particular sensor. Remove the mag-
net.
(6) Repeat step (5) on remaining sensors as indi-
cated by EVIC until all four TPM sensors positions
are trained.
(7) Once EVIC displays9TRAINING COMPLETE9,
pressing either STEP, C/T, RESET or MENU button
will exit training routine.
REMOVAL
(1) Remove tire and wheel assembly from vehicle.
(Refer to 22 - TIRES/WHEELS - REMOVAL)
CAUTION: The cap used on this valve stem con-
tains an O-ring seal to prevent contamination and
moisture from entering the valve stem. Retain this
valve stem cap for reuse. Do not substitute a regu-
lar valve stem cap in its place.
CAUTION: The valve stem used on this vehicle is
made of aluminum and the core is nickel plated
brass. The original valve stem core must be rein-
stalled and not substituted with a valve stem core
made of a different material. This is required to pre-
vent corrosion in the valve stem caused by the dif-
ferent metals.
(2) Dismount tire from wheel following tire
changer manufacturers instructions while paying
special attention to the following to avoid damaging
the pressure sensor:
(a) When breaking the tire bead loose from the
wheel rim, avoid using the Bead Breaker in the
area of the sensor. That includes both front and
rear beads of the tire.
(b) When preparing to dismount the tire from
the wheel, carefully insert the mounting/dimount-
ing tool at the valve stem   10É (Fig. 18), then pro-
ceed to dismount the tire from the wheel. Use this
process on both the upper and lower tire beads.
(3) Using a thin wall socket, remove special nut
retaining sensor to wheel (Fig. 19).
(4) Remove sensor from wheel (Fig. 19).
Fig. 17 Magnet Placement Over Valve Stem
1 - RE-LEARN MAGNET
2 - VALVE STEM
RSTIRES/WHEELS22-11
SENSOR - TPM (Continued)
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GLOVE BOX LATCH STRIKER
REMOVAL
(1) Open glove box door.
(2) Remove screws holding lock striker to instru-
ment panel.
(3) Remove glove box latch striker.
INSTALLATION
(1) Install the glove box latch striker.
(2) Install the screws holding latch striker to
instrument panel.
(3) Close glove box door.
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the lower console:
(a) Remove six retaining screws.
(b) Pull rearward and disconnect the auxiliary
power outlet.
(c) Remove lower console from vehicle.
(3) Remove the bolts attaching the lower supports
to the instrument panel frame (Fig. 3).
(4) Remove the bolts attaching the lower supports
to the floor pan.
(5) Disconnect the wire connectors from the Pas-
senger Airbag.
(6) Remove the two screws to each right and left
cowl trim covers.
(7) Remove the both left and right side A-pillar
trim covers using a trim stick (special tool #C-4755)
or equivalent gently pry out on the trim covers and
remove.
(8) Remove the glove box:
(a) Push in on sides of glove box bin and lower
door.
(b) Pivot glove box downward and disengage
hinge hooks from instrument panel.
(c) Remove glove box from vehicle.
(9) Disconnect the antenna lead connector from
behind the glove box.
(10) Remove the four screws to the lower steering
column cover.
(11) Remove the eight screws to the steering col-
umn backing plate.
(12) Unclip the Data Link Connector (DLC) from
the steering column backing plate.
(13) Disconnect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.(c) Five harness connectors.
(d) Driver airbag connector.
(14) Remove the two screws to the hood release
handle.
(15) Remove five screws to steering column back-
ing plate and remove (Refer to 23 - BODY/INSTRU-
MENT PANEL/KNEE BLOCKER - REMOVAL).
(16) Remove the two steering column shroud
retaining screws. Separate the shrouds and remove
from vehicle.
(17) Remove the screws attaching the instrument
panel reinforcement and remove (Fig. 4).
(18) Disconnect the steering column wiring. There
are seven connectors and then unclip the harness
from the column.
(19) Disconnect the Occupant Restraint Controller
(ORC) harness connector.
(20) Remove the four nuts retaining the steering
column to the dash panel steering column mounting
bracket and lower column to the floor (Fig. 5).
(21) Remove the four nuts attaching the instru-
ment panel to the brake pedal support bracket.
(22) Loosen the left side roll down bolt (Fig. 6).
(23) Remove the left side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(24) If equipped with a mechanical transmission
range indicator:
(a) Remove the indicator cable loop.
(b) Remove the clip holding gear shift cable end
to the gear selector adapter.
(c) Pull the cable end from gear selector.
(d) Disconnect the clip for the indicator cable
and guide tube from the shift cable bracket and
move out of the way.
(25) Remove the instrument panel top cover. Using
a trim stick or equivalent, gently pry up on the front
edge of the top cover, pull rearward and remove from
vehicle.
(26) Disconnect the right side wire connectors from
the HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
(27) Remove the right end cover by pulling out-
board.
(28) Remove the right side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(29) Loosen the right side roll down bolt.
(30) Disconnect the two front window defroster
grid wire connectors. One on each side of vehicle.
(31) Remove both the left and right power mirrors:
(a) Using a trim stick or equivalent, gently pry
out on mirror trim cover.
(b) Open door and remove the three torx retain-
ing screws.
(c) Disconnect the wire connector and remove
mirror from the vehicle.
23 - 64 INSTRUMENT PANELRS
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(11) If equipped with a mechanical transmission
range indicator:
(a) Connect the clip for the indicator cable and
guide tube to the shift cable bracket.
(b) Install the cable end to the gear selector.
(c) Install the clip holding the gear shift cable
end to the gear selector adapter.
(d) Install the indicator cable loop.
(12) Tighten the left side roll down bolt.
