2004 CHRYSLER VOYAGER steering wheel adjustment

WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
DESCRIPTION - WHEEL ALIGNMENT.......47
DIAGNOSIS AND TESTING - SUSPENSION
AND STEERING......................50
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL
ALIGNMENT.........................52STANDARD PROCEDURE - CURB HEIGHT
MEASUREMENT......................55
SPECIFICATIONS
WHEEL ALIGNMENT...................56
WHEEL ALIGNMENT
DESCRIPTION - WHEEL ALIGNMENT
Vehicle wheel alignment is the positioning of all
interrelated front and rear suspension angles. These
angles affect the handling and steering of the vehicle
when it is in motion. Proper wheel alignment is
essential for efficient steering, good directional stabil-
ity, and proper tire wear.
The method of checking a vehicle's front and rear
wheel alignment varies depending on the manufac-
turer and type of equipment used. The manufactur-
er's instructions should always be followed to ensure
accuracy of the alignment, except when
DaimlerChrysler Corporation's wheel alignment spec-
ifications differ.
On this vehicle, the suspension angles that can be
adjusted are as follows:
²Front Camber (with camber bolt package and
standard procedure)
²Front Toe
Check the wheel alignment and make all wheel
alignment adjustments with the vehicle standing at
its proper curb height specification. Curb height is
the normal riding height of the vehicle. It is mea-
sured from a certain point on the vehicle to the
ground or a designated area while the vehicle is sit-
ting on a flat, level surface. Refer to Curb Height
Measurement in this section for additional informa-
tion.
Typical wheel alignment angles and measurements
are described in the following paragraphs.
CAMBER
Camber is the inward or outward tilt of the top of
the tire and wheel assembly (Fig. 1). Camber is mea-
sured in degrees of angle relative to a true vertical
line. Camber is a tire wearing angle.
²Excessive negative camber will cause tread wear
at the inside of the tire.²Excessive positive camber will cause tread wear
on the outside of the tire.
CROSS CAMBER
Cross camber is the difference between left and
right camber. To achieve the cross camber reading,
subtract the right side camber reading from the left.
Fig. 1 Camber
1 - WHEELS TILTED OUT AT TOP
2 - WHEELS TILTED IN AT TOP
RSWHEEL ALIGNMENT2-47

CONDITION POSSIBLE CAUSES CORRECTION
Excessive Steering Free
Play1. Incorrect Steering Gear Adjustment 1. Adjust Or Replace Steering Gear
2. Worn or loose tie rod ends 2. Replace or tighten tie rod ends
3. Loose steering gear mounting bolts 3. Tighten steering gear bolts to specified
torque
4. Loose or worn steering shaft coupler 4. Replace steering shaft coupler
Excessive Steering Effort 1. Low tire pressure 1. Inflate all tires to recommended
pressure
2. Lack of lubricant in steering gear 2. Replace steering gear
3. Low power steering fluid level 3. Fill power steering fluid reservoir to
correct level
4. Loose power steering pump drive
belt4. Correctly adjust power steering pump
drive belt
5. Lack of lubricant in ball joints 5. Lubricate or replace ball joints
6. Steering gear malfunction 6. Replace steering gear
7. Lack of lubricant in steering coupler 7. Replace steering coupler
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL ALIGNMENT
PRE-WHEEL ALIGNMENT INSPECTION
Before any attempt is made to change or correct
the wheel alignment, the following inspection and
necessary corrections must be made to ensure proper
alignment.
(1) Verify that the fuel tank is full of fuel. If the
tank is not full, the reduction in weight will affect
the curb height of the vehicle and the alignment
angles.
(2) The passenger and luggage compartments of
the vehicle should be free of any load that is not fac-
tory equipment.
(3) Check the tires on the vehicle. All tires must be
the same size and in good condition with approxi-
mately the same amount of tread wear. Inflate all
the tires to the recommended air pressure.
(4) Check the front wheel and tire assemblies for
excessive radial runout.
(5) Inspect lower ball joints and all steering link-
age for looseness, binding, wear or damage. Repair as
necessary.
(6) Check suspension fasteners for proper torque
and retighten as necessary.
(7) Inspect all suspension component rubber bush-
ings for signs of wear or deterioration. Replace any
faulty bushings or components before aligning the
vehicle.
(8) Check the vehicle's curb height to verify it is
within specifications. Refer to Curb Height Measure-
ment.
WHEEL ALIGNMENT SETUP
(1) Position the vehicle on an alignment rack.
(2) Install all required alignment equipment on
the vehicle per the alignment equipment manufactur-
er's instructions. On this vehicle, a four-wheel align-
ment is recommended.
NOTE: Prior to reading the vehicle's alignment
readouts, the front and rear of vehicle should be
jounced. Induce jounce (rear first, then front) by
grasping the center of the bumper and jouncing
each end of vehicle an equal number of times. The
bumper should always be released when vehicle is
at the bottom of the jounce cycle.
(3) Read the vehicle's current front and rear align-
ment settings. Compare the vehicle's current align-
ment settings to the vehicle specifications for camber,
caster and toe-in. (Refer to 2 - SUSPENSION/
WHEEL ALIGNMENT - SPECIFICATIONS)
(4) If front camber and caster are not within spec-
ifications, proceed to CAMBER AND CASTER below.
