Orlando
PRE-DELIVERY INSPECTION
PDI Inspection
FOREWORD
GENERAL INTRODUCTION
1. EQUIPMENT AND MATERIAL FOR PDI AND SERVICE
TOOLS
FLUIDS
2. PRE-DELIVERY INSPECTION FORM
ENGINE COMPARTMENT
1. COMPONENTS CONNECTION LOOSE
2. HOSE AND ELECT. WIRES ROUTING
3. FREENESS OF MOVEMENT OF LINKAGE, VALVES AND OTHER COMPONENTS
4. UNUSUAL NOISES
5. SEEPAGE AND LEAKS AT HOSES AND PIPE CONNECTIONS, ETC.
6. POWER STEERING SYSTEM
7. ENGINE COOLANT PROTECTION
8. ALL FLUID LEVELS CHECK
9. THROTTLE LINKAGE
10. BELTS TENSION
BODY ACCESSORIES
1. HEADLAMPS OPERATION AND AIM
2. INDICATOR LAMPS
3. HAZARD WARNING LAMPS
4. REVERSE LAMPS
5. BRAKE LAMPS
6. TAIL LAMPS, POSITION LAMPS, NUMBER PLATE LAMPS, ADDITIONAL INDICATOR LAMPS
7. INSTRUMENT PANEL WARNING LAMPS AND INDICATORS
8. DOME AND COURTESY LIGHTS
9. GLOVE BOX ILLUMINATION, OPTION
10. HEADLIGHT LEVELLING SWITCH, OPTION
11. INSTRUMENT PANEL GAUGE OPERATION
12. FRONT FOG LIGHT SWITCH, OPTION
13. REAR FOG LIGHT SWITCH, OPTION
14. REAR WINDOW AND OUTSIDE MIRROR DEMISTER BUTTON
15. INSTRUMENT ILLUMINATION CONTROL SWITCH, OPTION
16. HORN SWITCH
17. WIPER AND WASHER OPERATION
18. TAILGATE WINDOW WIPER AND WASHER SWITCH, OPTION
19. RADIO/CASSETTE, SPEAKERS, AERIAL, OPTION
20. CUP HOLDER
21. CIGARETTE LIGHTER
22. CLOCK
23. DOOR LOCK
24. DOOR WINDOW
25. OUTSIDE REARVIEW MIRRORS
26. TILTABLE STEERING WHEEL, OPTION
27. POWER SUN ROOF, OPTION
28. SEAT
29. FUEL FILLER DOOR RELEASE LEVER
30. BOOT LID RELEASE LEVER
31. ENGINE BONNET RELEASE LEVER
32. THEFT DETERRENT SYSTEM, OPTION
33. KEYLESS ENTRY SYSTEM WITH ANTITHEFT FUNCTION, OPTION
34. SUNGLASSES HOLDER
35. SEAT HEATER SWITCH, OPTION
UNDER VEHICLE
UNDER VEHICLE INSPECTION
1. STEERING GEAR AND LINKAGE
2. PROPER TRACK ROD CLAMP POSITION
3. EXHAUST SYSTEM FOR PROPER ALIGNMENT AND CLEARANCE
4. FRONT AND REAR SUSPENSION
5. CHECK AXLE AND MANUAL GEARBOX FLUID LEVEL
6. BRAKE SYSTEM
7. FUEL SYSTEM
8. DRIVE SHAFT OF FRONT DRIVE AXLES
9. VISUALLY INSPECT WHEEL STUD AND FLANGE NUTS
10. INFLATE TYRES TO SPECIFIED PRESSURE
ROAD TEST
1. SEAT BELTS
2. FREE PLAY OF BRAKE AND CLUTCH
3. HORN
4. WIND NOISE
5. OPTIONS AND ACCESSORIES
6. HEATER AND AIR CONDITIONING
CONTROL PANEL
7. OPERATION OF WINDSCREEN WIPER AND WASHER FOR PATTERN, SPEED, AND PARKING POSITION INCLUDES AIM WASHER IF NECESSARY
8. ENGINE AND TRANSMISSION PERFORMANCE DURING ACCELERATION, DECELERATION, IDLE, CRUISE AND DOWN SHIFTS
9. SQUEAKS AND RATTLES
10. STEERING COLUMN IGNITION LOCK
11. INSTRUMENTS AND GAUGES
12. THROTTLE CONTROL FOR FREE OPERATIONS
13. STEERING WHEEL CENTRE POSITION AND HANDLING
14. BRAKES, INCLUDES HANDBRAKE AND WARNING LIGHT
APPEARANCE
1. INSPECT CONDITION AND PERFORM DETAIL OPERATION
2. CHECK FOR PROPER ASSEMBLY, FIT AND RETENTION OF PARTS AND COMPONENTS
3. EXTERIOR FINISH
4. INTERIOR TRIM AND CARPETS PROTECTIVE COVERINGS
5. SPARE WHEEL, JACK AND VEHICLE TOOLS
6. BATTERY
ANNEX
1. RECEIVING INSPECTION
2. DIRECTION FOR THE USE OF HY-600 TRANSIT COATING REMOVER IN A HAND WASH OPERATION
3. STORAGE AND MAINTENANCE OF NEW VEHICLE IN EXTREMELY HOT AND HUMID LOCATIONS
DESCRIPTION:
LABOUR TIME GUIDE
0. General Information
1. INTRODUCTION
1-1. PAGE LAYOUT
1-2. TYPES OF OPERATION
Major Operation
Supplementary Operation (Adds)
1-3. TIME ALLOWANCES
2. HOW TO READ THIS MANUAL
Section
Illustration Number
Operation Description
3A. Major Operation
3B. Supplementary Operation
Operation Code
1) Main Group Code
2) Basic Code
3) Auxiliary Code
Major Operation
Supplementary Operation (ADD)
Operation Times
Model Code
Engine Type
3. HOW TO USE THIS MANUAL
4. PAINT REPAIR
4-1. INSTRUCTION
4-2. LABOR TIME
4-3. REPAIR TYPE
4-4. HOW TO USE OPERATION CODE FOR PARTIAL PAINTING
5. DEFECT CODE
5-1. NATURE CODES
5-2. CAUSE CODES
5-3. PAINT CODES
6. ABBREVIATIONS
7. MAIN GROUP CODE
1. Engine
DIESEL SOHC ENGINE MECHANICAL
SOHC ENGINE UNIT
BELT SYSTEM
ENGINE BLOCK
CRANKSHAFT & PISTON
OIL PAN & PUMP
CYLINDER HEAD
CAM SUPPORT & SHAFT
TIMING COVER
ENGINE & TRANSAXLE MOUNT
PETROL DOHC ENGINE MECHANICAL
DOHC ENGINE UNIT
BELT SYSTEM
ENGINE BLOCK
CRANKSHAFT & PISTON
OIL PAN & PUMP
CYLINDER HEAD
CAM SUPPORT & SHAFT
TIMING COVER
ENGINE & TRANSAXLE MOUNT
DIESEL DOHC ENGINE MECHANICAL
DOHC ENGINE UNIT
BELT SYSTEM
ENGINE BLOCK
CRANKSHAFT & PISTON
OIL PAN & PUMP
CYLINDER HEAD
CAM SUPPORT & SHAFT
TIMING COVER
ENGINE & TRANSAXLE MOUNT
PETROL ENGINE COOLING
RADIATOR
COOLING FAN
RADIATOR HOSE & PIPE
THERMOSTAT
DIESEL ENGINE COOLING
RADIATOR
COOLING FAN
RADIATOR HOSE & PIPE
THERMOSTAT
PETROL ENGINE ELECTRICAL
IGNITION CABLE
ALTERNATOR UNIT
STARTER
BATTERY
FUSE & RELAY
DIESEL ENGINE ELECTRICAL
IGNITION CABLE
ALTERNATOR UNIT
STARTER
BATTERY
FUSE & RELAY
PETROL ENGINE CONTROLS
FUEL TANK
FUEL LINE
CANISTER & FUEL VACUUM
FUEL INJECTION
ACCELERATOR CONTROL
EMISSION CONTROL
DIESEL ENGINE CONTROLS
FUEL TANK
FUEL LINE
CANISTER & FUEL VACUUM
FUEL INJECTION
ACCELERATOR CONTROL
EMISSION CONTROL
PETROL ENGINE INTAKE & EXHAUST
AIR INTAKE SYSTEM
INTAKE MANIFOLD
EXHAUST MANIFOLD
VACUUM HOSE
EXHAUST PIPE LINE
DIESEL ENGINE INTAKE & EXHAUST
AIR INTAKE SYSTEM
INTAKE MANIFOLD
EXHAUST MANIFOLD
VACUUM HOSE
EXHAUST PIPE LINE
2. Suspension
FRONT SUSPENSION
KNUCKLE & HUB (213)
FRONT SHOCK ABSORBER (214)
CONTROL ARM (215)
REAR SUSPENSION
REAR AXLE (231)
REAR SHOCK ABSORBER (232)
EQUALISER BEAM SUPPORT (236)
TYRES & WHEEL
WHEELS & WHEEL COVER (241)
TYRE PRESSURE MONITORING SYSTEM (242)
3. Driveline Axle
DRIVE LINE / AXLE
AXLE SHAFT PARTS (321)
4. Brakes
HYDRAULIC BRAKE
BRAKE PIPE (425)
BRAKE PEDAL & MOUNT (428)
MASTER CYLINDER & POWER BOOSTER
MASTER CYLINDER & BOOSTER (431)
FRONT BRAKES
FRONT BRAKE (445)
REAR BRAKES
REAR BRAKE (456)
ANTI-LOCK BRAKES SYSTEM
ANTI-LOCK BRAKE SYSTEM (462)
PARKING BRAKES
PARKING BRAKE (478)
5. Transmissions/Transaxle
GMPT AUTO TRANSAXLE : 6T40/45
CASE AND ASSOCIATED PARTS (541)
TRANSMISSION CASE ASSEMBLY (542)
DRIVE LINK ASSEMBLY (543)
CONTROL VALVE BODY ASSEMBLY (544)
LOW/REVERSE AND CLUTCH ASSEMBLY (545)
INPUT, OUTPUT AND REACTION GEARSETS (546)
PARK SYSTEM COMPONENTS (547)
AUTOMATIC TRANSAXLE CONTROLS (548)
AUTOMATIC TRANSAXLE CONTROLS (549)
FIVE-SPEED MANUAL TRANSAXLE: D24, D33
MANUAL TRANSAXLE (561)
TRANSAXLE GEAR (563)
BEARING PLATE (565)
GEAR SHIFT COVER & FORK (566)
DIFFERENTIAL GEAR (567)
SHIFT CONTROL (569)
CLUTCH
CLUTCH PARTS (581)
HYDRAULIC CLUTCH (582)
CLUTCH PEDAL (583)
6. Steering
POWER STEERING SYSTEM
POWER STEERING GEAR (621)
