Suzuki Sidekick/Vitara/Grand Vitara/XL7 Repair Service Manual 1984-2014
Complete service repair manual with Electrical Wiring Diagrams for 1984-2014 Suzuki Sidekick, Vitara, Grand Vitara, XL7, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Suzuki Sidekick/Vitara/Grand Vitara/XL7 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MAKE: Suzuki
YEAR: 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
MODEL: Escudo/Sidekick/Sidekick Sport/Vitara/Grand Vitara/XL-7/XL7/Tracker (GEO)/Samurai (JA420, JA627, JB416, JB419, JB420, JB424, JB627, JB632, JC636, SE416, SJ413, SQ416, SQ420, SQ625, SQ420, SV620)
LANGUAGE: English/French/German/Spanish
TABLE OF CONTENTS
Precautions...7
Precautions...8
Precautions...8
Definition of Caution, Notice, and Important...8
Approved Equipment for Collision Repair Caution...8
Assistant Driving Caution...8
Cleaning Solvent Caution...8
Eye Protection Caution...9
Foam Sound Deadeners Caution...9
Gasoline/Gasoline Vapors Caution...9
Glass and Sheet Metal Handling Caution...9
Moving Parts and Hot Surfaces Caution...9
Protective Goggles and Glove Caution...9
Road Test Caution...9
Work Stall Test Caution...9
Belt Dressing Notice...10
Brake Fluid Effects on Paint and Electrical Components Notice...10
Clean, Dry, Low Pressure Gas Source Notice...10
Clearcoat/Ultraviolet Screeners Notice...10
Component Fastener Tightening Notice...10
Fastener Notice...10
Machined Surface Damage Notice...10
OBDII Symbol Description Notice...11
Pipe Wrench Positioning Notice...11
Test Probe Notice...11
General Information...13
General Information...14
General Description...14
Abbreviations and Meanings...14
Registered and Non-Registered Trademarks...19
Arrows and Symbols...20
RPO Code List...20
US English/Metric Conversion...21
Decimal and Metric Equivalents...22
Fasteners...23
Thread Inserts...26
Lifting and Jacking the Vehicle...27
Vehicle, Engine and Transmission, Transfer Case, Axle ID, and VIN Location, Derivative and Usage...28
Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label...29
Vibration Theory and Terminology...31
Service Programming System (SPS)...39
DTC Symptom Description - Vehicle Diagnostic Information...40
Service Materials (Lubricants, Oil, Grease, Sealant, Adhesive, Cleaner, etc)...42
Component Location...45
Engine Identification...45
Transmission Identification Information...46
Diagnostic Information and Procedures...46
Diagnostic Procedure Instructions - Vehicle Diagnostic Information...46
Strategy Based Diagnosis - Vehicle Diagnostic Information...49
Strategy Based Diagnosis...50
Vehicle-to-Vehicle Diagnostic Comparison...51
Diagnostic Trouble Code (DTC) List - Vehicle Diagnostic Information...52
Diagnostic Starting Point - Vehicle Diagnostic Information...68
Diagnostic Starting Point - Vibration Diagnosis and Correction...68
Diagnostic System Check - Vehicle Diagnostic Information...69
Diagnostic Repair Verification - Vehicle Diagnostic Information...71
Symptoms - Vehicle Diagnostic Information...71
Symptoms - Vibration Diagnosis and Correction...72
Squeaks and Rattles...73
Vibration Analysis - Road Testing...74
Vibration Diagnostic Aids...77
Vibration Diagnostic Aids - Vibration Intermittent or Not Duplicated...77
Vibration Diagnostic Aids - Vibration Duplicated, Component Not Identified...79
Vibration Diagnostic Aids - Vibration Duplicated, Difficult to Isolate/Balance Component...79
Vibration Diagnostic Aids - Vibration Duplicated, Appears to be Potential Operating Characteristic...79
Vibration in Service-Stall Test (Non-Torque Sensitive)...80
Vibration in Service-Stall Test (Torque Sensitive)...80
Control Module References...81
Special Tools and Equipment...83
Substitute Special Tool Table...83
Electronic Vibration Analyzer (EVA) Description and Operation...92
Vibrate Software Description and Operation...94
Reed Tachometer Description...94
Special Tools - Squeaks and Rattles...94
Special Tools and Equipment - Vibration Diagnosis and Correction...94
Maintenance and Lubrication...96
Scheduled Maintenance...96
Maintenance Items...96
Maintenance Schedule (North American Emissions)...96
Oil Life System Resetting...96
Specifications...96
Approximate Fluid Capacities...96
Fluid and Lubricant Recommendations...96
Engine...97
Engine General Information and Diagnosis...106
General Description...106
OBD System Description - Mode $06 Data Definitions...106
Schematic and Routing Diagram...109
Engine Controls Schematic Icons...109
Engine Controls Schematics...109
Engine Control Module Connector End Views...122
Engine Controls Connector End Views...124
Component Location...135
Engine Controls Component Views...135
Diagnostic Information and Procedures...143
Diagnostic Starting Point - Engine Controls...143
Diagnostic Starting Point - Engine Electrical...143
Scan Tool Output Controls - Engine Controls - 3.6L (LY7)...143
Scan Tool Output Controls - Engine Electrical...146
Scan Tool Data List - Engine Controls - 3.6L (LY7)...146
Scan Tool Data List - Engine Electrical...151
Scan Tool Data Definitions - Engine Controls - 3.6L (LY7)...153
Scan Tool Data Definitions - Engine Electrical...159
Powertrain Diagnostic Trouble Code (DTC) Type Definitions...160
DTC P0008 or P0009...161
DTC P0010, P0013, P0020, P0023, P2088, P2089, P2090, P2091, P2092, P2093, P2094, or P2095...162
DTC P0011, P0014, P0021, or P0024...164
DTC P0016, P0017, P0018, or P0019...166
DTC P0030, P0031, P0032, P0036, P0037, P0038, P0050, P0051, P0052, P0056, P0057, or P0058...168
DTC P0100, P0102, or P0103...171
DTC P0101...173
DTC P0111, P0112 or P0113...175
DTC P0116...177
DTC P0117 or P0118...180
DTC P0119...182
DTC P0121, P0122, P0123, P0221, P0222, or P0223...184
DTC P0125 or P0128...187
DTC P0131 or P0151...189
DTC P0132 or P0152...191
DTC P0133 or P0153...193
DTC P0134 or P0154...195
DTC P0135, P0141, P0155, or P0161...197
DTC P0137, P0138, P0140, P0157, P0158, or P0160...200
DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277...202
DTC P0300-P0306...204
DTC P0324...207
DTC P0326, P0327, P0328, P0331, P0332, or P0333...208
DTC P0335, P0336, or P0338...210
DTC P0341, P0342, P0343, P0346, P0347, P0348, P0366, P0367, P0368, P0391, P0392, or P0393...212
DTC P0420 or P0430...214
DTC P0442...216
DTC P0443, P0458, or P0459...218
DTC P0446...220
DTC P0449, P0498, or P0499...222
DTC P0451...224
DTC P0452 or P0453...225
DTC P0455...227
DTC P0496...230
DTC P0506, P0507, or P050A...232
DTC P0560...233
DTC P0562...234
DTC P0563...235
DTC P0601, P0602, P0603, P0604, P0605, P0606, P0607, P1600, P1621, P1627, P1680, P1681, P1683, or P2610...236
DTC P0627, P0628, or P0629...237
DTC P0638, P2100, P2101, or P2119...239
DTC P0642 or P0643...241
DTC P0650...243
DTC P0652 or P0653...244
DTC P0685, P0686, P0687, P0689, or P0690...245
DTC P0698 or P0699...248
DTC P0700...249
DTC P0864...249
DTC P1011-P1014...250
DTC P1380...251
DTC P1551...252
DTC P167D...254
DTC P2096 or P2098...255
DTC P2097 or P2099...257
DTC P2105...259
DTC P2107...260
DTC P2122, P2123, P2127, P2128, or P2138...261
DTC P2176...263
DTC P2177, P2179, P2187, or P2189...264
DTC P2178, 2180, P2188, or P2190...267
DTC P2227, P2228, or P2229...269
DTC P2231 or P2234...270
DTC P2232 or P2235...271
DTC P2270 or P2272...273
DTC P2271 or P2273...275
DTC P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310, P2312, P2313, P2315, or P2316...277
DTC P2636...279
Symptoms - Engine Controls...280
Engine Cranks but Does Not Run...282
Inspection/Maintenance (I/M) System Check...284
Inspection/Maintenance (I/M) Complete System Set Procedure...286
Inspection/Maintenance (I/M) System DTC Table...287
Repair Instructions...287
Idle Learn...287
Specifications...288
Temperature Versus Resistance - Engine Coolant Temperature Sensor...288
Temperature Versus Resistance - Intake Air Temperature Sensor...288
Altitude Versus Barometric Pressure...288
Special Tools and Equipment...289
Special Tools - Engine Controls - 3.6L (LY7)...289
Aux. Emission Control Devices...291
Precautions...291
Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Notice...291
General Description...291
Evaporative Emission Control System Description...291
Crankcase Ventilation System Description...292
Schematic and Routing Diagram...293
Emission Hose Routing Diagram...293
Evaporative Emissions Hose Routing Diagram...294
Repair Instructions...295
Evaporative Emission Canister Purge Solenoid Valve Replacement...295
Evaporative Emission Canister Vent Solenoid Valve Replacement...296
Evaporative Emission Canister Vent Hose Replacement...297
Evaporative Emission Pipe Replacement...298
Evaporative Emission Canister Replacement...302
Evaporative Emission Canister Filter Replacement...304
Evaporative Emission System Cleaning...305
Specifications...306
Fastener Tightening Specifications - Engine Controls - 3.6L (LY7)...306
Special Tools and Equipment...306
Special Tools - Engine Controls - 3.6L (LY7)...306
Engine Electrical Devices...307
Precautions...307
Heated Oxygen and Oxygen Sensor Notice...307
Heated Oxygen Sensor Resistance Learn Reset Notice...307
Silicon Contamination of Heated Oxygen Sensors Notice...307
General Description...308
Air Intake System Description...308
Camshaft Actuator System Description...309
Engine Control Module Description...310
Knock Sensor (KS) System Description...313
Throttle Actuator Control (TAC) System Description...313
Repair Instructions...315
Engine Coolant Temperature Sensor Replacement...315
Mass Airflow Sensor/Intake Air Temperature Sensor Replacement...316
Heated Oxygen Sensor Replacement - Bank 1 Sensor 1...317
Heated Oxygen Sensor Replacement - Bank 1 Sensor 2...318
Heated Oxygen Sensor Replacement - Bank 2 Sensor 1...320
Heated Oxygen Sensor Replacement - Bank 2 Sensor 2...322
Heated Oxygen Sensor Wiring Repairs...324
Accelerator Pedal Position Sensor Replacement...324
Crankshaft Position Sensor Replacement...326
Camshaft Position Sensor Replacement - Bank 1 (Right Side) Exhaust...327
Camshaft Position Sensor Replacement - Bank 1 (Right Side) Intake...328
Camshaft Position Sensor Replacement - Bank 2 (Left Side) Exhaust...329
Camshaft Position Sensor Replacement - Bank 2 (Left Side) Intake...330
Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 1 (Right Side) Intake...331
Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 1 (Right Side) Exhaust...332
Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 2 (Left Side) Intake...333
Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 2 (Left Side) Exhaust...334
Knock Sensor Replacement - Bank 1...335
Knock Sensor Replacement - Bank 2...336
Engine Control Module Replacement...337
Engine Control Module Programming and Setup...339
Specifications...340
Fastener Tightening Specifications - Engine Controls - 3.6L (LY7)...340
Special Tools and Equipment...340
Special Tools - Engine Controls - 3.6L (LY7)...340
Engine Mechanical...341
Precautions...341
Torque Reaction Against Timing Drive Chain Notice...341
General Description...341
Drive Belt System Description...341
Engine Component Description...341
Cleanliness and Care...343
Separating Parts...343
Replacing Engine Gaskets...344
Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealer...344
Schematic and Routing Diagram...346
Camshaft Timing Drive Chain Alignment Diagram (Third Design)...346
Camshaft Timing Drive Chain Alignment Diagram (Fourth Design)...349
Component Location...352
Disassembled Views...352
Diagnostic Information and Procedures...366
Diagnostic Starting Point - Engine Mechanical...366
Symptoms - Engine Mechanical...366
Base Engine Misfire without Internal Engine Noises...367
Base Engine Misfire with Abnormal Internal Lower Engine Noises...368
Base Engine Misfire with Abnormal Valve Train Noise...369
Base Engine Misfire with Coolant Consumption...369
Base Engine Misfire with Excessive Oil Consumption...369
Engine Noise on Start-Up, but Only Lasting a Few Seconds...369
Upper Engine Noise, Regardless of Engine Speed...370
Lower Engine Noise, Regardless of Engine Speed...370
Engine Noise Under Load...371
Engine Will Not Crank - Crankshaft Will Not Rotate...372
Coolant in Combustion Chamber...373
Coolant in Engine Oil...373
Engine Compression Test...374
Cylinder Leakage Test...374
Crankcase Ventilation System Inspection/ Diagnosis...375
Drive Belt Chirping, Squeal, and Whine Diagnosis...375
Drive Belt Rumbling and Vibration Diagnosis...378
Drive Belt Falls Off and Excessive Wear Diagnosis...380
Drive Belt Tensioner Diagnosis...381
Vibration Analysis - Engine...382
Vibration Analysis - Engine/Accessory Isolation...384
Vibration Analysis - Engine Balance...390
Engine Order Classification...395
Repair Instructions...398
Air Cleaner Outlet Duct Replacement...398
Air Cleaner Element Replacement...399
Air Cleaner Assembly Replacement...400
Throttle Body Assembly Replacement...401
Throttle Body Service...402
Drive Belt Replacement...402
Drive Belt Tensioner Replacement...403
Drive Belt Idler Pulley Replacement...404
Engine Mount Inspection...405
Engine Rear Mount Replacement...406
Engine Mount Replacement - Right Side...406
Engine Mount Bracket Replacement - Right Side...408
Engine Mount Strut Replacement - Right Side...410
Engine Mount Strut Bracket Replacement - Right Side...411
Fuel Injector Sight Shield Replacement...412
Crankcase Ventilation Hoses/Pipes Replacement (Front)...412
Crankcase Ventilation Hoses/Pipes Replacement (Rear)...413
Upper Intake Manifold Replacement...413
Lower Intake Manifold Replacement...417
Crankshaft Balancer Replacement...417
Crankshaft Front Oil Seal Replacement...419
Camshaft Cover Replacement - Left Side...420
Camshaft Cover Replacement - Right Side...422
Engine Front Cover Replacement...424
Secondary Camshaft Drive Chain Replacement - Left Side...428
Secondary Camshaft Drive Chain Replacement - Right Side...429
Secondary Camshaft Drive Chain Tensioner Replacement - Left Side...430
Secondary Camshaft Drive Chain Tensioner Replacement - Right Side...430
Secondary Camshaft Drive Chain Shoe Replacement - Left Side...431
Secondary Camshaft Drive Chain Shoe Replacement - Right Side...432
Secondary Camshaft Drive Chain Guide Replacement - Left Side...433
Secondary Camshaft Drive Chain Guide Replacement - Right Side...434
Primary Camshaft Drive Chain and Sprockets Replacement...435
Camshaft Intermediate Drive Chain Idler Sprocket Replacement - Left Side...437
Primary Camshaft Drive Chain Tensioner Replacement...439
Primary Camshaft Drive Chain Guide Replacement - Lower...440
Primary Camshaft Drive Chain Guide Replacement - Upper...440
Camshaft Position Actuator Replacement - Bank 2 (Left Side) Exhaust...441
Camshaft Position Actuator Replacement - Bank 1 (Right Side) Exhaust...444
Camshaft Position Actuator Replacement - Bank 2 (Left Side) Intake...444
Camshaft Position Actuator Replacement - Bank 1 (Right Side) Intake...445
Setting Camshaft Timing...445
Camshaft Replacement - Left Side...446
Camshaft Replacement - Right Side...448
Valve Rocker Arm Replacement - Left Side...450
Valve Rocker Arm Replacement - Right Side...450
Valve Lifter Replacement - Left Side...451
Valve Lifter Replacement - Right Side...451
