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B-Series 1997
User Manuals: Mazda B-Series 1997 Pickup truck
Manuals and User Guides for Mazda B-Series 1997 Pickup truck. We have
1
Mazda B-Series 1997 Pickup truck manual available for free PDF download: Workshop Manual
Mazda B-Series 1997 Workshop Manual (1419 pages)
Brand:
Mazda
| Category:
Automobile
| Size: 49.22 MB
Table of Contents
Contents
3
Vehicle Identification Numbers (VIN)
4
General Information
5
Table of Contents
5
Important Information
6
Basic Assumptions
6
Safety Risk
6
Possible Loss of Warranty
6
Warning on Lubricants and Greases
6
How to Use the Manual
7
How T O 1 Use this Manual
7
Preparation
7
Repair Procedure
8
Symbols
9
Notes, Cautions and Warnings
9
Fundamental Procedures
9
Protection of the Vehicle
9
A Word about Safety
10
Preparation of Tools and Measuring Equipment
10
Special Tools
10
Removal of Parts
10
Disassembly
10
Assembly
11
Adjustments
12
Rubber Parts and Tubing
12
Jack and Safety Stand (Rigid Rack) Positions
13
Front End
14
Vehicle Lift (2-Support Type) Positions
15
Towing - Preparation
17
Towing Two-Wheel Drive Vehicles
17
General Towing Procedure Preparatory Steps
17
Towing Four-Wheel Drive Vehicles
18
Towing Equipment
19
Towing Slings/Chains/Hooks
19
Towing Connections
20
Vehicles
20
Vehicle Identification Number
21
Sample VIN Number
22
Safety Compliance Certification Labels
23
Build Date Stamp Location
24
Exterior Paint Codes
25
Model Codes and Gvws
25
Wheelbase in Centimeters/Inches
25
Seat Types and Interior Fabric Codes
26
Rear Axle Codes
26
Tape Accent Codes
26
Transmission Codes
26
Units, Abbreviations
27
SAE Standard Name
28
Engine and Emission Systems Abbreviations
28
Transmission Abbreviations
29
Electrical Troubleshooting Tools
30
Test Light
30
Voltmeter
30
Ohmmeter
30
Caution
30
Caution with Electrical Parts
31
Wiring Color Codes
34
Generic OBD II PID List
35
Pre-Delivery Inspection and Scheduled Maintenance Services
37
Service Pre-Delivery Inspection Sheet a
38
Maintenance Tables
39
Services
39
Schedule 1 (Normal Driving Conditions)
40
Schedule 2 (Unique Driving Conditions)
42
Inspection and Adjustment of Drive Belt
44
Drive Belt Tension a
44
Replacement of Drive Belt
46
Replacement of Engine Oil
46
Replacement of Engine Oil Filter
47
Oil Capacity Table
47
Replacement of Engine Timing Belt (2.3L Only)
47
Inspection of Cooling System
48
Coolant Level (Engine Cold)
48
Coolant Quality
48
Coolant Leakage
48
Replacement of Engine Coolant
49
Coolant Protection
49
Antifreeze Solution Mixture Percentage
49
Replacement of Air Cleaner Element
50
Replacement of Fuel Filter
50
Ignition Timing
50
Inspection of Idle Speed
50
Inspection of Fuel Lines
51
Replacement of Spark Plugs
51
Inspection of Emission Hoses and Tubes
51
Inspection of Brake Lines, Hoses and Connections
52
Inspection of Disc Brake
52
Inspection of Drum Brake
52
Replacement of Brake Fluid
52
Inspection of Propeller Shaft Dust Boot(S)
53
Tightening of Bolts and Nuts on Chassis and Body
53
Inspection of Exhaust System Head Shield
53
Inspection of PCV Valve
53
Inspection of Front Suspension Ball Joints
53
Inspection of Brake and Clutch Fluid
54
Inspection of Power Steering Fluid Level
54
Inspection of Tires
54
Tire Wear
55
Abnormal Tire Wear
55
Air Pressure
55
Air Leakage
55
Inspection of Manual Transmission Oil
56
Loose Lug Nut
56
Tire Rotation
56
Wheel and Tire Runout
56
Replacement of Manual Transmission Oil
57
Inspection of Automatic Transmission Fluid Level
57
Replacement of Automatic Transmission Fluid
58
Inspection of Transfer Case Oil
59
Replacement of Transfer Case Oil
59
Engine (2.3L)
60
Engine (2.3L) View
61
Engine (2.3L) Outline/Specifications
62
Engine (2.3L) Troubleshooting Guide
62
Engine Tune-Up Procedure
64
Engine Oil Inspection
64
Engine Coolant Inspection
64
Drive Belt Inspection
64
HLA Troubleshooting Guide
65
Ignition Timing, Idle Speed
65
Compression
66
Engine On-Vehicle Maintenance (2.3L)
67
Sst
67
Timing Belt Removal/Installation
67
Removal Note - Timing Belt Outer Cover
68
Timing Belt
68
Installation Note - Timing Belt
68
Timing Belt Outer Cover
69
Checking Camshaft Timing
69
Adjusting Camshaft Timing
69
Cylinder Head Gasket Replacement
71
Removal Note - Spark Plugs
72
Exhaust Manifold Removal
72
Cylinder Head Cover
73
Lower Intake Manifold
74
Exhaust Manifold
74
Water Inlet Tube
74
DPF EGR Sensor
74
Hydraulic Lash Adjuster Removal/Installation
75
Front Oil Seal Replacement
76
Camshaft Oil Seal Replacement
78
Oil Pump Oil Seal Replacement
79
Rear Oil Seal Replacement
80
Engine (2.3L) Removal Procedure
82
Engine (2.3L) Disassembly - Preparation
83
Engine Auxiliary Parts
83
Engine (2.3L) Disassembly - Diagram
84
Timing Belt Disassembly
85
Cylinder Head Disassembly
87
Cylinder Block (External Parts) Disassembly
89
Oil Pan
91
Oil Pump Strainer and Tube
91
Front Cover Disassembly
92
Cylinder Block (Internal Parts) Disassembly
93
Connecting Rod Removal
94
Piston Ring
94
Piston Pin
94
Main Bearing Caps
94
Engine Inspection/Repair
95
Cylinder Head Inspection
95
Valve Mechanism Inspection
95
Valve and Valve Guide Inspection
95
Valve Seat Inspection
97
Valve Spring Inspection
97
Camshaft Inspection
98
Cylinder Block Inspection
99
Piston, Piston Ring and Piston Pin Inspection
100
Connecting Rod Inspection
102
Crankshaft Inspection
103
Main Bearing and Connecting Rod Bearing Inspection
104
Pulley Inspection
105
Timing Belt Outer Cover Inspection
105
Flywheel (MT) Inspection
105
Engine Assembly - Preparation
106
Cylinder Block (Internal Parts) Assembly
107
Oil Clearance Inspection
108
Rear Oil Seal Installation
109
Piston Pins Installation
109
Piston Rings Installation
110
Pistons Installation
110
Connecting Rod Cap
111
Front Cover Assembly
112
Cylinder Block (External Parts) Assembly
113
Oil Pump Strainer and Tub Installation
114
Oil Pan Installation
114
Water Pump Installation
116
Flywheel, Clutch Disc, and Clutch Cover (MT) Installation
116
Drive Plate (AT) Installation
116
Cylinder Head Assembly
117
Valve Seals
118
Valve Spring Assembly
118
Camshaft Bearings Installation
119
Camshaft Installation
119
Valve Keepers
120
Rocker Arms
120
Camshaft Thrust Plate
120
Cylinder Head
120
Timing Belt Assembly
121
Camshaft Pulley
122
Timing Belt Tensioner Installation
122
Timing Belt Outer Cover Installation
122
Crankshaft Pulley Installation
122
Exhaust Manifold Installation
124
Lower Intake Manifold Installation
124
Cylinder Head Cover Installation
125
Dipstick Tube and Bracket Installation
125
Engine Installation Procedure
126
Steps after Installation of the Engine
130
Engine 3.0L
131
Engine 3.0L View
132
Engine 3.0L Specifications
133
Engine 3.0L Troubleshooting
133
Engine Tune-Up Procedures
135
Engine Oil - to Inspect
135
Engine Coolant - to Inspect
135
Drive Belt - to Inspect
135
Ignition Timing, Idle Speed Initial Timing
136
Compression (3.0L)
137
Engine On-Vehicle Maintenance (3.0L)
138
Cylinder Head Gasket Replacement (3.0L)
138
Ignition Coil Removal (3.0L)
139
Auxiliary Parts Removal (3.0L)
139
Cylinder Head Cover (3.0L)
140
Rocker Arms (3.0L)
140
Lower Intake Manifold (3.0L)
140
Cylinder Head (3.0L)
141
Lower Intake Manifold Installation (3.0L)
142
Rocker Arms Installation (3.0L)
143
Dipstick Tube Installation (3.0L)
145
Spark Plugs Installation (3.0L)
145
Cylinder Head Covers Installation (3.0L)
145
Steps after Installation (Engine 3.0L)
146
Tappet Removal/Installation (3.0L)
146
No. 3 Intake Valve Rocker Arm Removal (3.0L)
147
Tappets Removal (3.0L)
147
Tappets Installation (3.0L)
147
Front Oil Seal Replacement (3.0L)
148
Damper (3.0L)
148
Front Oil Seal (3.0L)
148
Front Oil Seal Installation (3.0L)
149
Damper Installation (3.0L)
149
Rear Oil Seal Replacement (3.0L)
149
Flywheel (MT) Removal (3.0L)
150
Drive Plate (AT) Removal
150
Rear Oil Seal Installation (3.0L)
150
Engine (3.0L) Removal Procedure
151
Drive Plate (AT) Installation (3.0L)
151
Flywheel (MT) Installation (3.0L)
151
Wiring and Harness Connectors (3.0L Engine)
152
Hydraulic Clutch Pipe (MT) (3.0L)
152
Drive Plate (AT) (3.0L)
152
Engine (3.0L) Disassembly
153
Engine (3.0L) Disassembly - Diagram
154
Cylinder Head Cover Disassembly (3.0L)
155
Lower Intake Manifold Disassembly (3.0L)
155
Exhaust Manifolds (3.0L)
155
Timing Chain Disassembly (3.0L)
156
Damper Disassembly (3.0L)
156
Oil Pan Removal (3.0L)
157
Timing Cover Removal (3.0L)
157
Front Oil Seal Removal (3.0L)
157
Timing Chain Removal (3.0L)
158
Cylinder Head Disassembly (3.0L)