If caster and camber are within specifications, pro-
ceed to TOE which can be found following CAMBER
AND CASTER. Rear camber, caster and toe are not
adjustable. If found not to be within specifications,
reinspect for damaged suspension or body compo-
nents and replace as necessary.
CAMBER AND CASTER
Camber and caster settings on this vehicle are
determined at the time the vehicle is designed, by
the location of the vehicle's suspension components.
This is referred to as NET BUILD. The result is no
2 - 52 WHEEL ALIGNMENTRS
WHEEL ALIGNMENT (Continued)

required adjustment of camber and caster after the
vehicle is built or when servicing the suspension
components. Thus, when performing a wheel align-
ment, caster and camber are not normally considered
adjustable angles. Camber and caster should be
checked to ensure they meet vehicle specifications.
If front camber is found not to meet alignment
specifications, it can be adjusted using an available
camber adjustment bolt package. Before installing a
camber adjustment bolt package on a vehicle found
to be outside the specifications, inspect the suspen-
sion components for any signs of damage or bending.
CAUTION: Do not attempt to adjust the vehicles
wheel alignment by heating, bending or by perform-
ing any other modification to the vehicle's front
suspension components or body.
If camber readings are not within specifications,
use the following procedure to install the front cam-
ber adjustment bolt package and then adjust front
camber.
CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION
The camber adjustment bolt package contains 2
flange bolts, 2 cam bolts, 2 dog bone washers, and 4
nuts. This package services both sides of the vehicle.
Use the package to attach the strut clevis bracket to
the steering knuckle after the strut clevis bracket
has been modified. To install and adjust the camber
adjustment bolt package, follow the procedure below.
(1) Raise the vehicle until its tires are not support-
ing the weight of the vehicle.
(2) Remove the front tire and wheel assemblies.
CAUTION:
When removing the steering knuckle from
the strut clevis bracket, do not put a strain on the
brake flex hose. Also, do not let the weight of the
steering knuckle assembly be supported by the
brake flex hose when removed from the strut assem-
bly. If necessary use a wire hanger to support the
steering knuckle assembly or if required remove the
brake flex hose from the caliper assembly.
CAUTION: The knuckle to strut assembly attaching
bolt shanks are serrated and must not be turned
during removal. Remove the nuts while holding the
bolts stationary.
(3) Remove the top and bottom, strut clevis
bracket to steering knuckle attaching bolts (Fig.
7)and discard. Separate the steering knuckle from
the strut clevis bracket and position steering knuckle
so it is out of the way of the strut.
CAUTION: When slotting the bottom mounting hole
on the strut clevis bracket, do not enlarge the hole
beyond the indentations on the sides of the strut
clevis bracket (Fig. 8).(4) Using an appropriate grinder and grinding
wheel, slot the bottom hole in both sides of the strut
clevis bracket (Fig. 8).
CAUTION: After slotting the strut clevis bracket
hole, do not install the original attaching bolts when
assembling the steering knuckle to the strut assem-
bly. Only the flange bolts, cam bolts, and dog bone
washers from the service package must be used to
attach the steering knuckle to the strut after the
mounting hole is slotted.
Fig. 7 Clevis Bracket To Steering Knuckle Attaching
Bolts
1 - STRUT CLEVIS BRACKET
2 - ATTACHING BOLTS
3 - TIE ROD END
4 - ROTOR
5 - STEERING KNUCKLE
Fig. 8 Strut Clevis Bracket Bolt Hole Grinding Area
1 - UPPER STRUT TO STEERING KNUCKLE ATTACHING HOLE
2 - CAMBER ADJUSTMENT SLOT INDENTATION AREA ON
CLEVIS BRACKET
3 - LOWER STRUT TO STEERING KNUCKLE ATTACHING HOLE
4 - STRUT CLEVIS BRACKET
RSWHEEL ALIGNMENT2-53
WHEEL ALIGNMENT (Continued)

NOTE: The strut clevis-to-knuckle bolts are installed
differently on each side of the vehicle. Left-hand-
side bolts are installed from vehicle rear to front
(Fig. 9). Right-hand-side bolts are installed from
vehicle front to rear.
(5) Position the knuckle back into the strut clevis
bracket. Using the direction indicated in the above
note, install a flanged bolt from the service package
into the upper mounting hole. Using the direction
indicated in the above note, install a cam bolt into
the bottom mounting hole (Fig. 9).
(6) Install a dog bone washer on the steering
knuckle to strut clevis bracket attaching bolts, then
install the nuts onto the bolts from the service pack-
age (Fig. 10). Tighten the bolts just enough to hold
the steering knuckle in position when adjusting cam-
ber, while still allowing the steering knuckle to move
in clevis bracket.
(7) Repeat the procedure to the other side strut
clevis bracket.
(8) Reinstall both front tire and wheel assemblies
and tighten to specifications.
(9) Lower the vehicle. Jounce the front and rear of
vehicle an equal amount of times.
(10) Adjust the front camber to the preferred set-
ting by rotating the lower eccentric cam bolt against
the cam stop areas on the strut clevis bracket (Fig.
11). When camber is set, tighten the upper strut cle-
vis bracket bolt and lower cam bolt. Again jounce
front and rear of vehicle an equal amount of times
and verify front camber setting. Torque both front
strut to steering knuckle attaching bolts to 81 N´m
(60 ft. lbs.) plus an additional 1/4 (90É) turn after the
required torque is met.(11) If toe readings obtained are not within the
required specification range, adjust toe to meet the
preferred specification setting. Toe is adjustable
using the following procedure.