(13) Install the four nuts attaching the instrument
panel to the brake pedal support bracket.
(14) Install the four nuts retaining the steering
column and lower to the floor (Fig. 5).
(15) Connect the Occupant Restraint Controller
(ORC) harness connector.
(16) Connect the steering column wiring. There
are seven connectors and then clip the harness to the
column.
(17) Install the screws attaching the instrument
panel reinforcement (Fig. 4).
(18) Connect the shrouds and install the two steer-
ing column shroud retaining screws.
(19) Install five screws to the left under column
instrument panel reinforcement brace.
(20) Install the two screws to the hood release
handle.
(21) Connect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.(c) Five harness connectors.
(d) Driver airbag connector.
(22) Clip the Data Link Connector (DLC) to the
steering column backing plate.
(23) Install the eight screws to the steering column
backing plate.
(24) Install the four screws to the lower steering
column cover.
(25) Install the glove box:
(a) Install glove box into the vehicle. Line up the
hinges and firmly snap together.
(b) Push in on sides of glove box bin and raise
door.
(26) Install the both left and right side A-pillar
trim covers. Position trim cover over slots and firmly
snap into place.
(27) Install the two screws to each right and left
cowl trim covers.
(28) Connect the wire connectors to the Passenger
Airbag.
(29) Install the bolts attaching the lower supports
to the floor pan.
(30) Install the bolts attaching the lower supports
to the instrument panel frame (Fig. 3).
(31) Install the lower console:
(a) Install lower console to vehicle.
(b) Connect the auxiliary power outlet.
(c) Install the six retaining screws.
(32) Connect the battery negative cable.
Fig. 6 INSTRUMENT PANEL REMOVAL
1 - INSTRUMENT PANEL
2 - FIVE ATTACHING SCREWS
3 - 13 mm BOLT - TWO ON EACH SIDE4 - ROLL DOWN BRACKET
5 - 10 mm BOLT - STARTING BOLT ONE EACH SIDE
23 - 66 INSTRUMENT PANELRS
INSTRUMENT PANEL ASSEMBLY (Continued)
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crossmember and move the latch out of the way over
the top of the crossmember. Mark the location of
latch for reinstallation.
(6) Disconnect the hoses from the transmission oil
cooler fittings on the left side of the cooling module.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER LINES - REMOVAL).
(7) Remove the nut that secures the discharge line
fitting to the condenser on the right side of the cool-
ing module.
(8) Disconnect the discharge line fitting from the
condenser inlet port.
(9) Remove the seals from the discharge line fit-
ting and discard.
(10) Install plugs in, or tape over the opened dis-
charge line fitting and the condenser inlet port.
(11) Remove the nut that secures the liquid line
fitting to the condenser on the right side of the cool-
ing module.
(12) Disconnect the liquid line fitting from the con-
denser outlet port.
(13) Remove the seals from the liquid line fitting
and discard.
(14) Install plugs in, or tape over the opened liquid
line fitting and the condenser outlet port.
(15) Remove the screw that secures the top of the
mounting bracket on each side of the condenser to
the cooling module (Fig. 5).
(16) Lift the condenser, transmission oil cooler, and
mounting brackets as a unit far enough to disengage
the locating pin that secures the mounting brackets
in the lower mount rubber isolators on each side of
the cooling module.
(17) Remove the condenser, transmission oil cooler,
and mounting brackets from the vehicle as a unit.
(18) Remove the two screws that secure each
mounting bracket to the sides of the condenser.
(19) Remove the one screw that secures the left
mounting bracket to the side of the transmission oil
cooler.
(20) Remove the left mounting bracket from the
side of the condenser and transmission oil cooler.
(21) Remove the condenser from the right mount-
ing bracket and transmission oil cooler unit.
INSTALLATION
NOTE: If the condenser is being replaced, add 30
milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
NOTE: Be certain that each of the radiator and con-
denser air seals are reinstalled in their proper loca-
tions. These air seals are required in order for theair conditioning and engine cooling systems to per-
form as designed.
(1) Position the condenser to the right mounting
bracket and transmission oil cooler unit.
(2) Position the left mounting bracket onto the side
of the condenser and transmission oil cooler.
(3) Install and tighten the one screw that secures
the left mounting bracket to the side of the transmis-
sion oil cooler. Tighten the screw to 5 N´m (45 in.
lbs.).
(4) Install and tighten the two screws that secure
each mounting bracket to the sides of the condenser.
Tighten the screws to 5 N´m (45 in. lbs.).
(5) Position the condenser, transmission oil cooler,
and mounting brackets into the vehicle as a unit. Be
certain that the locating pins that secure the mount-
ing brackets are engaged in the lower mount rubber
isolators on each side of the cooling module.
NOTE: Verify that the condensor isolators are all
installed and positioned correctly.
(6) Install and tighten the two screws that secure
the top of the mounting bracket on each side of the
condenser to the cooling module. Tighten the screws
to 5 N´m (45 in. lbs.).
Fig. 5 Condenser Mounting
1 - SCREW (2)
2 - LOWER MOUNT ISOLATOR (2)
3 - CONDENSER
RSPLUMBING - FRONT24-67
CONDENSER (Continued)
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(7) Remove the tape or plugs from the condenser
outlet port and the liquid line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(9) Install a new dual plan seal and reconnect the
liquid line fitting to the condenser outlet port on the
right side of the cooling module.
(10) Install and tighten the nut that secures the
liquid line fitting to the condenser. Tighten the nut to
23 N´m (17 ft. lbs.).
(11) Remove the tape or plugs from the condenser
inlet port and the discharge line fitting.