Valve Stem Oil Seal and Valve Spring Replacement - Left Side...452
Valve Stem Oil Seal and Valve Spring Replacement - Right Side...454
Cylinder Head Replacement - Left Side...457
Cylinder Head Replacement - Right Side...458
Engine Flywheel Replacement...460
Crankshaft Rear Oil Seal and Housing Replacement...460
Engine Replacement...461
Drive Belt Tensioner Removal...470
Crankshaft Balancer Removal...470
Engine Flywheel Removal...471
Intake Manifold Removal...472
Camshaft Cover Removal - Left Side...475
Camshaft Cover Removal - Right Side...476
Engine Front Cover Removal (Third Design)...477
Engine Front Cover Removal (Fourth Design)...479
Secondary Camshaft Drive Chain Tensioner Removal - Right Side (Third Design)...481
Secondary Camshaft Drive Chain Tensioner Removal - Right Side (Fourth Design)...482
Secondary Camshaft Drive Chain Shoe Removal - Right Side (Third Design)...482
Secondary Camshaft Drive Chain Shoe Removal - Right Side (Fourth Design)...483
Secondary Camshaft Drive Chain Guide Removal - Right Side (Third Design)...483
Secondary Camshaft Drive Chain Guide Removal - Right Side (Fourth Design)...483
Secondary Camshaft Drive Chain Removal - Right Side (Third Design)...484
Secondary Camshaft Drive Chain Removal - Right Side (Fourth Design)...484
Primary Camshaft Drive Chain Tensionser Removal (Third Design)...484
Primary Camshaft Drive Chain Tensionser Removal (Fourth Design)...485
Primary Camshaft Drive Chain Guide Removal - Upper (Third Design)...485
Primary Camshaft Drive Chain Guide Removal - Upper (Fourth Design)...485
Primary Camshaft Drive Chain Guide Removal - Lower (Third Design)...486
Primary Camshaft Drive Chain Guide Removal - Lower (Fourth Design)...486
Primary Camshaft Drive Chain Removal (Third Design)...486
Primary Camshaft Drive Chain Removal (Fourth Design)...486
Camshaft Intermediate Drive Chain Idler Removal - Right Side (Third Design)...487
Camshaft Intermediate Drive Chain Idler Removal - Right Side (Fourth Design)...487
Secondary Camshaft Drive Chain Tensioner Removal - Left Side (Third Design)...487
Secondary Camshaft Drive Chain Tensioner Removal - Left Side (Fourth Design)...488
Secondary Camshaft Drive Chain Shoe Removal - Left Side (Third Design)...488
Secondary Camshaft Drive Chain Shoe Removal - Left Side (Fourth Design)...489
Secondary Camshaft Drive Chain Guide Removal - Left Side (Third Design)...489
Secondary Camshaft Drive Chain Guide Removal - Left Side (Fourth Design)...489
Secondary Camshaft Drive Chain Removal - Left Side (Third Design)...490
Secondary Camshaft Drive Chain Removal - Left Side (Fourth Design)...490
Camshaft Intermediate Drive Chain Idler Removal - Left Side (Third Design)...490
Camshaft Intermediate Drive Chain Idler Removal - Left Side (Fourth Design)...490
Crankshaft Sprocket Removal (Third Design)...491
Crankshaft Sprocket Removal (Fourth Design)...491
Camshaft Position Actuator Removal - Left Side Exhaust (Third Design)...491
Camshaft Position Actuator Removal - Left Side Exhaust (Fourth Design)...492
Camshaft Position Actuator Removal - Left Side Intake (Third Design)...492
Camshaft Position Actuator Removal - Left Side Intake (Fourth Design)...492
Camshaft Position Actuator Removal - Right Side Exhaust (Third Design)...493
Camshaft Position Actuator Removal - Right Side Exhaust (Fourth Design)...493
Camshaft Position Actuator Removal - Right Side Intake (Third Design)...493
Camshaft Position Actuator Removal - Right Side Intake (Fourth Design)...494
Camshaft Removal - Left Side...494
Valve Rocker Arm Removal - Left Side...495
Valve Lifter Removal - Left Side...495
Cylinder Head Removal - Left Side...496
Camshaft Removal - Right Side...496
Valve Rocker Arm Removal - Right Side...497
Valve Lifter Removal - Right Side...497
Cylinder Head Removal - Right Side...498
Crankshaft Rear Oil Seal and Housing Removal...498
Piston, Connecting Rod, and Bearing Removal...499
Crankshaft and Bearings Removal...501
Engine Block Disassemble...503
Engine Block Cleaning and Inspection...505
Crankshaft and Bearings Cleaning and Inspection...507
Crankshaft Balancer Cleaning and Inspection...510
Engine Flywheel Cleaning and Inspection...510
Piston and Connecting Rod Disassemble...511
Piston, Connecting Rod, and Bearings Cleaning and Inspection...512
Piston and Connecting Rod Assemble...515
Cylinder Head Disassemble...517
Cylinder Head Cleaning and Inspection...519
Valve Spring Inspection and Measurement...522
Valve and Seat Grinding...522
Cylinder Head Assemble...526
Camshaft Cleaning and Inspection...528
Valve Lifters Cleaning and Inspection...530
Valve Rocker Arms Cleaning and Inspection...531
Camshaft Timing Drive Components Cleaning and Inspection (Third Design)...531
Camshaft Timing Drive Components Cleaning and Inspection (Fourth Design)...537
Engine Front Cover Disassemble...544
Engine Front Cover Cleaning and Inspection...545
Engine Front Cover Assemble...546
Camshaft Cover Disassemble...547
Camshaft Cover Cleaning and Inspection...549
Camshaft Cover Assemble...551
Intake Manifold Disassemble...553
Intake Manifold Cleaning and Inspection...556
Intake Manifold Assemble...558
Thread Repair...561
Service Prior to Assembly...588
Engine Block Assemble...588
Crankshaft and Bearings Installation...591
Piston, Connecting Rod, and Bearing Installation...597
Crankshaft Rear Oil Seal and Housing Installation...601
Cylinder Head Installation - Right Side...603
Valve Lifter Installation - Right Side...604
Valve Rocker Arm Installation - Right Side...605
Camshaft Installation - Right Side...605
Cylinder Head Installation - Left Side...607
Valve Lifter Installation - Left Side...608
Valve Rocker Arm Installation - Left Side...609
Camshaft Installation - Left Side...610
Camshaft Position Actuator Installation - Right Side Intake (Third Design)...612
Camshaft Position Actuator Installation - Right Side Intake (Fourth Design)...613
Camshaft Position Actuator Installation - Right Side Exhaust (Third Design)...614
Camshaft Position Actuator Installation - Right Side Exhaust (Fourth Design)...615
Camshaft Position Actuator Installation - Left Side Intake (Third Design)...616
Camshaft Position Actuator Installation - Left Side Intake (Fourth Design)...616
Camshaft Position Actuator Installation - Left Side Exhaust (Third Design)...618
Camshaft Position Actuator Installation - Left Side Exhaust (Fourth Design)...618
Crankshaft Sprocket Installation (Third Design)...619
Crankshaft Sprocket Installation (Fourth Design)...620
Camshaft Intermediate Drive Chain Idler Installation - Left Side (Third Design)...620
Camshaft Intermediate Drive Chain Idler Installation - Left Side (Fourth Design)...621
Secondary Camshaft Drive Chain Installation - Left Side (Third Design)...622
Secondary Camshaft Drive Chain Installation - Left Side (Fourth Design)...624
Secondary Camshaft Drive Chain Guide Installation - Left Side (Third Design)...626
Secondary Camshaft Drive Chain Guide Installation - Left Side (Fourth Design)...626
Secondary Camshaft Drive Chain Shoe Installation - Left Side (Third Design)...627
Secondary Camshaft Drive Chain Shoe Installation - Left Side (Fourth Design)...627
Secondary Camshaft Drive Chain Tensioner Installation - Left Side (Third Design)...628
Secondary Camshaft Drive Chain Tensioner Installation - Left Side (Fourth Design)...630
Camshaft Intermediate Drive Chain Idler Installation - Right Side (Third Design)...633
Camshaft Intermediate Drive Chain Idler Installation - Right Side (Fourth Design)...633
Primary Camshaft Drive Chain Installation (Third Design)...634
Primary Camshaft Drive Chain Installation (Fourth Design)...635
Primary Camshaft Drive Chain Guide Installation - Lower (Third Design)...637
Primary Camshaft Drive Chain Guide Installation - Lower (Fourth Design)...637
Primary Camshaft Drive Chain Guide Installation - Upper (Third Design)...638
Primary Camshaft Drive Chain Guide Installation - Upper (Fourth Design)...638
Primary Camshaft Drive Chain Tensionser Installation (Third Design)...639
Primary Camshaft Drive Chain Tensionser Installation (Fourth Design)...642
Secondary Camshaft Drive Chain Installation - Right Side (Third Design)...645
Secondary Camshaft Drive Chain Installation - Right Side (Fourth Design)...647
Secondary Camshaft Drive Chain Guide Installation - Right Side (Third Design)...649
Secondary Camshaft Drive Chain Guide Installation - Right Side (Fourth Design)...649
Secondary Camshaft Drive Chain Shoe Installation - Right Side (Third Design)...650
Secondary Camshaft Drive Chain Shoe Installation - Right Side (Fourth Design)...650
Secondary Camshaft Drive Chain Tensioner Installation - Right Side (Third Design)...651
Secondary Camshaft Drive Chain Tensioner Installation - Right Side (Fourth Design)...654
Engine Front Cover Installation (Third Design)...656
Engine Front Cover Installation (Fourth Design)...658
Camshaft Cover Installation - Left Side...661
Camshaft Cover Installation - Right Side...664
Intake Manifold Installation...666
Engine Flywheel Installation...669
Crankshaft Balancer Installation...670
Drive Belt Tensioner Installation...671
Engine Prelubing...672
Specifications...674
Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7)...674
Fastener Tightening Specifications - Engine Controls - 3.6L (LY7)...675
Engine Mechanical Specifications...675
Sealers, Adhesives, and Lubricants...678
Thread Repair Specifications...679
Special Tools and Equipment...705
Engine Support Fixture...705
Tools and Equipment...708
Special Tools - Engine Mechanical - 3.6L (LY7)...708
Special Tools - Engine Controls - 3.6L (LY7)...713
Engine Lubrication System...714
General Description...714
Lubrication Description...714
Diagnostic Information and Procedures...715
Oil Consumption Diagnosis...715
Oil Pressure Diagnosis and Testing...715
Oil Leak Diagnosis...717
Repair Instructions...718
Oil Level Indicator and Tube Replacement...718
Engine Oil and Oil Filter Replacement...719
Oil Filter Adapter Replacement...719
Engine Oil Pressure Sensor and/or Switch Replacement...721
Oil Pan Replacement...721
Oil Pump Replacement...723
Oil Pump Suction Pipe and Screen Assembly Replacement...724
Oil Level Indicator and Tube Removal...725
Oil Filter Adapter Removal...726
Oil Pan Removal...727
Oil Pump Removal...728
Oil Pump Disassemble...728
Oil Pump Cleaning and Inspection...730
Oil Pump Assemble...732
Oil Filter Adapter Disassemble...733
Oil Filter Adapter Cleaning and Inspection...733
Oil Filter Adapter Assemble...734
Oil Pan Disassemble...735
Oil Pan Cleaning and Inspection...736
Oil Pump Pipe and Screen Cleaning and Inspection...737
Oil Pan Assemble...737
Oil Pump Installation...738
Oil Pan Installation...739
Oil Filter Adapter Installation...740
Oil Level Indicator and Tube Installation...741
Specifications...742
Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7)...742
Special Tools and Equipment...743
Tools and Equipment...743
Special Tools - Engine Mechanical - 3.6L (LY7)...743
Engine Cooling System...744
General Description...744
Cooling System Description and Operation...744
Schematic and Routing Diagram...746
Engine Cooling Schematics...747
Cooling System Connector End Views...748
Component Location...749
Cooling System Component Views...749
Diagnostic Information and Procedures...750
Diagnostic Starting Point - Engine Cooling...750
Scan Tool Output Controls (3.6L) - Engine Cooling...750
Scan Tool Data List (3.6L) - Engine Cooling...751
Scan Tool Data Definitions (3.6L) - Engine Cooling...751
DTC P0480, P0481, P0691, P0692, P0693, or P0694...752
Symptoms - Engine Cooling...754
Cooling Fan Always On...755
Cooling Fan Inoperative...756
Engine Overheating...758
Loss of Coolant...759
Thermostat Diagnosis...761
Engine Fails To Reach Normal Operating Temperature...762
Pressure Cap Testing...762
Cooling System Leak Testing...763
Repair Instructions...764
Radiator Drain Cock Replacement...764
Draining and Filling Cooling System (LY7 GE 47716 Fill)...764
Draining and Filling Cooling System (LY7 Static Fill)...769
Coolant System Flushing...770
Heater Inlet Pipe Replacement...770
Heater Outlet Pipe Replacement...771
Heater Outlet Hose Replacement...773
Radiator Surge Tank Inlet Hose/Pipe Replacement...774
Surge Tank Replacement...775
Radiator Inlet Hose Replacement...776
Radiator Outlet Hose Replacement...777
Cooling Fan and Shroud Replacement...778
Engine Coolant Fan Motor Replacement...781
Radiator Replacement...784
Engine Coolant Thermostat Housing Replacement...785
Thermostat Replacement...785
Coolant Air Bleed Pipe Assembly Replacement...786
Water Outlet Housing Replacement...787
Water Pump Replacement...787
Coolant Heater Replacement...789
Coolant Heater Cord Replacement...789
Water Outlet Removal...790
Engine Coolant Thermostat Housing Removal...791
Water Pump Removal...793
Water Pump Cleaning and Inspection...794
Water Pump Installation...795
Engine Coolant Thermostat Housing Installation...795
Water Outlet Installation...798
Specifications...799
Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7)...799
Fastener Tightening Specifications - Engine Cooling...799
Special Tools and Equipment...799
Tools and Equipment...799
Special Tools - Engine Mechanical - 3.6L (LY7)...800
Special Tools - Engine Cooling...800
Fuel System...801
Precautions...801
Fuel Pipe Fitting Caution...801
Relieving Fuel Pressure Caution...801
Fuel Rail Notice...801
General Description...802
Fuel System Description...802
Diagnostic Information and Procedures...808
Diagnostic Starting Point - Engine Controls...808
Scan Tool Output Controls - Engine Controls - 3.6L (LY7)...808
Scan Tool Data List - Engine Controls - 3.6L (LY7)...810
Scan Tool Data Definitions - Engine Controls - 3.6L (LY7)...816
Fuel Pump Electrical Circuit Diagnosis...822
Fuel System Diagnosis...824
Fuel Injector Solenoid Coil Test...825
Fuel Injector Balance Test with Special Tool...826
Fuel Injector Balance Test with Tech 2...828
Fuel Tank Leak Test...829
Alcohol/Contaminants-in-Fuel Diagnosis (w/o Special Tool)...830
Alcohol/Contaminants-in-Fuel Diagnosis (w/ Special Tool)...831
Repair Instructions...832
Fuel Pressure Relief (With J 34730-1A)...832
Fuel Pressure Relief (Without J 34730-1A)...833
Fuel Pressure Gage Installation and Removal...833
Metal Collar Quick Connect Fitting Service...834
Plastic Collar Quick Connect Fitting Service...836
Fuel Feed Pipe Replacement...839
Fuel Injector and Fuel Rail Replacement...843
Fuel Tank Draining...845
Filler Tube Replacement...848
Fuel Tank Replacement (FWD)...850
Fuel Tank Replacement (AWD)...853
Fuel Tank Pressure Sensor Replacement...855
Primary Fuel Tank Module Replacement...856
Secondary Fuel Tank Module Replacement...858
Primary Fuel Level Sensor Replacement...860
Fuel Level Sensor Replacement - Secondary...860
Fuel Tank Filler Vent Hose Replacement...861
Fuel System Cleaning...862
Specifications...862
Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7)...862
Fastener Tightening Specifications - Engine Controls - 3.6L (LY7)...862
Special Tools and Equipment...863
Special Tools - Engine Controls - 3.6L (LY7)...863
Ignition System...865
General Description...865