POWER STEERING PIPE LINE (623)
MANUAL STEERING GEAR
MANUAL STEERING GEAR (635)
STEERING WHEEL & COLUMN
STEERING WHEEL (641)
STEERING COLUMN COVER (642)
STEERING COLUMN (643)
TYRE ROD (647)
7. (HVAC) Heating, Ventilation, and Air Conditioning
HEATING & VENTILATION
AIR DISTRIBUTION (711)
EVAPORATOR (713)
BLOWER (714)
HVAC CONTROL
COMPRESSOR (732)
A/C HOSE & PIPE LINE (734)
A/C CONTROL SWITCH (735)
8. Restraints
SEAT BELTS
FRONT SEAT BELT (812)
SUPPLEMENTAL INFLATABLE RESTRAINTS
AIR BAG SYSTEM (832)
IMMOBILIZER (833)
9. Body and Accessories
BODY WIRING SYSTEM
WIRING HARNESS (911)
LIGHTING SYSTEM
FRONT LAMP (916/917)
WIPER/WASHER SYSTEM
WINDSCREEN WIPER (921)
INSTRUMENT DRIVER SYSTEM
INSTRUMENT CLUSTER (925)
AUDIO & ANTI-THEFT SYSTEM
AUDIO SYSTEM – ELECTRICAL PARTS (928)
AUDIO & ANTI-THEFT SYSTEM – AERIAL (929)
INTERIOR TRIM
PILLAR TRIM (931)
PILLAR TRIM (932)
PILLAR TRIM (936)
SEATS
FRONT SEAT (941)
REAR SEAT (942)
REAR SEAT #2 (943)
GLASS & MIRRORS
GLASS & OUT SIDE MIRRORS (946)
EXTERIOR PARTS
MUD GUARD (946)
MUD GUARD (952)
BUMPER & FASCIAS
FRONT BUMPER (956)
FRONT BUMPER (956) & REAR BUMPER (957)
REAR BUMPER (957)
DOORS
FRONT DOOR & LOCK (961A)
FRONT WINDOW LIFTER (961B)
FRONT WEATHER STRIP (961C)
REAR DOOR & LOCK (963A)
REAR WINDOW LIFTER (963B)
REAR WEATHERSTRIP (963C)
ELECTRIC DOOR LOCK (965)
FUEL FILLER LOCK & QUARTER WINDOW (966)
LOCK (967)
BOOT LID LOCK & TAILGATE LOCK CAR LOCK (968)
ROOF
HEADLINING & ROOF PANEL (971)
HEADLINING & ROOF PANEL (972)
BODY FRONT END
GRILLE (973)
GRILLE (974)
GRILLE (975)
BODY REAR END
BOOT LID PANEL & SPOILER (978)
BOOT LID PANEL & SPOILER (979)
10. Paint
PAINT
10 PAINT EXTERIOR
SERVICE MANUAL
1. Preface
Preface
Introduction
Danger
Title Page
Dangers, Warnings, and Cautions
Introduction
Definition of Danger, Warning, Caution, and Note
ABS Component Handling Warning
Actions to Take When Working with Fuel Warning
Approved Equipment for Collision Repair Warning
Assistant Driving Warning
Battery Disconnect Warning
Brake Dust Warning
Brake Fluid Irritant Warning
Checking Hot Transmission Fluid through Drain Plug Hole Warning
Cleaning Solvent Warning
Collision Sectioning Warning
Cracked Window Warning
Defroster Outlet Warning
DOT 4 Brake Fluid Warning
Exhaust Service Warning
Express Window Down Warning
Eye Protection Warning
Foam Sound Deadeners Warning
Fuel and Evaporative Emission Pipe Warning
Fuel Gauge Leak Warning
Fuel Pipe Fitting Warning
Fuel Storage Warning
Fuel Vapors in Evaporative Emission Components Warning
Gasoline/Gasoline Vapors Warning
Glass and Sheet Metal Handling Warning
Halogen Bulb Warning
Hood Hold-Open Device Warning
Hot Exhaust System Warning
Liftgate Hydraulic System Warning
Moving Parts and Hot Surfaces Warning
Parking Brake and Drive Wheels Warning
Protective Goggles and Glove Warning
Relieving Fuel Pressure Warning
Road Test Warning
Safety Glasses and Compressed Air Warning
Safety Glasses Warning
Safety Goggles and Fuel Warning
SIR Deployed Inflator Modules Are Hot Warning
SIR Inflatable Module Deployment Outside Vehicle Warning
SIR Inflator Module Disposal Warning
SIR Inflator Module Handling and Storage Warning
SIR Seatbelt Pretensioner Handling Warning
SIR Special Tool Warning
SIR Warning
Steering Angle Sensor Initialization Warning
Torque-to-Yield Fastener Warning
Window Retention Warning
Work Stall Test Warning
Air in the Power Steering System Caution
Avoid Chipping or Scratching the Coating Caution
Ball Stud Removal Caution
Belt Dressing Caution
Brake Caliper Caution
Brake Fluid Effects on Paint and Electrical Components Caution
Clearcoat/Ultraviolet Screeners Caution
Component Fastener Tightening Caution
Compressor Hose Clearance to the Exhaust Gas Circulation Pipe Caution
Drive Axle Caution
Engine Coolant Thermostat Housing Caution
Exterior Trim Emblem Removal Caution
Fastener Caution
Filling the Master Cylinder Caution
Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution
Heated Oxygen and Oxygen Sensor Caution
Heated Oxygen Sensor Resistance Learn Reset Caution
Installing Hoses without Twists or Bends Caution
Machined Surface Damage Caution
OBDII Symbol Description Caution
Pipe Wrench Positioning Caution
Power Steering Hose Disconnected Caution
Silicon Contamination of Heated Oxygen Sensors Caution
Steering Column in Lock Position Caution
Steering Wheel in the Full Turn Position Caution
Steering Wheel Straight and Column Locked Caution
Test Probe Caution
Three-Way Catalytic Converter Damage Caution
Torque Reaction Against Timing Drive Chain Caution
Torque-to-Yield Fastener Caution
Transmission Fluid Vent Cap Removal Caution
Transmission Overfill Caution
Using Proper Power Steering Fluid Caution
Valve Lifter Priming Caution
Window Edge Damage Caution
2. General Information
General Information
Specifications
Volatile Memory Programming
Introduction
US English/Metric Conversion
Decimal and Metric Equivalents
Arrows and Symbols
Vehicle, Engine and Transmission ID and VIN Location, Derivative and Usage
Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label
RPO Code List — GME
RPO Code List — LAAM
Fasteners
Thread Inserts
Abbreviations and Meanings
Registered and Non-Registered Trademarks
Lifting and Jacking the Vehicle
Diagnostic Information and Procedures
Customer Concern Verification Sheets
Air/Wind Noise
Diagnostic Information and Procedures
Air/Wind Noise
Tracing Powder or Chalk Test
Air Pressure Test
Soap Suds or Bubble Test
Repair Instructions
Exterior Windnoise
Interior Windnoise
Special Tools and Equipment
Special Tools
Maintenance and Lubrication
Specifications
Approximate Fluid Capacities
Fluid and Lubricant Recommendations
Maintenance Items
Maintenance
Maintenance Schedule
GM Oil Life System Resetting
Squeaks and Rattles
Diagnostic Information and Procedures
Squeaks and Rattles
Symptoms – Squeaks and Rattles
Special Tools and Equipment
Special Tools
Vibration Diagnosis and Correction
Specifications
Tire and Wheel Runout Specifications
Diagnostic Information and Procedures
Vibration Analysis – Road Testing
Component Rotational Speed Calculation
Vibration Analysis – Tire and Wheel
Vibration Analysis – Hub and/or Axle Input
Vibration Analysis – Engine
Engine Order Classification
Vibration Analysis – Engine/Accessory Isolation
Vibration Analysis – Engine Balance
Vibration Diagnostic Aids
Vibration Diagnostic Aids – Vibration Intermittent or Not Duplicated