(12) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(13) Install a new dual plan seal and reconnect the
discharge line fitting to the condenser inlet port on
the right side of the cooling module.
(14) Install and tighten the nut that secures the
discharge line fitting to the condenser. Tighten the
nut to 23 N´m (17 ft. lbs.).
(15) Reconnect the hoses to the transmission oil
cooler fittings on the left side of the cooling module.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER LINES - INSTALLATION).
(16) Reposition the hood latch unit to the front of
the radiator closure panel crossmember.
(17) Install and tighten the two screws that secure
the hood latch unit to the front of the radiator clo-
sure panel crossmember. Check and adjust the hood
latch as needed. Tighten the screws to 14 N´m (123
in. lbs.).
(18) Position the radiator sight shield onto the
radiator closure panel crossmember.
(19) Install and tighten the five small screws that
secure the front fascia grille inserts to the radiator
sight shield. Tighten the screws to 2 N´m (18 in. lbs.).
(20) Install and tighten the two large screws that
secure the front fascia and the outboard ends of the
radiator sight shield to the radiator closure panel
crossmember. Tighten the screws to 6 N´m (53 in.
lbs.).
(21) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(22) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).DISCHARGE LINE
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 CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Remove the two large screws that secure the
front fascia and the outboard ends of the radiator
sight shield to the radiator closure panel crossmem-
ber (Fig. 6).
(3) Remove the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
(4) Remove the radiator sight shield from the radi-
ator closure panel crossmember.
(5) Remove the nut that secures the discharge line
fitting to the condenser on the right side of the cool-
ing module (Fig. 7).
(6) Disconnect the discharge line fitting from the
condenser inlet port.
(7) Remove the seal from the discharge line fitting
and discard.
(8) Install plugs in, or tape over the opened dis-
charge line fitting and the condenser inlet port.
Fig. 6 Radiator Sight Shield
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
24 - 68 PLUMBING - FRONTRS
CONDENSER (Continued)
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ªBig Slopeº. The PCM checks the oxygen sensor volt-
age in increments of a few milliseconds.
Reduced Output Voltage (Half Cycle)ÐThe
output voltage of the O2S ranges from 0 to 1 volt
(voltages are offset by 2.5 volts on NGC vehicles). A
good sensor can easily generate any output voltage in
this range as it is exposed to different concentrations
of oxygen. To detect a shift in the A/F mixture (lean
or rich), the output voltage has to change beyond a
threshold value. A malfunctioning sensor could have
difficulty changing beyond the threshold value. Each
time the voltage signal surpasses the threshold, a
counter is incremented by one. This is called the Half
Cycle Counter.
Heater PerformanceÐThe heater is tested by a
separate monitor. Refer to the Oxygen Sensor Heater
Monitor.
OPERATIONÐAs the Oxygen Sensor signal
switches, the PCM monitors the half cycle and big
slope signals from the oxygen sensor. If during the
test neither counter reaches a predetermined value, a
malfunction is entered and Freeze Frame data is
stored. Only one counter reaching its predetermined
value is needed for the monitor to pass.
The Oxygen Sensor Monitor is a two trip monitor
that is tested only once per trip. When the Oxygen
Sensor fails the test in two consecutive trips, the
MIL is illuminated and a DTC is set. The MIL is
extinguished when the Oxygen Sensor monitor
passes in three consecutive trips. The DTC is erased
from memory after 40 consecutive warm-up cycles
without test failure.
Enabling ConditionsÐThe following conditions
must typically be met for the PCM to run the oxygen
sensor monitor:
²Battery voltage
²Engine temperature
²Engine run time
²Engine run time at a predetermined speed
²Engine run time at a predetermined speed and
throttle opening
²Transmission in gear and brake depressed (auto-
matic only)
²Fuel system in Closed Loop
²Long Term Adaptive (within parameters)
²Power Steering Switch in low PSI (no load)
²Engine at idle
²Fuel level above 15%
²Ambient air temperature
²Barometric pressure
²Engine RPM within acceptable range of desired
idle
Pending ConditionsÐThe Task Manager typi-
cally does not run the Oxygen Sensor Monitor if over-
lapping monitors are running or the MIL is
illuminated for any of the following:²Misfire Monitor
²Front Oxygen Sensor and Heater Monitor
²MAP Sensor
²Vehicle Speed Sensor
²Engine Coolant Temperature Sensor
²Throttle Position Sensor
²Engine Controller Self Test Faults
²Cam or Crank Sensor
²Injector and Coil
²Idle Air Control Motor
²EVAP Electrical
²EGR Solenoid Electrical (if equipped)
²Intake/inlet Air Temperature
²5 Volt Feed
ConflictÐThe Task Manager does not run the
Oxygen Sensor Monitor if any of the following condi-
tions are present:
²A/C ON (A/C clutch cycling temporarily sus-
pends monitor)
²Purge flow in progress
²Ethanol content learn is taking place and the
ethanol used once flag is set (if equipped)
SuspendÐThe Task Manager suspends maturing
a fault for the Oxygen Sensor Monitor if any of the
following are present:
²Oxygen Sensor Heater Monitor, Priority 1
²Misfire Monitor, Priority 2
OXYGEN SENSOR HEATER MONITOR
DESCRIPTIONÐIf there is an oxygen sensor
(O2S) DTC as well as a O2S heater DTC, the O2S
fault MUST be repaired first. After the O2S fault is
repaired, verify that the heater circuit is operating
correctly.
The voltage readings taken from the O2S are very
temperature sensitive. The readings are not accurate
below a sensor temperature of 300ÉC. Heating of the
O2S is done to allow the engine controller to shift to
closed loop control as soon as possible. The heating
element used to heat the O2S must be tested to
ensure that it is heating the sensor properly.