TOE
(1) Center the steering wheel and lock in place
using a steering wheel clamp.
CAUTION: Do not twist front inner tie rod to steer-
ing gear rubber boots during front wheel Toe
adjustment.
(2) Loosen front inner to outer tie rod end jam
nuts (Fig. 12). Grasp inner tie rods at serrations and
Fig. 9 Package Bolts Correctly Installed
1 - STEERING KNUCKLE
2 - FLANGED BOLT IN TOP HOLE
3 - CAM BOLT IN BOTTOM HOLE
4 - STRUT CLEVIS BRACKET
Fig. 10 Dog Bone Washer And Nuts Installed
1 - STEERING KNUCKLE
2 - DOG BONE WASHER
3 - STRUT CLEVIS BRACKET
4 - ATTACHING NUTS
Fig. 11 Camber Adjustment Cam Bolt
1 - STEERING KNUCKLE
2 - CLEVIS BRACKET CAM STOP AREAS
3 - LOWER ECCENTRIC CAMBER ADJUSTMENT BOLT
2 - 54 WHEEL ALIGNMENTRS
WHEEL ALIGNMENT (Continued)

rotate inner tie rods of steering gear (Fig. 12) to set
front toe to the preferred toe specification. (Refer to 2
- SUSPENSION/WHEEL ALIGNMENT - SPECIFI-
CATIONS)
(3) Tighten tie rod jam nuts (Fig. 12) to 75 N´m
(55 ft. lbs.) torque.
(4) Adjust steering gear to tie rod boots at the
inner tie rod.
(5) Remove steering wheel clamp.
(6) Remove the alignment equipment.
(7) Road test the vehicle to verify the steering
wheel is straight and the vehicle does not wander or
pull.STANDARD PROCEDURE - CURB HEIGHT
MEASUREMENT
The wheel alignment is to be checked and all align-
ment adjustments made with the vehicle at its
required curb height specification.
Vehicle height is to be checked with the vehicle on
a flat, level surface, preferably a vehicle alignment
rack. The tires are to be inflated to the recommended
pressure. All tires are to be the same size as stan-
dard equipment. Vehicle height is checked with the
fuel tank full of fuel, and no passenger or luggage
compartment load.
Vehicle height is not adjustable. If the measure-
ment is not within specifications, inspect the vehicle
for bent or weak suspension components. Compare
the parts tag on the suspect coil spring(s) to the
parts book and the vehicle sales code, checking for a
match. Once removed from the vehicle, compare the
coil spring height to a correct new or known good coil
spring. The heights should vary if the suspect spring
is weak.
(1) Measure from the inboard edge of the wheel
opening fender lip directly above the wheel center
(spindle), to the floor or alignment rack surface.
(2) When measuring, the maximum left-to-right
differential is not to exceed 12.5 mm (0.5 in.).
(3) Compare the measurements to the specifica-
tions listed in the following Curb Height Specifica-
tions charts.
CURB HEIGHT SPECIFICATIONS
VEHICLE FRONT REAR
CARGO VAN755mm 11mm
29.72 in.   0.43 in795mm 11mm
31.30 in.   0.43 in.
ALL OTHERS755mm 11mm
29.72 in.   0.43 in770mm 11mm
30.31 in.   0.43 in.
Fig. 12 Front Wheel Toe Adjustment
1 - INNER TIE ROD SERRATION
2 - OUTER TIE ROD JAM NUT
3 - OUTER TIE ROD END
4 - INNER TIE ROD
5 - STEERING KNUCKLE
RSWHEEL ALIGNMENT2-55
WHEEL ALIGNMENT (Continued)

INSTALLATION - PARKING BRAKE CABLE
(LEFT REAR)
(1) Install the rear parking brake cable in the
brake support plate. Insert cable housing retainer
into brake support plate making certain that cable
housing retainer fingers lock the housing and
retainer firmly into place.
(2) Attach the parking brake cable onto the park
brake actuator lever.
(3) Install the brake shoes on the rear brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION).
(4) Insert cable housing retainer into body outrig-
ger bracket making certain that cable housing
retainer fingers lock the housing firmly into place.
(5) Connect rear parking brake cable to the equal-
izer bracket (Fig. 99).
(6) Install brake drum, and wheel and tire assem-
bly.
(7) Remove the locking pliers from the front park
brake cable. This will automatically adjust the park
brake cables.
(8) Apply and release park brake pedal 1 time.
This will seat the park brake cables.
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE CABLES
The park brake cables on this vehicle have an
automatic self adjuster built into the park brake
pedal mechanism. When the foot operated park brake
pedal is in its released (upward most) position, a
clock spring automatically adjusts the park brake
cables. The park brake cables are adjusted (ten-
sioned) just enough to remove all the slack from the
cables. The automatic adjuster system will not over
adjust the cables causing rear brake drag.
Due to the automatic adjust feature of the park
brake pedal, adjustment of the parking brake cables
on these vehicles relies on proper drum brake and
park brake shoe adjustment. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/DRUM - ADJUST-
MENTS) and (Refer to 5 - BRAKES/PARKING
BRAKE/SHOES - ADJUSTMENTS).
When the park brake pedal is applied the self
adjuster is by-passed and the pedal operates nor-
mally to engage the park brakes.