Vibration Diagnostic Aids – Vibration Duplicated, Component Not Identified
Vibration Diagnostic Aids – Vibration Duplicated, Difficult to Isolate/Balance Component
Vibration Diagnostic Aids – Vibration Duplicated, Appears to Be Potential Operating Characteristic
Symptoms – Vibration Diagnosis and Correction
Vehicle-to-Vehicle Diagnostic Comparison
Tire and Wheel Inspection
Tire and Wheel Assembly Runout Measurement – On-Vehicle
Tire and Wheel Assembly Runout Measurement – Off Vehicle
Brake Rotor/Drum Balance Inspection
Hub/Axle Flange and Wheel Stud Runout Inspection
Tire and Wheel Assembly Isolation Test
Repair Instructions
Tire and Wheel Assembly Balancing – Off Vehicle
Description and Operation
Vibration Theory and Terminology
Electronic Vibration Analyzer (EVA) Description and Operation
Vibrate Software Description and Operation
Special Tools and Equipment
Special Tools and Equipment
Waterleaks
Diagnostic Information and Procedures
Waterleak Test Preparation
Water Hose Test
Air Hose Test
Repair Instructions
Body Waterleak Repair
Stationary Window Waterleak Repair
3. Body Hardware and Trim
Exterior Trim
Repair Instructions
Liftgate Side Applique Replacement
Front Fog Lamp Bezel Replacement
Front License Plate Bracket Replacement
Front Bumper Fascia Front Tow Eye Access Hole Cover Replacement
Rear Bumper Fascia Rear Tow Eye Access Hole Cover Replacement
Front Side Door Window Frame Cover Replacement
Rear Side Door Window Frame Rear Cover Replacement
Rear Side Door Window Frame Front Cover Replacement
Front Bumper Fascia Emblem/Nameplate Replacement
Liftgate Emblem/Nameplate Replacement — Bowtie
Liftgate Emblem/Nameplate Replacement — Chevrolet
Liftgate Emblem/Nameplate Replacement — Orlando
Liftgate Emblem/Nameplate Replacement — Orlando LS
Liftgate Emblem/Nameplate Replacement — Orlando LT
Radiator Upper Grille Replacement
Radiator Lower Grille Replacement
Radiator Outer Grille Replacement
Front Side Door Lower Molding Replacement
Front Fender Wheel Opening Molding Replacement
Rear Side Door Lower Molding Replacement
Rear Wheel Opening Molding Replacement
Rocker Panel Molding Replacement
Floor Coverings and Headlinings
Repair Instructions
Eliminating Unwanted Odors in Vehicles
Floor Carpet Drying
Front Floor Panel Carpet Replacement
Load Floor Carpet Replacement
Headlining Trim Panel Replacement — with Sunroof
Headlining Trim Panel Replacement — without Sunroof
Special Tools and Equipment
Special Tools
Instrument Panel and Console Trim
Specifications
Fastener Tightening Specifications
Repair Instructions
Instrument Panel Location Guide Replacement
Instrument Panel Center Upper Molding Replacement
Driver Information Display Bezel Replacement
Instrument Panel Outer Trim Cover Replacement – Right Side
Instrument Panel Outer Trim Cover Replacement – Left Side
Instrument Panel Lower Trim Pad Cover Replacement
Instrument Panel Lower Center Trim Panel Replacement
Instrument Panel Compartment Replacement
Instrument Panel Molding Replacement – Driver Side
Instrument Panel Molding Replacement – Passenger Side
Instrument Panel Center Molding Replacement
Instrument Panel Lower Molding Replacement
Instrument Panel Lower Extension Side Trim Panel Replacement
Inflatable Restraint Instrument Panel Module Inner Bracket Replacement
Instrument Panel Inflatable Restraint Module Housing Side Bracket Replacement
Instrument Panel Assembly Replacement
Instrument Panel Tie Bar Replacement
Instrument Panel Tie Bar Brace Replacement
Instrument Panel Wiring Harness Replacement
Front Floor Cup Holder Replacement
Front Floor Console Compartment Replacement
Front Floor Console Compartment Liner Replacement
Front Floor Console Extension Panel Replacement – Right Side
Front Floor Console Extension Panel Replacement – Left Side
Front Floor Front Console Replacement
Front Floor Rear Console Replacement
Front Floor Rear Console Rear Cover Replacement
Front Floor Console Bracket Replacement
Front Floor Console Front Cover Replacement
Front Floor Console Rear Cover Replacement
Roof Rail Front Stowage Compartment Replacement
Special Tools and Equipment
Special Tools
Interior Trim and Paneling
Specifications
Fastener Tightening Specifications
Repair Instructions
Front Side Door Window Switch Bezel Replacement
Rear Side Door Window Switch Bezel Replacement
Front Side Door Pull Handle Cover Replacement
Rear Side Door Pull Handle Cover Replacement
Front Side Door Trim Replacement
Front Side Door Water Deflector Replacement
Rear Side Door Water Deflector Replacement
Front Side Door Sill Trim Plate Replacement
Rear Side Door Sill Trim Plate Replacement — 4-Door Notchback 69
Roof Rail Front Assist Handle Replacement
Roof Rail Rear Assist Handle Replacement
Sunshade Replacement
Sunshade Support Replacement
Sunshade Retainer Replacement
Sunshade Retainer Bolt Cover Replacement
Windshield Garnish Molding Replacement
Center Pillar Upper Garnish Molding Replacement
Center Pillar Lower Garnish Molding Replacement
Quarter Window Garnish Molding Replacement
Body Side Trim Panel Replacement – Left Side
Body Side Trim Panel Replacement – Right Side
Rear Compartment Floor Stowage Compartment Replacement
Rear Side Door Trim Replacement
Liftgate Trim Finish Panel Replacement
Liftgate Trim Finish Access Hole Cover Replacement
Rear License Plate Access Hole Cover Replacement
Liftgate Upper Trim Finish Panel Replacement
Liftgate Lower Trim Finish Panel Replacement
Rear Compartment Sill Trim Plate Replacement
Cargo Tie Down Hook Replacement
Convenience Net Replacement
Cargo Net Replacement
Liftgate Inside Pull Handle Replacement
Special Tools and Equipment
Special Tools
4. Body Repair
Bolted Exterior Body Panels and Closures
Specifications
Fastener Tightening Specifications
Repair Instructions
Front Fender Front Lower Bracket Replacement
Hood Primary Latch Release Cable Replacement
Rear Side Door Check Replacement
Front Side Door Adjustment
Front Side Door Replacement
Rear Side Door Adjustment
Rear Side Door Replacement
Front Fender Replacement
Front Fender Shipping Cover Replacement
Liftgate Adjustment
Liftgate Replacement
Front Side Door Wiring Harness Replacement
Liftgate Wiring Harness Replacement
Liftgate Jumper Wiring Harness Replacement
Rear Side Door Wiring Harness Replacement
Hood Primary Latch Release Cable Handle Replacement
Front Side Door Upper Hinge and Lower Hinge Replacement
Hood Hinge Replacement