The heater element itself is not tested. The sensor
output is used to test the heater by isolating the
effect of the heater element on the O2S output volt-
age from the other effects. The resistance is normally
between 100 ohms and 4.5 megaohms. When oxygen
sensor temperature increases, the resistance in the
internal circuit decreases. The PCM sends a 5 volts
biased signal through the oxygen sensors to ground
this monitoring circuit. As the temperature increases,
resistance decreases and the PCM detects a lower
voltage at the reference signal. Inversely, as the tem-
perature decreases, the resistance increases and the
PCM detects a higher voltage at the reference signal.
The O2S circuit is monitored for a drop in voltage.
RSEMISSIONS CONTROL25-3
EMISSIONS CONTROL (Continued)
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BODY CONTROL MODULE -
INSTALLATION........................8E-5
BODY CONTROL MODULE - OPERATION . . . 8E-3
BODY CONTROL MODULE - REMOVAL.....8E-4
BODY LUBRICATION, SPECIFICATIONS....23-12
BODY OPENING DIMENSIONS -
SPECIFICATIONS....................23-124
BODY PANEL REPAIR - STANDARD
PROCEDURE, PLASTIC.................23-3
BODY SEALING LOCATIONS -
SPECIFICATIONS....................23-127
BODY SIDE MOLDINGS - INSTALLATION . . 23-45
BODY SIDE MOLDINGS - REMOVAL......23-44
BODY, SPECIAL TOOLS................23-13
BOLSTER - INSTALLATION, QUARTER
TRIM..............................23-77
BOLSTER - REMOVAL, QUARTER TRIM . . . 23-77
BOOSTER - DESCRIPTION, POWER
BRAKE..............................5-40
BOOSTER - DIAGNOSIS AND TESTING,
POWER BRAKE.......................5-41
BOOSTER - OPERATION, POWER BRAKE . . . 5-41
BOOT - INNER - INSTALLATION, CV........3-6
BOOT - INNER - REMOVAL, CV...........3-6
BOOT - INNER/OUTER - INSTALLATION,
CV .................................3-17
BOOT - INNER/OUTER - REMOVAL, CV....3-15
BOOT - INSTALLATION, BALL JOINT
SEAL...............................2-11
BOOT - INSTALLATION, GEARSHIFT........21-73
BOOT - OUTER - INSTALLATION, CV......3-10
BOOT - OUTER - REMOVAL, CV..........3-10
BOOT - REMOVAL, BALL JOINT SEAL.....2-11
BOOT - REMOVAL, GEARSHIFT..........21-72
BORE FITTING - STANDARD
PROCEDURE, PISTON TO CYLINDER......9-42
BORE HONING - STANDARD
PROCEDURE, CYLINDER...........9-112,9-35
BOX - INSTALLATION, GLOVE...........23-63
BOX - REMOVAL, GLOVE..............23-63
BOX LAMP SWITCH - INSTALLATION,
GLOVE.............................8L-26
BOX LAMP SWITCH - REMOVAL, GLOVE . . 8L-26
BOX LATCH - INSTALLATION, GLOVE.....23-63
BOX LATCH - REMOVAL, GLOVE.........23-63
BOX LATCH STRIKER - INSTALLATION,
GLOVE.............................23-64
BOX LATCH STRIKER - REMOVAL,
GLOVE.............................23-64
B-PILLAR - INSTALLATION, A-PILLAR-
HEADER, OR........................23-17
B-PILLAR - REMOVAL, A-PILLAR-
HEADER, OR........................23-17
B-PILLAR LOWER TRIM - INSTALLATION . . 23-74
B-PILLAR LOWER TRIM - REMOVAL.....23-73
B-PILLAR SWITCH - DESCRIPTION, LEFT . 8N-32
B-PILLAR SWITCH - DESCRIPTION,
RIGHT.............................8N-32
B-PILLAR SWITCH - INSTALLATION,
LEFT..............................8N-32
B-PILLAR SWITCH - INSTALLATION,
RIGHT.............................8N-32
B-PILLAR SWITCH - OPERATION, LEFT . . . 8N-32
B-PILLAR SWITCH - OPERATION, RIGHT . . 8N-32
B-PILLAR SWITCH - REMOVAL, LEFT....8N-32
B-PILLAR SWITCH - REMOVAL, RIGHT . . . 8N-32
B-PILLAR UPPER TRIM - INSTALLATION
. . 23-74
B-PILLAR UPPER TRIM - REMOVAL
......23-74
BRACKET - 2.4L ENGINE -
INSTALLATION, COMPRESSOR
MOUNTING
.........................24-66
BRACKET - 2.4L ENGINE - REMOVAL,
COMPRESSOR MOUNTING
.............24-65
BRACKET - DESCRIPTION, TRANSVERSE
. . 8N-18
BRACKET - INSTALLATION, TRANSVERSE
. 8N-18
BRACKET - OPERATION, TRANSVERSE
. . . 8N-18
BRACKET - REMOVAL, TRANSVERSE
.....8N-18
BRACKET ASSEMBLY - INSTALLATION,
FLOOR CONSOLE TRAY
................23-82
BRACKET ASSEMBLY - REMOVAL,
FLOOR CONSOLE TRAY
................23-82
BRAKE - DESCRIPTION, CONTROLLER
ANTILOCK
...........................8E-5
BRAKE - INSTALLATION, CONTROLLER
ANTILOCK