When a service procedure needs to be performed on
the park brake pedal or the park brake cables, the
automatic self adjuster can be manually locked out
by the service technician.
CABLES - PARKING BRAKE
(EXPORT)
REMOVAL - FRONT CABLE
(Refer to 5 - BRAKES - BASE/PARKING BRAKE/
LEVER - REMOVAL)
INSTALLATION - FRONT CABLE
(Refer to 5 - BRAKES - BASE/PARKING BRAKE/
LEVER - INSTALLATION)
LEVER - PARKING BRAKE
REMOVAL
(1) Manually release the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES/PARKING BRAKE -
STANDARD PROCEDURE).
(2) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal.
(3) Remove sill scuff plate from left door sill.
(4) Remove the left side kick panel.
(5) Remove the silencer panel under the instru-
ment panel.
(6) Remove the steering column cover from the
lower instrument panel.
(7) Remove the reinforcement from the lower
instrument panel.
(8) Remove the front parking brake cable from the
parking brake cable equalizer (Fig. 102).
(9) Remove tension from front park brake cable.
Tension is removed by releasing the locking pliers
from the front park brake cable.
Fig. 102 Parking Brake Cable Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
5 - 64 BRAKES - BASERS
CABLES - PARKING BRAKE (Continued)

FILL/CHECK LOCATIONS - DESCRIPTION,
FLUID...............................0-7
FILLER CAP - DESCRIPTION, FUEL.......25-12
FILLER CAP - OPERATION, FUEL........25-12
FILLER NECK SEAL - DIAGNOSIS AND
TESTING, RADIATOR CAP TO............7-27
FILLER TUBE - INSTALLATION, FUEL
TANK ..............................14-13
FILLER TUBE - REMOVAL, FUEL TANK....14-12
FILLING - STANDARD PROCEDURE,
COOLING SYSTEM.....................7-5
FILLING - STANDARD PROCEDURE,
REAR HEATER CORE.................24-101
FILTER - DESCRIPTION, AIR............24-43
FILTER - DESCRIPTION, OIL.............9-53
FILTER - INSTALLATION, AIR...........24-44
FILTER - INSTALLATION, INLET..........14-13
FILTER - INSTALLATION, OIL.......9-139,9-53
FILTER - REMOVAL, AIR...............24-43
FILTER - REMOVAL, INLET.............14-13
FILTER - REMOVAL, OIL...........9-139,9-53
FILTER ADAPTER - INSTALLATION, OIL . . . 9-139
FILTER ADAPTER - REMOVAL, OIL.......9-139
FILTER CHANGE - STANDARD
PROCEDURE, ENGINE OIL..........9-137,9-53
FILTER SERVICE - STANDARD
PROCEDURE, FLUID..........21-203,21s-104
FINAL DRIVE - ASSEMBLY......21-195,21s-99
FINAL DRIVE - DESCRIPTION............21s-95
FINAL DRIVE - DISASSEMBLY....21-190,21s-96
FINAL DRIVE - OPERATION............21s-96
FINESSE SANDING/BUFFING &
POLISHING - DESCRIPTION............23-85
FINISH - DESCRIPTION, BASE
COAT/CLEARCOAT....................23-85
FIRING ORDER, SPECIFICATIONS.........8I-3
FIRST ROW - BENCH - INSTALLATION,
SEAT BELT BUCKLE..................8O-13
FIRST ROW - BENCH - REMOVAL, SEAT
BELT BUCKLE.......................8O-13
FIRST ROW - OUTBOARD -
INSTALLATION, SEAT BELT &
RETRACTOR........................8O-14
FIRST ROW - OUTBOARD - REMOVAL,
SEAT BELT & RETRACTOR.............8O-14
FIRST ROW INBOARD - QUAD BUCKET -
INSTALLATION, SEAT BELT BUCKLE......8O-12
FIRST ROW INBOARD - QUAD BUCKET -
REMOVAL, SEAT BELT BUCKLE.........8O-12
FITTING - CONNECTING ROD............9-45
FITTING - PISTON RING................9-45
FITTING - STANDARD PROCEDURE,
MAIN BEARING......................9-123
FITTING - STANDARD PROCEDURE,
PISTON RING.......................9-121
FITTING - STANDARD PROCEDURE,
PISTON TO CYLINDER BORE............9-42
FITTING CONNECTING RODS -
STANDARD PROCEDURE...............9-116
FITTING PISTONS - STANDARD
PROCEDURE........................9-117
FITTINGS - STANDARD PROCEDURE,
HANDLING TUBING...................24-70
FITTINGS - STANDARD PROCEDURE,
QUICK-CONNECT.....................14-14
FLANGE SEAL - INSTALLATION, INPUT....3-45
FLANGE SEAL - INSTALLATION, OUTPUT . . . 3-46
FLANGE SEAL - REMOVAL, INPUT
........3-44
FLANGE SEAL - REMOVAL, OUTPUT
.......3-45
FLANGE SHIM SELECTION,
ADJUSTMENTS - OUTPUT
...............21-7