Electronic Ignition (EI) System Description...865
Diagnostic Information and Procedures...866
Electronic Ignition (EI) System Diagnosis...866
Repair Instructions...867
Ignition Coil Replacement - Bank 1...867
Ignition Coil Replacement - Bank 2...868
Spark Plug Replacement...869
Spark Plug Inspection...870
Specifications...872
Fastener Tightening Specifications - Engine Controls - 3.6L (LY7)...872
Ignition System Specifications...872
Special Tools and Equipment...872
Special Tools - Engine Controls - 3.6L (LY7)...872
Starting System...873
General Description...873
Starting System Description and Operation...873
Schematic and Routing Diagram...873
Starting and Charging Schematics...873
Engine Electrical Connector End Views...876
Component Location...877
Engine Electrical Component Views...877
Diagnostic Information and Procedures...880
Diagnostic Starting Point - Engine Electrical...880
Scan Tool Output Controls - Engine Electrical...880
Scan Tool Data List - Engine Electrical...880
Scan Tool Data Definitions - Engine Electrical...882
DTC P0615...882
DTC P0616...884
DTC P0617...885
Symptoms - Engine Electrical...886
Starter Solenoid Does Not Click...886
Starter Solenoid Clicks, Engine Does Not Crank...888
Engine Cranks Slowly...888
Starter Motor Noise Diagnosis...889
Repair Instructions...890
Starter Motor Replacement...890
Starter Removal...891
Starter Installation...892
Specifications...893
Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7)...893
Fastener Tightening Specifications - Engine Electrical...893
Special Tools and Equipment...893
Special Tools - Engine Electrical...893
Charging System...894
Precautions...894
Battery Disconnect Caution...894
Batteries Produce Explosive Gases Caution...894
General Description...895
Battery Description and Operation...895
Charging System Description and Operation...896
Electrical Power Management Description and Operation...899
Schematic and Routing Diagram...899
Starting and Charging Schematics...899
Engine Electrical Connector End Views...902
Component Location...903
Engine Electrical Component Views...903
Diagnostic Information and Procedures...906
Diagnostic Starting Point - Engine Electrical...906
Scan Tool Output Controls - Engine Electrical...906
Scan Tool Data List - Engine Electrical...906
Scan Tool Data Definitions - Engine Electrical...908
DTC B1325...908
DTC B1405...910
DTC B1424...911
DTC B1516...912
DTC B1517...913
DTC B1527...915
DTC P0621...915
DTC P0622...916
DTC P0625...917
DTC P0626...919
DTC C0899...920
DTC C0900...920
Symptoms - Engine Electrical...921
Charging System Test...922
Battery Charging...925
Battery Common Causes of Failure...926
Jump Starting in Case of Emergency...927
Charge Indicator Always On...928
Charge Indicator Inoperative...929
Generator Noise Diagnosis...929
Engine Cranks Slowly...931
Battery Inspection/Test...931
Battery Electrical Drain/Parasitic Load Test...934
Repair Instructions...936
Battery Negative Cable Disconnection and Connection...936
Battery Current Sensor Replacement...938
Battery Negative Cable Replacement...939
Battery Positive Cable Replacement...941
Battery Replacement...943
Battery Tray Replacement...945
Battery Box Replacement...945
Generator Replacement...947
Specifications...948
Fastener Tightening Specifications - Engine Electrical...948
Battery Usage...949
Generator Usage...949
Special Tools and Equipment...949
Special Tools - Engine Electrical...949
Exhaust System...950
Precautions...950
Exhaust Service Caution...950
Hot Exhaust System Caution...950
Three-Way Catalytic Converter Damage Notice...950
General Description...951
Exhaust System Description...951
Diagnostic Information and Procedures...953
Diagnostic Starting Point - Engine Exhaust...953
Symptoms - Engine Exhaust...953
Restricted Exhaust...954
Exhaust Leakage...956
Exhaust Noise...956
Repair Instructions...957
Exhaust Manifold Replacement - Left Side...957
Exhaust Manifold Replacement - Right Side...958
Exhaust Flexible Pipe Replacement...959
Catalytic Converter Replacement - Left Side...961
Catalytic Converter Replacement - Right Side...963
Muffler Replacement...965
Catalytic Converter Heat Shield Replacement...966
Exhaust Heat Shield Replacement - Dash Panel...967
Exhaust Manifold Heat Shield Replacement...968
Exhaust Manifold Heat Shield Replacement - Right Side...969
Exhaust Manifold Heat Shield Replacement - Left Side...970
Exhaust Manifold Removal - Left Side...971
Exhaust Manifold Removal - Right Side...972
Exhaust Manifold Cleaning and Inspection - Left Side...975
Exhaust Manifold Cleaning and Inspection - Right Side...976
Exhaust Manifold Installation - Left Side...977
Exhaust Manifold Installation - Right Side...978
Specifications...982
Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7)...982
Fastener Tightening Specifications - Engine Exhaust...982
Special Tools and Equipment...982
Tools and Equipment...982
Special Tools - Engine Exhaust...982
Suspention...983
Suspension General Diagnosis...985
Diagnostic Information and Procedures...985
Diagnostic Starting Point - Suspension General Diagnosis...985
Symptoms - Suspension General Diagnosis...985
Ride Diagnosis...985
Vehicle Leads/Pulls...986
Body Leans or Sways in Corners...987
Suspension Bottoms...987
Torque Steer...988
Memory Steer...989
Noise Diagnosis - Front Suspension...989
Noise Diagnosis - Rear Suspension...991
Wheel Bearings Diagnosis...992
Suspension Strut and Shock Absorber Testing - On Vehicle...993
Ball Joint Inspection...994
Trim Height Inspection...994
Specifications...996
Trim Height Specifications...996
Special Tools and Equipment...998
Special Tools - Suspension General Diagnosis...998
Front Suspension...999
General Description...999
General Description...999
Caster Description...999
Camber Description...1000
Toe Description...1000
Setback Description...1000
Thrust Angles Description...1000
Lead/Pull Description...1001
Torque Steer Description...1001
Memory Steer Description...1001
Wander Description...1001
Scrub Radius Description...1001
Diagnostic Information and Procedures...1002
Vibration Analysis - Hub and/or Axle Input...1002
Repair Instructions...1005
Stabilizer Shaft Link Replacement...1005
Stabilizer Shaft Insulator Replacement...1006
Stabilizer Shaft Replacement...1007
Lower Ball Joint Replacement...1008
Front Wheel Bearing and Hub Replacement...1009
Wheel Stud Replacement...1012
Hub/Axle Flange and Wheel Stud Runout Inspection...1013
Lower Control Arm Replacement...1014
Front Lower Control Arm Bushing Replacement (Rear Bushing)...1016
Strut Assembly Replacement...1016
Suspension Strut Disposal...1018
Strut, Strut Component and/or Spring Replacement...1019
Steering Knuckle Replacement...1021
Measuring Wheel Alignment...1023
Front Caster Adjustment...1024
Front Camber Adjustment...1024
Front Toe Adjustment...1025
Specifications...1026
Fastener Tightening Specifications - Front Suspension...1026
Fastener Tightening Specifications - Wheel Alignment...1026
Wheel Alignment Specifications...1026
Special Tools and Equipment...1027
Special Tools - Front Suspension...1027
Rear Suspension...1028
General Description...1028
General Description...1028
Camber Description...1028
Toe Description...1028
Setback Description...1029
Thrust Angles Description...1029
Lead/Pull Description...1029
Scrub Radius Description...1029
Diagnostic Information and Procedures...1030
Vibration Analysis - Hub and/or Axle Input...1030
Repair Instructions...1032
Measuring Wheel Alignment...1032
Hub/Axle Flange and Wheel Stud Runout Inspection...1033
Stabilizer Shaft Link Replacement...1034
Stabilizer Shaft Insulator Replacement...1036
Stabilizer Shaft Replacement...1037
Rear Wheel Bearing and Hub Replacement...1038
Wheel Stud Replacement...1040
Rear Axle Upper Control Arm Replacement...1041
Rear Axle Lower Control Arm Replacement...1042
Shock Absorber Replacement...1044
Shock Absorber Disposal...1045
Coil Spring Replacement...1046
Coil Spring Insulators Replacement...1048
Trailing Arm Replacement...1049
Trailing Arm Bracket Replacement...1050
Adjustment Link Replacement...1051
Spring Jounce Bumper Replacement...1052
Knuckle Replacement...1053
Support Replacement (AWD Vehicles)...1056
Support Replacement (FWD Vehicles)...1059
Rear Camber Adjustment...1062
Rear Toe Adjustment...1062
Specifications...1063
Fastener Tightening Specifications - Rear Suspension...1063
Fastener Tightening Specifications - Wheel Alignment...1063
Wheel Alignment Specifications...1063
Special Tools and Equipment...1064
Special Tools - Rear Suspension...1064
Wheels and Tires...1065
General Description...1065
General Description...1065
Tread Wear Indicators Description...1065
Metric Wheel Nuts and Bolts Description...1065
Tire Inflation Description...1065
All Seasons Tires Description...1066
P-Metric Sized Tires Description...1066
Replacement Wheels Description...1067
Steel Wheel Repair Description...1067
Diagnostic Information and Procedures...1068
Component Rotational Speed Calculation...1068
Tire Diagnosis - Irregular or Premature Wear...1071
Tire Diagnosis - Waddle Complaint...1072
Tire and Wheel Inspection...1073
Tire and Wheel Assembly Runout Measurement - On-Vehicle...1074
Tire and Wheel Assembly Runout Measurement - Off Vehicle...1075
Wheel Mounting Surface Check...1078
Radial Tire Lead/Pull Correction...1079
Vibration Analysis - Tire and Wheel...1080
Tire and Wheel Assembly Isolation Test...1083
Repair Instructions...1084
Tire and Wheel Removal and Installation...1084
Tire and Wheel Assembly Balancing - Off Vehicle...1086
Tire and Wheel Assembly Balancing - On- Vehicle...1089
Tire Rotation...1090
Tire Mounting and Dismounting...1090
Tire Repair...1091
Tire-to-Wheel Match-Mounting (Vectoring)...1095
Tire and Wheel Assembly-to-Hub/Axle Flange Match-Mounting...1096
Specifications...1097
Fastener Tightening Specifications - Tires and Wheels...1097
Tire and Wheel Runout Specifications...1097
Special Tools and Equipment...1097
Special Tools - Tires and Wheels...1097
Driveline / Axle...1099
Drive Shaft...1101
General Description...1101
Wheel Drive Shafts Description and Operation...1101
Component Location...1102
Wheel Drive Shafts Disassembled Views...1102
Diagnostic Information and Procedures...1103
Diagnostic Starting Point - Wheel Drive Shafts...1103
Symptoms - Wheel Drive Shafts...1103
Click Noise In Turns...1103
Clunk When Accelerating from Coast...1103
Clunk Noise When Accelerating During Turns...1104
Shudder or Vibration During Acceleration...1104
Vibration Analysis - Driveline...1104
Vibration Analysis - Hub and/or Axle Input...1108
Repair Instructions...1110
Front Wheel Drive Shaft Replacement (AWD)...1110
Front Wheel Drive Shaft Replacement (FWD)...1112
Intermediate Shaft Replacement...1114
Rear Wheel Drive Shaft Replacement...1115
Front Wheel Drive Shaft Inner Joint and Seal Replacement...1118
Front Wheel Drive Shaft Outer Joint and Seal Replacement...1120
Rear Wheel Drive Shaft Inner Joint and Seal Replacement...1123
Rear Wheel Drive Shaft Outer Joint and Seal Replacement...1125
Specifications...1128
Fastener Tightening Specifications - Wheel Drive Shafts...1128
Special Tools and Equipment...1128
Special Tools - Wheel Drive Shafts...1129
Differential...1130
General Description...1130
Rear Drive Axle Description and Operation...1130
All-Wheel Drive Description and Operation...1130
Diagnostic Information and Procedures...1131
Diagnostic Starting Point - Rear Drive Axle...1131
Scan Tool Output Controls - Rear Drive Axle...1131
Scan Tool Data List - Rear Drive Axle...1131
Scan Tool Data Definitions - Rear Drive Axle...1131
DTC C0393...1132
DTC C0394...1133
DTC C0550...1134
DTC C0558...1134
DTC C0561...1135
Symptoms - Rear Drive Axle...1136
All-Wheel Drive (AWD) Disabled Indicator Always On...1136
Service All-Wheel Drive Indicator Always On...1137
Noisy in Drive...1138
Noisy When Coasting...1139
Intermittent Noise...1139
Constant Noise...1140
Noisy on Turns...1140
Rear Axle Lubricant Leak Diagnosis...1141
Repair Instructions...1141
Rear Axle Lubricant Level Inspection...1141
Rear Axle Lubricant Replacement...1142
Rear Wheel Drive Module Clutch Housing Replacement...1143
Differential Carrier Assembly Mount Replacement...1144
Differential Carrier Cover and Seal Replacement - Left Side...1145
Rear Axle Shaft Seal Replacement - Left Side...1145
Rear Axle Shaft Seal Replacement - Right Side...1147
Drive Pinion Flange/Yoke and/or Oil Seal Replacement...1148
Differential Replacement...1149
Differential Housing Support Bushing Replacement (Front)...1151
Differential Housing Support Bushing Replacement (Rear)...1151
Rear Differential Clutch Control Module Replacement...1154
Rear Differential Clutch Control Module Calibration...1155
Rear Differential Clutch Control Module Programming and Setup...1155
Specifications...1155
Fastener Tightening Specifications - Rear Drive Axle...1155
Rear Axle Specifications...1155
Sealers, Adhesives, and Lubricants...1155
Special Tools and Equipment...1156
Special Tools - Rear Drive Axle...1156
Transfer...1157
General Description...1157
Transfer Case Description and Operation...1157
Schematic and Routing Diagram...1157
All-Wheel Drive Schematics...1157
Transfer Case Control Connector End Views...1159
Component Location...1160
Transfer Case Control Component Views...1160
Transfer Case Disassembled View...1161
Diagnostic Information and Procedures...1162
Diagnostic Starting Point - Transfer Case...1162
Symptoms - Transfer Case...1162
Noisy in Drive...1162
Noisy When Coasting...1163
Intermittent Noise...1163
Constant Noise...1164
Transfer Case Leak Diagnosis...1164
Repair Instructions...1165
Transfer Case Fluid Replacement...1165
Transfer Case Assembly Replacement...1165
Transfer Case Disassemble...1167
Transfer Case Cleaning and Inspection...1173
Rear Output Drive Housing Cleaning and Inspection...1174
Input Shaft Seal Replacement - Right...1175
Input Shaft Seal Replacement - Left...1176
Front Drive Axle Inner Shaft Seal Replacement...1177
Input Shaft and Rear Output Drive Shaft Cleaning and Inspection...1178
Transfer Case Assemble...1179
Specifications...1186
Fastener Tightening Specifications - Transfer Case - Getrag 760...1186
Sealers, Adhesives, and Lubricants...1186
Approximate Fluid Capacities...1186
Special Tools and Equipment...1186
Special Tools - Transfer Case - Getrag 760...1186
Propeller Shafts...1188
General Description...1188
Propeller Shaft Description and Operation...1188
Diagnostic Information and Procedures...1189
Component Rotational Speed Calculation...1189
Diagnostic Starting Point - Propeller Shaft...1192
Symptoms - Propeller Shaft...1192
Roughness or Vibration...1192
Ping, Snap, or Click Noise...1193
Knock or Clunk Noise...1193
Scraping Noise...1193
Squeak Noise...1193
Shudder on Acceleration at Low Speed...1193
Vibration Analysis - Driveline...1193
Transfer Case Output Flange Runout Measurement...1197
Propeller Shaft Runout Measurement...1197
Torque Tube Input Flange Runout Measurement...1200
Pinion Flange Runout Measurement...1200
Differential Pinion Input Shaft Runout Measurement...1202
Driveline Working Angles Measurement...1203
Repair Instructions...1206