Liftgate Hinge Replacement
Rear Side Door Upper Hinge and Lower Hinge Replacement
Hood Adjustment
Hood Replacement
Front Fender Insulator Replacement
Headlamp Mount Panel Bracket Replacement
Headlamp and Front Bumper Fascia Mount Panel Replacement
Hood Insulator Replacement
Hood Primary and Secondary Latch Replacement
Front Side Door Check Replacement
Fuel Tank Filler Door Replacement
Fuel Tank Filler Pipe Housing Replacement
Hood Hold-Open Rod Replacement
Hood Front Seal Replacement
Hood Rear Weatherstrip Replacement
Liftgate Strut Replacement
Front or Rear Side Door Lower Weatherstrip Replacement
Front Side Door Weatherstrip Replacement – Door Side
Front Side Door Weatherstrip Replacement – Body Side
Liftgate Weatherstrip Replacement
Rear Side Door Weatherstrip Replacement – Door Side
Rear Side Door Weatherstrip Replacement – Body Side
Bumpers and Fascias
Specifications
Fastener Tightening Specifications
Repair Instructions
Front Bumper Energy Absorber Replacement
Front Bumper Energy Absorber Bracket Replacement
Front Bumper Impact Bar Replacement
Radiator Opening Upper Cover Replacement
Front Bumper Fascia Removal and Installation
Front Bumper Fascia Guide Replacement
Front Bumper Lower Fascia Replacement
Front Bumper Upper Fascia Replacement
Front Bumper Fascia Upper Support Replacement
Front Bumper Fascia Lower Stiffener Replacement
Front Bumper Fascia Air Deflector Replacement
Front Bumper Fascia Skid Plate Replacement
Rear Bumper Fascia Lower Skid Plate Replacement
Rear Bumper Fascia Removal and Installation
Rear Bumper Fascia Guide Replacement
Rear Bumper Fascia Inner Guide Replacement
Rear Bumper Fascia Outer Guide Replacement
Rear Bumper Upper Fascia Replacement
Rear Bumper Lower Fascia Replacement
Rear Bumper Energy Absorber Replacement
Rear Bumper Impact Bar Replacement
Rear Bumper Step Pad Replacement
Rear Bumper Reflector Replacement
Special Tools and Equipment
Special Tools
Collision Repair
Specifications
Dimensions – Body
Visual Identification
Structure Identification
Repair Instructions
Overlap/Backing Plate Sectioning — Welding
Front Bumper Impact Bar Replacement
Headlamp Mount Panel Replacement — Welding
Headlamp Mount Panel Replacement — Brazing
Headlamp Mount Panel Outer Bracket Replacement — Brazing
Headlamp Mount Panel Outer Bracket Replacement — Welding
Front End Upper Tie Bar Support Sectioning — MAG Welding
Front End Upper Tie Bar Support Sectioning — MIG Brazing
Front End Upper Tie Bar Replacement — Brazing
Front End Upper Tie Bar Replacement — Welding
Front Wheelhouse Front Panel Replacement — Welding
Front Wheelhouse Front Panel Replacement — Brazing
Front Wheelhouse Panel Replacement — Welding
Front Wheelhouse Panel Replacement — Brazing
Front Wheelhouse Panel Rear Reinforcement Replacement — Welding
Front Wheelhouse Panel Rear Reinforcement Replacement — Brazing
Front Compartment Upper Side Rail Replacement — Welding
Front Compartment Upper Side Rail Replacement — Brazing
Front Compartment Side Rail Sectioning — Brazing
Front Compartment Side Rail Sectioning — Welding
Body Hinge Pillar Outer Panel Sectioning — Welding
Body Hinge Pillar Outer Panel Sectioning — Brazing
Roof Front Header Panel Replacement — Brazing
Roof Front Header Panel Replacement — Welding
Roof Rear Inner Panel Replacement — Welding
Roof Rear Inner Panel Replacement — Brazing
Rocker Inner Panel Replacement — Welding
Rocker Inner Panel Replacement — Brazing
Body Lock Pillar Upper Reinforcement Replacement — Welding
Body Lock Pillar Upper Reinforcement Replacement — Brazing
Rocker Outer Panel Reinforcement Replacement — Welding
Rocker Outer Panel Reinforcement Replacement — Brazing
Rocker Outer Panel Sectioning — Welding
Rocker Outer Panel Sectioning — Brazing
Body Side Inner Panel Sectioning — Welding
Body Side Inner Panel Sectioning — Brazing
Body Side Outer Lower Panel Replacement — Welding
Body Side Outer Lower Panel Replacement — Brazing
Rear Floor Panel Sectioning — Brazing
Rear Floor Panel Sectioning — Welding
Rear Wheelhouse Panel Replacement — Welding
Rear Wheelhouse Panel Replacement — Brazing
Quarter Outer Panel Sectioning — Welding
Quarter Outer Panel Sectioning — Brazing
Floor Panel Number 5 Cross Bar Replacement — Welding
Floor Panel Number 5 Cross Bar Replacement — Brazing
Floor Panel Number 6 Cross Bar Replacement — Welding
Floor Panel Number 6 Cross Bar Replacement — Brazing
Underbody Rear Side Rail Sectioning — Welding
Underbody Rear Side Rail Sectioning — Brazing
Rear Bumper Fascia Bracket Replacement
Rear Bumper Impact Bar Stud Plate Replacement — Welding
Rear Bumper Impact Bar Stud Plate Replacement — Brazing
Body Hinge Pillar Reinforcement Replacement — Welding
Body Hinge Pillar Reinforcement Replacement — Brazing
Center Pillar Inner Panel Replacement — Welding
Center Pillar Inner Panel Replacement — Brazing
Center Pillar Outer Panel Reinforcement Replacement — Welding
Center Pillar Outer Panel Reinforcement Replacement — Brazing
Center Pillar Sectioning – Outer — Welding
Center Pillar Sectioning – Outer — Brazing
Roof Panel Replacement — Brazing
Roof Panel Replacement — Welding
Rear End Lower Panel Reinforcement Replacement — Welding
Rear End Lower Panel Reinforcement Replacement — Brazing
Rear End Panel Replacement — Welding
Rear End Panel Replacement — Brazing
Tail Lamp Mount Panel Replacement — Brazing
Tail Lamp Mount Panel Replacement — Welding
Description and Operation
Dual Phase Steel
High Strength Low Alloy Steel
Mild Steel
Ultra High Strength Dual Phase Steel
Special Tools and Equipment
Special Tools
Frame and Underbody
Specifications
Fastener Tightening Specifications
Repair Instructions
Front Compartment Insulator Replacement
Front Compartment Splash Shield Replacement
Drivetrain and Front Suspension Frame Replacement
Spare Wheel and Carrier Replacement
Spare Wheel Carrier Hook Replacement
Drivetrain and Front Suspension Frame Insulator Replacement
Front Wheelhouse Liner Replacement
Rear Wheelhouse Panel Liner Replacement
Special Tools and Equipment
Special Tools
Paint and Coatings
Introduction
Basecoat/Clearcoat Paint Systems
Anti-Corrosion Treatment and Repair — Base
Repair Instructions
Clearcoat Repair without Repainting
Environmental Fallout (Acid Rain)
Paint Gauges
Clearcoat Thickness
Rail Dust Damage Repair
Plastic Panel Information and Repair
Repair Instructions
General Plastic Repair
Introduction
