Page 357 of 467

WARNING!
Battery fluid is a corrosive acid solution; do not
allow battery fluid to contact eyes, skin or clothing.
Don’t lean over battery when attaching clamps or
allow the clamps to touch each other. If acid splashes
in eyes or on skin, flush contaminated area immedi-
ately with large quantities of water.
A battery generates hydrogen gas which is flam-
mable and explosive. Keep flame or spark away
from the vent holes.
Do not use a booster battery or any other booster
source that has a greater than 12 volt system, i.e. Do
not use a 24 volt power source.
1. Remove all metal jewelry such as watch bands or
bracelets which might make an unintended electrical
contact.2. Park the booster vehicle within cable reach but with-
out letting the vehicles touch. Set the parking brake on
both vehicles, place the automatic transmission in Park or
the manual transmission in Neutral, and turn the ignition
OFF.
3. Turn off the heater, radio, and all unnecessary electri-
cal loads.
4. Connect one end of a jumper cable to the positive
terminal of the booster battery. Connect the other end of
the same cable to the positive terminal of the discharged
battery.
WARNING!
Do not permit vehicles to touch each other as this
could establish a ground connection and personal
injury could result.
WHAT TO DO IN EMERGENCIES 357
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Page 368 of 467

For states which have an I/M (Inspection and
Maintenance) requirement, this check verifies the
following: the MIL (Malfunction Indicator Lamp)
is functioning and is not on when the engine is running,
and that the OBD (On Board Diagnostic) system is ready
for testing.
Normally, the OBD system will be ready. The OBD
system maynotbe ready if your vehicle was recently
serviced, if you recently had a dead battery, or a battery
replacement. If the OBD system should be determined
not ready for the I/M test, your vehicle may fail the test.
Your vehicle has a simple ignition key actuated test
which you can use prior to going to the test station. To
check if your vehicle’s OBD system is ready, you must do
the following:
1. Insert your ignition key into the ignition switch.2. Turn the ignition to the ON position, but do not crank
or start the engine.
3. If you crank or start the engine, you will have to start
this test over.
4. As soon as you turn your key to the ON position, you
will see your MIL symbol come on as part of a normal
bulb check.
5. Approximately 15 seconds later, one of two things will
happen:
a. The MIL light will blink for approximately 5 sec-
onds and then remain on until the first engine crank or
the key is turned off. This means that your vehicle’s
OBD system isnot readyand you shouldnotproceed
to the I/M station.
368 MAINTAINING YOUR VEHICLE
Page 377 of 467

WARNING!
A hot exhaust system can start a fire if you park over
materials that can burn. Such materials might be
grass or leaves coming into contact with your ex-
haust system. Do not park or operate your vehicle in
areas where your exhaust system can contact any-
thing that can burn.
In unusual situations involving grossly malfunctioning
engine operation, a scorching odor may indicate severe
and abnormal catalyst overheating. If this occurs, the
vehicle should be stopped, the engine shut off and the
vehicle allowed to cool. Thereafter, service, including a
tune-up to manufacturer’s specifications, should be ob-
tained immediately.To minimize the possibility of catalyst damage:
•Do not shut off the engine or interrupt the ignition
when the transmission is in gear and the vehicle is in
motion.
•Do not try to start engine by pushing or towing the
vehicle.
•Do not idle the engine with any spark plug wires
disconnected or removed, such as when diagnostic
testing, or for prolonged periods during very rough
idling or malfunctioning operating conditions.
MAINTAINING YOUR VEHICLE 377
7
Page 405 of 467
Replace the belts if they appear frayed or worn or if the
buckles do not work properly.
Dry with a soft tissue.
INTEGRATED POWER MODULE
An integrated Power Module is located in the engine
compartment near the battery. This center contains maxi
fuses and mini fuses. A label that identifies each compo-
nent is printed on the inside cover.
1. Disconnect the battery negative (-) cable before remov-
ing the cover.
2. Use specified fuses only.
3. Always properly reinstall the cover.
VEHICLE STORAGE
If you are storing your vehicle for more than 21 days, we
recommend that you take the following steps to mini-
mize the drain on your vehicle’s battery:
•Disconnect the Ignition-Off Draw fuse (I.O.D.) fuse
located in the Integrated Power Module, located in the
engine compartment. The I.O.D. cavity includes a
snap-in retainer that allows the fuse to be discon-
nected, without removing it from the fuse block.
Integrated Power Module Location
MAINTAINING YOUR VEHICLE 405
7
Page 406 of 467

•The electronic shift transfer case should be placed in
the 4HI mode and kept in this position to minimize the
battery drain.
•As an alternative to the above steps you may, discon-
nect the negative cables from both batteries.
NOTE:When reinstalling the IOD fuse, the gages in the
Instrument Cluster will do a full sweep, when the
ignition key is cycled to RUN. This is a normal condition.
REPLACEMENT LIGHT BULBS
LIGHT BULBS — Inside Bulb No.
Overhead Console Lights............... TS212-2
Dome Light............................7679
All of the inside bulbs are brass or glass wedge base.
Aluminum base bulbs are not approved.LIGHT BULBS — Outside Bulb No.
Back-Up..............................3057
Center High Mounted Stop Lamp............. 912
Fog Lamp...........................9006LL
Headlamp (Halogen)..................... H13
Side Marker Bulb....................... W5W
Park & Turn Signal...................3157NAK
Rear License Plate Lamp................... 168
Rear Cargo Light......................... 912
Tail & Stop............................3057
406 MAINTAINING YOUR VEHICLE
Page 430 of 467
Miles 48,000 51,000 54,000 57,000 60,000
(Kilometers) (80 000) (85 000) (90 000) (95 000) (100 000)
Inspect brake linings. X X
Inspect engine air cleaner filter, replace if neces-
sary.X
Replace spark plugs.X
Replace ignition cables.X
Inspect PCV valve, replace as necessary.**X
Drain and refill automatic tranmission fluid and
change main sump filter (545RFE only).X
430 SCHEDULE “B”
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Page 436 of 467
Miles 105,000 108,000 111,000 114,000 117,000 120,000
(Kilometers) (175 000) (180 000) (185 000) (190 000) (195 000) (200 000)
Replace ignition cables.X
Inspect PCV valve, replace as necessary.**X
Inspect auto tension drive belt and replace if
required.XX
Drain and refill automatic tranmission fluid
and change main sump and spin-on cooler
return filter (if equipped) [545RFE only].X
Flush and replace engine coolant at 120
months, if not replaced at 102,000 miles (170
000 km).X
* This applies only if the vehicle is used for frequent
trailer towing, snowplowing, fleet vehicle or commercial
service.
**This maintenance is recommend, but not required.Inspection and service should also be performed anytime
a malfunction is observed or suspected. Retain all re-
ceipts.
436 SCHEDULE “B”
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Page 439 of 467
Miles 36,000 42,000 48,000 54,000 60,000 66,000
(Kilometers) (60 000) (70 000) (80 000) (90 000) (100 000) (110 000)
[Months] [36] [42] [48] [54] [60] [66]
Inspect engine air cleaner filter, replace if
necessary.X
Replace spark plugs.X
Inspect PCV valve, replace as necessary.**X
Replace ignition cables.X
SCHEDULE “A” 439
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