...........................8E-6
BRAKE - INSTALLATION, LEVER -
PARKING
............................5-65BRAKE - INSTALLATION, SHOES -
PARKING............................5-72
BRAKE - INSTALLATION, SUPPORT
PLATE - DRUM.......................5-56
BRAKE - OPERATION, CONTROLLER
ANTILOCK...........................8E-5
BRAKE - REMOVAL, CONTROLLER
ANTILOCK...........................8E-6
BRAKE - REMOVAL, LEVER - PARKING....5-64
BRAKE - REMOVAL, SHOES - PARKING....5-67
BRAKE - REMOVAL, SUPPORT PLATE -
DRUM..............................5-56
BRAKE AUTOMATIC ADJUSTER -
DIAGNOSIS AND TESTING, DRUM........5-13
BRAKE AUTOMATIC ADJUSTER TENSION
RELEASE - STANDARD PROCEDURE,
PARKING............................5-58
BRAKE AUTOMATIC ADJUSTER TENSION
RESET - STANDARD PROCEDURE,
PARKING............................5-59
BRAKE BLEEDING - STANDARD
PROCEDURE, BASE.....................5-7
BRAKE BOOSTER - DESCRIPTION,
POWER.............................5-40
BRAKE BOOSTER - DIAGNOSIS AND
TESTING, POWER.....................5-41
BRAKE BOOSTER - OPERATION, POWER . . . 5-41
BRAKE CABLE (FRONT) - INSTALLATION,
PARKING............................5-63
BRAKE CABLE (FRONT) - REMOVAL,
PARKING............................5-59
BRAKE CABLE (INTERMEDIATE) -
INSTALLATION, PARKING...............5-63
BRAKE CABLE (INTERMEDIATE) -
REMOVAL, PARKING...................5-60
BRAKE CABLE (LEFT REAR) -
INSTALLATION, PARKING...............5-64
BRAKE CABLE (LEFT REAR) - REMOVAL,
PARKING............................5-62
BRAKE CABLE (RIGHT REAR) -
INSTALLATION, PARKING...............5-63
BRAKE CABLE (RIGHT REAR) -
REMOVAL, PARKING...................5-60
BRAKE CABLES - ADJUSTMENT,
PARKING............................5-64
BRAKE CALIPER - INSTALLATION, REAR
DISC...............................5-30
BRAKE CALIPER - REMOVAL, REAR
DISC...............................5-27
BRAKE CALIPER ADAPTER -
INSTALLATION, FRONT DISC.............5-31
BRAKE CALIPER ADAPTER - REMOVAL,
FRONT DISC.........................5-31
BRAKE CALIPER (DISC/DISC BRAKES) -
INSTALLATION, FRONT DISC.............5-27
BRAKE CALIPER (DISC/DISC BRAKES) -
REMOVAL, FRONT DISC................5-24
BRAKE CALIPER (DISC/DRUM BRAKES) -
INSTALLATION, FRONT DISC.............5-27
BRAKE CALIPER (DISC/DRUM BRAKES) -
REMOVAL, FRONT DISC................5-24
BRAKE CALIPER GUIDE PINS (DISC/
DRUM BRAKES) - INSTALLATION, DISC....5-31
BRAKE CALIPER GUIDE PINS (DISC/
DRUM BRAKES) - REMOVAL, DISC.......5-31
BRAKE FASTENER TORQUE,
SPECIFICATIONS.......................5-9
BRAKE FLUID CONTAMINATION -
DIAGNOSIS AND TESTING..............5-32
BRAKE FLUID LEVEL CHECKING -
STANDARD PROCEDURE................5-32
BRAKE FLUID LEVEL SWITCH -
DESCRIPTION........................5-10
BRAKE FLUID LEVEL SWITCH -
INSTALLATION........................5-11
BRAKE FLUID LEVEL SWITCH -
OPERATION..........................5-10
BRAKE FLUID LEVEL SWITCH -
REMOVAL...........................5-11
BRAKE FLUID, SPECIFICATIONS..........5-33
BRAKE LAMP SWITCH - DESCRIPTION....8L-4
BRAKE LAMP SWITCH - DIAGNOSIS
AND TESTING
........................8L-5
BRAKE LAMP SWITCH - INSTALLATION
....8L-5
BRAKE LAMP SWITCH - OPERATION
......8L-4
BRAKE LAMP SWITCH - REMOVAL
.......8L-5
BRAKE LEVER AND FRONT CABLE -
INSTALLATION, PARKING
...............5-66BRAKE LEVER AND FRONT CABLE -
REMOVAL, PARKING...................5-65
BRAKE PROPORTIONING -
DESCRIPTION, ELECTRONIC VARIABLE....5-75
BRAKE PROPORTIONING - OPERATION,
ELECTRONIC VARIABLE................5-77
BRAKE ROTOR - DIAGNOSIS AND
TESTING............................5-51
BRAKE ROTOR - INSTALLATION, FRONT . . . 5-54
BRAKE ROTOR - REMOVAL, FRONT.......5-54
BRAKE ROTOR, EXPORT................5-55
BRAKE ROTOR MACHINING - STANDARD
PROCEDURE.........................5-53
BRAKE ROTOR, SPECIFICATIONS.........5-55
BRAKE SHOE LINING - INSPECTION,
REAR DRUM.........................5-22
BRAKE SHOES - ADJUSTMENT, PARKING . . 5-73
BRAKE SHOES - ADJUSTMENT, REAR
DRUM..............................5-23
BRAKE SHOES - CLEANING, DISC....5-16,5-18
BRAKE SHOES - INSPECTION, DISC . . . 5-16,5-18