How to Identify Plastic Parts
Plastic Identification and Refinishing Systems
5. Body Systems
Fixed and Moveable Windows
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Moveable Window Schematics
Defogger Schematics
Component Locator
Window Systems Component Views
Diagnostic Information and Procedures
DTC B0283
DTC B316B, B317A, B318A, or B319A
DTC B3205, B3210, B3215, or B3220
Symptoms – Fixed and Moveable Windows
Rear Window Defogger Malfunction
Power Windows Malfunction — Driver Window Express Up and Down
Power Windows Malfunction — All Windows Express Down Only
Repair Instructions
Windshield Replacement
Windshield Upper Reveal Molding Replacement
Front Side Door Window Adjustment
Front Side Door Window Replacement
Rear Side Door Window Adjustment
Rear Side Door Window Replacement
Quarter Window Replacement
Liftgate Window Replacement
Front Side Door Stationary Window Replacement
Rear Side Door Window Front Channel Insulator Replacement
Rear Side Door Window Rear Channel Insulator Replacement
Front Side Door Window Switch Replacement – Right Side
Front Side Door Window and Multifunction Switch Replacement
Rear Side Door Window Switch Replacement
Front Side Door Window Regulator Replacement
Front Side Door Window Regulator Guide Replacement
Rear Side Door Window Regulator Replacement
Rear Side Door Window Rear Guide Replacement
Front Side Door Window Outer Sealing Strip Replacement
Front Side Door Window Inner Sealing Strip Replacement
Rear Side Door Window Inner Sealing Strip Replacement
Rear Side Door Window Outer Sealing Strip Replacement
Front Side Door Window Weatherstrip Replacement
Rear Side Door Window Weatherstrip Replacement
Front Side Door Window Front Channel Replacement
Description and Operation
Adhesive Service Kit Description
Power Windows Description and Operation
Rear Window Defogger Description and Operation
Stationary Window Description
Special Tools and Equipment
Special Tools
Horns
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Horn Schematics
Diagnostic Information and Procedures
DTC B2750
Symptoms – Horns
Horns Malfunction
Repair Instructions
Horn Replacement
Steering Wheel Horn Contact Replacement
Description and Operation
Horns System Description and Operation
Lighting
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Headlights/Daytime Running Lights (DRL) Schematics
Fog Lights Schematics
Exterior Lights Schematics
Interior Lights Schematics
Interior Lights Dimming Schematics
Diagnostic Information and Procedures
DTC B096A
DTC B2530
DTC B2540
DTC B2545
DTC B2575 or B2699
DTC B257A
DTC B257B
DTC B2580
DTC B2585 or B3867
DTC B2610
DTC B2740
DTC B3445 or B3878
DTC B3588
DTC B3596
DTC B3600
DTC B3650
DTC B3806
DTC B3883
DTC B3884
DTC B3948 or B3949
DTC B3950 or B3951
DTC C0277 or C0890
DTC P0504 — AT
DTC P0504 — MT
Symptoms – Lighting
Automatic Light Malfunction
Backup Lamps Malfunction — AT
Backup Lamps Malfunction — MT
Cargo Lamps Malfunction
Courtesy Lamps Malfunction
Dome Lamps Malfunction
Front Fog Lamps Malfunction
Rear Fog Lamps Malfunction
Glove Box Illumination Malfunction
Hazard Lamps Malfunction
Headlamps Malfunction
Headlamp Leveling Malfunction
Interior Backlighting Malfunction
Lights On Indicator Malfunction
Park, License, and/or Tail Lamps Malfunction
Reading Lamps Malfunction
Stop Lamps Malfunction
Sunshade Illumination Malfunction
Turn Signal Lamps and/or Indicators Malfunction
Repair Instructions
Brake Pedal Position Sensor Calibration
Brake Pedal Position Sensor Replacement — Left Hand Drive
Headlamp Switch Replacement
Hazard Warning Switch Replacement
Headlamp Automatic Control Ambient Light Sensor Replacement
Reading Lamp Bulb Replacement
Reading Lamp Replacement
Dome and Reading Lamp Lens Replacement
Dome Lamp Bezel Replacement — Front
Dome Lamp Bezel Replacement — Rear
Instrument Panel Compartment Lamp Replacement
Instrument Panel Compartment Lamp Bulb Replacement
Dome Lamp Replacement
Dome Lamp Bulb Replacement
Headlamp Replacement
Headlamp Bulb Replacement
Headlamp Bracket Replacement
Headlamp Aiming
Front Fog Lamp Replacement
Front Fog Lamp Bulb Replacement
Rear Fog Lamp Bulb Replacement
Fog Lamp Aiming
Front Side Turn Signal Lamp Replacement
Front Side Turn Signal Lamp Bulb Replacement
High Mount Stop Lamp Replacement
Cargo Center Courtesy Lamp Bulb Replacement
Backup Lamp Replacement
Backup Lamp Bulb Replacement
Backup and Rear Fog Lamp Replacement
Forward Lamp Wiring Harness Replacement
Rear License Plate Lamp Replacement
Rear License Plate Lamp Bulb Replacement
Rear License Plate Lamp Wiring Harness Replacement
Tail Lamp Replacement
Tail Lamp Bulb Replacement
Stop and Tail Lamp Bulb Replacement
Rear Turn Signal Lamp Bulb Replacement
Rear Compartment Courtesy Lamp Replacement
Description and Operation
Exterior Lighting Systems Description and Operation
Interior Lighting Systems Description and Operation
Special Tools and Equipment
Special Tools
Mirrors
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Inside Rearview Mirror Schematics
Outside Rearview Mirror Schematics
Diagnostic Information and Procedures
Symptoms – Mirrors
Heated Mirrors Malfunction
Automatic Day-Night Mirrors Malfunction
Power Mirror Folding Malfunction
Power Mirror Malfunction
Repair Instructions
Outside Rearview Mirror Replacement
Outside Rearview Mirror Bracket Cover Replacement
Outside Rearview Mirror Remote Control and Multifunction Switch Replacement
Outside Rearview Mirror Inner Actuator Replacement
Outside Rearview Mirror Glass Replacement
Outside Rearview Mirror Housing Replacement
Inside Rearview Mirror Replacement
Description and Operation
Automatic Day-Night Mirror Description and Operation
Outside Mirror Description and Operation
Special Tools and Equipment
Special Tools
Vehicle Access
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Door Lock/Indicator Schematics
Release Systems Schematics
Diagnostic Information and Procedures
DTC B1474
DTC B1534 or B1535
DTC B1543
DTC B250B
DTC B2516
DTC B251A-B251F
DTC B252A or B252B
DTC B297B or B297C
DTC B3125, B3130, or B3135
DTC B3155
DTC B3265
DTC B3618
DTC B3849
Symptoms – Vehicle Access
Fuel Filler Door Release Malfunction
Door Ajar Indicator Malfunction
Power Door Latch System Malfunction
Power Door Locks Malfunction
Power Door Lock Switch Malfunction – DTC B3140, B3145, B3150, or B3155
Trunk Release Malfunction
Trunk Ajar Indicator Malfunction