Driveline System Balance Adjustment (Using EVA)...1206
Driveline System Balance Adjustment (Without EVA)...1209
Driveline Working Angles Adjustment...1211
Propeller Shaft Phasing Inspection...1212
Propeller Shaft Phasing Correction...1212
Propeller Shaft Replacement...1213
Specifications...1215
Fastener Tightening Specifications - Propeller Shaft...1215
Sealers, Adhesives, and Lubricants...1215
Propeller Shaft Runout Specifications...1215
Driveline Runout Specifications...1215
Brakes...1217
Brake Control System and Diagnosis...1220
General Description...1220
Hydraulic Brake System Description and Operation...1220
Brake Assist System Description and Operation...1220
Brake Warning System Description and Operation...1220
Schematic and Routing Diagram...1221
Hydraulic Brake Schematics...1222
Hydraulic Brake Connector End Views...1223
Hydraulic Brake Pipe Routing - Master Cylinder to ABS...1224
Component Location...1225
Hydraulic Brake Component Views...1225
Diagnostic Information and Procedures...1227
Diagnostic Starting Point - Hydraulic Brakes...1227
Scan Tool Data List - Hydraulic Brakes...1227
Scan Tool Data Definitions - Hydraulic Brakes...1227
DTC C0267...1227
Symptoms - Hydraulic Brakes...1228
Brake Warning Indicator Malfunction...1229
Brake Pulsation...1230
Brake System Noise...1230
Braking Action Uneven - Pulls to One Side...1231
Braking Action Uneven - Front to Rear...1232
Brake Pedal Excessive Travel...1232
Brake Pedal Excessive Effort...1233
Brakes Drag...1233
Brake System Slow Release...1234
Brake Fluid Loss...1235
Hydraulic Brake System Diagnosis...1235
Brake Assist System Diagnosis...1239
Brake System Vehicle Road Test...1241
Brake Pedal Travel Measurement and Inspection...1242
Brake System Vacuum Source Test...1242
Brake System External Leak Inspection...1243
Brake System Internal Leak Test...1243
Hydraulic Brake Component Operation Visual Inspection...1244
Repair Instructions...1245
Master Cylinder Reservoir Filling...1245
Hydraulic Brake System Bleeding (Pressure)...1245
Hydraulic Brake System Bleeding (Manual)...1247
Hydraulic Brake System Flushing...1248
Brake Pedal Assembly Replacement...1249
Brake Pedal Pushrod Inspection...1252
Brake Pedal Position Sensor Replacement...1253
Brake Pedal Position Sensor Calibration...1254
Stop Lamp Switch Adjustment...1254
Stop Lamp Switch Replacement...1255
Front Brake Hose Replacement...1255
Rear Brake Hose Replacement...1257
Brake Pipe Replacement...1259
Brake Pipe and Hose Inspection...1262
Master Cylinder Fluid Level Sensor Replacement...1263
Master Cylinder Reservoir Replacement...1264
Master Cylinder Replacement...1265
Master Cylinder Bench Bleeding...1267
Vacuum Brake Booster Check Valve and/or Hose Replacement...1268
Vacuum Brake Booster Replacement...1269
Specifications...1271
Fastener Tightening Specifications - Hydraulic Brakes...1271
Fastener Tightening Specifications - Lighting...1271
Brake Component Specifications...1272
Brake System Specifications...1272
Special Tools and Equipment...1272
Special Tools - Hydraulic Brakes...1272
Front Brakes...1273
Precautions...1273
Brake Dust Caution...1273
Brake Fluid Irritant Caution...1273
General Description...1273
Disc Brake System Description and Operation...1273
Diagnostic Information and Procedures...1274
Diagnostic Starting Point - Disc Brakes...1274
Disc Brake System Diagnosis...1274
Brake Rotor Thickness Measurement...1280
Brake Rotor Thickness Variation Measurement...1280
Brake Rotor Assembled Lateral Runout Measurement...1281
Repair Instructions...1283
Front Disc Brake Pads Replacement...1283
Brake Pad Inspection...1285
Brake Pad and Rotor Burnishing...1285
Front Brake Caliper Replacement...1286
Brake Caliper Inspection...1288
Front Disc Brake Hardware Replacement...1289
Front Disc Brake Mounting and Hardware Inspection...1291
Front Brake Caliper Bracket Replacement...1292
Front Brake Rotor Replacement...1293
Brake Rotor Surface and Wear Inspection...1294
Brake Rotor/Drum Balance Inspection...1295
Front Brake Shield Replacement...1296
Brake Rotor Assembled Lateral Runout Correction...1296
Brake Rotor Assembled Lateral Runout Correction - Indexing...1297
Brake Rotor Assembled Lateral Runout Correction - Correction Plates...1298
Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe...1299
Brake Rotor Refinishing...1300
Specifications...1301
Fastener Tightening Specifications - Disc Brakes...1301
Disc Brake Component Specifications...1301
Special Tools and Equipment...1302
Special Tools - Disc Brakes...1302
Rear Brakes...1303
Precautions...1303
Brake Dust Caution...1303
Brake Fluid Irritant Caution...1303
General Description...1303
Disc Brake System Description and Operation...1303
Diagnostic Information and Procedures...1304
Diagnostic Starting Point - Disc Brakes...1304
Disc Brake System Diagnosis...1304
Brake Rotor Thickness Measurement...1310
Brake Rotor Thickness Variation Measurement...1310
Brake Rotor Assembled Lateral Runout Measurement...1311
Repair Instructions...1313
Brake Pad and Rotor Burnishing...1313
Rear Disc Brake Pads Replacement...1313
Brake Pad Inspection...1315
Rear Brake Caliper Replacement...1316
Brake Caliper Inspection...1318
Rear Disc Brake Hardware Replacement...1319
Rear Disc Brake Mounting and Hardware Inspection...1320
Rear Brake Caliper Bracket Replacement...1322
Rear Brake Rotor Replacement...1323
Brake Rotor Surface and Wear Inspection...1324
Brake Rotor/Drum Balance Inspection...1325
Rear Disc Brake Backing Plate Replacement...1326
Brake Rotor Assembled Lateral Runout Correction...1326
Brake Rotor Assembled Lateral Runout Correction - Indexing...1327
Brake Rotor Assembled Lateral Runout Correction - Correction Plates...1328
Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe...1329
Brake Rotor Refinishing...1330
Specifications...1331
Fastener Tightening Specifications - Disc Brakes...1331
Disc Brake Component Specifications...1331
Special Tools and Equipment...1332
Special Tools - Disc Brakes...1332
Parking Brake...1333
General Description...1333
Park Brake System Description and Operation...1333
Diagnostic Information and Procedures...1334
Diagnostic Starting Point - Park Brake...1334
DTC B0005...1334
Symptoms - Park Brake...1335
Park Brake Will Not Hold or Release...1335
Park Brake System Diagnosis...1336
Repair Instructions...1338
Park Brake Adjustment...1338
Park Brake Shoe Replacement...1340
Park Brake Lever Assembly Replacement...1341
Park Brake Warning Lamp Switch Replacement...1343
Parking Brake Front Cable Replacement...1343
Parking Brake Rear Cable Replacement...1344
Parking Brake Actuator Replacement...1348
Park Brake Hardware Inspection...1349
Specifications...1350
Fastener Tightening Specifications - Park Brake...1350
Special Tools and Equipment...1350
Special Tools - Park Brake...1350
ABS...1351
Precautions...1351
ABS Component Handling Caution...1351
General Description...1351
ABS Description and Operation...1351
Schematic and Routing Diagram...1354
Antilock Brake System Schematic Icons...1354
Antilock Brake System Schematics...1354
Antilock Brake System Connector End Views...1358
Component Location...1362
Antilock Brake System Component Views...1362
Diagnostic Information and Procedures...1367
Diagnostic Starting Point - Antilock Brake System...1367
Scan Tool Output Controls - Antilock Brake System...1367
Scan Tool Data List - Antilock Brake System...1367
Scan Tool Data Definitions - Antilock Brake System...1368
Diagnostic Test Drive...1369
Initialization Sequence...1369
DTC C0035-C0050...1370
DTC C0110...1372
DTC C0131...1374
DTC C0161...1375
DTC C0186...1376
DTC C0196...1378
DTC C0201...1380
DTC C0252...1381
DTC C0280...1382
DTC C0292...1383
DTC C0460...1384
DTC C0550...1385
DTC C0551...1386
DTC C0561...1386
DTC C0899...1387
DTC C0900...1388
Symptoms - Antilock Brake System...1388
ABS Active Indicator Always On...1389
ABS Active Indicator Inoperative...1390
Traction Control Indicator Always On...1392
Traction Control Indicator Inoperative...1394
Repair Instructions...1396
Antilock Brake System Automated Bleed Procedure...1396
Steering Angle Sensor Centering...1397
Electronic Brake Control Module Replacement...1397
Electronic Brake Control Module Programming and Setup...1398
Brake Pressure Modulator Valve Replacement...1399
Brake Pressure Modulator Valve Bracket Replacement...1401
Front Wheel Speed Sensor Replacement...1402
Rear Wheel Speed Sensor Replacement...1403
Electronic Traction Control Switch Replacement...1404
Vehicle Yaw Sensor Replacement...1405
Specifications...1405
Fastener Tightening Specifications - Antilock Brake System...1405
Transmission / Transaxle...1407
Automatic Transmission...1411
General Description...1411
Transmission General Description...1411
Transmission General Information...1412
Definitions and Abbreviations...1412
Automatic Transmission Shift Lock Control Description and Operation...1414
Transmission Component and System Description...1414
Transmission Adaptive Functions...1414
Transmission Oil Life Monitor...1414
Transmission Indicators and Messages...1415
Electronic Component Description...1415
Park - Engine Running...1419
Reverse...1422
Reverse Inhibit...1425
Neutral - Engine Running...1428
Drive and M Range - First Gear...1431
M Range - First Gear, Engine Braking...1434
Drive and M Range - Second Gear...1437
Drive and M Range - Third Gear...1440
Drive Range - Fourth Gear...1443
Drive Range Fifth Gear - Torque Converter Clutch Released...1446
Drive Range Fifth Gear - Torque Converter Clutch Applied...1449
Drive Range - Emergency Fifth Gear...1452
Schematic and Routing Diagram...1454
Automatic Transmission Schematic Icons...1454
Automatic Transmission Controls Schematics...1454
Shift Lock Control Schematics...1458
Automatic Transmission Inline Harness Connector End View...1459
Automatic Transmission Internal Connector End Views...1460
Automatic Transmission Related Connector End Views...1463
Shift Lock Control Connector End Views...1466
Component Location...1467
Automatic Transmission Electronic Component Views...1467
Shift Lock Control Component Views...1468
Disassembled Views...1469
Bearing, Race, Thrust Washer and Seal Locations...1490
Fluid Passages...1492
Diagnostic Information and Procedures...1513
Diagnostic Starting Point - Automatic Transmission...1513
Diagnostic Starting Point - Automatic Transmission Shift Lock Control...1513
Scan Tool Output Controls - Automatic Transaxle - AF33-5...1514
Scan Tool Output Controls - Shift Lock Control...1518
Scan Tool Data List - Automatic Transaxle - AF33-5...1519
Scan Tool Data List - Shift Lock Control...1520
Scan Tool Data Definitions - Automatic Transaxle - AF33-5...1521
Scan Tool Data Definitions - Shift Lock Control...1523
Diagnostic Trouble Code (DTC) Type Definitions...1524
Diagnostic Trouble Code (DTC) List/Type...1524
DTC P0115, P0120, P0703, P0727, P0826, P1779, P2544, or P2637...1526
DTC P0562 or P0563...1527
DTC P0601, P0602, P0603, or P0604...1528
DTC P0706-P0708...1529
DTC P0711, P0712, or P0713...1530
DTC P0717 or P0722...1532
DTC P0730...1533
DTC P0731...1535
DTC P0732...1537
DTC P0733...1539
DTC P0734...1541
DTC P0735...1543
DTC P0736...1545
DTC P0741...1546
DTC P0742...1548
DTC P0762...1549
DTC P081A or P081B...1551
DTC P0851 or P0852...1552
DTC P0897...1553
DTC P0962, P0963, P0966, P0967, P0970, or P0971...1554
DTC P0973, P0974, P0976, P0977, P0979, P0980, P0982, P0983, P0985, or P0986...1556
DTC P1719...1557
DTC P2534...1559
DTC P2536...1560
DTC B2705...1561
DTC P280A...1563
Symptoms - Automatic Transmission...1564
Symptoms - Automatic Transmission Shift Lock Control...1565
Transmission Adaptive Learn and Transmission Neutral Learn...1565
Road Test...1567
Torque Converter Diagnosis...1567
Flexplate/Torque Converter Vibration Test...1569
Stall Speed Test...1569
Engagement Delay Test...1570
Noise and Vibration Analysis...1571
Clutch Plate Diagnosis...1571
Engine Coolant/Water in Transmission...1572
Fluid Leak Diagnosis...1572
Case Porosity Repair...1575
Transmission Fluid Cooler Flushing and Flow Test...1575
Transmission Overheats...1580
No Forward and Reverse...1581
Slips in Drive or No Drive...1582
Slips in Reverse or No Reverse...1583
Engagement Time From Park or Neutral to Drive is Not Within Specifications...1584
Engagement Time From Park or Neutral to Reverse is Not Within Specifications...1584
Engine Stalls During Reverse or Drive Engagement...1585
Slips on Acceleration...1585
Harsh Feel at Light Acceleration or Deceleration Without Causing an Upshift or Downshift...1586
No 1-2 Upshift...1587
No 2-3 Upshift...1587
No 3-4 Upshift...1588
No 4-5 Upshift...1588
No 5-4 Downshift...1589
No 4-3 Downshift...1589
No 3-2 Downshift...1590
No 2-1 Downshift...1590
Torque Converter Clutch Stuck On or Off...1591
No Engine Braking in Fourth Gear...1591
No Engine Braking in Third Gear...1592
No Engine Braking in Second Gear...1592
No Response to Movement of Shift Lever...1593
Transmission Attempts to Move but Appears Locked Up...1593
Vibration at Idle...1593
Vibration While Driving...1593
Hum or Rattle Noise at Idle...1594
Whine/Growl Noise That Changes with Vehicle Speed...1594
Automatic Transmission Fluid Leaks...1594
Harsh Park or Neutral to Drive Engagement...1596
Harsh Park or Neutral to Reverse Engagement...1597
Harsh Upshift...1598
Harsh Shift on Coastdown...1599
Harsh Forced Downshift...1600
Shift Lever Does Not Move with Brake Pedal Depressed...1602
Shift Lever Can Be Moved without Brake Pedal Depressed...1603
Repair Instructions...1604
Transmission Fluid Check...1604
Line Pressure Check...1605
Transaxle Fluid Replacement...1607
Transmission Control Lever Knob Replacement...1608
Automatic Transmission Control Indicator Replacement...1609
Transmission Control Boot Replacement...1610
Shift Control Replacement...1611
Shift Lock Solenoid/Switch Assembly Replacement...1612
Transmission Control Bracket Replacement...1613
Shift Control Cable Replacement...1613
Shift Control Cable Adjustment...1615
Shift Control Cable Bracket Replacement...1616
Automatic Transmission Range Selector Lever Replacement...1617
Transmission Control Module Replacement...1618
Transmission Control Module Programming and Setup...1620
Transaxle Brace Replacement...1620
Transmission Mount Inspection...1621
Transmission Front Mount Replacement...1621
Transmission Rear Mount Replacement (Getrag 760 Transfer Case)...1622
Transmission Mount Replacement - Left Side...1623
Transmission Rear Mount Bracket Replacement (AWD)...1624
Transmission Rear Mount Bracket Replacement (FWD)...1625
Transmission Mount Bracket Replacement - Left Side...1625
Fluid Level Indicator Replacement...1626
Input Speed Sensor Replacement...1627
Output Speed Sensor Replacement...1628
Control Valve Body Cover Replacement...1629
Automatic Transmission Wiring Harness Replacement...1630
Control Valve Body Replacement...1632
Oil Cooler Line Replacement...1635
Fluid Cooler Pipe Seal Replacement...1636
Drive Axle Shaft Seal Replacement (Left)...1638
Drive Axle Shaft Seal Replacement (Right)...1639
Transaxle Replacement...1640
Torque Converter Assembly Removal...1642
Holding Fixture Installation...1642
Transmission Fluid Draining...1643