FLAP AND SPRING ASSEMBLY -
INSTALLATION, QUAD BUCKET SEAT
SIDE SHIELD/CUPHOLDER
............23-107
FLAP AND SPRING ASSEMBLY -
REMOVAL, QUAD BUCKET SEAT SIDE
SHIELD/CUPHOLDER
.................23-107
FLEX DRIVE - DESCRIPTION
...........8N-36
FLEX DRIVE - INSTALLATION
...........8N-37
FLEX DRIVE - OPERATION
.............8N-36
FLEX DRIVE - REMOVAL
...............8N-37
FLEX PLATE - INSTALLATION
...........9-131
FLEX PLATE - REMOVAL
...............9-131
FLEXIBLE FUEL ENGINE OIL -
DESCRIPTION
.........................0-3
FLOOR CONSOLE TRAY - BRACKET
ASSEMBLY - INSTALLATION
............23-83FLOOR CONSOLE TRAY - BRACKET
ASSEMBLY - REMOVAL................23-83
FLOOR CONSOLE TRAY - INSTALLATION . . 23-83
FLOOR CONSOLE TRAY - REMOVAL......23-83
FLOOR DISTRIBUTION DUCTS -
INSTALLATION.......................24-50
FLOOR DISTRIBUTION DUCTS -
REMOVAL..........................24-50
FLOOR HEAT DUCT - INSTALLATION,
REAR..............................24-63
FLOOR HEAT DUCT - REMOVAL, REAR . . . 24-62
FLOOR MATS - INSTALLATION, CARPETS . 23-76
FLOOR MATS - REMOVAL, CARPETS.....23-75
FLOW AND PRESSURE TEST -
DIAGNOSIS AND TESTING, POWER
STEERING SYSTEM....................19-1
FLOW CHECK - DIAGNOSIS AND
TESTING, COOLING SYSTEM.............7-3
FLUID - DESCRIPTION, AUTOMATIC/
MANUAL TRANSAXLE...................0-4
FLUID - DESCRIPTION, AWD POWER
TRANSFER UNIT.......................0-6
FLUID AND FILTER SERVICE -
STANDARD PROCEDURE.......21-203,21s-104
FLUID CAPACITIES - SPECIFICATIONS......0-6
FLUID CHANGE - STANDARD
PROCEDURE, DIFFERENTIAL
ASSEMBLY..........................3-40
FLUID CHANGE - STANDARD
PROCEDURE, OVERRUNNING CLUTCH
HOUSING............................3-41
FLUID CHANGE - STANDARD
PROCEDURE, PTU......................21-5
FLUID CONTAMINATION - DIAGNOSIS
AND TESTING, BRAKE.............5-32,5s-31
FLUID COOLER - DESCRIPTION.........19-44
FLUID COOLER - INSTALLATION.........19-45
FLUID COOLER - OPERATION...........19-44
FLUID COOLER - REMOVAL............19-44
FLUID DRAIN AND FILL - STANDARD
PROCEDURE........................21-71
FLUID FILL/CHECK LOCATIONS -
DESCRIPTION.........................0-7
FLUID LEAK DIAGNOSIS, DIAGNOSIS
AND TESTING........................21-3
FLUID LEAKAGE - DIAGNOSIS AND
TESTING, TORQUE CONVERTER
HOUSING....................21-123,21s-31
FLUID LEVEL AND CONDITION CHECK,
STANDARD PROCEDURE.......21-201,21s-102
FLUID LEVEL CHECK - STANDARD
PROCEDURE........................21-71
FLUID LEVEL CHECKING - STANDARD
PROCEDURE, BRAKE..............5-32,5s-31
FLUID LEVEL CHECKING - STANDARD
PROCEDURE, POWER STEERING........19-44
FLUID LEVEL INSPECTION - STANDARD
PROCEDURE.........................21-4
FLUID LEVEL SWITCH - DESCRIPTION,
BRAKE..........................5-10,5s-9
FLUID LEVEL SWITCH - INSTALLATION,
BRAKE.........................5-11,5s-10
FLUID LEVEL SWITCH - INSTALLATION,
WASHER...........................8R-12
FLUID LEVEL SWITCH - OPERATION,
BRAKE..........................5-10,5s-9
FLUID LEVEL SWITCH - REMOVAL,
BRAKE
.........................5-11,5s-10
FLUID LEVEL SWITCH - REMOVAL,
WASHER
...........................8R-12
FLUID, SPECIFICATIONS - BRAKE
....5-33,5s-32
FLUIDS - DESCRIPTION, AWD REAR
DRIVELINE MODULE
....................0-6
FLUSH MEASUREMENTS -
SPECIFICATIONS, GAP
................23-124
FLYWHEEL - INSTALLATION
.............6-12
FLYWHEEL - REMOVAL
.................6-12
FOG LAMP - DIAGNOSIS AND TESTING,
FRONT
..............................8L-7
FOG LAMP - INSTALLATION, FRONT
.......8L-8
FOG LAMP - REMOVAL, FRONT
..........8L-8
FOG LAMP UNIT ALIGNMENT - EXPORT
- STANDARD PROCEDURE, FRONT
........8L-9
FOG LAMP UNIT ALIGNMENT -
STANDARD PROCEDURE, FRONT
.........8L-9
FOLDAWAY MIRROR SWITCH - EXPORT
- DESCRIPTION, POWER
..............8N-48FOLDAWAY MIRROR SWITCH - EXPORT
- INSTALLATION, POWER..............8N-49
FOLDAWAY MIRROR SWITCH - EXPORT
- OPERATION, POWER................8N-48
FOLDAWAY MIRROR SWITCH - EXPORT