BRAKE SHOES - INSTALLATION, REAR
DISC...............................5-19
BRAKE SHOES - INSTALLATION, REAR
DRUM..............................5-22
BRAKE SHOES - REMOVAL, REAR DISC....5-17
BRAKE SHOES - REMOVAL, REAR DRUM . . 5-19
BRAKE SHOES (DISC/DISC BRAKES) -
INSTALLATION, FRONT DISC.............5-16
BRAKE SHOES (DISC/DISC BRAKES) -
REMOVAL, FRONT DISC..................5-14
BRAKE SHOES (DISC/DRUM BRAKES) -
INSTALLATION, FRONT DISC.............5-17
BRAKE SHOES (DISC/DRUM BRAKES) -
REMOVAL, FRONT DISC................5-15
BRAKE SYSTEM - DESCRIPTION,
ANTILOCK...........................5-75
BRAKE SYSTEM - DIAGNOSIS AND
TESTING, BASE........................5-4
BRAKE SYSTEM - OPERATION,
ANTILOCK...........................5-76
BRAKE SYSTEM BLEEDING - STANDARD
PROCEDURE, ANTILOCK................5-78
BRAKE SYSTEM (EXPORT) -
DESCRIPTION, ANTILOCK...............5-75
BRAKE SYSTEM, SPECIAL TOOLS - BASE . . 5-10
BRAKE TUBES AND HOSES -
DESCRIPTION........................5-14
BRAKE TUBES AND HOSES -
INSPECTION.........................5-14
BRAKE TUBES AND HOSES - OPERATION . . 5-14
BRAKES - DESCRIPTION, BASE...........5-3
BRAKES - OPERATION, BASE.............5-3
BRAKES (EXPORT) - DESCRIPTION,
BASE................................5-3
BRAKES (EXPORT) - DESCRIPTION, DISC . . 5-13
BRAKES (FRONT) - DESCRIPTION, DISC . . . 5-11
BRAKES (FRONT) - OPERATION, DISC.....5-13
BRAKES (REAR) - DESCRIPTION, DISC
....5-12
BRAKES (REAR) - DESCRIPTION, DRUM
. . . 5-13
BRAKES (REAR) - OPERATION, DISC
......5-13
BRAKE/TRANSMISSION SHIFT
INTERLOCK SOLENOID - DIAGNOSIS
AND TESTING
......................21-235
BREAK-IN - STANDARD PROCEDURE,
COMPRESSOR CLUTCH
...............24-17
BUCKET - INSTALLATION, BUCKET SEAT
BACK - QUAD
.......................23-97
BUCKET - INSTALLATION, SEAT BELT
BUCKLE - FIRST ROW INBOARD -
QUAD
.............................8O-11
BUCKET - REMOVAL, BUCKET SEAT
BACK - QUAD
.......................23-97
BUCKET - REMOVAL, SEAT BELT BUCKLE
- FIRST ROW INBOARD - QUAD
.........8O-11
BUCKET, 50/50 SPLIT, BENCH -
INSTALLATION, SEAT BACK HINGE
COVERS - QUAD
....................23-100
BUCKET, 50/50 SPLIT, BENCH -
INSTALLATION, SEAT CUSHION COVER
- QUAD
............................23-99
BUCKET, 50/50 SPLIT, BENCH -
REMOVAL, SEAT BACK HINGE COVERS
- QUAD
...........................23-100
BUCKET, 50/50 SPLIT, BENCH -
REMOVAL, SEAT CUSHION COVER -
QUAD
..............................23-98
4 INDEXRS
Description Group-Page Description Group-Page Description Group-Page
ProCarManuals.com

COLUMN COVER BACKING PLATE -
REMOVAL, STEERING.................23-69
COLUMN TORQUE, SPECIFICATIONS.....19-14
COMBUSTION PRESSURE LEAKAGE
TEST - DIAGNOSIS AND TESTING,
CYLINDER........................9-83,9-9
COMMON PROBLEM CAUSES -
DIAGNOSIS AND TESTING.............21-30
COMMUNICATION RECEIVE - PCM INPUT
- OPERATION, DATA BUS..............8E-15
COMMUNICATIONS INTERFACE (PCI)
BUS, OPERATION - PROGRAMMABLE....14-21
COMPASS CALIBRATION - STANDARD
PROCEDURE.........................8M-3
COMPASS DEMAGNETIZING -
STANDARD PROCEDURE...............8M-4
COMPASS MINI-TRIP COMPUTER -
DIAGNOSIS AND TESTING.............8M-10
COMPASS VARIATION ADJUSTMENT -
STANDARD PROCEDURE...............8M-5
COMPASS/MINI-TRIP COMPUTER -
DESCRIPTION........................8M-9
COMPASS/MINI-TRIP COMPUTER -
INSTALLATION......................8M-10
COMPASS/MINI-TRIP COMPUTER -
OPERATION.........................8M-9
COMPASS/MINI-TRIP COMPUTER -
REMOVAL..........................8M-10
COMPLAINTS - DIAGNOSIS AND
TESTING, CLUTCH CHATTER..............6-6
COMPRESSION PRESSURE TEST -
DIAGNOSIS AND TESTING, CYLINDER . . 9-83,9-9
COMPRESSOR - 2.4/3.3/3.8L ENGINES -
REMOVAL............................24-64
COMPRESSOR - DESCRIPTION, A/C......24-63
COMPRESSOR - INSTALLATION.........24-65
COMPRESSOR - OPERATION, A/C........24-63
COMPRESSOR CLUTCH - DESCRIPTION . . 24-16
COMPRESSOR CLUTCH - OPERATION....24-17
COMPRESSOR CLUTCH AIR GAP -
STANDARD PROCEDURE...............24-17
COMPRESSOR CLUTCH BREAK-IN -
STANDARD PROCEDURE...............24-17
COMPRESSOR CLUTCH COIL -