159
Rocker Arm Removal (3.0L)
159
Valve Keepers Removal (3.0L)
159
Valve Seals Removal (3.0L)
160
Cylinder Block (External Parts) Disassembly (3.0L)
160
Flywheel Removal (3.0L)
160
Drive Plate Removal (3.0L)
160
Oil Pump Removal (3.0L)
161
Cylinder Block (Internal Parts) Disassembly (3.0L)
162
Tappets Removal
163
Camshaft Removal (3.0L)
163
12. Crankshaft
163
14. Rear Oil Seal
163
Pistons
163
Camshaft Bearings (3.0L)
164
Connecting Rods Removal (3.0L)
164
Piston Rings Removal (3.0L)
165
Piston Pins Removal (3.0L)
165
Engine (3.0L) Inspection/Repair
166
Cylinder Head Inspection (3.0L)
166
Main Bearing Caps Removal (3.0L)
166
Crankshaft Removal (3.0L)
166
Valve Mechanism Inspection (3.0L)
167
Valve and Valve Guide Inspection (3.0L)
167
Valve Seat Removal (3.0L)
168
Valve Spring Inspection (3.0L)
169
Camshaft Inspection (3.0L)
169
Tappet Inspection (3.0L)
171
Cylinder Block Inspection (3.0L)
171
Pistons Inspection (3.0L)
172
Piston Rings Inspection (3.0L)
173
Piston Pins (3.0L)
174
Connecting Rods Inspection (3.0L)
174
Crankshaft Inspection (3.0L)
175
Main Bearing and Connecting Rod Bearing Check (3.0L)
176
Pulleys Check (3.0L)
176
Timing Chain Outer Cover Inspection (3.0L)
176
Engine (3.0L) Assembly
177
Cylinder Block (Internal Parts) Assembly (3.0L)
177
Upper Main Bearing, Lower Main Bearing and Main Bearing Cap - Assembly Note
178
Oil Clearance Inspection (3.0L)
178
Connecting Rods Installation (3.0L)
180
Piston Rings Installation (3.0L)
180
Piston and Connecting Rods Assembly (3.0L)
180
Connecting Rod Cap Installation (3.0L)
181
Crankshaft Rear Main Oil Seal (3.0L)
183
Camshaft Bearings Installation (3.0L)
183
Cylinder Block (External Parts) Assembly (3.0L)
184
Camsharft and Camshaft Thrust Plate (3.0L)
184
Tappets - Installation (3.0L)
184
Oil Pump with Intermediate Shaft (3.0L)
185
Drive Plate Installation (3.0L)
185
Flywheel Installation (3.0L)
185
Cylinder Head Assembly (3.0L)
186
Valves Installation (3.0L)
186
Valve Seals Installation (3.0L)
187
Valve Springs, Valve Spring Seat and Valve Keepers Installation (3.0L)
187
To Install the Rocker Arms (3.0L)
187
Cylinder Head Installation (3.0L)
188
Timing Chain Installation (3.0L)
190
Timing Cover Installation (3.0L)
190
Oil Pan Installation (3.0L)
191
To Install the Damper (3.0L)
192
Crankshaft Pulley Installation (3.0L)
192
Clutch and Fan Assembly Installation (3.0L)
192
Auxiliary Parts Installation (3.0L)
193
Step 2: 66-41 {6.9-8.1,50-59)
193
Exhaust Manifolds Installation (3.0L)
194
To Install the Lower Intake Manifold
194
Engine (3.0L) Installation Procedure
196
Cylinder Head Covers (3.0L)
196
Dipstick Tube and Bracket - to Install
196
EGR Valve Installation
196
Engine (3.0L) Installation Note
197
Air Conditioning Bracket Installation
197
Harness Connectors and Wires (3.0L)
198
Air Conditioner Compressor Installation (3.0L)
198
Power Steering Oil Pump Installation (3.0L)
198
Steps after Installation (Engine 3.0L)
198
Engine (4.0L)
199
Engine (4.0L) Diagrams
200
Engine (4.0L) Specifications
202
Engine (4.0L) Troubleshooting
202
Engine Tune-Up Procedure (4.0L)
204
Engine Oil Inspection (4.0L)
204
Engine Coolant Inspection (4.0L)
204
Drive Belt Inspection (4.0L)
205
Drive Belt Adjustment (4.0L)
205
Ignition Timing, Idle Speed (4.0L)
206
Compression (4.0L)
207
Engine (4.0L) On-Vehicle Maintenance
208
Cylinder Head Gasket Replacement (4.0L)
208
Step 1
208
Rocker Arm and Shaft Assembly Removal (4.0L)
209
Cylinder Head Bolt Installation (4.0L)
209
Rocker Arm and Shaft Assembly (4.0L)
210
Spark Plugs Installation (4.0L)
211
Tappets Removal/Inspection/Installation (4.0L)
211
Cylinder Head Cover Gasket Removal (4.0L)
212
Air Intake Hose Removal (4.0L)
213
Filler Neck Vacuum Hose Removal (4.0L)
213
Right Wire Harness Removal (4.0L)
213
Vacuum Hoses Removal (4.0L)
214
Left Wire Harness Removal (4.0L)
214
Cylnder Head Cover Installation (4.0L)
214
Cylinder Head Cover Reinforcement Plates and Cylinder Head Cover Gasket
215
Left Wire Harness Installation (4.0L)
215
Vacuum Hoses Installation (4.0L)
216
A/C Compressor Installation (4.0L)
216
Right Wire Harness Installation (4.0L)
216
Filler Neck Vacuum Hose Installation (4.0L)
216
Rocker Arm Assembly Removal/Installation (4.0L)
217
Air Intake Hose Installation (4.0L)
217
Accelerator Cable Shield Installation (4.0L)
217
Timing Chain Cover (4.0L)
218
Timing Chain Cover Removal/Installation (4.0L)
219
Fan Assembly Removal (4.0L)
219
Crankshaft Pulley Removal (4.0L)
219
Crankshaft Position Sensor (4.0L)
219
Timing Chain Cover Removal (4.0L)
220
Timing Chain Cover Installation (4.0L)
220
Crankshaft Position Sensor Installation
220
Crankshaft Pulley Installation (4.0L)
220
Fan Assembly Installation (4.0L)
221
Timing Chain Removal/Inspection/Installation (4.0L)
222
Front Oil Seal Replacement (4.0L)
223
Retaining Clip Installation
223
Camshaft Pulley, Timing Chain and Timing Chain Pulley (4.0L)
223
Rear Oil Seal Installation (4.0L)
224
Engine Removal Procedure (4.0L)
225
Air Intake Hose - to Remove (4.0L)
226
A/C Compressor Removal (4.0L)
226
Power Steering Oil Pump Removal (4.0L)
226
Fuel Hoses Removal (4.0L)
226
Engine Disassembly (4.0L)
227
Vacuum Hoses - to Remove (4.0L)
227
Engine Mount Nuts Removal (4.0L)
227
Torque Converter Nuts (at Only)
227
Engine Auxiliary Parts (4.0L)
228
Ignition Coil Pack Removal (4.0L)
228
Upper Intake Manifold Removal (4.0L)
228
Fuel Supply Manifold Removal (4.0L)
229
Lower Intake Manifold Removal (4.0L)
229
Fan Assembly - to Remove (4.0L)
229
Cylinder Block (External Parts) Removal (4.0L)
230
Oil Pan Removal (4.0L)
230
Oil Pump Removal (4.0L)
230
Oil Filter and Oil Filter Adapter Removal (4.0L)
230
Baffle Removal (4.0L)
231
Water Pump Removal (4.0L)
231
Crankshaft Position Sensor Removal
231
Crankshaft Pulley Removal
231
Timing Chain Disassembly (4.0L)
232
Timing Chain, Camshaft Pulley, Timing Chain Pulley - Disassembly Note
232
Cylinder Head Disassembly (4.0L)
233
Cylinder Head Cover Removal (4.0L)
234
Rocker Arm Assemblies and Push Rods Disassembly
234
Valve Keeper, Valve Spring Seat and Valve Spring Removal (4.0L)
234
Cylinder Block (Internal Parts) Disassembly (4.0L)
235
Connecting Rod Cap Removal (4.0L)
236
Connecting Rod Removal (4.0L)
236
Connecting Rod Bearings
236
Piston Ring Removal (4.0L)
237
Piston Pin Removal (4.0L)
237
Camshaft Removal (4.0L)
237
Engine Inspection/Repair (4.0L)
238
Cylinder Head Inspection (4.0L)
238
Valve Mechanism Inspection (4.0L)
239
Valve and Valve Guide Inspection (4.0L)
239
Valve Seat Inspection (4.0L)
240
Valve Spring Inspection (4.0L)
241
Camshaft Inspection (4.0L)
241
Tappets Inspection (4.0L)
242
Cylinder Block Inspection (4.0L)
242
Piston Inspection
243
Piston and Piston Rings Inspection (4.0L)
244
Piston and Piston Pin Inspection (4.0L)
244
Connecting Rod Inspection (4.0L)
245
Crankshaft Inspection (4.0L)
245
Bearing Inspection (4.0L Engine)
246
Timing Chain Inspection (4.0L)
246
Pulley Inspection (4.0L)
246
Timinc Chain Cover Inspection (4.0L)
246
Engine Assembly (4.0L)
247
Cilinder Block (Internal Parts) Assembly (4.0L)
248
Assembly Note -Upper Main Bearing, Crankshaft, Lower Main Bearing and Main Bearing Cap
249
Connecting Rod Caps Assembly Note
249
Piston, Pistoin Pin and Connecting Rod Installation (4.0L)
250
Piston Ring Installation (4.0L)
250
Piston, Piston Pin and Connecting Rod Assembly (4.0L)
251
Connecting Rod Cap and Connecting Rod Bearing (4.0L)
251
Camshaft Installation (4.0L)
253
Cylinder Head Assembly (4.0L)
253
Tappets Installation (4.0L)
254
Valve Seal (4.0L)
255
Valve Spring and Valve Keepers (4.0L)
255
Rocker Arm Shat Assemblies and Push Rods (4.0L)
255
Timing Chain Assembly (4.0L)
256
Timing Chain Pulley, Timing Chain and Camshaft Pulley Installation (4.0L)
257
Cylinder Block (External Parts) Assembly (4.0L)
257
Timing Chain Cover Installation (4.0L)
257
Crankshaft Pulley Installation (4.0L)
257
Crankshaft Position Sensor Installation (4.0L)
258
Water Pump Installation (4.0L)
258
Baffle Installation (4.0L)
258
Oil Pump Installation (4.0L)
258
Rear Oil Seal Installation (4.0L)
259
Auxiliary Parts Installation (4.0L)
259
Exhaust Manifolds Installation (4.0L)
259
Oil Filter and Oil Filter Adapter Installation
260
Fan Assembly Installation (4.0L)
260
Fuel Supply Manifold Installation (4.0L)
260
Upper Intake Manifold Installation (4.0L)
261
Ignition Coil Pack Installation (4.0L)
261
Engine Installation (4.0L)
262
Torque Converter Nuts (at Only) (4.0L)
263
Engine Mount Nuts (4.0L)
263