- REMOVAL, POWER..................8N-48
FORK AND SHAFT - DESCRIPTION,
SHIFT.............................21-113
FORM-IN-PLACE GASKETS AND
SEALERS - STANDARD PROCEDURE . . 9-11,9-84
FRAME DIMENSIONS, SPECIFICATIONS....13-4
FRONT - DESCRIPTION, HALF SHAFT.......3-1
FRONT - INSTALLATION, CRANKSHAFT
OIL SEAL.......................9-127,9-40
FRONT - INSTALLATION, HALF SHAFT......3-4
FRONT - INSTALLATION, SEAT BELT &
RETRACTOR - OUTBOARD.............8O-14
FRONT - INSTALLATION, SPRING
MOUNTS............................2-44
FRONT - INSTALLATION, WHEEL
MOUNTING STUDS...................22-21
FRONT - REMOVAL, CRANKSHAFT OIL
SEAL..........................9-127,9-40
FRONT - REMOVAL, HALF SHAFT..........3-2
FRONT - REMOVAL, SEAT BELT &
RETRACTOR - OUTBOARD.............8O-14
FRONT - REMOVAL, SPRING MOUNTS.....2-43
FRONT - REMOVAL, WHEEL MOUNTING
STUDS.............................22-20
FRONT - SPECIFICATIONS, HALF SHAFT . . . 3-15,
3-6
FRONT BRAKE ROTOR - INSTALLATION.....5-54,
5s-57
FRONT BRAKE ROTOR - REMOVAL . . . 5-54,5s-57
FRONT BUMPER REINFORCEMENT -
INSTALLATION........................13-2
FRONT BUMPER REINFORCEMENT -
REMOVAL...........................13-2
FRONT BUSHING - INSTALLATION, LEAF
SPRING.............................2-30
FRONT BUSHING - REMOVAL, LEAF
SPRING.............................2-29
FRONT CABLE - INSTALLATION.....5-64,5s-67
FRONT CABLE - INSTALLATION,
PARKING BRAKE LEVER...........5-66,5s-69
FRONT CABLE - REMOVAL.........5-64,5s-67
FRONT CABLE - REMOVAL, PARKING
BRAKE LEVER...................5-65,5s-68
FRONT CONTROL MODULE -
DESCRIPTION........................8E-7
FRONT CONTROL MODULE - DIAGNOSIS
AND TESTING........................8E-7
FRONT CONTROL MODULE -
INSTALLATION........................8E-8
FRONT CONTROL MODULE - OPERATION . . 8E-7
FRONT CONTROL MODULE - REMOVAL....8E-8
FRONT CRADLE CROSSMEMBER -
DESCRIPTION........................13-9
FRONT CRADLE CROSSMEMBER
THREAD REPAIR - DESCRIPTION
.........13-9
FRONT CROSSMEMBER MOUNT
BUSHINGS - INSTALLATION
............13-12
FRONT CROSSMEMBER MOUNT
BUSHINGS - REMOVAL
................13-12
FRONT DISC BRAKE CALIPER ADAPTER
- INSTALLATION
.................5-31,5s-30
FRONT DISC BRAKE CALIPER ADAPTER
- REMOVAL
.....................5-31,5s-30
FRONT DISC BRAKE CALIPER
(CONTINENTAL TEVES BRAKES) -
INSTALLATION
.......................5s-26
FRONT DISC BRAKE CALIPER
(CONTINENTAL TEVES BRAKES) -
REMOVAL
..........................5s-23
FRONT DISC BRAKE CALIPER
(DISC/DISC BRAKES) - INSTALLATION
.....5-27
FRONT DISC BRAKE CALIPER
(DISC/DISC BRAKES) - REMOVAL
.........5-24
FRONT DISC BRAKE CALIPER
(DISC/DRUM BRAKES) -
INSTALLATION
........................5-27
FRONT DISC BRAKE CALIPER
(DISC/DRUM BRAKES) - REMOVAL
.......5-24
FRONT DISC BRAKE CALIPER (TRW
BRAKES) - INSTALLATION
..............5s-26
FRONT DISC BRAKE CALIPER (TRW
BRAKES) - REMOVAL
.................5s-23
14 INDEXRS
Description Group-Page Description Group-Page Description Group-Page

FRONT DISC BRAKE SHOES
(CONTINENTAL TEVES BRAKES) -
INSTALLATION.......................5s-15
FRONT DISC BRAKE SHOES
(CONTINENTAL TEVES BRAKES) -
REMOVAL..........................5s-14
FRONT DISC BRAKE SHOES (DISC/DISC
BRAKES) - INSTALLATION...............5-16
FRONT DISC BRAKE SHOES (DISC/DISC
BRAKES) - REMOVAL..................5-14
FRONT DISC BRAKE SHOES (DISC/
DRUM BRAKES) - INSTALLATION.........5-17
FRONT DISC BRAKE SHOES (DISC/
DRUM BRAKES) - REMOVAL............5-15
FRONT DISC BRAKE SHOES (TRW
BRAKES) - INSTALLATION..............5s-16
FRONT DISC BRAKE SHOES (TRW
BRAKES) - REMOVAL.................5s-14
FRONT DOOR GLASS RUN
WEATHERSTRIP - INSTALLATION.......23-113
FRONT DOOR GLASS RUN
WEATHERSTRIP - REMOVAL...........23-113
FRONT DOOR INNER BELT MOLDING -
INSTALLATION......................23-115
FRONT DOOR INNER BELT MOLDING -
REMOVAL.........................23-115
FRONT DOOR OUTER BELT MOLDING -
INSTALLATION......................23-113
FRONT DOOR OUTER BELT MOLDING -