Repair Instructions
Front Side Door Inside Handle Cable Replacement
Rear Side Door Inside Handle Cable Replacement
Front Side Door Outside Handle Replacement
Front Side Door Outside Handle Bracket Replacement
Rear Side Door Outside Handle Bracket Replacement
Liftgate Latch Replacement
Rear Side Door Outside Handle Replacement
Front Side Door Latch Replacement
Rear Side Door Latch Replacement
Front Side Door Locking Rod Replacement
Front Side Door Lock Cylinder Rod Replacement
Front Side Door Outside Handle Rod Adjustment
Rear Side Door Locking Rod Replacement
Rear Side Door Outside Handle Rod Adjustment
Rear Side Door Outside Handle Rod Replacement
Front Side Door Lock Striker Replacement
Liftgate Latch Striker Replacement
Rear Side Door Lock Striker Replacement
Liftgate Release Switch Replacement
Door Lock Switch Replacement
Description and Operation
Door Ajar Indicator Description and Operation
Fuel Fill Door Description and Operation
Luggage Compartment Description and Operation
Power Door Latch Description and Operation
Power Door Locks Description and Operation
Special Tools and Equipment
Special Tools
Wipers and Washers
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Wiper/Washer Schematics
Diagnostic Information and Procedures
DTC B370A
DTC B370B
DTC B3715 or B3875
DTC B3811
DTC B3873
Symptoms – Wiper/Washer Systems
Windshield Wiper System Malfunction
Washer Malfunction
Rain Sensor Malfunction
Rear Wiper System Malfunction
Rear Washer System Malfunction
Repair Instructions
Windshield Wiper and Washer Switch Replacement
Windshield Washer Nozzle Hose Replacement
Windshield Washer Nozzle Replacement
Rear Window Washer Nozzle Replacement
Windshield Washer Solvent Container Filler Tube Replacement
Windshield Washer Solvent Container Grommet Replacement
Windshield Washer Solvent Container Replacement
Windshield Washer Pump Replacement
Windshield Washer Pump Seal Replacement
Dash Upper Extension Panel Opening Cover Replacement
Air Inlet Grille Panel Replacement
Windshield Wiper Arm Replacement
Rear Window Wiper Arm Replacement
Windshield Wiper Blade Replacement — Complete Assembly
Rear Window Wiper Blade Replacement
Windshield Wiper Motor Replacement
Rear Window Wiper Motor Replacement
Windshield Wiper Transmission Replacement — Left Hand Drive
Windshield Outside Moisture Sensor Cover Replacement
Windshield Outside Moisture Sensor Replacement
Wiper Blade Element Cleaning
Description and Operation
Wiper/Washer System Description and Operation
Special Tools and Equipment
Special Tools
6. Brakes
Antilock Brake System
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Antilock Brake System Schematics
Diagnostic Information and Procedures
DTC B2745
DTC C0000
DTC C0035, C0040, C0045, or C0050
DTC C0110
DTC C0131
DTC C0161
DTC C0186, C0196, or C019B
DTC C0280
DTC C0710
DTC P0856
Symptoms – Antilock Brake System
ABS Indicator Malfunction
Traction Control/Stability Control Indicator Malfunction
Repair Instructions
Steering Angle Sensor Centering
Electronic Brake Control Module Replacement
Brake Pressure Modulator Valve Replacement
Brake Pressure Modulator Valve Pressure Sensor Calibration
Brake Pressure Modulator Valve Bracket Replacement
Front Wheel Speed Sensor Replacement
Rear Wheel Speed Sensor Replacement — Disc Brake
Vehicle Yaw Sensor Learn
Vehicle Yaw Sensor Replacement
Description and Operation
ABS Description and Operation
Special Tools and Equipment
Special Tools
Disc Brakes
Specifications
Fastener Tightening Specifications
Disc Brake Component Specifications
Adhesives, Fluids, Lubricants, and Sealers
Diagnostic Information and Procedures
Brake Rotor Thickness Measurement
Brake Rotor Thickness Variation Measurement
Brake Rotor Surface and Wear Inspection
Brake Rotor Assembled Lateral Runout Measurement
Brake Pad Inspection
Brake Caliper Inspection
Front Disc Brake Mounting and Hardware Inspection
Rear Disc Brake Mounting and Hardware Inspection
Repair Instructions
Front Disc Brake Pads Replacement
Rear Disc Brake Pads Replacement
Brake Pad and Rotor Burnishing
Front Brake Caliper Replacement
Rear Brake Caliper Replacement — without Dampener
Front Brake Caliper Overhaul
Front Brake Caliper Hardware Replacement
Rear Brake Caliper Hardware Replacement
Front Brake Caliper Bracket Replacement — 16 inch Brake System
Rear Brake Caliper Bracket Replacement
Front Brake Rotor Replacement
Rear Brake Rotor Replacement
Front Brake Shield Replacement
Rear Brake Shield Replacement
Brake Rotor Assembled Lateral Runout Correction
Brake Rotor Assembled Lateral Runout Correction – Indexing
Brake Rotor Assembled Lateral Runout Correction – Correction Plates
Brake Rotor Assembled Lateral Runout Correction – On Vehicle Lathe
Brake Rotor Refinishing
Description and Operation
Disc Brake System Description and Operation
Special Tools and Equipment
Special Tools
Hydraulic Brakes
Specifications
Fastener Tightening Specifications
Brake Component Specifications
Adhesives, Fluids, Lubricants, and Sealers
Schematic and Routing Diagrams
Hydraulic Brake Schematics
Diagnostic Information and Procedures
DTC C0267
DTC C1100
Symptoms – Hydraulic Brakes
Brake Booster Pump Motor Malfunction
Brake Warning Indicator Malfunction — With Antilock Brake System
Brake Warning Indicator Malfunction — Without Antilock Brake System
Brake Pulsation
Brake System Noise
Braking Action Uneven – Pulls to One Side
Braking Action Uneven – Front to Rear
Brake Pedal Excessive Travel
Brake Pedal Excessive Effort
Brakes Drag
Brake System Slow Release
Brake Fluid Loss
Disc Brake System Diagnosis
Hydraulic Brake System Diagnosis
Brake Assist System Diagnosis
Brake System Vehicle Road Test
Brake Pedal Travel Measurement and Inspection
Brake System Vacuum Source Test
Brake System External Leak Inspection
Brake System Internal Leak Test
Hydraulic Brake Component Operation Visual Inspection
Brake Pipe and Hose Inspection
Brake Pedal Pushrod Inspection
Repair Instructions
Master Cylinder Reservoir Filling
Master Cylinder Reservoir Replacement
Master Cylinder Replacement — Left Hand Drive
Master Cylinder Bench Bleeding
Brake Fluid Level Indicator Switch Replacement
Brake, Accelerator, and Clutch Pedal Replacement — Left Hand Drive
Brake Pipe Replacement
Front Brake Hose Replacement
Rear Brake Hose Replacement — Disc Brake
Hydraulic Brake System Bleeding
Power Brake Booster Vacuum Pipe Replacement — Left Hand Drive