Accelerator Cable Chield Installation (4.0L)
263
Fuel Hoses Installation (4.0L)
263
Vacuum Hoses Installation (4.0L)
264
A/C Compressor Installation (4.0L)
264
Power Steering Oil Pump Installation (4.0L)
264
Air Intake Hose Installation (4.0L)
264
Lubrication System
265
Lubrication System Diagram
266
Lubrication System Specifications
267
Lubrication System Troubleshooting
267
Oil Pressure - Inspection
268
Engine Oil Inspection Steps
268
Engine Oil Replacement
269
Oil Capacity
269
Fuel Filter Replacement
269
Oil Pan Removal/Installation
270
Oil Pan Inspection
271
To Install the Oil Pan
271
Oil Pump - Installation Note
273
Oil Pump Strainer and Tube Removal/Installation
273
Lubrication System 3.0L
274
Lubrication System Diagram (3.0L)
275
Index
275
Lubrication System Specifications (3.0L)
276
Lubrication System Troubleshooting (3.0L)
276
Outline
276
Troubleshooting Guide
276
Oil Pressure - Inspection (3.0L)
277
Engine Oil Inspection (3.0L)
278
Replacement
278
Oil Filter Replacement (3.0L)
279
Oil Pan Removal/Installation (3.0L)
280
Oil Pan Inspection (3.0L)
280
Removal / Installation
280
Oil Pan Installation Note (3.0L)
281
Oil Pump Removal/Installation (3.0L)
282
Removal / Installation
282
Refer to Section D3
282
Oil Pump Inspection (3.0L)
283
Lubrication System (4.0L)
284
Lubrication System (4.0L) Diagram
285
Index
285
Lubrication System Specifications (4.0L)
286
Lubrication System Troubleshooting (4.0L)
286
Outline
286
Oil Pressure - Inspection (4.0L)
287
Preparation
287
Engine Oil (4.0L)
288
To Replace Engine Oil (4.0L)
288
Inspection
288
Replacement
288
Oil Filter Replacement (4.0L)
289
Oil Filter Adapter Removal/Installation (4.0L)
289
Removal 1 Installation
289
Oil Pan Removal/Installation (4.0L)
290
Preparation
290
Removal / Installation
290
Oil Pan Inspection (4.0L)
291
Oil Pan Installation (4.0L)
293
Rear Oil Seal (4.0L)
293
Oil Pump Disassembly/Assembly (4.0L)
294
Removal I Installation
294
Outer Race, Rotor and Shaft Assembly Installation (4.0L)
295
Cooling System (2.3L)
296
Cooling System Diagrams (2.3L)
297
Cooling System Specifications (2.3L)
298
Cooling System Troubleshooting (2.3L)
298
Engine Coolant Inspection (2.3L)
299
Coolant Leakage (2.3L)
299
Coolant Protection (2.3L)
299
Antifreeze Solution Mixture Percentage (2.3L)
299
Engine Coolant Replacement (2.3L)
300
Air Bleeding (2.3L)
300
Radiator Cap Inspection (2.3L)
301
Radiator Cap Valve Inspection (2.3L)
301
Negative Pressure Valve Inspection (2.3L)
301
Radiator Removal/Installation (2.3L)
302
Radiator Inspection (2.3L)
303
Radiator Hoses Installation (2.3L)
303
Thermostat Removal/Installation (2.3L)
304
Thermostat Inspection (2.3L)
305
Gasket Installation (2.3L)
306
Thermostat Installation (2.3L)
306
Thermostat Cover Installation (2.3L)
306
Water Pump Removal/Installation (2.3L)
307
Cooling Fan and Clutch Removal/Installation
308
Engine Block Heater Removal/Installation
309
Block Heater Cable Installation
310
Block Heater Installation
310
Cooling System (3.0L)
311
Cooling System (3.0L) Diagrams
312
Cooling System Specifications (3.0L)
313
Cooling System Troubleshooting (3.0L)
313
Engine Coolant Inspection (3.0L)
314
Coolant Leakage (3.0L)
314
Coolant Protection (3.0L)
315
Antifreeze Solution Mixture Percentage (3.0L)
315
Coolant Replacement (3.0L)
315
Air Bleeding (3.0L)
316
Radiator Cap Inspection (3.0L)
317
Negative Pressure Valve Inspection (3.0L)
317
Radiator Removal/Installation (3.0L)
318
Radiator Inspection (3.0L)
319
Radiator Hoses Inspection (3.0L)
319
Thermostat Removal/Installation (3.0L)
320
Thermostat Inspection (3.0L)
321
Gasket Installation (3.0L)
322
Thermostat Installation (3.0L)
322
Water Pump Removal/Installation (3.0L)
323
Cooling Fan and Clutch Removal/Installation (3.0L)
325
Engine Block Heater Removal/Installation (3.0L)
327
Cooling System (4.0L)
328
Cooling System (4.0L) Diagrams
329
Cooling System (4.0L) Specifications
330
Cooling System (4.0L) Troubleshooting
330
To Inspect the Engine Coolant (4.0L)
331
Coolant Replacement (4.0L)
332
Air Bleeding (4.0L)
333
Radiator Cap Inspection (4.0L)
334
Negative Pressure Valve (4.0L)
334
Radiator Removal/Installation (4.0L)
335
Radiator Removal/Installation (4.0L) - Diagram
336
Radiator Inspection (4.0L)
337
Radiator Installation (4.0L)
337
Thermostat Removal/Installation (4.0L)
338
Thermostat Inspection (4.0L)
339
Thermostat Installation (4.0L)
340
Water Pump Removal/Installation (4.0L)
341
Cooling Fan and Clutch Removal/Installation (4.0L)
342
Engine Bock Heater Removal/Installation (4.0L)
344
Engine Control Troubleshooting - 2.3L/3.0L/4.0L
346
Engine Control - Diagram (4.0L)
347
Engine Control - Diagram (3.0L)
348
Engine Control - Diagram (2.3L)
349
Engine Control - Diagram (4.0L/3.0L)
350
Diagram for 2.3L
351
Index
351
Diagram for 4.0L/3.0L/2.3L
352
Engine Control - Specifications for 4.0L, 3.0L, 2.3L
355
Outline
355
Engine Control - Wiring Diagram for 4.0L
356
Engine Control - Wiring Diagram for 3.0L
361
Engine Control - Wiring Diagram for 2.3L
366
EEC-V Component Descriptions
371
Troubleshooting Guide (Engine Control System)
376
Using this Section
376
Diagnostic Index
376
Troubleshooting Chart
377
Diagnostic Index
378
Symptom Troubleshooting (Engine Control System)
380
Melts Fuse
380
Will Not Crank
381
Hard Start/Long Crank/Erratic Start/Erratic Crank
382
Engine Stalls
384
Cranks Normally but will Not Start
386
Slow Return to Idle
388
Engine Runs Rough/Rolling Idle
388
Fast Idle
390
Low Idle/Stalls During Deceleration
391
Engine Stalls/Quits/Runs Rough/Misses/Buck/Jerk/Hesitation/Stumble
392
Momentary Minor Irregularity in Engine Output
394
Backfires
396
Lack/Loss of Power
397
Knocking/Pinging
399
Poor Fuel Economy
400
Fails Emissions Test
402
MIL/TCIL Never on or Always on
404
High Oil Consumption/Leaks
405
Cooling System Concerns
405
Exhaust Smoke
406
Fuel Odor (in Engine Compartment)
408
Engine Noise
409
Vibration Concerns (Engine)
410
A/C Does Not Work
410
A/C Always On/A/C Compressor Runs Continuously
411
A/C Does Not Cut off under Wide Open Throttle Conditions
412
Exhaust Sulphur Smell
413
Intermittent Concerns
414
Output Test Mode Not Functioning
414
On-Board Diagnostic System
415
Quick Test Description
415
Preparation
415
Diagnostic Trouble Code (DTC) Number
416
Next Generation Start (NGS) Hook-Up Procedure
416
Retreiving DTC(S)
416
Retrieve/Clear Continuous Dtcs
418
KOEO On-Demand Self-Test
418
KOER On-Demand Self-Test
419
After Repair Procedure
419
PID/DATA Monitor and Record
419
Playback of Stored Pids
420
Output Test Mode - Procedure
420
Oxygen Sensor Monitoring Test Results Access
421
OBD II Drive Cycle
421
Diagnostic Trouble Code Numbers
422
On-Board Diagnostic System - Troubleshooting
427
Mass Air Flow (MAF) Sensor
427
Intake Air Temperature (IAT) Sensor/Engine Coolant Temperature (ECT) Sensor
430
Throttle Position (TP) Sensor Circuit Malfunction
432
Cylinder Side Upstream Heated Oxygen Sensor/Other Side Upstream Heated Oxygen Sensor
435
Cylinder Side Upstream Heated Oxygen Sensor Heater/Downstream Heated Oxygen Sensor Heater/Other Side Upstream Heated Oxygen Sensor Heater
437
Adaptive Fuel Control
439
Downstream Heated Oxygen Sensor
444
Upstream Heated Oxygen Sensor
445
Fuel Pump (FP) Primary or Secondary Circuit
447
Misfire Detection Monitor
451
Suspect Injector
452
Camshaft Position (CMP) Sensor Malfunction
452
EGR System
454
DPFE Sensor
463
EVR Circuit
466
Catalyst Monitoring System
467
Evaporative Emission (EVAP) Canister Purge Solenoid
467
Vehicle Speed Sensor (VSS)
469
Idle Air Control (IAC) System
470
Powertrain Control Module (PCM)
471
Brake On/Off (BOO) Switch
472
Clutch Pedal Position (CPP) Switch
473
OBD II Drive Cycle (DTC P1000)
474
Drive Instructions over Time Chart
475
Unable to Access Continuous Memory Dtcs or to Activate KOEO or KOER Self-Test
476
Anti-Theft System (DTC P1260)
477
Engine Rpm/Vehicle Speed Limiter
477
Octane Adjust (OCT ADJ) Circuit
478
Purge Flow System Circuit
479
Purge Flow Sensor (PF) Circuit Malfunction
481
Wide Open Throttle A/C Cut-Off (WAC) Relay/A/C Control Signal (ACCS)
483
Idle Air Control (IAC) System Circuit
485
Power Steering Pressure (PSP) Switch Circuit (2.3L Only)
488
VREF (Reference Voltage)
489
Intake Air System (for 2.3L/3.0L/4.0L)
491
Throttle Body
491
Throttle Return Screw Inspection/Removal/Installation
491
Idle-Speed Control System (for 2.3L/3.0L/4.0L) Description
492
Idle Air Control Solenoid
492
Fuel System (for 2.3L/3.0L/4.0L) Description
493