Input and Output Speed Sensor Removal...1644
Transmission Control Module Removal...1644
Control Valve Body Cover Removal...1644
Wiring Harness Removal...1645
Control Valve Body Assembly Removal...1646
Fluid Pump Assembly Removal...1647
Second Coast, Second Clutch Hub and Second Clutch Sprag Assembly Removal...1647
Torque Converter Housing Removal...1647
Front Differential Assembly Removal...1648
Fluid Filter Removal...1648
Transmission Fluid Baffle Removal...1648
Third Gear Band Apply Tube Removal...1649
Manual Shift Detent Lever and Park Pawl Removal...1649
Front Differential Transfer Drive Gear Assembly Removal...1652
Third Gear Band Servo Piston Pin Measurement...1652
4-5 Clutch Assembly Removal...1653
Third Gear Band Assembly Removal...1653
1-2-Reverse Carrier Gear Assembly Removal...1654
Third Gear Band Servo Piston Assembly Removal...1654
Case Cover and 1-2 Reverse Clutch Assembly Removal...1655
Forward and Direct Clutch Assembly Removal...1656
Rear Internal Gear and Front Carrier Removal...1656
Front Internal Gear and Low and Reverse Clutch Assembly Removal...1659
Low and Reverse Clutch Piston Removal...1660
Output Gear Assembly Removal...1660
Transmission Cooler Line Seals Removal...1661
Transmission Case Inspection...1662
Transmission Cooler Line Seals Installation...1663
Rotational Torque Measurement...1663
Front Differential Bearing Race and Selective Shim Removal...1664
Front Differential Bearing Race and Selective Shim Installation...1665
Manual Shift Shaft Seal and Bearing Removal...1666
Manual Shift Shaft Seal and Bearing Installation...1666
Front Wheel Drive Shaft Oil Seal Removal...1667
Front Wheel Drive Shaft Oil Seal Installation...1667
Front Differential Carrier Seal Removal...1667
Front Differential Carrier Seal Installation...1667
4-5 Clutch Drum Assembly Disassemble...1668
4-5 Clutch Drum Assembly Assemble...1670
4-5 Clutch Piston Travel Measurement...1672
Output Gear Assembly Installation...1672
Low and Reverse Clutch Piston Installation...1673
Front Internal Gear and Overrun Clutch Disassemble...1674
Front Internal Gear Cleaning and Inspection...1674
Front Internal Gear and Overrun Clutch Assemble...1675
Front Internal Gear and Low and Reverse Clutch Installation...1675
Low and Reverse Clutch Piston Travel Measurement...1676
Rear Internal Gear and Front Carrier Installation...1677
Forward and Direct Clutch Assembly Disassemble...1678
Forward and Direct Clutch Assembly Assemble...1681
Direct Clutch Piston Travel Check...1684
Forward Clutch Piston Travel Check...1685
Forward and Direct Clutch Assembly Installation...1685
Case Cover Assembly Disassemble...1687
1-2 Reverse Clutch Disassemble...1688
Case Cover Cleaning and Inspection...1689
1-2 Reverse Clutch Assemble...1689
Case Cover Assembly Assemble...1691
1-2-Reverse Clutch Piston Travel Measurement...1692
Forward and Direct Clutch End Play Measurement...1693
Transmission Case Cover and 1-2 Reverse Clutch Assembly Installation...1694
Third Gear Band Servo Piston Disassemble...1695
Third Gear Band Servo Piston Assemble...1695
Third Gear Band Servo Piston Installation...1696
1-2-Reverse Carrier Gear Assembly Installation...1697
Third Gear Band Assembly Installation...1697
4-5 Clutch Assembly Installation...1698
Front Differential Transfer Drive Gear Assembly Installation...1698
Manual Shift Detent Lever and Park Pawl Installation...1700
Third Gear Band Apply Tube Installation...1702
Transmission Fluid Baffle Installation...1703
Fluid Filter Installation...1703
Front Differential Assembly Cleaning and Inspection...1704
Front Differential Assembly Installation...1704
Torque Converter Housing Cleaning and Inspection...1704
Torque Converter Housing Installation...1706
Second Coast Clutch Disassemble...1707
Second Clutch Disassemble...1708
Transmission Fluid Pump Disassemble...1709
Fluid Pump Cleaning and Inspection...1711
Transmission Fluid Pump Assemble...1711
Second Clutch Assemble...1713
Second Coast Clutch Assemble...1714
Second Clutch Piston Travel Measurement...1715
Second Coast Clutch Piston Travel Measurement...1716
Second Coast, Second Clutch Hub and Second Clutch Sprag Disassemble...1717
Second Coast, Second Clutch Hub and Second Clutch Sprag Assemble...1717
Fluid Pump Installation...1718
Control Valve Body Assembly Disassemble...1720
Middle Control Valve Body Disassemble...1723
Middle Control Valve Body Assemble...1725
Control Valve Rear Body Disassemble...1727
Control Valve Rear Body Assemble...1730
No. 2 Rear Control Valve Body Disassemble...1733
No. 2 Rear Control Valve Body Assemble...1734
Control Valve Front Body Disassemble...1735
Control Valve Front Body Assemble...1737
Control Valve Body Assembly Assemble...1738
Control Valve Body Assembly Installation...1743
Wiring Harness Installation...1744
Control Valve Body Cover Installation...1745
Transmission Control Module Installation...1746
Input and Output Speed Sensor Installation...1747
Drain Plug Installation...1747
Holding Fixture Removal...1748
Torque Converter Assembly Installation...1748
Specifications...1749
Fastener Tightening Specifications - Automatic Transaxle - AF33-5...1749
Transmission Fluid Temperature Sensor Specifications...1751
Transmission General Specifications...1752
Fluid Capacity Specifications...1752
Shim Size Specifications...1752
Transmission Clearance Specifications...1753
Race and Bearing Specifications...1755
Range Reference...1756
Shift Solenoid Valve State and Gear Ratio...1757
Shift Speed...1757
Line Pressure...1757
Component Resistance...1758
Third Gear Band Servo Piston Pin Selection...1758
Sealers, Adhesives, and Lubricants...1759
Special Tools and Equipment...1759
Special Tools - Automatic Transaxle - AF33- 5...1759
Steering...1763
Steering Wheel and Column...1764
General Description...1764
Steering Wheel and Column Description and Operation...1764
Electronic Park Lock Description and Operation...1764
Component Location...1765
Steering Column Disassembled View...1765
Diagnostic Information and Procedures...1766
Symptoms - Steering Wheel and Column...1766
Noise in Steering Column...1766
Looseness in Steering Column...1767
Ignition Key Cannot Be Removed from the Ignition Lock Cylinder...1767
Ignition Key Cannot Turn or Sticks in Any Position...1768
Ignition Can/Cannot Be Turned Off with Transmission in Any Gear...1768
Repair Instructions...1770
Intermediate Steering Shaft Replacement...1770
Steering Column Accident Damage Inspection...1771
Steering Column Trim Covers Replacement...1772
Multifunction Turn Signal Switch Housing Replacement...1773
Turn Signal Multifunction Switch Replacement...1774
Steering Wheel Replacement...1775
Steering Column Replacement...1776
Steering Wheel Position Sensor Replacement...1778
Ignition Lock Cylinder Case Replacement...1779
Ignition Lock Cylinder Replacement...1780
Ignition and Start Switch Replacement...1781
Specifications...1782
Fastener Tightening Specifications - Wiring Systems and Power Management...1782
Fastener Tightening Specifications - Steering Wheel and Column - Tilt...1782
Special Tools and Equipment...1782
Special Tools - Steering Wheel and Column - Tilt...1782
Power Assisted Steering System...1783
General Description...1783
Power Steering System Description and Operation...1783
Diagnostic Information and Procedures...1783
Diagnostic Starting Point - Power Steering System...1783
Symptoms - Power Steering System...1783
Power Steering System Test...1784
Power Steering Fluid Leaks...1787
Rattle, Clunk, or Shudder Noise from the Power Steering System...1788
Whine or Growl Noise from the Power Steering System...1789
Poor Return of Steering Wheel...1789
Steering Effort Too Easy in One or Both Directions...1791
Steering Effort Hard in One or Both Directions...1791
Repair Instructions...1792
Power Steering System Bleeding...1792
Checking and Adding Power Steering Fluid...1792
Power Steering System Flushing...1792
Remote Power Steering Fluid Reservoir Replacement...1793
Power Steering Pump Pulley Replacement...1795
Power Steering Pump Replacement...1796
Rack and Pinion Outer Tie Rod End Replacement...1798
Power Steering Cooler Pipe/Hose Replacement...1799
Power Steering Fluid Reservoir Outlet Hose Replacement...1800
Power Steering Pump Inlet Pipe Replacement...1802
Power Steering Gear Inlet Pipe/Hose Replacement...1803
Steering Gear Replacement...1804
Steering Gear Boot Replacement - Off Vehicle...1806
Steering Gear Inner Tie Rod Replacement - Off Vehicle...1808
Steering Gear Cylinder Pipe Assembly and Seals Replacement - Off Vehicle...1809
Specifications...1810
Fastener Tightening Specifications - Power Steering System...1810
Power Steering Pump Specifications...1810
Special Tools and Equipment...1811
Special Tools - Power Steering System...1811
HVAC...1813
Heating, Ventilation and Air Conditioning...1815
General Description...1815
Air Delivery Description and Operation...1815
Air Temperature Description and Operation...1817
Schematic and Routing Diagram...1820
HVAC Schematics...1820
HVAC Connector End Views...1826
Component Location...1834
HVAC Component Views...1834
Diagnostic Information and Procedures...1838
Diagnostic Starting Point - Heating, Ventilation and Air Conditioning...1838
Scan Tool Output Controls - HVAC - Automatic...1838
Scan Tool Data List - HVAC - Automatic...1839
Scan Tool Data Definitions - HVAC - Automatic...1840
DTC B0158...1841
DTC B0228, B0413, B0423, B0433, B3779 or B3782...1842
DTC B3933...1846
DTC P0532 or P0533...1847
DTC P0645, P0646, or P0647...1849
Symptoms - HVAC Systems - Automatic...1850
Odor Diagnosis...1851
Air Conditioning Compressor Malfunction...1852
Blower Motor Malfunction...1854
Auxiliary Blower Motor Malfunction...1856
Upper or Lower Duct Air Temperature Sensor Malfunction...1858
Heating Performance Diagnostic...1858
Defrosting Insufficient...1860
Noise Diagnosis - Auxiliary Blower Motor...1861
Noise Diagnosis - Blower Motor...1862
Noise Diagnosis - Air Conditioning (A/C) System...1863
Noise Diagnosis - HVAC Module...1865
Too Hot in Vehicle...1866
Too Cold in Vehicle...1867
Too Hot in Vehicle - Auxiliary...1869
Too Cold in Vehicle - Auxiliary...1871
Air Delivery Improper...1873
Air Delivery Improper - Auxiliary...1875
Air Recirculation Malfunction...1877
Inside Air Temperature Sensor Malfunction...1878
Sun Load Sensor Malfunction...1879
Afterblow Enabling...1880
Actuator Recalibration...1880
Leak Testing...1881
Air Conditioning (A/C) System Performance Test (w/ C69)...1882
Air Conditioning (A/C) System Performance Test (w/o C69)...1886
Air Conditioning (A/C) Diagnostics - Pressure Zone A...1889
Air Conditioning (A/C) Diagnostics - Pressure Zone B...1892
Air Conditioning (A/C) Diagnostics - Pressure Zone C...1894
Air Conditioning (A/C) Diagnostics - Pressure Zone D...1896
Repair Instructions...1898
Odor Correction...1898
Refrigerant Recovery and Recharging...1899
Compressor Oil Balancing...1900
Compressor Hose Assembly Replacement...1901
Compressor Replacement...1902
Compressor Clutch Assembly Replacement...1903
Compressor Pressure Relief Valve Replacement...1906
Sealing Washer Replacement...1907
O-Ring Replacement...1908
Liquid Line Replacement...1909
Evaporator Outlet Hose Replacement...1912
Air Conditioning Refrigerant Service Valve Core Replacement...1913
Receiver Dehydrator Replacement...1914
Thermal Expansion Valve Replacement...1915
Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement...1917
Air Conditioning (A/C) Refrigerant Low Temperature Sensor Replacement...1918
Condenser Replacement...1918
Air Conditioning (A/C) Evaporator Case Assembly Replacement...1921
Blower Case Assembly Replacement...1923
HVAC Module Assembly Replacement...1925
HVAC Control Module Programming and Setup...1929
Evaporator Core Replacement...1929
Heater Inlet Hose Replacement (w/o C69)...1931
Heater Inlet Hose Replacement (w/ C69)...1932
Heater Outlet Hose Replacement (w/o C69)...1933
Heater Outlet Hose Replacement (w/C69)...1935
Passenger Compartment Air Filter Housing Replacement...1936
Passenger Compartment Air Filter Replacement...1938
Air Inlet Assembly Replacement...1940
Blower Motor Control Module Replacement...1941
Blower Control Module Programming and Setup...1941
Blower Motor Replacement...1941
Instrument Panel Outer Air Outlet Replacement - Left Side...1942
Instrument Panel Center Air Outlet Replacement...1943
Instrument Panel Outer Air Outlet Replacement - Right Side...1944
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side...1945
Instrument Panel Outer Air Outlet Upper Duct Replacement - Right Side...1946
Floor Air Outlet Replacement - Center...1947
Rear Floor Air Outlet Replacement...1947
Center Air Outlet Duct Replacement...1948
Windshield Defroster Duct Replacement...1948
Side Window Defogger Outlet Duct Replacement - Left Side...1949
Side Window Defogger Outlet Duct Replacement - Right Side...1949
Defroster Air Outlet Replacement...1950
Air Temperature Door Replacement...1951
Defroster Door Replacement...1953
Panel Air Door Replacement...1955
Heater Core Replacement...1957
Air Temperature Door Replacement - Auxiliary...1958
Auxiliary Heater Pipe Replacement...1959
Auxiliary Blower Control Module Replacement...1960
Auxiliary Blower Motor Replacement...1961
Auxiliary Air Distributor Lower Duct Replacement...1962
Auxiliary Air Distributor Duct Replacement - Upper...1963
Auxiliary Heater Core Replacement...1964
Auxiliary Air Conditioning Evaporator Thermal Expansion Valve Replacement...1965
Auxiliary HVAC Module Replacement...1966
Auxiliary Heating, Ventilation, and Air Conditioning Control Module Programming and Setup...1967
Auxiliary Air Conditioning Evaporator Core Replacement...1967
Auxiliary Air Conditioning Evaporator Tube Replacement...1969
Auxiliary Heater and Air Conditioning Pipe Repair...1970
HVAC Control Assembly Replacement...1972
Auxiliary Heater and Air Conditioning Control Replacement...1973
Recirculation Actuator Replacement...1974
Mode Actuator Replacement...1974
Air Temperature Actuator Replacement...1975
Auxiliary Air Temperature Actuator Replacement...1976
Auxiliary Mode Actuator Replacement...1977
Air Temperature Sensor Replacement - Upper...1978
Air Temperature Sensor Replacement - Lower...1979
Inside Air Temperature Sensor Assembly Replacement...1980
Specifications...1981
Fastener Tightening Specifications - Heating, Ventilation and Air Conditioning...1981
Fastener Tightening Specifications - HVAC - Automatic...1982
Refrigerant System Capacities...1982
Sensor Resistance Table (Volts to Temp to Resistance)...1982
Special Tools and Equipment...1983
Special Tools - Heating, Ventilation and Air Conditioning...1983
Special Tools - HVAC - Automatic...1984
Restraints...1985
Seat Belts...1987
Precautions...1987
Seat Belt Service Precautions...1987
General Description...1987
Seat Belt System Description and Operation...1987
Schematic and Routing Diagram...1988
Seat Belt Schematics...1989
Seat Belt Connector End Views...1990
Component Location...1991
Seat Belt Component Views...1991
Diagnostic Information and Procedures...1993
Diagnostic Starting Point - Seat Belts...1993
Scan Tool Data List - Seat Belts...1993