DIAGNOSIS AND TESTING.............24-20
COMPRESSOR CLUTCH RELAY -
DESCRIPTION.......................24-21
COMPRESSOR CLUTCH RELAY -
DIAGNOSIS AND TESTING.............24-22
COMPRESSOR CLUTCH RELAY -
INSTALLATION.......................24-22
COMPRESSOR CLUTCH RELAY -
OPERATION.........................24-21
COMPRESSOR CLUTCH RELAY -
REMOVAL..........................24-22
COMPRESSOR CLUTCH/COIL -
INSPECTION........................24-18
COMPRESSOR MOUNTING BRACKET -
2.4L ENGINE - INSTALLATION...........24-66
COMPRESSOR MOUNTING BRACKET -
2.4L ENGINE - REMOVAL..............24-65
COMPRESSOR NOISE DIAGNOSIS -
DIAGNOSIS AND TESTING.............24-63
COMPUTER - DESCRIPTION, COMPASS/
MINI-TRIP..........................8M-9
COMPUTER - DIAGNOSIS AND TESTING,
COMPASS MINI-TRIP
.................8M-10
COMPUTER - INSTALLATION, COMPASS/
MINI-TRIP
.........................8M-10
COMPUTER - OPERATION, COMPASS/
MINI-TRIP
..........................8M-9
COMPUTER - REMOVAL, COMPASS/
MINI-TRIP
.........................8M-10
CONCENTRATION TESTING - DIAGNOSIS
AND TESTING, COOLANT
...............7-19
CONDENSER - DESCRIPTION
...........24-66
CONDENSER - INSTALLATION
...........24-67
CONDENSER - OPERATION
.............24-66
CONDENSER - REMOVAL
..............24-66
CONDITION CHECK, STANDARD
PROCEDURE - FLUID LEVEL
...........21-201
CONDITIONING LINES - INSTALLATION,
REAR AIR
.........................24-105
CONDITIONING LINES - REMOVAL, REAR
AIR
..............................24-104
CONNECTING ROD - DESCRIPTION,
PISTON
........................9-116,9-42CONNECTING ROD - INSTALLATION,
PISTON.............................9-44
CONNECTING ROD - REMOVAL, PISTON . . . 9-43
CONNECTING ROD BEARING
CLEARANCE - STANDARD
PROCEDURE, MEASURING.............9-120
CONNECTING ROD, FITTING.............9-45
CONNECTING RODS - STANDARD
PROCEDURE, FITTING.................9-116
CONNECTOR - DESCRIPTION, DATA LINK . . 8E-6
CONNECTOR - INSTALLATION.......8W-01-11
CONNECTOR - OPERATION, DATA LINK....8E-7
CONNECTOR - REMOVAL...........8W-01-11
CONNECTOR, GROUND AND SPLICE
INFORMATION - DESCRIPTION........8W-01-7
CONNECTOR/GROUND/SPLICE LOCATION
- DESCRIPTION....................8W-91-1
CONSOLE - DESCRIPTION, OVERHEAD....8M-1
CONSOLE - DIAGNOSIS AND TESTING,
OVERHEAD..........................8M-2
CONSOLE - INSTALLATION, LOWER......23-68
CONSOLE - OPERATION, OVERHEAD......8M-2
CONSOLE - REMOVAL, LOWER..........23-68
CONSOLE - REMOVAL, OVERHEAD.......8M-6
CONSOLE LAMP SWITCH -
INSTALLATION, CENTER...............8L-26
CONSOLE LAMP SWITCH - REMOVAL,
CENTER............................8L-26
CONSOLE, SPECIAL TOOLS - OVERHEAD . . 8M-6
CONSOLE TRAY - BRACKET ASSEMBLY -
INSTALLATION, FLOOR................23-82
CONSOLE TRAY - BRACKET ASSEMBLY -
REMOVAL, FLOOR....................23-82
CONSOLE TRAY - INSTALLATION, FLOOR . . 23-81
CONSOLE TRAY - REMOVAL, FLOOR.....23-81
CONTAINER - DESCRIPTION, COOLANT
RECOVERY..........................7-19
CONTAINER - INSTALLATION, COOLANT
RECOVERY..........................7-20
CONTAINER - OPERATION, COOLANT
RECOVERY..........................7-19
CONTAINER - REMOVAL, COOLANT
RECOVERY..........................7-20
CONTAMINATION - DIAGNOSIS AND
TESTING, BRAKE FLUID................5-32
CONTINUITY - STANDARD PROCEDURE,
TESTING.........................8W-01-9
CONTROL (4 SPEED EATX ONLY) -
OPERATION, INTERACTIVE SPEED........8P-2
CONTROL ARM - DESCRIPTION, LOWER . . . 2-12
CONTROL ARM - INSPECTION, LOWER....2-14
CONTROL ARM - INSTALLATION, LOWER . . 2-15
CONTROL ARM - OPERATION, LOWER.....2-12
CONTROL ARM - REMOVAL, LOWER......2-12
CONTROL ARM (REAR BUSHING -
HYDRO) - ASSEMBLY, LOWER...........2-14
CONTROL ARM (REAR BUSHING -
HYDRO) - DISASSEMBLY, LOWER........2-14
CONTROL ARM (REAR BUSHING -
STANDARD) - ASSEMBLY, LOWER........2-14
CONTROL ARM (REAR BUSHING -
STANDARD) - DISASSEMBLY, LOWER.....2-13
CONTROL CABLE - INSTALLATION,
THROTTLE..........................14-35
CONTROL CABLE - REMOVAL,
THROTTLE..........................14-35
CONTROL CALIBRATION - STANDARD
PROCEDURE, HEATER-A/C..............24-8