Power Brake Booster Vacuum Pipe Replacement — Left Hand Drive with Electric Pump
Power Brake Booster Vacuum Pipe Replacement — Right Hand Drive
Power Brake Booster Replacement — Left Hand Drive
Power Brake Booster Pump Replacement
Description and Operation
Brake Assist System Description and Operation
Brake Booster Vacuum Assist Description and Operation
Brake Fluid and Brake Fluid Handling
Brake Warning System Description and Operation — With Antilock Brake System
Hydraulic Brake System Description and Operation
Special Tools and Equipment
Special Tools
Park Brake
Specifications
Fastener Tightening Specifications
Diagnostic Information and Procedures
Symptoms – Park Brake
Park Brake Will Not Hold or Release
Handbrake System Diagnosis — Disc Brakes
Repair Instructions
Parking Brake Lever Replacement
Parking Brake Lever Boot Replacement
Parking Brake Indicator Switch Replacement
Parking Brake Cable Replacement
Handbrake Adjustment — Manual Handbrake
Description and Operation
Park Brake System Description and Operation
7. Diagnostic Overview, Starting Point, and Programming
Programming and Setup
Diagnostic Information and Procedures
Control Module References
Repair Instructions
Audio Amplifier Programming and Setup
Body Control Module Programming and Setup
Control Solenoid Valve and Transmission Control Module Assembly Programming and Setup — 6T30/6T40/6T45/6T50
Electronic Brake Control Module Programming and Setup
Engine Control Module Programming and Setup — LNP
Engine Control Module Programming and Setup — LXV, 2H0
Heated Seat Control Module Programming and Setup
HVAC System Control Module Programming and Setup
Inflatable Restraint Sensing and Diagnostic Module Programming and Setup
Instrument Cluster Programming and Setup
Keyless Entry Control Module Programming and Setup
Mobile Telephone Control Module Programming and Setup
Multifunction Chime Alarm Programming and Setup
Multimedia Player Interface Module Programming and Setup
Object Alarm Module Programming and Setup
Power Steering Control Module Programming and Setup — Electronic Power Steering
Radio Control Programming and Setup
Radio Programming and Setup
Service Programming System (SPS)
Steering Column Lock Control Module Programming and Setup
Sunroof Control Module Programming and Setup — Existing Motor
Sunroof Control Module Programming and Setup — New Motor
Theft Deterrent Module Programming and Setup
Window Regulator Motor Programming and Setup
Special Tools and Equipment
Special Tools
Vehicle Diagnostic Information
Specifications
Body Control Module Scan Tool Information
Multifunction Chime Alarm Scan Tool Information
Digital Radio Receiver Scan Tool Information
Driver Seat and Passenger Seat Heater Control Module Scan Tool Information
Electronic Brake Control Module Scan Tool Information
Engine Control Module Scan Tool Information — LNP
Engine Control Module Scan Tool Information — LDE or 2H0
Heating, Ventilation and Air Conditioning Control Module Scan Tool Information
Inflatable Restraint Sensing and Diagnostic Module Scan Tool Information
Instrument Cluster Scan Tool Information
Keyless Entry Control Module Scan Tool Information
Multimedia Player Interface Module Scan Tool Information
Object Alarm Module Scan Tool Information
Power Steering Control Module Scan Tool Information
Radio Scan Tool Information
Transmission Control Module Scan Tool Information — 6T30/6T40/6T45/6T50
Diagnostic Information and Procedures
Strategy Based Diagnosis
Diagnostic Procedure Instructions
Diagnostic System Check Instructions
Diagnostic Starting Point – Vehicle
Diagnostic System Check – Vehicle
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Diagnostic Trouble Code (DTC) List – Vehicle
Symptoms – Vehicle
Engine Does Not Crank
Engine Cranks But Does Not Run
Inspection/Maintenance System Check
Diagnostic Repair Verification
8. Driveline/Axle
Wheel Drive Shafts
Specifications
Fastener Tightening Specifications
Diagnostic Information and Procedures
Symptoms – Wheel Drive Shafts
Click Noise In Turns
Clunk When Accelerating from Coast
Clunk Noise When Accelerating During Turns
Repair Instructions
Front Wheel Drive Intermediate Shaft Replacement
Front Wheel Drive Intermediate Shaft Bracket Replacement
Front Wheel Drive Intermediate Shaft Bearing Replacement
Front Wheel Drive Shaft Replacement – Left Side
Front Wheel Drive Shaft Replacement – Right Side
Front Wheel Drive Shaft Inner Joint and Boot Replacement — with Tripod Joint
Front Wheel Drive Shaft Outer Joint and Boot Replacement
Description and Operation
Wheel Drive Shafts Description and Operation
Special Tools and Equipment
Special Tools
9. Driver Information and Entertainment
Cellular, Entertainment, and Navigation
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Radio/Navigation System Schematics
Diagnostic Information and Procedures
DTC B0000
DTC B1020
DTC B1025, B1035, B1045, or B1055
DTC B1259
DTC B1265
DTC B1271
DTC B1278 or B1279
DTC B1287
DTC B2462 — Navigation Radio
Symptoms – Entertainment
Digital Radio Poor or No Reception
No Global Positioning System (GPS) Reception
Radio Displays CAL or CAL ERR
Radio Displays LOC, LOCKED, or CODE
Radio Poor Reception
Speaker Replacement Reference
Speaker Malfunction
Repair Instructions
Compact Disc Care and Cleaning
Radio Replacement
Audio Disc Player Receptacle Replacement
Mobile Telephone Control Module Replacement
Radio Antenna Base Replacement
Radio Antenna Replacement
Radio and Telephone Control Switch Replacement
Radio Front Side Door Upper Speaker Replacement
USB Receptacle Replacement
Radio Front Side Door Speaker Replacement
Radio Control Switch Replacement
Radio Control Switch Replacement – Steering Wheel
Radio Rear Side Door Speaker Replacement
Description and Operation
Navigation System Description and Operation
Radio/Audio System Description and Operation
Displays and Gauges
Specifications
Fastener Tightening Specifications
Ambient Air Temperature Sensor Resistance
Schematic and Routing Diagrams
Instrument Cluster Schematics
Driver Information System Schematics
Audible Warnings Schematics
Diagnostic Information and Procedures
DTC B0158
DTC B0550
DTC B3567
DTC P0461-P0464
DTC P0520-P0523
Symptoms – Displays and Gauges
Charge Indicator Malfunction
Chime Malfunction
Driver Information Center Switch Malfunction
Engine Oil Pressure Indicator Malfunction