Scan Tool Data Definitions - Seat Belts...1993
Operational and Functional Checks...1993
Symptoms - Seat Belts...1994
Seat Belt Does Not Retract...1994
Seat Belt Indicator Circuit Malfunction - Driver...1994
Seat Belt Indicator Circuit Malfunction - Passenger...1995
Repair Instructions...1997
Repairs and Inspections Required After a Collision...1997
Front Seat Belt Buckle Replacement...1998
Rear Seat Center Belt Buckle Replacement...1999
Seat Belt Buckle Replacement - No. 2 Rear...2000
Front Seat Belt Replacement (Quick Connect)...2001
Rear Seat Belt Replacement...2002
Seat Belt Replacement - Center Rear...2003
Seat Belt Height Adjuster Replacement - Front...2004
Seat Belt Retractor Anchor Plate Replacement...2005
Seat Belt Retractor Replacement - No. 2 Rear...2006
Guide Replacement - Rear Seat Shoulder Belt...2007
Seat Belt Retractor Pretensioner Replacement - Front...2008
Pretensioner Handling and Scrapping...2009
Specifications...2012
Fastener Tightening Specifications - Seat Belts...2012
Air Bag System...2013
Precautions...2013
SIR Caution...2013
SIR Deployed Inflator Modules are Hot Caution...2013
SIR Inflatable Module Deployment Outside Vehicle Caution...2013
SIR Inflator Module Disposal Caution...2013
SIR Inflator Module Handling and Storage Caution...2013
SIR Special Tool Caution...2013
General Description...2014
SIR System Description and Operation...2014
Schematic and Routing Diagram...2017
SIR Schematic Icons...2017
SIR Schematics...2018
SIR Connector End Views...2022
Component Location...2028
SIR Identification Views...2028
SIR Component Views...2029
Diagnostic Information and Procedures...2034
Diagnostic Starting Point - SIR...2034
Scan Tool Data List - SIR...2035
Scan Tool Data Definitions - SIR...2036
DTC B0012 or B0013...2036
DTC B0014-B0045...2038
DTC B0052 or B0053...2041
DTC B0055...2042
DTC B0056...2043
DTC B0057...2044
DTC B0058...2045
DTC B0073...2046
DTC B0081...2047
DTC B0083 or B0084...2049
DTC B0085 or B0086...2051
DTC B0090...2052
DTC B1001 (SDM)...2054
DTC B1019...2055
DTC B1370...2056
Symptoms - SIR...2058
Passenger Presence System Rezeroing...2058
Air Bag Indicator Circuit Malfunction...2059
Passenger Presence System Indicator Circuit Malfunction...2060
Repairs and Inspections Required After a Collision...2061
Repair Instructions...2062
SIR Disabling and Enabling...2062
Inflatable Restraint Front End Sensor Replacement...2064
Inflatable Restraint Side Impact Sensor Replacement...2065
Inflatable Restraint Vehicle Rollover Sensor Replacement...2066
Inflatable Restraint Vehicle Rollover Sensor Programming and Setup...2066
Inflatable Restraint Sensing and Diagnostic Module Replacement...2067
Inflatable Restraint Sensing and Diagnostic Module Programming and Setup...2068
Inflatable Restraint Steering Wheel Module Replacement...2069
Inflatable Restraint Steering Wheel Module Coil Replacement...2070
Inflatable Restraint Steering Wheel Module Coil Centering...2071
Inflatable Restraint Instrument Panel Module Replacement...2072
Inflatable Restraint Passenger Presence System Replacement - Front...2074
Passenger Presence System Programming and Setup...2075
Instrument Panel Inflatable Restraint Module Indicator Replacement...2075
Inflatable Restraint Roof Rail Module Replacement - Front...2076
Inflator Module Handling and Scrapping...2077
SIR/SRS Wiring Repairs...2091
Connector Repairs...2094
Connector Position Assurance Locks...2097
Terminal Position Assurance Locks...2097
Specifications...2098
Fastener Tightening Specifications - SIR...2098
Special Tools and Equipment...2098
Special Tools - SIR...2098
Body, Cab and Accessories...2099
Wiring Systems...2109
General Description...2109
Electrical Center Identification Views...2109
Circuit Protection - Fuses...2114
Circuit Protection - Circuit Breakers...2114
Circuit Protection - Fusible Links...2115
Electrical Symbols...2115
Schematic and Routing Diagram...2123
Power and Grounding Schematic Icons...2123
Power Distribution Schematics...2123
Power Moding Schematics...2139
Ignition Lock Schematics...2141
Ground Distribution Schematics...2142
Trailer Connector/Provision Schematics...2151
Harness Routing Views...2153
Power and Grounding Connector End Views...2166
Splice Pack Connector End Views...2167
Inline Harness Connector End Views...2167
Component Location...2220
Utility/Van Zoning...2220
Master Electrical Component List...2221
Power and Grounding Component Views...2235
Diagnostic Information and Procedures...2245
Diagnostic Starting Point - Wiring Systems and Power Management...2245
Scan Tool Data Definitions - Wiring Systems and Power Management...2245
Scan Tool Data List - Wiring Systems and Power Management...2246
DTC B1370...2246
DTC B1380...2249
DTC B1428...2252
DTC B1433...2253
DTC B1441...2255
DTC B1475...2258
Symptoms - Wiring Systems...2259
General Electrical Diagnosis...2259
Checking Aftermarket Accessories...2259
Circuit Testing...2259
Using Connector Test Adapters...2260
Probing Electrical Connectors...2260
Troubleshooting with a Digital Multimeter...2262
Troubleshooting with a Test Lamp...2262
Using Fused Jumper Wires...2262
Measuring Voltage...2263
Measuring Voltage Drop...2263
Measuring Frequency...2263
Testing for Continuity...2263
Testing for Short to Ground...2264
Testing for a Short to Voltage...2264
Testing for Intermittent Conditions and Poor Connections...2264
Inducing Intermittent Fault Conditions...2266
Testing for Electrical Intermittents...2268
Scan Tool Snapshot Procedure...2268
Repair Instructions...2269
Wiring Repairs...2269
Repairing Damaged Wire Insulation...2269
Flat Wire Repairs...2269
GMLAN Wiring Repairs...2269
High Temperature Wiring Repairs...2272
Splicing Copper Wire Using Splice Clips...2274
Splicing Copper Wire Using Splice Sleeves...2276
Splicing Twisted or Shielded Cable...2277
Splicing Inline Harness Diodes...2278
Connector Repairs...2279
Connector Position Assurance Locks...2282
Terminal Position Assurance Locks...2282
AFL/EPC Connectors...2282
Bosch Connectors (BSK)...2284
Bosch Connectors (0.64)...2285
Bosch Connectors (2.8 JPT)...2286
Bosch Connectors (ECM)...2287
Delphi Connectors (Weather Pack)...2288
Delphi Connectors (Push To Seat)...2289
Delphi Connectors (Pull To Seat)...2290
Delphi Connectors (Micro-Pack 100W)...2291
Delphi Connectors (Micro.64)...2294
Delphi Connectors (12-Way)...2298
FCI Connectors...2300
JST Connectors...2301
Kostal Connectors...2302
Molex Connectors...2304
Sumitomo Connectors...2306
Tyco/AMP Connectors (CM 42-Way)...2308
Tyco/AMP Connectors (Sensor)...2309
Tyco/AMP Connectors (0.25 Cap)...2310
Tyco/AMP Connectors (43-Way)...2311
Tyco/AMP Connectors (Door Module)...2312
Yazaki Connectors (2-Way)...2314
Yazaki Connectors (16-Way)...2314
Repairing Connector Terminals...2316
Relay Replacement (Within an Electrical Center)...2316
Relay Replacement (Attached to Wire Harness)...2317
Underhood Electrical Center or Junction Block Replacement...2318
Instrument Panel Electrical Center or Junction Block Replacement...2319
Specifications...2320
Fastener Tightening Specifications - Wiring Systems and Power Management...2320
Special Tools and Equipment...2320
Special Tools - Wiring Systems and Power Management...2320
Lighting Systems...2322
Precautions...2322
Halogen Bulb Caution...2322
General Description...2322
Exterior Lighting Systems Description and Operation...2322
Interior Lighting Systems Description and Operation...2324
Schematic and Routing Diagram...2324
Headlights/Daytime Running Lights (DRL) Schematics...2325
Fog Lights Schematics...2326
Exterior Lights Schematics...2327
Interior Lights Schematics...2334
Interior Lights Dimming Schematics...2335
Lighting Systems Connector End Views...2336
Component Location...2347
Lighting Systems Component Views...2347
Diagnostic Information and Procedures...2353
Diagnostic Starting Point - Lighting Systems...2353
Scan Tool Output Controls - Lighting...2353
Scan Tool Data List - Lighting...2354
Scan Tool Data Definitions - Lighting...2354
DTC B257A...2356
DTC B2530...2357
DTC B2545...2358
DTC B2575...2359
DTC B2580...2361
DTC B2585...2362
DTC B2600...2363
DTC B2610...2365
DTC B2615...2366
DTC B2645...2367
DTC B2652...2368
DTC B3445...2370
DTC B3600...2371
DTC B3867...2372
DTC B3884...2374
DTC C0277 or DTC C0890...2375
DTC C0297...2376
DTC P0572...2378
DTC P0573...2379
Symptoms - Lighting Systems...2380
Backup Lamps Malfunction...2381
Courtesy Lamps Always On...2382
Courtesy Lamps Inoperative...2383
Daytime Running Lamps (DRL) Inoperative...2385
Fog Lamps Always On...2386
Fog Lamps Inoperative...2387
Hazard Lamps Inoperative...2389
Headlamp Low or High Beams Always On...2390
Headlamps Inoperative - High Beams...2392
Headlamps Inoperative - Low Beams...2393
Low and High Beams Headlamps Inoperative...2395
Headlamps Flash to Pass Inoperative...2396
Interior Backlighting Does Not Dim...2397
Interior Backlighting Inoperative...2398
Park Lamps Always On...2399
Park Lamps Inoperative...2400
Reading Lamp(s) Inoperative...2401
Stop Lamps Always On...2402
Stop Lamps Inoperative...2404
Turn Signal Lamps and/or Indicators Always On or Flashing...2405
Turn Signal Lamps and/or Indicators Inoperative...2406
Repair Instructions...2408
Fog Lamp Switch Replacement...2408
Hazard Warning Switch Replacement...2409
Instrument Panel Dimmer Switch Replacement...2410
Ambient Light Sensor Replacement...2411
Daytime Running Lamps (DRL) Resistor Replacement...2412
Reading Lamp Bulb Replacement (Without CF5)...2413
Reading Lamp Bulb Replacement (With CF5)...2414
Dome Lamp Replacement (Without DVD)...2415
Dome Lamp Bulb Replacement (Without DVD)...2416
Dome Lamp Bulb Replacement (With DVD)...2417
Headlamp Replacement...2418
Headlamp Bulb Replacement...2419
Headlamp Aiming (VOR)...2420
Front Fog Lamp Replacement...2422
Front Fog Lamp Bulb Replacement...2423
Front Fog Lamp Cover Replacement...2423
Fog Lamp Aiming...2424
Front Side Marker Lamp Bulb Replacement...2425
Park/Turn Signal Lamp Bulb Replacement...2425
Cornering Lamp Bulb Replacement...2426
High Mount Stop Lamp Replacement...2426
Cargo Lamp Replacement...2427
Cargo Lamp Bulb Replacement...2428
Backup Lamp Bulb Replacement...2429
Rear License Lamp Replacement...2429
License Lamp Bulb Replacement...2430
Tail Lamp Replacement...2430
Tail Lamp Bulb Replacement...2431
Specifications...2431
Fastener Tightening Specifications - Lighting...2431
Instrumentation / Driver Info. / Horn...2432
General Description...2432
Instrument Cluster Description and Operation...2432
Indicator/Warning Message Description and Operation...2433
Audible Warnings Description and Operation...2437
Door Ajar Indicator Description and Operation...2437
Horns System Description and Operation...2438
Schematic and Routing Diagram...2438
Horn Schematic Icons...2438
Instrument Cluster Schematics...2438
Driver Information System Schematics...2441
Audible Warnings Schematics...2442
Cigar Lighter/Power Outlet Schematics...2443
Horn Schematics...2444
Displays and Gages Connector End Views...2445
Horn Connector End Views...2446
Power Outlet Connector End Views...2446
Component Location...2448
Displays and Gages Component Views...2448
Horn Component Views...2449
Power Outlet Component Views...2451
Diagnostic Information and Procedures...2452
Diagnostic Starting Point - Displays and Gages...2452
Scan Tool Output Controls - Displays and Gages...2452
Scan Tool Output Controls - Horns...2453
Scan Tool Data List - Displays and Gages...2453
Scan Tool Data List - Horns...2457
Scan Tool Data Definitions - Displays and Gages...2457
Scan Tool Data Definitions - Horns...2458
DTC B2750...2459
DTC B2965...2460
DTC P0461...2461
DTC P0462...2462
DTC P0463...2464
DTC P0464...2465
DTC P0520...2466
Symptoms - Displays and Gages...2467
Symptoms - Horns...2468
Daytime Running Lamps (DRL) Indicator Inoperative...2469
Fog Lamp Indicator Inoperative...2470
High Beam Indicator Inoperative...2471
Chime Always On...2472
Chime Inoperative...2472
Door Ajar Indicator Malfunction...2473
Horns Malfunction...2474
Engine Coolant Temperature Indicator Always On...2475
Engine Coolant Temperature Gage Inaccurate or Inoperative...2476
Engine Oil Pressure Indicator Always On...2476
Fuel Gage Inaccurate or Inoperative...2477
Instrument Cluster Gages Inoperative...2477
Odometer Trip/Reset Switch Inoperative...2478
Rear Hatch/Gate Ajar Indicator Always On...2479
Rear Hatch/Gate Ajar Indicator Inoperative...2480
Speedometer and/or Odometer Inaccurate or Inoperative...2481
Tachometer Inaccurate or Inoperative...2481
Turn Signal Lamps and/or Indicators Always On or Flashing...2482
Turn Signal Lamps and/or Indicators Inoperative...2483
Repair Instructions...2485
Instrument Panel Insulator Panel Replacement - Right Side...2485
Instrument Panel Insulator Panel Replacement - Left Side...2486
Instrument Panel Lower Brace Bezel Replacement...2487
Knee Bolster Replacement...2488
Driver Knee Bolster Reinforcement Replacement...2489
Instrument Panel Accessory Trim Plate Replacement...2490
Instrument Panel Outer Trim Cover Replacement...2491
Instrument Panel Lower Trim Panel Replacement - Right Side...2492
Instrument Panel Upper Trim Panel Replacement...2493
Instrument Panel Lower Trim Panel Replacement - Left Side...2494
Instrument Panel Cluster Trim Plate Bezel Replacement...2495
Instrument Panel Lower Center Trim Panel Replacement...2496
Instrument Panel Compartment Door Latch Replacement...2497
Instrument Panel Compartment Door Replacement...2498
Instrument Panel Compartment Replacement...2499
Instrument Panel Compartment Door Lock Striker Replacement...2500
Instrument Panel Compartment Door Dampener Replacement...2501
Ambient Air Temperature Sensor Replacement...2502
Driver Information Display Switch Replacement...2503
Instrument Cluster Replacement...2504
Instrument Cluster Programming and Setup...2504
Instrument Panel Cluster Trim Plate Cover Replacement...2505
Instrument Panel Retainer Replacement...2506
Instrument Panel Tie Bar Replacement...2507
Horn Replacement...2509
Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement...2509
Specifications...2510
Fastener Tightening Specifications - Instrument Panel and Console Trim...2510
Fastener Tightening Specifications - Displays and Gages...2511
Fastener Tightening Specifications - Horns...2511
Fastener Tightening Specifications - Power Outlets...2511
Fuel Level Specifications...2511
Special Tools and Equipment...2511
Special Tools - Power Outlets...2511
Wipers / Washers...2512
General Description...2512
Wiper/Washer System Description and Operation...2512
Schematic and Routing Diagram...2512
Wiper/Washer Schematics...2512
Wiper/Washer Connector End Views...2515
Component Location...2517
Wiper/Washer Component Views...2517
Diagnostic Information and Procedures...2520
Diagnostic Starting Point - Wipers and Washers...2520
Scan Tool Output Controls - Wipers/Washer Systems...2520
Scan Tool Data List - Wipers/Washer Systems...2520
Scan Tool Data Definitions - Wipers/Washer Systems...2520
DTC B3715...2521
DTC B3873...2522
DTC B3875...2523
DTC B3922...2525
Symptoms - Wipers and Washers...2527
Windshield Wiper System Malfunction (Front)...2527
Windshield Wiper System Malfunction (Rear)...2530