CONTROL CIRCUIT TEST - DIAGNOSIS
AND TESTING.......................8F-30
CONTROL INFORMATION LABEL -
DESCRIPTION, VEHICLE EMISSION.......25-1
CONTROL MODULE - DESCRIPTION,
BODY...............................8E-3
CONTROL MODULE - DESCRIPTION,
FRONT..............................8E-7
CONTROL MODULE - DESCRIPTION,
POWER LIFTGATE....................8E-10
CONTROL MODULE - DESCRIPTION,
SIDE IMPACT AIRBAG
.................8O-17
CONTROL MODULE - DESCRIPTION,
SLIDING DOOR
......................8E-19
CONTROL MODULE - DESCRIPTION,
TRANSMISSION
......................8E-20
CONTROL MODULE - DIAGNOSIS AND
TESTING, FRONT
......................8E-7
CONTROL MODULE - INSTALLATION,
BODY
...............................8E-5CONTROL MODULE - INSTALLATION,
FRONT..............................8E-8
CONTROL MODULE - INSTALLATION,
POWER LIFTGATE....................8E-11
CONTROL MODULE - INSTALLATION,
SIDE IMPACT AIRBAG.................8O-17
CONTROL MODULE - INSTALLATION,
SLIDING DOOR......................8E-20
CONTROL MODULE - OPERATION, BODY . . . 8E-3
CONTROL MODULE - OPERATION,
FRONT..............................8E-7
CONTROL MODULE - OPERATION,
POWER LIFTGATE....................8E-11
CONTROL MODULE - OPERATION, SIDE
IMPACT AIRBAG.....................8O-17
CONTROL MODULE - OPERATION,
SLIDING DOOR......................8E-19
CONTROL MODULE - OPERATION,
TRANSMISSION......................8E-20
CONTROL MODULE - REMOVAL, BODY....8E-4
CONTROL MODULE - REMOVAL, FRONT . . . 8E-8
CONTROL MODULE - REMOVAL, POWER
LIFTGATE...........................8E-11
CONTROL MODULE - REMOVAL, SIDE
IMPACT AIRBAG.....................8O-17
CONTROL MODULE - REMOVAL,
SLIDING DOOR......................8E-19
CONTROL MOTOR - DESCRIPTION, IDLE
AIR ...............................14-28
CONTROL MOTOR - INSTALLATION, IDLE
AIR ...............................14-29
CONTROL MOTOR - OPERATION, IDLE
AIR.................................14-28
CONTROL MOTOR - REMOVAL, IDLE AIR . . 14-29
CONTROL RELAY - DESCRIPTION,
TRANSMISSION.....................21-247
CONTROL RELAY - OPERATION,
TRANSMISSION.....................21-248
CONTROL SWITCH - DIAGNOSIS AND
TESTING, TRACTION...................5-82
CONTROL SYSTEM - DESCRIPTION,
TRACTION...........................5-76
CONTROL SYSTEM - OPERATION,
EVAPORATION.......................25-10
CONTROL SYSTEM - OPERATION,
TRACTION...........................5-77
CONTROLLER - DESCRIPTION,
OCCUPANT RESTRAINT................8O-7
CONTROLLER - INSTALLATION,
OCCUPANT RESTRAINT................8O-7
CONTROLLER - INSTALLATION, SBEC....8E-17
CONTROLLER - OPERATION, 8-VOLT
SUPPLY - PCM OUTPUT - SBEC.........8E-15
CONTROLLER - OPERATION, OCCUPANT
RESTRAINT..........................8O-7
CONTROLLER - REMOVAL, NGC.........8E-17
CONTROLLER - REMOVAL, OCCUPANT
RESTRAINT..........................8O-7
CONTROLLER - REMOVAL, SBEC........8E-16
CONTROLLER ANTILOCK BRAKE -
DESCRIPTION........................8E-5
CONTROLLER ANTILOCK BRAKE -
INSTALLATION........................8E-6
CONTROLLER ANTILOCK BRAKE -
OPERATION..........................8E-5
CONTROLLER ANTILOCK BRAKE -
REMOVAL...........................8E-6
CONVENTIONAL BATTERY CHARGING -
STANDARD PROCEDURE...............8F-11
CONVERTER - DESCRIPTION, CATALYTIC . . . 11-4
CONVERTER - DESCRIPTION, TORQUE . . . 21-242
CONVERTER - INSPECTION, CATALYTIC....11-5
CONVERTER - INSTALLATION, CATALYTIC . . 11-6
CONVERTER - INSTALLATION, TORQUE . . 21-247
CONVERTER - OPERATION, CATALYTIC....11-4
CONVERTER - OPERATION, TORQUE....21-245
CONVERTER - REMOVAL, CATALYTIC......11-5
CONVERTER - REMOVAL, TORQUE......21-247
CONVERTER HOUSING FLUID LEAKAGE -
DIAGNOSIS AND TESTING, TORQUE.....21-123
COOL DOWN TEST - DIAGNOSIS AND
TESTING, A/C
........................24-4
COOLANT - DESCRIPTION, ENGINE
.......7-19
COOLANT - DESCRIPTION, ENGINE
........0-3
COOLANT - STANDARD PROCEDURE,
ADDING ADDITIONAL
...................7-5
COOLANT CONCENTRATION TESTING -
DIAGNOSIS AND TESTING
..............7-19
RSINDEX7
Description Group-Page Description Group-Page Description Group-Page
ProCarManuals.com