Fuel System (for 2.3L/3.0L/4.0L) Precaution
494
Fuel Pressure and Servicing Fuel System Releasing
494
Preparation
494
Fuel System Operation
495
Fuel Line Pressure/Fuel Pressure Hold Inspection
495
Fuel Line Pressure under Load Inspection
496
Fuel Pump
496
Continuity Inspection (Fuel System)
496
Voltage Inspection (Fuel System)
497
Ground Inspection (Fuel System)
497
Inertia Fuel Shutoff Switch Inspection
497
Fuel Pump Relay
497
Fuel Pump Relay
498
Pressure Regulator Inspection
499
High Pressure Inspection
499
Diaphragm Inspection
499
Injector Inspection
500
Fuel Leakage Test
500
Exhaust System Components Inspection (on Vehicle)
501
Exhaust System (for 2.3L. 3.Ol. 4.Ol
501
PCV Valve (for 2.3L/4.0L) Inspection
502
PCV Valve (for 3.0L) Inspection
502
Positive Crankcase Ventilation (Pcv) System (for 2.3L. 3.Ol. 4.Ol
502
EGR Vacuum Regulator Solenoid
503
Exhaust Gas Recirculation (Egr) Function Control System (for 2.3L. 3.Ol. 4.Ol
503
EGR Valve Inspection
504
EGR Valve Replacement
504
Fuel Evaporative Emission System
505
Evaporative Emission Canister Purge Solenoid Valve
505
Purge Flow Sensor
505
Description
505
Fuel Evaporative Emission System Operation
506
Evaporative Emission (EVAP) Canister Purge Solenoid Inspection
506
Purge Flow Sensor (PFS) Inspection
507
Dechoke Control System (2.3L Only) Operation
508
Evaporative Emission Canister Inspection
508
Fuel Vapor Valve Inspection
508
Description
508
A/C Cutoff System
509
A/C Signal
509
Control System
509
Powertrain Control Module (PCM) Removal/Installation/Inspection
509
Control System (for 4.0L) Specification
510
Control System (for 3.0L) Specification
513
Control System Specification (for 4.0L)
514
PID Data Monitor (4.0L)
515
Control System Specification (for 3.0L)
516
PID Data Monitor (for 3.0L)
521
Control System Specification (for 2.3L)
522
PID Data Monitor (for 2.3L)
527
PCM Power Relay (Battery Power)
528
EEC PWR Fuse (PCM Memory Power)
528
Ground
528
Mass Air Flow Sensor
529
Voltage to Mass Air Flow Conversion Table
529
Vehicle Speed Senros (VSS)
530
Throttle Position Sensor Inspection
530
Throttle Position Sensor Removal/Installation
530
Engine Coolant Temperature Sensor
531
Intake Air Temperature Sensor
532
Octane Adjust Shorting Bar
532
Heated Oxygen Sensors
533
Differential Pressure Feedback EGR Sensor
533
Sensor (A/T Only)
533
Clutch Pedal Position (CPP) Switch (MT Only)
534
Transmission Range Sensor (A/T Only)
534
Transmission Fluid Temperature (TFT) Sensor (A/T Only)
535
Turbine Shaft Speed (TSS) Sensor (A/T Only)
535
Power Steering Pressure Switch (2.3L Only)
536
Crankshaft Position Sensor
536
Camshaft Position Sensor
537
Fuel and Emission Control Systems - 2.3L
540
Intake Air System (2.3L)
541
Intake Air System (2.3L) Diagrams
542
Fuel Rail Removal (2.3L)
543
Intake Manifold Installation (2.3L)
543
Upper Intake Manifold Installation (2.3L)
543
Upper Intake Manifold/Intake Manifold Inspection (2.3L)
543
Accelerator Pedal and Pedal Removal/Inspection/Installation (2.3L)
544
Accelerator Pedal Inspection/Adjustment (2.3L)
544
Fuel System Prepapation (2.3L)
545
Precaution: Fuel Pressure and Servicing Fuel System Releasing (2.3L)
545
Injector/Pressur Regulator Removal/Installation (2.3L)
546
Fuel Lines Removal (2.3L)
547
Exhaust System Components Removal/Inspection/Installation (2.3L)
547
Exhaust System Diagrams (2.3L)
548
Rear Bracket and Insulator Assembly Removal (2.3L)
549
Exhaust Manifold Removal (2.3L)
549
Rear Bracket and Insulator Assembly Installation (2.3L)
549
Exhaust Manifold Installation (2.3L)
549
Fuel and Emission Control Systems - 3.0L
550
Intake Air System Components Removal/Inspectioninstallation (3.0L)
551
Upper Intake Manifold/Throttle Body Assembly Removal (3.0L)
552
Intake Manifold Removal (3.0L)
552
Intake Manifold Installation (3.0L)
553
Upper Intake Manifold/Throttle Body Assembly Installation (3.0L)
554
Upper Intake Manifold/Throttle Body Assembly Inspection (3.0L)
555
Accelerator Cable and Pedal Removal/Inspection/Installation (3.0L)
556
Fuel System (3.0L)
557
Precaution: Fuel Pressure and Servicing Fuel System Releasing (3.0L)
557
Injector/Pressure Regulator Removal/Installation (3.0L)
558
Fuel Lines Removal (3.0L)
559
Pressure Regulator Removal (3.0L)
559
Pressure Regulator Installation (3.0L)
559
Exhaust System Components Removal/Installation/Inspection (3.0L)
560
Rear Bracket and Insulator Assembly Removal (3.0L)
560
Silencer Heat Shield Removal (3.0L)
561
Exhaust Manifold Removal (3.0L)
561
Rear Bracket and Insulator Assembly Installation (3.0L)
561
Exhaust Manifold Installation (3.0L)
561
Fuel and Emission Control Systems - 4.0L
562
Intake Air System Components Removal/Inspection/Installation (4.0L)
563
Intake Air System Diagrams (4.0L)
564
Intake Manifold Removal (4.0L)
565
Intake Manifold Installation (4.0L)
565
Upper Intake Manifold Inspection (4.0L)
567
Intake Manifold Inspection (4.0L)
567
Accelerator Cable and Pedal Removal/Inspection/Installation (4.0L)
568
Accelerator Cable Inspection/Adjustment (4.0L)
568
Fuel System Preparation (4.0L)
569
Precaution: Fuel Pressure and Servicing Fuel System Releasing (4.0L)
569
Fuel Tank Removal/Inspection/Installation (4.0L)
569
Regular Cab Diagram (4.0L)
570
Cab Plus Diagram (4.0L)
571
Fuel Tank Removal (4.0L)
572
Fuel Filter Replacement (4.0L)
572
Fuel Pump Removal/Installation (4.0L)
573
Fuel Pump Ring (Cab Plus Only) Installation
573
Injector/Pressure Regulator Removal/Installation (4.0L)
574
Fuel Lines Removal (4.0L)
575
Exhaust System Components Removal/Inspection/Installation (4.0L)
576
Rear Bracket and Insulator Assembly Removal (4.0L)
577
Silencer Heat Shield Removal (4.0L)
577
Exhaust Manifold Removal (4.0L)
577
Rear Bracket and Insulator Assembly Installation (4.0L)
577
Exhaust Manifold Installation (4.0L)
578
Electrical System
579
Electrical System Diagrams
580
Engine Ignition System Diagrams (2.3L)
580
Index
580
Engine Ignition System Diagram (3.0L)
581
Engine Ignition System Diagram (4.0L)
581
Electrical System Specifications
583
Electrical System Troubleshooting
583
Outline
583
Troubleshooting Guide
583
Diagnostic Index
583
Symptom Troubleshooting
584
Charging System
586
Charging System Circuit Diagram, MT
587
Charging System
589
Charging System Troubleshooting
590
Battery Inspection
591
Battery Discharge Test
591
Terminal and Cable
591
Recharging
592
Slow Charging
592
Quick Charging
592
Generator Removal/Installation
593
Brush Holder Assembly
593
Generator Installation
594
Voltage Regulator/Brush Holder Assembly Removal/Installation
595
Generator Pulley and Regulator Terminal Removal/Installation
597
Drive Belt
598
Electronic Ignition System
600
Electronic Ignition System Circuit Diagram (2.3L)
601
Electronic Ignition System Circuit Diagram (3.0L)
603
Electronic Ignition System Circuit Diagram (4.0L)
605
EI (High Data Rate) Diagnostic Cables (49 UN01 057)
607
Electronic Ignition System Troubleshooting
608
Electronic Ignition System
610
Secondary Ignition System Display Diagnosis
619
Evaluation of Secondary Display
619
Ignition Timing Adjustment
620
Spark Plugs Removal/Installation
621
High-Tension Lead Removal
622
Spark Test
622
Spark Plugs Inspection
622
Plug Gap
622
High-Tension Lead
624
Ignition Coil Assemblies Removal/Installation
624
Ignition Coil Removal
626
Ignition Coil Assembly (2.3L)
626
Ignition Coil (3.0L)
627
Ignition Coil (4.0L)
628
Crankshaft Position Sensor Inspection
628
Crankshaft Position Sensor Removal (2.3L)
629
Crankshaft Position Sensor Removal (3.0L/4.0L)
630
Crankshaft Position Sensor - Installation
631
Starting System Circuit Diagram, MT
632
Starter Relay Inspection (on Vehicle)
634
Starter Inspection (on Vehicle)
634
Starter Removal/Installation
634
Starter Performance Inspection
635
Starter Disassembly/Assembly
636
Brush Holder Assembly
637
Pinion and Reduction Gear
637
Magnetic Switch Inspection
638
Brush and Brush Holder Inspection
639
Armature Inspection
639
Internal Gear and Platenary Gears Check
640
Yoke Check
640
Pinion and Reduction Gear Check
640
Clutch Pedal Position Switch (MT) Inspection
641
Clutch
642
Clutch Diagram
643
Index
643
Clutch Specifications
644
Clutch Troubleshooting
644
Troubleshooting Guide
644
Clutch Fluid Inspection
645
Air Bleeding (Clutch)
645
In-Vehicle Bleeding Procedure
645
Replacement
645
Bench Bleeding Procedure
646
Clutch Pedal Adjustment
647
Clutch Pedal Removal/Installation
647
Removal / Installation
647
Clutch Pedal Position Switch Removal/Installation
648