Washer Malfunction (Front)...2532
Washer Malfunction (Rear)...2534
Repair Instructions...2535
Wipers/Washer Switch Replacement...2535
Windshield Washer Nozzle Replacement...2536
Rear Window Washer Nozzle Replacement...2537
Windshield Washer Hose Replacement...2537
Washer Solvent Container Replacement...2538
Washer Pump Filter Grommet Replacement...2539
Washer Pump Replacement...2539
Wiper Arm Replacement...2540
Rear Window Wiper Arm Replacement...2541
Wiper Arm Blade Replacement...2542
Rear Window Wiper Blade Replacement...2542
Wiper Blade Element Replacement...2543
Rear Window Wiper Blade Element Replacement...2543
Blade Element Cleaning...2544
Wiper Motor Module Replacement...2544
Wiper Motor Module Grommet Replacement...2545
Wiper Motor Replacement...2546
Liftgate Wiper Motor Replacement...2547
Rear Washer Hose Replacement...2547
Specifications...2548
Fastener Tightening Specifications - Wipers/Washer Systems...2548
Glass / Windows / Mirrors...2549
Precautions...2549
Cracked Window Caution...2549
Defroster Outlet Caution...2549
Safety Glasses Caution...2549
Safety Glasses and Compressed Air Caution...2549
Window Retention Caution...2549
Window Edge Damage Notice...2549
General Description...2550
Full-Cut Method Description...2550
Adhesive Service Kit Description...2550
Stationary Window Description...2550
Power Windows Description and Operation...2550
Rear Window Defogger Description and Operation...2551
Outside Mirror Description and Operation...2552
Automatic Day-Night Mirror Description and Operation...2552
Compass Calibration and Magnetic Variance...2553
Schematic and Routing Diagram...2553
Moveable Window Schematics...2554
Defogger Schematics...2555
Inside Rearview Mirror Schematics...2556
Outside Rearview Mirror Schematics...2557
Window Systems Connector End Views...2558
Mirror Connector End Views...2561
Component Location...2564
Window Systems Component Views...2564
Mirror Component Views...2570
Diagnostic Information and Procedures...2574
Diagnostic Starting Point - Fixed and Moveable Windows...2574
Scan Tool Output Controls - Fixed and Moveable Windows...2574
Scan Tool Data List - Fixed and Moveable Windows...2574
Scan Tool Data Definitions - Fixed and Moveable Windows...2574
DTC B0285 or B0286...2574
Symptoms - Fixed and Moveable Windows...2576
Power Windows Inoperative - All...2577
Rear Window Defogger Inoperative...2580
Automatic Day-Night Mirrors Inoperative...2582
Power Mirrors Inoperative...2583
Mirror Compass Display Inoperative or Inaccurate...2584
Mirrors - Temperature Displays SC or OC...2585
Air/Wind Noise...2586
Exterior Windnoise...2587
Interior Windnoise...2587
Waterleak Test Preparation...2587
Dust Leaks...2589
Water Hose Test...2589
Air Hose Test...2589
Tracing Powder or Chalk Test...2590
Air Pressure Test...2590
Soap Suds or Bubble Test...2590
Repair Instructions...2590
Rearview Mirror Replacement...2590
Inside Rearview Mirror Programming and Setup...2591
Rearview Mirror Support Installation...2591
Windshield Replacement...2592
Windshield Glass Cleaning...2593
Adhesive Installation of Stationary Windows (Windshield)...2594
Front Side Door Window Replacement...2599
Rear Side Door Window Replacement...2600
Quarter Window Replacement...2602
Adhesive Installation of Encapsulated Stationary Windows...2604
Liftgate Window Replacement...2606
Adhesive Installation of Stationary Windows (Liftgate)...2607
Stationary Window Reveal Molding Repair...2610
Front Side Door Window Switch Replacement...2612
Rear Side Door Window Switch Replacement...2613
Front Side Door Window Regulator Replacement...2614
Front Side Door Window Regulator Motor Replacement...2615
Rear Side Door Window Regulator Replacement...2615
Rear Side Door Window Regulator Motor Replacement...2616
Power Mirror Switch Replacement...2617
Mirror Replacement...2618
Outside Rearview Mirror Glass Replacement...2618
Body Waterleak Repair...2619
Stationary Window Waterleak Repair...2620
Specifications...2620
Fastener Tightening Specifications - Fixed and Moveable Windows...2620
Fastener Tightening Specifications - Mirrors...2620
Special Tools and Equipment...2621
Special Tools - Air/Wind Noise...2621
Special Tools - Fixed and Moveable Windows...2621
Security and Locks...2622
General Description...2622
Power Door Locks Description and Operation...2622
Rear Hatch/Gate Description and Operation...2623
Keyless Entry System Description and Operation...2623
Content Theft Deterrent (CTD) Description and Operation...2625
Key and Lock Cylinder Coding...2626
Schematic and Routing Diagram...2627
Door Lock/Indicator Schematics...2627
Release Systems Schematics...2630
Remote Function Schematics...2631
Theft Deterrent System Schematics...2632
Vehicle Access Connector End Views...2634
Remote Function Connector End Views...2637
Component Location...2638
Vehicle Access Component Views...2638
Remote Function Component Views...2644
Diagnostic Information and Procedures...2645
Diagnostic Starting Point - Vehicle Access...2645
Diagnostic Starting Point - Remote Functions...2645
Diagnostic Starting Point - Theft Deterrent...2645
Scan Tool Output Controls - Vehicle Access...2645
Scan Tool Output Controls - Remote Functions...2645
Scan Tool Data List - Vehicle Access...2646
Scan Tool Data List - Remote Functions...2646
Scan Tool Data List - Theft Deterrent...2647
Scan Tool Data Definitions - Vehicle Access...2648
Scan Tool Data Definitions - Remote Functions...2648
Scan Tool Data Definitions - Theft Deterrent...2649
DTC B2495...2649
DTC B3105...2650
DTC B3109...2651
DTC B3110...2652
DTC B3111...2652
DTC B3112...2653
DTC B3125, B3130, or B3135...2654
DTC B3140, B3145, B3150, or B3155...2655
DTC B3265...2657
Symptoms - Vehicle Access...2658
Symptoms - Remote Functions...2659
Symptoms - Theft Deterrent...2659
Liftgate Release Inoperative...2660
Power Door Locks Inoperative...2662
Keyless Entry System Inoperative...2665
Remote Vehicle Start Inoperative...2666
Content Theft Deterrent Malfunction...2667
Security Indicator Malfunction...2667
Repair Instructions...2668
Opening the Liftgate without Electrical Power...2668
Front Side Door Lock Cylinder Replacement...2669
Front Side Door Latch Replacement...2669
Rear Side Door Latch Replacement...2671
Liftgate Latch Replacement...2674
Front Side Door Lock Striker Adjustment...2675
Front Side Door Lock Striker Replacement...2676
Rear Side Door Lock Striker Adjustment...2677
Rear Side Door Lock Striker Replacement...2678
Liftgate Lock Striker Adjustment...2679
Liftgate Lock Striker Replacement...2680
Power Door Lock Switch Replacement...2681
Transmitter Battery Replacement...2682
Transmitter Programming...2683
Remote Control Door Lock Receiver Replacement...2683
Remote Control Door Lock Receiver Antenna Replacement...2684
Remote Control Door Lock Receiver Programming and Setup...2684
Theft Deterrent Module Replacement...2685
Theft Deterrent Control Module Programming and Setup...2685
Specifications...2686
Fastener Tightening Specifications - Vehicle Access...2686
Seats...2687
General Description...2687
Manual Seats Description...2687
Power Seats System Description and Operation...2687
Heated Seats Description and Operation...2688
Schematic and Routing Diagram...2688
Driver Seat Schematics...2689
Heated/Cooled Seat Schematics...2690
Power Seat Connector End Views...2691
Heated/Cooled Seat Connector End Views...2692
Component Location...2695
Power Seat Component Views...2695
Heated/Cooled Seat Component Views...2696
Diagnostic Information and Procedures...2698
Diagnostic Starting Point - Seats...2698
Scan Tool Data List - Seat Heating and Cooling...2698
Scan Tool Data Definitions - Seat Heating and Cooling...2698
DTC B1395...2699
DTC B1925 or B2170...2700
DTC B2345...2702
DTC B2425 or B2430...2704
DTC B2508 or B2509...2707
Symptoms - Seats...2708
Symptoms - Seats...2709
Symptoms - Seat Heating and Cooling...2709
Power Seat Inoperative...2710
Seat - Hard to Move Forward and Rearward...2711
Seat - Manual Adjuster Does Not Lock...2711
Seat - Manual Adjuster Does Not Unlock...2711
Seat - Manual Adjuster Locks Between Lock Positions...2711
Seats - Adjuster Track Locks Ahead of Other Track...2712
Heated Seat Inoperative...2712
Repair Instructions...2713
Front Seat Adjuster Switch Knob Replacement...2713
Front Seat Back Recliner Outer Trim Panel Replacement (Fold Flat)...2714
Front Seat Back Recliner Inner Trim Panel Replacement (Fold Flat)...2715
Front Seat Recliner Mechanism Replacement...2716
Driver Seat Recliner Handle and Passenger Seat Recliner Handle Replacement...2717
Driver Seat Recliner Actuator Cable and Passenger Seat Recliner Actuator Cable Replacement (Fold Flat)...2718
Power Seat Switch Replacement...2719
Front Seat Cushion Outer Trim Panel Replacement (Non Fold Flat)...2720
Front Seat Cushion Outer Trim Panel Replacement (Fold Flat)...2721
Front Seat Cushion Inner Trim Panel Replacement (Non Fold Flat)...2722
Front Seat Cushion Inner Trim Panel Replacement (Fold Flat)...2723
Front Seat Replacement - Bucket...2724
Front Seat Cushion Cover and Pad Replacement...2726
Front Seat Adjuster Replacement...2727
Front Seat Adjuster Replacement (2-way Manual)...2728
Front Seat Back Panel Replacement (Fold Flat)...2729
Front Seat Head Restraint Replacement...2730
Front Seat Head Restraint Guide Replacement (Non Fold Flat)...2730
Front Seat Head Restraint Guide Replacement (Fold Flat)...2731
Front Seat Cushion Frame Replacement...2732
Front Seat Back Cushion Cover and Cushion Pad Replacement (Non Fold Flat)...2733
Front Seat Back Cushion Cover and Cushion Pad Replacement (Fold Flat)...2734
Front Seat Lumbar Support Replacement...2735
Lumbar Support Knob Replacement...2736
Lumbar Support Actuator Replacement...2737
Front Seat Back Frame Replacement (Non- Fold Flat)...2738
Front Seat Back Frame Replacement (Fold Flat)...2741
Front Seat Heater Control Module Replacement...2742
Heated Seat Control Module Programming and Setup...2742
Driver Seat Back Cushion Heater and Passenger Seat Back Cushion Heater Replacement (Non Fold Flat)...2743
Driver Seat Back Cushion Heater and Passenger Seat Back Cushion Heater Replacement (Fold Flat)...2744
Driver Seat Cushion Heater and Passenger Seat Cushion Heater Replacement...2745
Rear Seat Armrest Replacement...2746
Rear Seat Shoulder Belt Opening Bezel Replacement...2747
Rear Seat Strut Replacement...2748
Rear Seat Head Restraint Replacement (Inner)...2749
Rear Seat Head Restraint Replacement (Outer)...2750
Rear Seat Head Restraint Guide Replacement (Inner)...2751
Rear Seat Head Restraint Guide Replacement (Outer)...2752
Rear Seat Recliner Handle Replacement (Rear No. 1)...2753
Rear Seat Back Recliner Cover Replacement (Inner)...2754
Rear Seat Back Recliner Cover Replacement (Outer)...2755
Rear Seat Front Riser Finish Cover Replacement...2756
Rear Seat Latch Replacement...2757
Rear Seat Replacement...2758
Rear Seat Cushion Cover and Pad Replacement...2760
Rear Seat Cushion Frame Replacement...2761
Rear Seat Back Cushion Latch Cable Replacement...2762
Rear Seat Back Cushion Cover and Pad Replacement (60% Seat)...2763
Rear Seat Back Cushion Cover and Pad Replacement (40% Seat)...2764
Rear Seat Back Filler Panel Replacement...2765
Rear Seat Back Cushion Frame Replacement...2766
Rear Seat Number 2 Head Restraint Replacement...2767
Rear Seat Number 2 Head Restraint Guide Replacement...2768
Rear Seat Recliner Handle Replacement (Rear No. 2)...2769
Rear Seat Number 2 Back Cushion Latch Release Handle Replacement...2770
Rear Seat Latch Finish Cover Replacement...2771
Rear Seat Number 2 Back Cushion Panel Replacement...2772
Rear Seat Number 2 Cushion Trim Panel Replacement...2773
Rear Number 2 Seat Replacement...2774
Rear Seat Back Cushion Outer Pivot Support Cover Replacement...2775
Rear Seat Number 2 Hinge Front Link Replacement...2776
Rear Seat Number 2 Cushion Cover and Pad Replacement...2777
Rear Seat Number 2 Back Cushion Latch Replacement...2778
Rear Seat Number 2 Cushion Frame Replacement...2779
Rear Seat Number 2 Back Cushion Cover and Pad Replacement...2780
Rear Seat Recliner Replacement (Rear No. 2)...2781
Rear Seat Number 2 Back Cushion Frame Replacement...2782
Specifications...2783
Fastener Tightening Specifications - Seat Hardware, Trim, and Upholstery...2783
Fastener Tightening Specifications - Power Seats...2783
Fastener Tightening Specifications - Seat Heating and Cooling...2783
Special Tools and Equipment...2783
Special Tools - Seat Hardware, Trim, and Upholstery...2783
Interior Trim...2784
Repair Instructions...2784
Eliminating Unwanted Odors in Vehicles...2784
Liftgate Door Sill Plate Replacement...2785
Windshield Upper Garnish Molding Replacement...2786
Center Pillar Lower Garnish Molding Replacement...2787
Center Pillar Upper Garnish Molding Replacement...2788
Rear Storage Compartment Replacement...2789
Body Rear Corner Garnish Molding Replacement...2790
Child Restraint Tether Anchor Bezel Replacement...2791
Lock Pillar Upper Garnish Molding Replacement (Left Side)...2792
Lock Pillar Upper Garnish Molding Replacement (Right Side)...2793
Front Floor Console Armrest Replacement...2794
Console Replacement...2795
Console Rear Trim Plate Replacement...2796
Front Floor Upper Console Trim Plate Replacement...2797
Console Compartment Door Replacement...2798
Front Floor Console Side Trim Panel Replacement - Right Side...2799
Front Floor Console Side Trim Panel Replacement - Right Side...2800
Front Floor Console Side Trim Panel Replacement - Left Side...2801
Front Floor Console Side Trim Panel Replacement - Left Side...2802
Front Carpet Retainer Replacement...2803
Rear Carpet Retainer Replacement...2804
Floor Panel Carpet Replacement (Front)...2805
Floor Panel Carpet Replacement (Rear)...2806
Floor Carpet Drying...2806
Roof Console Replacement...2807
Headlining Trim Panel Replacement...2808
Rear Quarter Lower Trim Panel Replacement...2809
Specifications...2810
Fastener Tightening Specifications - Instrument Panel and Console Trim...2810
Fastener Tightening Specifications - Interior Trim and Paneling...2810
Sun Roof / T-Top / Convertible Top...2811
General Description...2811
Sunroof Description and Operation...2811
Schematic and Routing Diagram...2812
Sunroof Schematics...2813
Sunroof Connector End Views...2814
Component Location...2816
Sunroof Component Views...2816
Diagnostic Information and Procedures...2817
Diagnostic Starting Point - Roof...2817
Symptoms - Roof...2817
Power Sunroof Inoperative...2818
Power Sunroof Does Not Open to Express Position...2821
Power Sunroof Does Not Close...2822
Repair Instructions...2824
Sunroof Air Deflector Replacement...2824
Sunroof Housing Front Drain Hose Replacement...2825
Sunroof Housing Rear Drain Hose Replacement...2826
Sunroof Drain Inspection and Cleaning...2827
Sunroof Sunshade Replacement...2828
Sunroof Switch Replacement...2829
Sunroof Window Height and Opening Fit Adjustment...2830
Sunroof Window Replacement...2830
Sunroof Control Module Replacement...2831
Sunroof Control Module Programming and Setup...2832
Sunroof Module Assembly Replacement...2832
Sunroof Motor/Actuator Replacement...2833