REMOVAL.........................23-113
FRONT DOOR WEATHERSTRIP -
INSTALLATION......................23-114
FRONT DOOR WEATHERSTRIP -
REMOVAL.........................23-114
FRONT FASCIA - INSTALLATION..........13-1
FRONT FASCIA - REMOVAL..............13-1
FRONT FENDER - INSTALLATION........23-52
FRONT FENDER - REMOVAL............23-52
FRONT FOG LAMP - DIAGNOSIS AND
TESTING............................8L-7
FRONT FOG LAMP - INSTALLATION.......8L-8
FRONT FOG LAMP - REMOVAL...........8L-8
FRONT FOG LAMP UNIT ALIGNMENT -
EXPORT - STANDARD PROCEDURE.......8L-9
FRONT FOG LAMP UNIT ALIGNMENT -
STANDARD PROCEDURE................8L-9
FRONT INBOARD - INSTALLATION, SEAT
BELT BUCKLE.......................8O-12
FRONT INBOARD - REMOVAL, SEAT
BELT BUCKLE.......................8O-12
FRONT MOUNT - INSTALLATION....9-131,9-49
FRONT MOUNT - REMOVAL........9-131,9-49
FRONT SEAT - INSTALLATION...........23-91
FRONT SEAT - REMOVAL..............23-91
FRONT SEAT BACK - INSTALLATION......23-92
FRONT SEAT BACK - REMOVAL.........23-92
FRONT SEAT CUSHION SIDE COVER -
INSTALLATION.......................23-94
FRONT SEAT CUSHION SIDE COVER -
REMOVAL..........................23-94
FRONT SEAT RISER - MANUAL TRACK -
INSTALLATION.......................23-95
FRONT SEAT RISER - MANUAL TRACK -
REMOVAL..........................23-94
FRONT SEAT TRACK - REAR COVER -
INSTALLATION.......................23-96
FRONT SEAT TRACK - REAR COVER -
REMOVAL..........................23-96
FRONT SEAT TRACK MANUAL
ADJUSTER - INSTALLATION............23-95
FRONT SEAT TRACK MANUAL
ADJUSTER - REMOVAL................23-95
FRONT SEAT TRACK POWER ADJUSTER
- INSTALLATION.....................23-95
FRONT SEAT TRACK POWER ADJUSTER
- REMOVAL.........................23-95
FRONT SEATBACK ASSIST STRAP -
INSTALLATION.......................23-92
FRONT SEATBACK ASSIST STRAP -
REMOVAL..........................23-92
FRONT SEATBACK COVER -
INSTALLATION.......................23-93
FRONT SEATBACK COVER - REMOVAL
....23-93
FRONT SEATBACK PANEL -
INSTALLATION
.......................23-93
FRONT SEATBACK PANEL - REMOVAL
....23-92
FRONT SUSPENSION - DESCRIPTION
......2-2
FRONT SUSPENSION - OPERATION
........2-2FRONT SUSPENSION FASTENER
TORQUE, SPECIFICATIONS...............2-3
FRONT SUSPENSION, SPECIAL TOOLS.....2-3
FRONT WASHER PUMP MOTOR -
INSTALLATION.......................8R-8
FRONT WASHER PUMP MOTOR -
REMOVAL...........................8R-8
FRONT WHEEL SPEED SENSOR -
INSTALLATION........................5-80
FRONT WHEEL SPEED SENSOR -
REMOVAL...........................5-79
FRONT WHEELHOUSE SPLASH SHIELD -
INSTALLATION.......................23-55
FRONT WHEELHOUSE SPLASH SHIELD -
REMOVAL..........................23-55
FRONT WIPER ARM ALIGNMENT -
STANDARD PROCEDURE...............8R-8
FRONT WIPER ARMS - INSTALLATION....8R-9
FRONT WIPER ARMS - REMOVAL........8R-9
FRONT WIPER MOTOR - INSTALLATION . . . 8R-9
FRONT WIPER MOTOR - REMOVAL.......8R-9
FRONT WIPER SYSTEM - DIAGNOSIS
AND TESTING........................8R-2
FRONT WIPER/WASHER SWITCH -
DIAGNOSIS AND TESTING..............8R-2
FRONT/QUAD SEAT CUSHION -
INSTALLATION.......................23-93
FRONT/QUAD SEAT CUSHION -
REMOVAL..........................23-93
FRONT-WHEEL-DRIVE - INSTALLATION....2-36
FRONT-WHEEL-DRIVE - REMOVAL........2-36
FUEL CORRECTION OR ADAPTIVE
MEMORIES, OPERATION...............14-20
FUEL DELIVERY - DESCRIPTION..........14-2
FUEL DELIVERY - OPERATION...........14-2
FUEL DELIVERY SYSTEM - DIAGNOSIS
AND TESTING........................14-2
FUEL DOSING PUMP - DESCRIPTION....24-115
FUEL DOSING PUMP - INSTALLATION . . . 24-116
FUEL DOSING PUMP - OPERATION.....24-115
FUEL DOSING PUMP - REMOVAL.......24-115
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.....................23-53
FUEL FILLER CAP - DESCRIPTION.......25-12
FUEL FILLER CAP - OPERATION.........25-12
FUEL INJECTOR - DESCRIPTION.........14-26
FUEL INJECTOR - OPERATION..........14-26