Clutch Master Cylinder Removal/Installation
649
Removal / Installation
649
Clutch Release Cylinder Removal/Installation
650
Air Bleeding (Refer to
650
Overhaul
650
Release Collar Travel Inspection
652
Clutch Unit Removal/Installation
653
Clutch Unit
654
Flywheel
654
Pilot Bearing
655
Clutch Disc
655
Clutch Cover
655
Clutch Release Cylinder
655
Clutch Cover Inspection
656
Clutch Disc Inspection
656
Clutch Release Collar Inspection
656
Pilot Bearing Inspection
657
Flywheel Inspection
657
Manual Transmission
658
Manual Transmission Diagram
659
Index
659
Manual Transmission Specifications
660
Manual Transmission Troubleshooting
660
Outline
660
Transmission Oil Inspection
661
Transmission Oil Replacement
661
Transmission Removal
662
Preparation
662
Gear Shift Lever
663
Clutch Pipe
663
Transmission - Removal Note
663
Transmission Disassembly
664
Rear Seal
665
Extension Housing
665
Locknuts
666
Reverse Idler Gear
666
Secondary Shaft Rear Bearing
666
Front Bearing Cover
667
Primary Shaft
667
Secondary Shaft Parts
668
Secondary Shaft
669
Control Case
669
Shift Rod
670
Gears Inspection
670
Synchronizer Ring Inspection
671
Clutch Hub Assembly
671
Reverse Idler Gear Inspection
671
Countershaft Gear Inspection
672
Speedometer Gears Inspection
672
Transmission Assembly
672
Interlock Pins Installation
673
3Rd/4Th Shift Rods Installation
673
3St/2Nd Shift Rods Installation
674
5Th/Reverse Shift Rods Installation
674
Secondary Shaft Parts Assembly
675
Clutch Hub and Sleeve Assembly (3Rd/4Th)
676
Retaining Ring Select Chart
677
Transmission Diagram
678
Assembly Note: Secondary Shaft Center Bearing Outer Race
679
Secondary Shaft Shim Select Chart
680
Countershaft Spacer Select Chart
681
Shift Fork Assembly
682
Split Washer
682
Thrust Washer
683
Reverse Idler Gear Installation
683
Countershaft Rear Bearing Installation
684
Secondary Shaft Rear Bearing Installation
684
Locknuts Installation
684
Oil Passage Installation
684
Speedometer Drive Gear
685
Extension Housing Installation
685
Control Case Installation
685
Drain Plug Installation
685
Transmission Installation
686
Transfer Case
687
Manual Shift Transfer Case Diagram
688
Index
688
Electronic Shift Transfer Case Diagram
689
Transfer Case Specifications
690
Powerflow (Transfer)
690
Outline
690
Transfer Case Oil Inspection
692
Transfer Case Oil Replacement
692
Oil Seal
693
Front Output Shaft Replacement
693
Preparation
693
Vent Hose
695
Rubber Boot and Floor Pan Cover
695
Shift Ball
695
Shift Linkage (Manual Shift Transfer Case) Inspection
696
Shift Linkage (Manual Shift Transfer Case) Adjustment
696
Manual Shift Transfer Case - SST
697
Manual Shift Transfer Case Troubleshooting
698
Manual Shift Transfer Case Removal/Installation
698
Transfer Case Drain Plug
700
Damper
700
Skid Plate
700
Manual Shift Transfer Case Disassembly
701
Manual Shift Transfer Case Exploded View
702
19. Rear Output Shaft
703
2W-4W Shift Fork and Lockup Assembly
704
Chain, Drive Sprocket and Front Drive Sprocket
704
Rear Output Shaft, Pump Assembly and Oil Pump Filter
704
Oil Pump Drive Pin
704
Manual Shift Transfer Case
704
Front Adapter, Planet Carrier and Input Shaft
705
Needle Bearing and Bearing Sleeve
705
Shift Shaft Lever
706
Shift Shaft
706
Ring Gear
706
Front Output Shaft Bearing
706
Front Output Shaft Bearing Installation
708
Oil Seal Installation
708
Ring Gear Installation
708
Shift Shaft Lever Installation
709
4L Assist Roller/Assist Spring
709
Front Adapter, Planet Carrier and Input Shaft Assembly
710
H-L Shift Fork and H-L Hub
711
Rear Output Shaft, Pump Assembly and Oil Pump Filter Installation
711
Chain, Drive Sprocket and Front Drive Sprocket Installation
712
2W-4W Lockup Assembly and 2W-4W Shift Fork Installation
712
Transfer Case Installation
712
Electronic Shift Transfer Case Troubleshooting
713
4X4 Shift Operation
713
4X4 Shift Control Switch Removal/Installation
714
4X4 Transmission Select Relay Removal/Installation
714
Electronic Shift Transfer Case
714
Electronic Shift Motor Assembly Removal/Installation
715
Motor Connector Removal
716
Electronic Shift Transfer Case Removal/Installation
716
Transfer Case Installation Note
718
Vent Hose Installation
718
Electronic Shift Transfer Case Disassembly
719
Electronic Shift Transfer Case Exploded View
720
Electronic Shift Transfer Case - Disassembly Note
722
Shift Cam Assembly
724
2W-4W Lockup Assembly and 2W -4W Shift Fork
724
Clutch Housing Installation
725
Clutch Coil Installation
725
Assembly
725
Motor Assembly
726
Electronic Shift Transfer Case Troubleshooting/Circuit Diagram
727
Retrieving Dtcs
728
Erasing Dtcs
729
Electronic Shift Transfer Case - Diagnostic Troubleshooting Guide
731
Electronic Shift Transfer Case - Diagnostic Trouble Code List
733
Cannot Change 4X4 Mode
735
Cannot Change 4X4 Gears
736
4WD High Indicator Lamp Never Illuminates
741
4X4 Shift Control Switch Inspection
743
Check Shift Motor
743
System Inspection
743
Electronic Shift Motor Assembly Inspection
744
Check Shift Motor Sensors
744
Check Magnetic Clutch
744
Automatic Transmission (Electronically Controlled)
746
Automatic Transmission (Electronically Controlled) - Diagrams
747
Automatic Transmission (Electronically Controlled) Specifications
749
Automatic Transmission (Electronically Controlled) Cross-Sectional View
750
Operation of Components
750
4R44E
750
Automatic Transmission (Electronically Controlled) Troubleshooting
751
Automatic Transmission Diagnostic Flow Chart
752
Road Test
753
Range Test
753
In-Shop Test
754
Vehicle Speed at Shift Point Tables - 2.3L
754
Vehicle Speed at Shift Point Tables - 3.0L 4X2
755
Vehicle Speed at Shift Point Tables - 3.0L 4X4
755
Vehicle Speed at Shift Point Tables - 4.0L 4X2
756
Vehicle Speed at Shift Point Tables - 4.0L 4X4
756
Automatic Transmission Fluid (ATF)
757
Fluid Leaks (ATF)
758
Quick Diagnosis Chart
759
Automatic Transmission (Electronically Controlled) Symptom Troubleshooting
763
Will Start in Other than P and N Ranges
764
Engine Stalls, Idle When Shifter from N or P to Other Ranges
765
Engine Stalls on Deceleration
766
Engine Runs Rough on Deceleration
766
Poor Acceleration
767
Surges While Cruising
768
Lack of Power
768
Poor Fuel Economy (Symptom)
768
Vehicle Does Not Move in D, 2, 1 And/Or R Ranges
769
Vehicle Moves in N Range
769
Vehicle Moves in P Range
769
Excessive Creep
769
No Shift
770
Abnormal Shift
770
Frequent Shifting
770
Shift Point High or Low
770
No Lockup
771
No Kick down
771
Engine Speed Flares up
771
Excessive Shift Shock
772
No Engine Braking
772
Transmission Noise
772
Transmission Overheats
773
Delayed Shift
773
Automatic Transmission (Electronically Controlled) - On-Board Diagnosis System
774
Diagnostic Trouble Code Number
775
New Generation Star (NGS) Hook-Up Procedure
775
Key on Engine off Quick Test
776
Key on Engine Running Quick Test
776
Accessing All Continuous Memory Dtcs Procedure
777
Output Control Test
778
Accelerating OBD II PID Mode Procedure
779
Diagnostic Trouble Code Numbers Table
781
Shift Solenoids (SS1, SS2, SS3) - 4R44E Only
783
Shift Solenoids and Torque Converter Clutch (TCC), Solenoid - 5R55E Only
786
Solenoid Mechanism Failure - 5R55E Only
787
Electronic Pressure Control Solenoid (EPC)-4R44E Only
788
Electronic Pressure Control Solenoid (EPC) - 5R55E Only
790
Torque Converter Clutch (TCC) Solenoid-4R44E Only
791
Coast Clutch Solenoid (CCS) - 4R44E Only
793
4R44E Table
797
5R55E Table
798
Transmission Control Switch (TCS) or Transmission Control Indicator Lamp (TCIL) Circuit Malfunction
799
Transmission Fluid Temperature (TFT) Sensor Malfunction - 4R44E Only
801
Transmission Fluid Temperature (TFT) Sensor Malfunction - 5R55E Only
803
Transmission Fluid Temperature (TFT) Sensor - Table
805
Digital Transmission Range (TR) Sensor Circuit Malfunction - 4R44E and 5R55E
806
Turbine Shaft Speed (TSS) Sensor Malfunction
809
Turbine Shaft Speed (TSS) Sensor, Output Shaft Speed (OSS) Sensor and Overdrive Drum Speed Sensor (ODS) 5R55E Only
811
Electical System Components
812
Engine Coolant Temperature Sensor Inspection
812
Engine Coolant Temperature Sensor Replacement
813
Vehicle Speed Sensor Inspection
813
Vehicle Speed Sensor Replacement
813
Transmission Range (TR) Sensor Replacement/Adjustment
815
Brake On/Off (BOO) Inspection
816
Throttle Position Sensor Inspection/Specifications
816
Throttle Position Sensor Replacement
816
Transmission Fluid Temperature (TFT) Sensor Inspection
817
Transmission Fluid Temperature (TFT) Sensor Replacement