Center Pillar Assist Handle Replacement...2834
Coat Hook Replacement...2835
Sunshade Replacement...2836
Sunshade Anchor Replacement...2837
Specifications...2838
Fastener Tightening Specifications - Interior Trim and Paneling...2838
Fastener Tightening Specifications - Sunroof...2838
Hood / Fenders / Doors...2839
Repair Instructions...2839
Hood Bumper Replacement...2839
Hood Strut Replacement...2840
Hood Adjustment...2841
Hood Hinge Replacement...2842
Hood Replacement...2843
Hood Insulator Replacement...2844
Hood Latch Release Cable Replacement...2845
Hood Primary Latch Striker Replacement...2846
Hood Primary Latch Replacement...2847
Hood Secondary Latch Replacement...2848
Hood Front Seal Replacement...2849
Hood Rear Seal Replacement...2849
Hood Rear Outer Seal Replacement...2850
Hood Open Assist Rod Stud Replacement...2851
Air Inlet Grille Panel Replacement...2852
Front Fender Replacement...2853
Front Fender Upper Bracket Replacement...2854
Front Fender Insulator Replacement...2855
Front Side Door Outside Handle Replacement...2856
Rear Side Door Outside Handle Replacement...2857
Door Handle Bezel Replacement...2858
Upper Extension Trim Panel Replacement (Front Side Door)...2859
Front Side Door Trim Panel Replacement...2860
Rear Side Door Trim Panel Replacement...2861
Door Inside Handle Replacement...2862
Front Side Door Water Deflector Replacement...2863
Rear Side Door Water Deflector Replacement...2864
Front Side Door Window Belt Inner Sealing Strip Replacement...2865
Front Side Door Window Belt Outer Sealing Strip Replacement...2865
Rear Door Window Belt Inner Sealing Strip Replacement...2866
Rear Door Window Belt Outer Sealing Strip Replacement...2866
Front Side Door Window Channel Replacement...2867
Front Side Door Window Channel Replacement...2867
Rear Side Door Window Channel Replacement...2868
Rear Side Door Window Channel Replacement...2869
Front Door Opening Weatherstrip Replacement...2870
Rear Door Opening Weatherstrip Replacement...2870
Front Side Door Adjustment...2871
Rear Door Adjustment...2872
Front Side Door Hinge Replacement...2872
Rear Side Door Hinge Replacement...2873
Front Side Door Check Link Replacement...2874
Rear Side Door Check Link Replacement...2875
Front Side Door Replacement...2876
Rear Door Replacement...2877
Liftgate Bumper Replacement...2878
Liftgate Outside Handle Replacement...2879
Liftgate Trim Panel Replacement (Upper)...2880
Liftgate Trim Panel Replacement (Lower)...2881
Liftgate Weatherstrip Replacement...2882
Liftgate Strut Replacement...2883
Liftgate Strut Ball Stud Replacement...2884
Liftgate Adjustment...2885
Liftgate Hinge Replacement...2886
Liftgate Wedge Replacement (Body Side)...2887
Liftgate Wedge Replacement (Liftgate Side)...2888
Liftgate Replacement...2889
Fuel Tank Filler Door Replacement...2890
Specifications...2891
Fastener Tightening Specifications - Wipers/Washer Systems...2891
Fastener Tightening Specifications - Interior Trim and Paneling...2891
Fastener Tightening Specifications - Fixed and Moveable Windows...2891
Fastener Tightening Specifications - Bolted Exterior Body Panels and Closures...2891
Special Tools and Equipment...2892
Special Tools - Fixed and Moveable Windows...2892
Body Structure...2893
Repair Instructions...2893
Metal Panel Bonding...2893
General Plastic Repair Instructions...2893
How to Identify Plastic Parts...2894
Plastic Identification and Refinishing Systems...2895
Front Bumper Fascia Replacement...2897
Front Bumper Fascia Energy Absorber Replacement...2898
Front Bumper Impact Bar Replacement...2899
Front Bumper Lower Fascia Grille Replacement...2900
Front Bumper Upper Fascia Grille Replacement...2901
Front Bumper Lower Fascia Replacement...2902
Front Bumper Upper Fascia Replacement...2903
Front Bumper Fascia Support Replacement...2904
Front Bumper Fascia Upper Support Replacement...2905
Rear Bumper Lower Fascia Replacement...2906
Rear Bumper Bracket Replacement...2907
Rear Bumper Upper Fascia Replacement...2908
Rear Energy Absorber Replacement...2909
Rear Bumper Impact Bar Replacement...2910
Rear Bumper Fascia Reflector Replacement...2911
Tie Bar Replacement...2912
Front Wheelhouse Replacement...2913
Front Wheelhouse Extension Replacement...2915
Front Compartment Upper Side Rail Replacement...2917
Front Compartment Front Rail Replacement...2919
Front Compartment Front Side Lower Inner Rail Replacement...2920
Front Compartment Front Side Lower Inner Rail Sectioning...2922
Underbody Outer Front Side Rail Replacement...2924
Underbody Outer Front Side Rail Sectioning...2925
Front Hinge Pillar Body Sectioning...2927
Roof Outer Panel Replacement...2929
Front Side Door Outer Panel Replacement...2931
Rear Side Door Outer Panel Replacement...2935
Rear Compartment Floor Panel Sectioning...2938
Body Rear End Panel Replacement...2940
Center Pillar Sectioning...2942
Quarter Panel Sectioning...2944
Rear Rail Replacement...2946
Rail Replacement - Rear Section...2949
Resistance Spot Welded Full Panel Replacement...2951
MIG Welded Full Panel Replacement...2952
Specifications...2954
Fastener Tightening Specifications - Bumpers and Fascias...2954
Dimensions - Body...2954
Structure Identification...2956
Special Tools and Equipment...2958
Flexible Plastic Part Repair Materials...2958
Rigid Plastic Part Repair Materials...2959
Paint / Coatings...2960
General Description...2960
Basecoat/Clearcoat Paint Systems...2960
Anti-Corrosion Treatment and Repair...2960
Repair Instructions...2961
Clearcoat Repair without Repainting...2961
Environmental Fallout (Acid Rain)...2961
Paint Gages...2962
Clearcoat Thickness...2962
Rail Dust Damage Repair...2962
Specifications...2963
Clearcoat Repair Specifications - 3M Products...2963
Clearcoat Repair Specifications - Meguiar Products...2965
Exterior Body Panels...2966
Precautions...2966
Exterior Trim Emblem Removal Notice...2966
Repair Instructions...2966
Rocker Panel Molding Replacement...2966
Rocker Panel Molding Support Replacement...2967
Front Wheelhouse Liner Replacement...2968
Rear Wheelhouse Liner Panel Replacement...2969
Engine Splash Shield Replacement - Left Side...2970
Engine Splash Shield Replacement - Right Side...2971
Luggage Carrier Replacement (Without Sunroof)...2972
Luggage Carrier Replacement (With Sunroof)...2975
Front Door Frame Applique Replacement...2976
Rear Door Frame Applique Replacement...2977
Liftgate Center Applique Replacement...2977
Rear Side Door Window Frame Front Applique and Front Channel Replacement...2978
Rear Side Door Window Frame Rear Applique Replacement...2979
Windshield Frame Applique Replacement...2979
Liftgate Emblem and Nameplate Replacement...2980
Specifications...2981
Fastener Tightening Specifications - Luggage Rack and Roof Trim...2981
Fastener Tightening Specifications - Exterior Trim...2981
Fastener Tightening Specifications - Frame and Underbody...2981
Special Tools and Equipment...2981
Special Tools - Frame and Underbody...2981
Cellular / Entertainment / Navigation / Audio...2982
General Description...2982
Radio/Audio System Description and Operation...2982
Navigation System Description and Operation...2986
Video Entertainment System Description and Operation...2987
Steering Wheel Controls Description and Operation...2987
Schematic and Routing Diagram...2987
Radio/Navigation System Schematics...2987
Steering Wheel Secondary/Configurable Control Schematics...2995
Entertainment/Communication Connector End Views...2997
Secondary/Configurable Control Connector End Views...3005
Component Location...3006
Entertainment/Communication Component Views...3006
Secondary/Configurable Control Component Views...3011
Diagnostic Information and Procedures...3012
Diagnostic Starting Point - Cellular, Entertainment, and Navigation...3012
Diagnostic Starting Point - Secondary and Configurable Customer Controls...3012
Scan Tool Output Controls - Cellular, Entertainment, and Navigation...3012
Scan Tool Data List - Cellular, Entertainment, and Navigation...3013
Scan Tool Data List - Secondary and Configurable Customer Controls...3014
Scan Tool Data Definitions - Secondary and Configurable Customer Controls...3014
DTC B0000...3014
DTC B1025, B1035, B1045, or B1055...3015
DTC B1259...3016
DTC B1287...3017
DTC B1288...3018
DTC B1289...3019
DTC B1529...3020
DTC B2462...3021
DTC B2474...3022
DTC B3622...3023
Symptoms - Entertainment...3023
Symptoms - Secondary and Configurable Customer Controls...3024
Audio System Troubleshooting Hints...3024
Video Entertainment System Troubleshooting Hints...3026
Audio Distortion - One or More Speakers...3027
Radio Setup...3027
Digital Radio Receiver Setup...3027
Audio/Video Disc Player Adapter - Audio or Video Inoperative or Degraded Quality...3028
Digital Radio Poor or No Reception...3028
Radio Displays CAL or CAL ERR...3029
Radio Displays LOC, LOCKED, or CODE...3029
Radio Poor Reception...3029
Navigation System - Voice Guidance Inoperative or Degraded Quality...3030
Navigation System - Voice Recognition Inoperative...3030
No Global Positioning System (GPS) Reception...3031
Video Display is Poor or Blank...3031
Video Entertainment System Inoperative...3032
Video Entertainment System Remote Control Inoperative...3032
Video Entertainment System Wireless Headphone Inoperative...3033
Steering Wheel Controls Inoperative...3034
Reduced Volume - One or More Speakers...3035
Speaker Replacement Reference...3035
Speakers Inoperative - One or More...3036
Repair Instructions...3037
Compact Disc Care and Cleaning...3037
Mobile Telephone Microphone Replacement (Without CF5)...3038
Mobile Telephone Microphone Replacement (With CF5)...3039
Amplifier Replacement...3040
Audio Amplifier Programming and Setup...3040
Radio Replacement...3041
Radio Programming and Setup...3041
Digital Radio Receiver Replacement...3042
Digital Radio Receiver Programming and Setup...3042
Cellular and Navigation Antenna Assembly Replacement...3043
Digital Radio Antenna Replacement...3044
Global Positioning System (GPS) Antenna Replacement...3045
Digital Radio Antenna Cable Replacement...3046
Antenna Cable Replacement...3047
Video Display Replacement...3048
Auxiliary Audio/Video Input Control Replacement...3049
Rear Seat Audio Control Replacement...3050
Radio Front Side Door Upper Speaker Replacement...3051
Radio Front Side Door Speaker Replacement...3052
Radio Rear Speaker Replacement...3053
Radio Rear Side Door Speaker Replacement...3054
Steering Wheel Control Switch Assembly Replacement...3055
Specifications...3056
Fastener Tightening Specifications - Cellular, Entertainment, and Navigation...3056
Special Tools and Equipment...3056
Special Tools - Cellular, Entertainment, and Navigation...3056
Control Systems...3057
Cruise Control System...3059
General Description...3059
Cruise Control Description and Operation...3059
Schematic and Routing Diagram...3060
Cruise Control Schematics...3061
Cruise Control Connector End Views...3062
Component Location...3063
Cruise Control Component Views...3063
Diagnostic Information and Procedures...3065
Diagnostic Starting Point - Cruise Control...3065
Scan Tool Data List - Cruise Control...3065
Scan Tool Data Definitions (Disengage History) - Cruise Control...3066
DTC B3794...3067
DTC B0835...3069
DTC P0571...3070
DTC P0575...3071
Symptoms - Cruise Control...3072
Cruise Control Switch Indicator Inoperative...3072
Cruise Control Inoperative/Malfunctioning...3073
Repair Instructions...3074
Cruise Release Switch Adjustment...3074
Cruise Release Switch Replacement...3075
Data Communications...3077
General Description...3077
Body Control System Description and Operation...3077
Data Link Communications Description and Operation...3078
Power Mode Description and Operation...3079
Retained Accessory Power (RAP) Description and Operation...3080
Schematic and Routing Diagram...3080
Data Communication Schematic Icons...3080
Data Communication Schematics...3080
Body Control System Schematics...3083
Data Communication Connector End Views...3088
Component Location...3093
Data Communication Component Views...3093
Diagnostic Information and Procedures...3094
Diagnostic Starting Point - Data Communications...3094
DTC B1000...3094
DTC B1001...3095
DTC B1016...3096
DTC U0073...3096
DTC U0100-U0299...3097
DTC U1500...3099
DTC U1814...3100
DTC U2099...3101
DTC U2100...3102
DTC U2105-U2199 (Except U2142 and U2143)...3103
DTC U2105-U2199 (U2142 or U2143 only)...3105
Symptoms - Data Communications...3106
Scan Tool Does Not Power Up...3107
Scan Tool Does Not Communicate with High Speed GMLAN Device...3108
Scan Tool Does Not Communicate with Low Speed GMLAN Device...3110
Illuminated Entry Lamps Inoperative...3111
Power Mode Mismatch...3112
Retained Accessory Power (RAP) Malfunction...3115
Data Link References...3116
Repair Instructions...3117
Body Control Module Replacement...3117
Body Control Module Programming and Setup...3118
Special Tools and Equipment...3119
Special Tools - Wiring Systems and Power Management...3119
Immobilizer Control System...3120
General Description...3120
Immobilizer Description and Operation...3120
Schematic and Routing Diagram...3120
Immobilizer Schematics...3120
Immobilizer Connector End Views...3122
Component Location...3123
Immobilizer Component Views...3123
Diagnostic Information and Procedures...3124
Diagnostic Starting Point - Immobilizer...3124
Scan Tool Data List - Immobilizer...3124
Scan Tool Data Definitions - Immobilizer...3125
DTC B3006...3126
DTC B3031...3127
DTC B3055...3128
DTC B3060...3129
DTC B3935...3130
DTC B3976...3131
DTC P0513...3131
DTC P0633...3132
DTC P1629...3133
DTC P1631...3134
DTC P1632...3135
Repair Instructions...3136
Programming Immobilizer System Components...3136
Adding Keys...3136
Replacing Keys...3136
Tire Pressure Monitoring System...3138
General Description...3138
Tire Pressure Monitor Description and Operation...3138
Diagnostic Information and Procedures...3139
Diagnostic Starting Point - Tire Pressure Monitoring...3139
Diagnostic System Check - Tire Pressure Monitoring...3139
Scan Tool Output Controls - Tire Pressure Monitoring...3139
Scan Tool Data List - Tire Pressure Monitoring...3140
Scan Tool Data Definitions - Tire Pressure Monitoring...3141
DTC C0750, C0755, C0760, or C0765...3142
DTC C0775...3143
Symptoms - Tire Pressure Monitoring...3144
Low Tire Pressure Indicator Always On...3144
Low Tire Pressure Indicator Inoperative...3145
Repair Instructions...3145
Tire Pressure Indicator Sensor Replacement...3145
Tire Pressure Sensor Grommet Replacement...3147
Tire Pressure Sensor Learn...3148
Specifications...3149
Fastener Tightening Specifications - Tire Pressure Monitoring...3149
Frame and Frame Accessories...3151
Body Frame...3152
Diagnostic Information and Procedures...3152
Alignment Checking...3152
Repair Instructions...3152
Drivetrain and Front Suspension Frame Reinforcement Replacement...3152
Frame Replacement...3153
Front Frame Cushion or Insulator Replacement...3157
Underbody Inspection...3158
Specifications...3158
Fastener Tightening Specifications - Frame and Underbody...3158
Special Tools and Equipment...3158
Special Tools - Frame and Underbody...3158
...
Suzuki Sidekick/Vitara/Grand Vitara/XL7 Repair Service Manual 1984-2014