FUEL LEVEL SENDING UNIT / SENSOR -
DESCRIPTION........................14-5
FUEL LEVEL SENDING UNIT / SENSOR -
INSTALLATION........................14-5
FUEL LEVEL SENDING UNIT / SENSOR -
OPERATION..........................14-5
FUEL LEVEL SENDING UNIT / SENSOR -
REMOVAL...........................14-5
FUEL LINE - INSTALLATION...........24-118
FUEL LINE - REMOVAL...............24-117
FUEL LINES/HOSES AND CLAMPS -
DESCRIPTION........................14-6
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 - INSTALLATION....14-9
FUEL PUMP MODULE - OPERATION
.......14-8
FUEL PUMP MODULE - REMOVAL
........14-8
FUEL PUMP RELAY - DESCRIPTION
......14-28
FUEL PUMP RELAY - OPERATION
........14-28
FUEL REQUIREMENTS - DESCRIPTION
......0-4FUEL REQUIREMENTS - DIESEL ENGINE
- DESCRIPTION........................0-6
FUEL, SPECIAL TOOLS............14-23,14-4
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE - STANDARD
PROCEDURE.........................14-2
FUEL SYSTEM PRESSURE,
SPECIFICATIONS......................14-3
FUEL TANK - DESCRIPTION............14-10
FUEL TANK - INSTALLATION............14-12
FUEL TANK - OPERATION..............14-11
FUEL TANK - REMOVAL...............14-11
FUEL TANK - STANDARD PROCEDURE,
DRAINING...........................14-2
FUEL TANK FILLER TUBE -
INSTALLATION.......................14-13
FUEL TANK FILLER TUBE - REMOVAL....14-12
FULL OPEN SWITCH - DESCRIPTION....8N-12,
8N-31
FULL OPEN SWITCH - INSTALLATION....8N-13
FULL OPEN SWITCH - OPERATION . 8N-12,8N-31
FULL OPEN SWITCH - REMOVAL........8N-13
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 - INSTALLATION..................2-45
FWD - INSTALLATION, REAR WHEEL
SPEED SENSOR.......................5-81
FWD - INSTALLATION, SPRING...........2-42
FWD - REMOVAL......................2-45
FWD - REMOVAL, REAR WHEEL SPEED
SENSOR............................5-81
FWD - REMOVAL, SPRING..............2-41
GALLERY PLUGS - STANDARD
PROCEDURE, ENGINE CORE AND OIL . 9-10,9-86
GAP AND FLUSH MEASUREMENTS -
SPECIFICATIONS....................23-124
GAP, SPECIFICATIONS - WHEEL SPEED
SENSOR AIR.........................5-79
GAS - INSTALLATION, MODULAR
CLUTCH ASSY - 2.4L..................6-11
GAS - REMOVAL, MODULAR CLUTCH
ASSY - 2.4L..........................6-11
GASKET - DIAGNOSIS AND TESTING,
CYLINDER HEAD.............9-24,9-99,9s-16
GASKET SURFACE PREPARATION -
STANDARD PROCEDURE, ENGINE....9-11,9-85
GASKETS AND SEALERS - STANDARD
PROCEDURE, FORM-IN-PLACE.......9-11,9-84
GASOLINE ENGINES - DIAGNOSIS AND
TESTING, SYSTEM CHARGE LEVEL
TEST..............................24-67
GEAR - DESCRIPTION.................19-26
GEAR - INSTALLATION, LHD............19-32
GEAR - INSTALLATION, RHD............19-33
GEAR & LINK ROD - DESCRIPTION, LIFT . 8N-16
GEAR & LINK ROD - INSTALLATION,
LIFT...............................8N-16
GEAR & LINK ROD - OPERATION, LIFT . . . 8N-16
GEAR & LINK ROD - REMOVAL, LIFT.....8N-16
GEAR - OPERATION...................19-27
GEAR - REMOVAL, LHD...............19-27
GEAR - REMOVAL, RHD...............19-31
GEAR END PLAY - ADJUSTMENT,
DIFFERENTIAL SIDE..................21-70
GEAR SHIFT CABLE - INSTALLATION....21-205
GEAR SHIFT CABLE - REMOVAL . 21-204,21s-105
GEAR SHIFT LEVER - INSTALLATION.....19-21
GEAR SHIFT LEVER - REMOVAL.........19-21
GEAR, SPECIAL TOOLS - POWER
STEERING..........................19-34
GEARSHIFT BOOT - INSTALLATION......21-73
GEARSHIFT BOOT - REMOVAL..........21-72
GEARSHIFT CABLE - CROSSOVER -
INSTALLATION.......................21-76
GEARSHIFT CABLE - CROSSOVER -
REMOVAL..........................21-73
GEARSHIFT CABLE - SELECTOR -
INSTALLATION
.......................21-84
GEARSHIFT CABLE - SELECTOR -
REMOVAL
..........................21-81
GEARSHIFT CABLE ADJUSTMENT,
ADJUSTMENTS
.....................21-206
GEARSHIFT KNOB - INSTALLATION
......21-87
GEARSHIFT KNOB - REMOVAL
..........21-87
RSINDEX15
Description Group-Page Description Group-Page Description Group-Page