817
Turbine Shaft Speed (TSS) Sensor Inspection
817
Turbine Shaft Speed (TSS) Sensor Replacement
817
Overdrive Drum Speed (ODS) Sensor - 5R55 Only
818
Output Shaft Speed (OSS) Sensor - 5R55 Only
818
Transmission Tester
819
Tester Jacks
819
Tester Leds and Controls
819
Tester Use (4R44E Only)
820
Tester Hook-Up Procedure
820
Transmission Solenoids and Sensors Resistance Inspection
821
Solenoid Voltage Test
823
Check EPC Solenoid
823
Check Engagements
824
Check Upshifts and Downshifts
824
Check Torque Converter Engagement
825
Check Turbine Shaft Speed Sensor (TSS)
825
Check Coast Clutch Engagement
825
Transmission Tester Removal
826
Transmission Range (TR) Sensor Testing Using Tranmission Tester (4R44E and 5R55E)
826
NGS Tester (5R55E Only)
827
Output Test Mode
828
Output State Control
828
OSC-Transmission Bench Mode
829
SS1, SS2, SS3, SS4, and TCC in Bench Mode
829
EPC in Bench Mode
830
OSC - Transmission Drive Mode
830
GR-CM in Drive Mode
831
TCC in Drive Mode
831
EPC in Drive Mode
832
Linking OSC and Plds
833
Powertrain Control Module (PCM) Inspection
834
Powertrain Control Module (PCM) Replacement
834
Transmission Control Switch (TCS) Inspection
834
Mechanical System Test
835
Torque Converter Clutch Test
835
Line Pressure Test - Preparation
836
Line Pressure Test - Procedure
837
Evaluation of Line Pressure
838
Stall Test
838
Evaluation of Stall Test
840
Air Pressure Test
841
Transmission Unit Removal
843
Selector Cable
844
Transmission Range (TR) Sensor
844
Solenoid Valve Connector
845
Rear Engine Mount and Engine Mounting Member
845
Upper Transmission Mounting Bolts
845
Oil Cooler Pipes
846
Transmission Mounting Bolts
846
Transmission Unit Disassembly
847
Transmission Unit Components View
848
Transmission Unit Disassembly Procedure
849
Torque Converter Inspection
866
End Play Check
867
Stator to Impeller Interference Check
867
Wash Inside of the Converter
867
Converter Housing and Oil Pump Assembly (4R44E/5R55E) Disassembly/Inspection/Assembly
868
Oil Pump Disassembly
869
Pump Gears
869
Front Oil Pump Seal
870
Oil Pump
871
Coasting Clutch Drum Assembly Disassembly/Inspection/Assembly
872
Snap Ring
873
Reverse and High Piston
873
Snap Ring Sizes Table
876
Overdrive Shaft and Carrier Hub Assembly Disassembly/Inspection/Assembly
877
Forward Clutch Assembly Disassembly/Assembly
880
Reverse and High Clutch Disassembly/Assembly
885
Extension Housing Disassembly/Assembly
889
Control Valve Body Disassembly/Inspection
891
Main Control Valve Body Disassembly/Inspection/Assembly
891
Control Valve Body (Assembly)
896
Control Valve Body On-Vehicle Removal/Installation
897
Transmission Unit (Assembly)
902
Bearing, Washer and Bushing Locations (4R44E and 5R55E)
903
Transmission Unit Components Diagram
904
Transmission Unit Assembly Procedure
905
Transmission Unit Installation
936
Automatic Transmission Power Flushing
937
Upper and Lower Transmission Mounting Bolts
937
Oil Dipstick Tube
937
Oil Cooler - Auxiliary - Removal/Inspection/Installation
940
Oil Cooler Pipes Removal/Inspection/Installation
942
Drive Plate Removal/Inspection/Installation
943
Shift Mechanism Troubleshooting
944
Shift Mechanism Inspection and Verification
944
Shift Mechanism - Symptom Chart
944
Shift Lock Actuator and Shift Lock Actuator Connector
945
Pinpoint Tests
946
Shift Interlock System Does Not Release or Lock Properly
946
Shift Control Linkage Binding, out of Proper Gear Relationship
946
Selector Cable Removal/Inspection/Installation
947
Selector Cable Adjustment
948
Selector Lever Removal/Inspection/Installation
949
On-Board Diagnosis System, Service Points
950
Electrical Diagnosis Support EEC PWR Fuse (PCM Memory Power)
952
Propeller Shaft
957
Propeller Shaft Troubleshooting
958
Propeller Shaft Removal/Installation
958
Dust Boot Inspection
959
U-Joint Assembly Inspection
959
Propeller Shaft Overhaul
960
Bearing Cup
962
Spider
963
Centering Socket Yoke
964
Center Yoke
964
Slip Yoke, Dust Boot
964
Center Bearing Support
965
Front Propeller Shaft, Rear Propeller Shaf Inspection
965
Center Bearing Support and Half-Round Yoke Inspection
965
Coupling Shaft and Rear Yoke (Cab Plus) Inspection
965
Dust Boot, Slip Yoke
966
Centering Yoke and Centering Socket Yoke
967
Bearing Cup, Spider
967
Driveline Angularity Adjustment
969
Engine Angle Adjustment
971
Propeller Shaft Balancing
971
Front and Rear Axle
974
Front and Rear Axle Diagrams
975
Front and Rear Axle Specifications
976
Front Axle Troubleshooting
977
Front Differential Troubleshooting
977
Rear Axle Troubleshooting
978
Rear Differential Troubleshooting
978
Front Axle (4X2)
979
Wheel Bearing Play
979
Knuckle Removal/Installation
980
Front Axle (4X4) - Wheel Bearing Play
982
Knuckle and Spindle Removal/Installation
984
Tie Rod Nut Removal
985
Camber/Caster Adjuster Removal
985
Lower Ball Joint Removal
985
Upper Ball Joint Removal
985
Upper Ball Joint Installation
986
Camber/Caster Adjuster Installation
986
Tie Rod Nut Installation
986
Front Axle Drive Shaft (Dana 28 and Dana 36) Removal/Inspection/Installation
987
Front Axle Drive Shaft (Dana 28 and Dana 36) Diagram
988
Seal Removal
989
Inner Bearing Cup Removal
989
Outer Bearing Cup Removal
989
Rubber Boot Removal
989
Slinger Removal
990
Slinger Installation
990
Rubber Boot Installation
990
Clamps Installation
990
Inner Bearing Cup Installation
991
Outer Bearing Cup Installation
991
Spindle Installation
991
Seal Installation
991
Front Axle Drive Shaft (Dana 28 and Dana 36) Disassembly/Assembly
992
Front Axle Casing (4X4) Removal/Installation
993
Tie-Rod End Removal
994
Spring Removal
994
Shock Absorber Removal
994
Front Axle Casing, Right and Left Removal
994
Radius Arm and Bracket
995
Spring Installation
995
Shock Absorber Installation
995
Tie-Rod End Installation
995
Rear Axle
996
Rear Differential Oil Inspection
996
Bearing and Seal Replacement
997
Wheel Bearing Play Inspection
997
Wheel Bearing Play Adjustment
997
Rear Axle Removal/Installation
999
Rear Axle Casing Removal/Installation
1002
Front Differential - Preparation
1006
Front Differential On-Vehicle Maintenance
1007
Front Differential Oil Inspection
1007
Oil Seal Replacement
1008
Front Differential Removal
1009
Differential Gear Assembly Removal
1010
Snap Ring Removal
1010
Right Oil Seal Removal
1011
Left Oil Seal Removal
1011
Needle Bearing
1011
Front Differential Disassembly
1012
Differential Casing
1013
Differential Gear Assembly
1013
Companion Flange
1014
Drive Pinion, Oil Slinger/Selective Shim and Inner Bearing
1014
Bearing Inner Race
1014
Oil Baffle
1015
Bearing Outer Race
1015
Side Bearing
1015
Shims
1015
Front Differential Inspection
1016
Pinion Gear and Thrust Washer
1016
Rear Bearing
1016
Front Differential Assembly
1017
Total Differential Gear Assembly End Play
1018
Oil Slinger/Selective Shim Thickness Check
1019
Oil Slinger/Selective Shim, Drive Pinion and Rear Bearing
1020
Collapsible Spacer
1020
Differential Gear Assembly and Shims
1025
Front Differential Installation
1030
Rear Differential - Preparation
1033
Rear Differential Standard Removal
1034
Ring Gear Runout Test
1035
Ring Gear Backlash Check
1035
Rear Differential Disassembly/Inspection
1037
Speed Sensor Ring
1038
Pinion Shaft, Pinion Gears and Thrust Washers, Side Gears and Thrust Washers
1038
Rear Differential Assembly
1041
Rear Differential Installation
1047
Backlash Specifications
1049
Shim Code Chart - Differential Side Bearing
1049
Limited Slip Disassembly/Inspection
1050
Limited Slip Assembly
1054
Wheel Hubs
1059
Automatic Locking Wheel Hub Removal/Installation
1059
Manual Locking Wheel Hub Removal/Installation
1062
Inner Locknut Installation
1063
Washer Installation
1064
Outer Locknut Installation
1064
Spacer Installation
1064
Steering System
1065
Steering System Diagram
1066
Steering Specifications
1068
Manual Steering Troubleshooting Guide
1069
Steering Wheel and Column On-Vehicle Inspection
1070
Preload and Meshload Check
1070
Preload and Meshload Check Adjustment
1070
Fixed and Tilt Steering Column Removal/Installation
1072
Steering Column Opening Cover, Steering Column Cover Reinforcement and Steering Column Center Reinforcement
1073
Transmission Control Shift Indicator Removal
1073
Steering Column Removal
1073
Transmission Shift Cable Removal
1074
Transmission Shift Cable Installation
1074
Steering Column Installation
1075
Transmission Control Shift Indicator
1075
Steering Column Opening Cover Reinforcement
1075
Manual Steering Disassembly/Assembly
1076
Ignition Switch Lock Cylinder
1078
Air Bag Sliding Contact
1078
Turn Indicator Cancel Cam
1079
Shift Interlock Solenoid and Shift Selector Position Insert
1079
Steering Column Lock Actuator Lever Pin
1081
Steering Column Lower Bearing Spring
1081
Lock Cylinder Housing
1081
Lock Levers
1082
Lock Actuators
1082
Lock Cylinder Housing, Tilt Steering
1084
Fixed Steering
1084
Upper Bearing Snap Ring and Spring
1085
Steering Column Lock Gear
1086
Steering Column Lock Housing Bearing
1086
Transmission Column Shift Selector Tube
1086
Steering Gear Removal/Installation
1087
Pitman Arm Removal
1088
Steering Gear Installation
1088
Pitman Arm Installation
1088
Sector Cover and Bushing Assembly
1090
Wormshaft Lower Bearing Cup
1090
Wormshaft Upper Bearing Cup
1090
Warmshaft, Ball Nut Inspection
1091
Housing Inspection
1091
Sector Shaft Inspection
1091
Wormshaft Seal Installation
1092
Sector Shaft Seal Installation
1092
Wormshaft Upper Bearing Cup Installation
1092
Wormshaft Lower Bearing Cup Installation
1093
Wormshaft Installation
1093
Sector Cover and Bushing Assembly, Housing
1093
Steering Linkage Removal/Installation
1095
Center Link Removal
1096
Inner Tie Rod Removal
1097
Outer Tie Rod Removal
1097
Pitman Arm Removal (Steering Linkage)
1097
Pitaman Arm Installation (Steering Linkage)
1097
Outer Tie Rod Installation
1098
Inner Tie Rod Installation
1098
Center Link Installation
1098
Power Steering Troubleshooting
1099
Air Bleeding - Procedure a
1100
Vacuum Fill Process
1100
Air Bleeding - Procedure B
1101
Devac System
1101
Lnspection of Power Steering Fluid Level
1101
Fluid Pressure
1102
Steering Wheel and Column Inspection
1103
Steering Gear Removal and Installation
1104
Steering Gear Disassembly and Assembly
1105
Race Locknut Set Screw
1106
Worm Bearing Race Locknut
1107
Worm and Valve Sleeve Assembly (Valve Sleeve Seals)
1107
Worm and Valve Sleeve Assembly
1107
Steering Gear Housing
1109
Valve Housing
1111
Power Steering Disassembly Note
1112
Power Steering Assembly Note
1112
Oil Pump Removal and Installation
1113
Oil Pump Pulley
1116
Power Steering Disassembly/Assembly
1118
Lower Plate, Disc Spring
1120
Shaft Seal, Retainer
1120
Rotor Shaft Retaining Ring Installation
1121
Shaft Seal, Retainer Installation
1121
Disc Spring Installation
1121
Lower Plate Installation
1121
Rotor, Slippers
1123
Upper Plate Installation
1123
Rotor Shaft Installation
1123
Valve Cover Installation
1124
Retaining Ring Installation
1124
O-Ring Installation
1124
Drive Belt Check
1125
Drive Belt Replacement
1126
Braking System
1127
Braking System Diagrams
1128
Parking Brake Diagram
1130
Rear Anti-Lock Brake System Diagram
1131
4-Wheel Anti-Lock Brake System Diagrams
1133
Brake System Specifications
1134
Conventional Brake System Troubleshooting
1135
Air Bleeding (Vehicle Equipped with RABS)
1136
Air Bleeding (Vehicle Equipped with 4WABS)
1137
Brake Hydraulic Line Inspection (on Vehicle)
1138
Brake Fluid Inspection
1139
Brake Fluid Replacement
1139
Vacuum Line/Check Valve Inspection
1139
Brake Pedal Inspection (on Vehicle)
1140
Brake Pedal Removal/Inspection/Installation
1141
Master Cylinder Removal/Installation
1143
Power Brake Unit Push Rod Adjustment
1144
Brake Pipes
1144
Master Cylinder Disassembly/Inspection/Assembly
1145
Power Brake Unit Quick Inspection (on Vehicle)
1146
Secondary Piston
1146
Brake Fluid Level Sensor Inspection
1146
Power Brake Unit Removal/Installation
1147
Front Brake (Disc) Inspection (on Vehicle)
1148
Power Brake Unit Disassemby/Assembly
1148
Front Brake (Disc) Removal/Inspection/Installation
1149
Caliper, Disc Pad Removal
1150
Disc Plate Removal
1151
Disc Plate Installation
1152
Caliper, Disc Pad Installation
1152
Disc Plate Inspection
1152
Disc Plate Runout
1153
Rotor Turning
1153
Caliper Disassembly/Inspection/Assembly
1155
Rear Brake (Drum) Removal/Inspection/Installation
1156
Brake Drum Removal
1157
Brake Shoe Removal
1157
Brake Drum Inspection
1157
Brake Shoe Installation
1158
Brake Drum Installation
1158
Wheel Cylinder Disassembly/Inspection/Assembly
1160
Parking Brake System Troubleshooting
1161
Releasing Cable Tension
1161
Resetting Pedal Control Spring Tension
1162
Parking Brake Shoe Removal/Inspection/Installation
1163
Parking Brake (Pedal Type) Adjustment
1163
Front Parking Brake Cable Removal/Installation/Inspection
1163
Rear Parking Brake Cable Removal/Inspection/Installation
1163
Rear Anti-Lock Brake System (RABS) Troubleshooting
1164
Parking Brake Pedal Removal/Inspection/Installation
1164
Rear Anti-Lock Brake System Wiring Diagram
1165
Rear Anti-Lock Brake System - Relationship Chart
1166
Rear Anti-Lock Brake System - Diagnostic Chart
1166
Rear Anti-Lock Brake System - Diagnostic Index
1167
Rear Anti-Lock Brake System - System Troubleshooting
1168
Yellow Rear ABS Warning Light Does Not Illuminate for 1-2 Seconds When Ignition Switch Is Turned on
1168
Red Brake System Warning Light Does Not Illuminate When Ignition Switch Is Turned to START
1169
Red Brake System Warning Light Illuminates When Ignition Switch Is Turned on and Parking Brake Released
1170
Yellow Rear ABS Warning Light Remains Illuminated When Ignition Switch Is Turned on
1171
Yellow Rear ABS Warning Light Remains Illuminated with the Ignition Switch on after One Blinking Illumination
1171
Yellow Rear ABS Warning Light Automatically Begins to Flash with the Ignition Switch on
1172
Yellow Rear ABS Warning Light Does Not Flash the Code When Self-Diagnosis Function Is Started
1173
Other Concerns
1174
Rear Anti-Lock Brake System Self-Diagnosis Function. Inspection by Diagnostic Test Mode
1175
Memory Cancel
1176
Service Code Table
1176
Pattern of Output Signal (Rear ABS Warning Light)
1176
Open Isolation Valve Circuit
1177
Open Dump Valve Circuit
1177
Open or Short in Hydraulic Unit Valve Reset Switch Circuit, Hydraulic Leak into Dump Section of Hydraulic Unit
1178
Excessive Dump Valve Activity
1178
Rear Axle Speed Sensor Signal Rapidly Cuts in and out While Driving
1179
No Isolation Valve Self-Test (Isolation Valve Circuit Short to Ground)
1179
No Dump Valve Self-Test (Dump Valve Circuit Short to Ground)
1180
High Rear Axle Speed Sensor Resistance
1180
Low Rear Axle Speed Sensor Resistance
1180
Brake On/Off (BOO) Switch Circuit Always Closed
1181
Loss of Hydraulic Brake Fluid for One or more Seconds During an Anti-Lock Stop/Damaged Brake Fluid Level Sensor or Related Circuit
1181
RABS Control Unit Failure
1182
Rabs Ok
1182
Intermittent Diagnosis
1182
Inspection of RABS System
1184
Check Rear ABS Warning Light Harness
1184
Check Rear ABS Warning Light Bulb
1184
Check Brake System Warning Light Bulb
1184
Check Brake On/Off (BOO) Switch
1185
Check Stoplight Switch Harness at RABS Control Unit
1185
Check Isolation Valve Solenoid
1185
Check Isolation Valve Orifice
1185
Check Dump Valve Solenoid
1186
Check Hvdraulic Unit Internal Circuit
1186
Check Hydraulic Unit Valve Reset Switch
1186
Check Hydraulic Unit for Leakage
1186
Check RABS Control Unit
1187
Check Rear Axle Speed Sensor
1188
Check Resistance of Rear Axle Speed Sensor
1188
Check Voltage of Rear Axle Speed Sensor
1188
Check Sensor Rotor
1189
Check Normal Braking System Operation
1189
Stopping Test
1189
RABS Operation on Hoist
1189
RABS Hydraulic Unit Removal/Installation
1190
RABS Control Unit Removal/Installation
1191
Rear Speed Sensor (RABS and ABS) Removal/Installation
1191
Rear Speed Sensor Rotor (RABS and ABS) Removal/Inspection/Installation
1192
Ring Gear and Sensor Rotor Installation
1192
Ring Gear and Sensor Rotor Inspection
1193
4-Wheel Anti-Lock Brake System (4WABS) Description
1194
4-Wheel Anti-Lock Brake System (4WABS) Troubleshooting
1194
4-Wheel Anti-Lock Brake System (4WABS) Wiring Diagram
1195
To Retrieve Dtcs
1197
Clearing Dtcs
1198
4-Wheel Anti-Lock Brake System (4WABS) - Diagnostic Trouble Code
1199
Breakout Box Function
1200
4-Wheel Anti-Lock Brake System (4WABS) Precheck
1201
Intermittent Valve Failure
1203
Main Relay Circuit Output Failure
1204
Battery Voltage High
1206
Battery Voltage Low
1207
Left Front ISO Valve Coil Circuit Failure
1208
Left Front Dump Valve Coil Circuit Failure
1210
Right Front ISO Valve Coil Circuit Failure
1212
Right Front Dump Valve Coil Circuit Failure
1214
Rear ISO Valve Coil Circuit Failure
1216
Rear Dump Valve Coil Circuit Failure
1218
Left Front Wheel Speed Sensor Input Circuit Failure
1220
Left Front Wheel Speed Sensor
1222
Right Front Wheel Speed Sensor Input Circuit Failure
1225
Right Front Wheel - Speed Sensor Input Circuit Failure
1227
Rear Axle Speed Sensor Input Circuit Failure
1230
Rear Axle Speed Sensor
1232
Front Left Valve Pair Function Test
1234
Front Right Valve Pair Function Test
1235
Rear Axle Valve Pair Function Test
1236
Pump Motor Triggered but DID Not Run
1237
G-Switch (Acceleration Sensor) Failure
1240
Pump Motor Running but Not Triggered
1242
No Communication
1243
4-Wheel Anti-Lock Brake System (4WABS) Drive Test
1244
Intermittent Diagnostic Procedure
1246
ABS Hydraulic Unit Removal/Installation
1248
Acceleration Sensor (G-Switch)
1248
ABS Control Unit Removal/Installation
1249
Front Speed Sensor Rotor Removal/Installation
1250
Front Speed Sensor Removal/Installation
1250
Wheels and Tires
1251
Wheels and Tires Specifications
1252
Wheels and Tires Troubleshooting
1253
Special Notes about Wheels and Tires
1254
Notes Regarding Tire Replacement
1254
Wheels and Tires Inspection/Adjustment
1254
Tire Wear Check
1254
Abnormal Tire Wear Check
1255
Air Pressure Check
1255
Air Leakage Check
1255
Loose Lug Nut Check
1255
Tire Rotation Check
1256
Wheel Balance Adjustment
1256
Suspension
1257
Front Suspension (2X4) Diagram
1258
Front Suspension (4X4) Diagram
1259
Rear Suspension (4X2, 4X4) Diagram
1260
Suspension Specifications
1261
Suspension Troubleshooting
1262
NVH Troubleshooting Guide
1263
Description of Underbody Noises
1264
Wheel Alignment - Preinspection
1265
Vehicle Lean Specification
1266
Front Lean Adjustment
1266
Rear Lean Adjustment
1267
Side-To-Side Lean
1268
Inspection - Dogtracking
1268
Diagnosis - Dogtracking
1269
Front Wheel Alignment
1269
Total Toe-In Adjustment
1269
Camber and Caster Adjustment
1270
Camber/Caster Adjuster Selection Table
1271
Front Suspension
1272
Front Shock Absorber (4X2, 4X4) Removal/Inspection/Installation
1272
Front Coil Spring (4X2) Removal/Inspection/Installation
1274
Front Coil Spring (4X4) Removal/Inspection/Installation
1276
Lower Arm and Pivot Bracket (4X2) Removal/Inspection/Installation
1278
Pivot Bracket (4X4) Removal/Inspection/Installation
1280
Camber/Caster Adjuster (4X2 and 4X4) Removal/Inspection/Installation
1282
Radius Arm (4X2 and 4X4) Removal/Inspection/Installation
1283
Front Stabilizer Bar (4X2 and 4X4) Removal/Inspection/Installation
1286
Jounce Bumper (4X2) Removal/Inspection/Installation
1287
Jounce Bumper (4X4) Removal/Inspection/Installation
1288
Rear Suspension
1289
Rear Shock Absorber Removal/Inspection/Installation
1289
Leaf Spring Removal/Inspection/Installation
1291
U-Bolts
1292
Leaf Spring
1292
Tip Liner Installation
1292
Service Clip Installation
1292
Rear Stabilizer Bar Removal/Inspection/Installation
1294
Body
1295
Body View
1296
Hood Components Removal/Installation
1298
Release Cable Installation
1300
Lock Assembly (Hood)
1300
Hood Hinge Installation
1301
Hood Installation
1301
Hood Adjustment
1301
Fender Panel Components Removal/Installation
1303
Front Door Components Removal/Installation
1305
Front Door Adjustment
1307
Door Lock Striker
1307
Weatherstrips Components Removal/Installation
1308
Tailgate Components Removal/Installation
1309
Fuel-Filler Lid Components Removal/Installation
1311
Front Bumper Components Removal/Installation
1312
Front Bumper Disassembly/Assembly
1313
Front Chrome Bumper Stripe Removal/Installation
1314
Rear Bumper Components Removal/Installation
1315
Rear Bumper Disassembly/Assembly
1316
Radiator Grille Components Removal/Installation
1317
Radiator Grille Inspection
1318
Radiator Grille Disassembly/Assembly
1318
Extractor Chamber Components Removal/Installation
1319
Dashboard Components Removal/Installation
1320
Console Components Removal/Installation
1323
Molding Components Removal/Installation
1324
Wheel Opening Moldings
1325
Front Door Belt Line Moldings
1325
Quarter Window (Stationary) Molding Installation
1325
Wheel Opening Moldings Installation
1325
Splash Shields (Front) Removal/Installation
1326
Splash Shields (Rear) Removal/Installation
1327
Windshield Components Removal/Installation
1328
Rearview Mirror Removal
1328
Windshield Removal
1329
Rear Window Glass Removal/Installation
1331
Rear Window Glass (Stationary Glass) Removal
1332
Rear Window Glass (Sliding Glass) Removal
1332
Rear Window Glass (Stationary Glass) Installation
1332
Rear Window Glass (Sliding Glass) Installation
1333
Trim Components Removal/Installation
1334
A-Pillar Trim
1334
Scuff Plate
1334
Front Side Trim
1334
B-Pillar Trim (Regular Cab)
1335
B-Pillar Trim (Cab Plus)
1336
Front Door Trim
1336
Lower Back Trim (Cab Plus)
1337
Assist Handles Removal
1337
B-Pillar Trim (Cab Plus) Installation
1338
B-Pillar Trim (Regular Cab) Installation
1338
Floormat/Carpet Removal/Installation
1339
Headliner Removal/Installation
1341
Sunvisors Removal
1342
A-Pillar Trim Removal
1342
Rear Window Garnish Lower Molding
1342
Headliner Removal
1342
Seat Belts Removal/Installation (Front)
1343
Shoulder Height Adjuster Removal
1345
Webbing and Fittings Inspection
1345
Rear Seat Remoal/Installation
1346
Retractor Inspection
1346
Shoulder Height Adjuster Installation
1346
Front Seat Belt Installation
1346
Rear Seat Belt Webbing and Fittings Inspection
1347
Retractor (Rear) Inspection
1347
Rear Seat Belt Installation
1347
Rear Seat Belt Buckle Installation
1347
Box - Cab and Box Alignment
1348
Cab and Box Alignment Adjustment
1348
Spare Tire Stowage Components Removal/Installation
1350
Spare Tire Components Removal/Installation
1352
Body Dimensions (Short Bed)
1353
Body Dimensions (Long Bed)
1354
Body Dimensions (Cab Plus)
1355
Seats
1356
Bench Seat Removal/Installation
1356
Bench Seat Disassembly/Assembly
1357
Manual Bucket Seat Removal/Installation
1358
Manual Bucket Seat Assembly/Disassembly
1359
Six-Way Power Bucket Seat Removal/Installation
1360
Six-Way Power Bucket Seat Disassembly/Assembly
1361
Lumbar Support Pad Removal/Installation
1362
Jump Seat Removal/Installation
1363
Seat Bracket Disassembly/Assembly
1364
Split Bench Seat Disassembly/Assembly
1365
Box Lean
1366
Box Shimming
1367
Troubleshooting Guide - Diagnostic Index (Body)
1368
Windnoise Troubleshooting
1368
SE/LE Mirror out of Position
1368
Fender Stuffer Not Seated
1368
Primary Door Seal Pinched by Lower A-Pillar Trim
1369
Air Leaks from Heater or A/C System
1369
DLO Molding Not Flush with Vehicle (LE/SE Cab-Plus Only)
1369
Poor Body Sealant at A-Pillar Body Seam and Poor Seal of Front Windshield
1370
Cab Quarter Seam Not Sealed (Regular Cab)
1370
Poor Seal of Rear Window
1371
Waterleak Troubleshooting
1372
Waterleak at Front of Cab
1372
Pinched Primary Door Seal
1372
Poor Body Sealant at A-Pillar Body Seam and Poor Seal at Front Windshield
1372
Waterleak at Heater Case
1373
Waterleak from Inner Fender Apron to Firewall Body Seam
1374
Leaks from PCM Box
1375
Waterleaks above Upper A-Pillar Trim on Headliner
1376
Waterleaks at Rear of Cab-Plus
1377
DLO Molding/Ditch Molding Not Sealed
1377
Poor Seal of Cab Quarter Window
1378
Rear Window's Poor Seal
1379
Waterleaks at Rear or Regualar Cab
1380
Cab Quarter Seam Not Sealed
1380
Special Tools
1381
Special Tools - Engine
1382
Special Tools - Manual Transmission
1383
Special Tools - Automatic Transmission
1384
Special Tools - Chassis
1386
Special Tools - Checker and Other Equipment
1389
Technical Data
1390
Compression Pressure Limit Chart
1391
Engine (2.3L) Technical Data
1392
Engine (3.0L) Technical Data
1395
Engine (4.0L) Technical Data
1398
Lubrication System Technical Data
1401
Cooling System Technical Data
1401
Fuel and Emission Control Systems Technical Data
1402
Engine Electrical System Technical Data
1403
Clutch Technical Data
1403
Manual Transmission Technical Data
1404
Transfer Case Technical Data
1405
Automatic Transmission Technical Data
1406
Line Pressure Specifications
1407
Coasting Clutch Snap Ring Selection
1407
Forward Clutch Snap Ring Selection
1407
Reverse and High Clutch Snap Ring Selection
1408
Total End Play (Thrust Bearing No. 4) Selection
1408
Oil Pump Thrust Washer Selection
1408
Vehicle Speed Shiftpoint Table
1409
Propeller Shaft Technical Data
1411
Rear Propeller Shaft Angles
1412
Front and Rear Axles Technical Data
1413
Steering System Technical Data
1414
Braking System Technical Data
1415
Wheels and Tires Technical Data
1415
Size, Offset and Pitch Circuit Diameter (Wheels)
1415
Temporary Spare Tire Technical Data
1417
Suspension Technical Data
1417
Standard Bolt and Nut Tightening Torque
1418
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