Fuel Gauge Inaccurate or Inoperative
Instrument Cluster Gauges Inoperative
Odometer Trip/Reset Switch Inoperative
Outside Air Temperature Display Inaccurate or Inoperative
Speedometer and/or Odometer Inaccurate or Inoperative
Repair Instructions
Driver Information Display Replacement — UDK
Instrument Cluster Replacement
Description and Operation
Audible Warnings Description and Operation
Driver Information Center (DIC) Description and Operation
Indicator/Warning Message Description and Operation
Instrument Cluster Description and Operation
Special Tools and Equipment
Special Tools
Secondary and Configurable Customer Controls
Schematic and Routing Diagrams
Steering Wheel Secondary/Configurable Control Schematics
Diagnostic Information and Procedures
DTC B1405
DTC B1529
DTC B3622
Symptoms – Secondary and Configurable Customer Controls
Steering Wheel Controls Malfunction
Description and Operation
Steering Wheel Controls Description and Operation
10. Engine
Cruise Control
Schematic and Routing Diagrams
Cruise Control Schematics
Diagnostic Information and Procedures
DTC B3794
DTC P0564
DTC P0571
DTC P0703
Symptoms – Cruise Control
Cruise Control Indicator Malfunction
Cruise Control Malfunction
Repair Instructions
Cruise Control Switch Replacement
Description and Operation
Cruise Control Description and Operation
LDE, LLU, or LXV or 1.8L 2H0 or LUW
Specifications
Temperature Versus Resistance — IAT
Temperature Versus Resistance — ECT
Altitude Versus Barometric Pressure
Ignition System Specifications
Fastener Tightening Specifications — LDE, LXV, LUW, 2H0
Fastener Tightening Specifications — 1.6L LDE, LXV, and 1.8L 2H0
Engine Mechanical Specifications — 1.8L 2H0
Adhesives, Fluids, Lubricants, and Sealers
Schematic and Routing Diagrams
Engine Controls Schematics
Engine Mechanical Schematics
Diagnostic Information and Procedures
DTC P0010 or P0013
DTC P0011 or P0014
DTC P0016 or P0017
DTC P0030, P0036, P0053, P0054, P0135, or P0141
DTC P0068 or P1101
DTC P0101
DTC P0102 or P0103
DTC P0106
DTC P0107 or P0108
DTC P0112, P0113, or P0114
DTC P0116
DTC P0117 or P0118
DTC P0121-P0123, P0222, P0223, or P2135
DTC P0128
DTC P0131, P0132, P0137, or P0138
DTC P0133, P0134, P0140, P1133, P2270, P2271, or P2A00
DTC P0171 or P0172
DTC P0201, P0202, P0203, or P0204
DTC P0300-P0304
DTC P0315
DTC P0324 or P06B6
DTC P0325, P0327, or P0328
DTC P0335 or P0336
DTC P0340, P0341, P0365, or P0366
DTC P0351-P0354
DTC P0420
DTC P0443
DTC P0601-P0604, P0606, P0607, P062F, P16F3, or P2610
DTC P0610
DTC P0627-P0629
DTC P0630
DTC P0641, P0651, P0697, or P06A3
DTC P0660
DTC P0685, P0689, or P0690
DTC P1104
DTC P1516, P2100-P2103, P2119, or P2176
DTC P1682
DTC P2122, P2123, P2127, P2128, or P2138
Symptoms – Engine Controls
Poor Fuel Fill Quality
Malfunction Indicator Lamp (MIL) Diagnosis
Engine Cranks But Does Not Run
Fuel System Diagnosis
Fuel Injector Diagnosis — Special Tool
Fuel Injector Diagnosis — Scan Tool
Fuel Injector Circuit Diagnosis
Alcohol/Contaminants-in-Fuel Diagnosis
Ignition Relay Diagnosis
Electronic Ignition System Diagnosis
Fuel Pressure Measurement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Symptoms – Engine Mechanical
Oil Pressure Diagnosis and Testing
Oil Leak Diagnosis
Oil Consumption Diagnosis
Coolant in Combustion Chamber
Coolant in Engine Oil
Engine Noise Under Load
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Base Engine Misfire without Internal Engine Noises
Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Will Not Crank – Crankshaft Will Not Rotate
Engine Compression Test
Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Cylinder Leakage Test — 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
Crankcase Ventilation System Inspection/Diagnosis — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Tensioner Diagnosis
Dual Mass Flywheel Diagnosis
Repair Instructions
Engine Control Module Replacement — 1.6L LDE, LXV, 1.8L 2H0, LFH, and LUW
Crankshaft Position System Variation Learn
Engine Coolant Temperature Sensor Replacement — Thermostat Housing
Engine Coolant Temperature Sensor Replacement — Radiator
Intake Air Temperature Sensor Replacement
Manifold Absolute Pressure Sensor Replacement — 1.8L 2H0 and LUW
Heated Oxygen Sensor Replacement – Sensor 1 — LDE, LXV, LUW, 2H0
Heated Oxygen Sensor Replacement – Sensor 2
Engine Oil Pressure Indicator Switch Replacement
Accelerator Pedal Position Sensor Replacement
Throttle Body Assembly Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Throttle Body Inspection and Cleaning — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Fuel Pressure Relief
Plastic Collar Quick Connect Fitting Service
Fuel Tank Draining
Fuel Tank Replacement — 1.8L 2H0
Fuel Tank Vent Pipe Replacement
Fuel Tank Filler Pipe Replacement
Fuel Feed Pipe Replacement
Fuel Tank Fuel Pump Module Replacement — 1.8L 2H0
Fuel System Cleaning
Fuel Injector Replacement
Evaporative Emission Canister Replacement
Ignition Coil Replacement
Spark Plug Inspection
Spark Plug Replacement
Crankshaft Position Sensor Replacement
Camshaft Position Sensor Replacement — LDE, LXV, LUW, 2H0 and LFH
Knock Sensor Replacement — LDE, LXV, LUW, 2H0 and LFH
Air Cleaner Inlet Duct Replacement
Air Cleaner Outlet Duct Replacement
Air Cleaner Element Replacement — 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
Air Cleaner Assembly Replacement — LDE, LXV, LUW, 2H0 and LFH
Drive Belt Replacement
Drive Belt Tensioner Replacement
Power Steering Pump Belt Replacement
Engine Mount Replacement
Engine/Transmission Mounting
Engine Mount Bracket Replacement
Intake Manifold Replacement
Timing Belt Replacement — 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
Timing Belt Idler Pulley Replacement
Timing Belt Tensioner Replacement — 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
Timing Belt Center Front Cover Replacement
Timing Belt Upper Front Cover Replacement — 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
Timing Belt Lower Front Cover Replacement
Timing Belt Rear Cover Replacement — 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
Tappet Replacement — 1.6L LDE, LXV, LLU and 1.8L 2H0, LFH
Cylinder Head Replacement
Oil Pan Replacement
Automatic Transmission Flex Plate Replacement — 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
Engine Flywheel Replacement — Manual Transmission – D16
Crankshaft Balancer Replacement — LXV, LXT, 2H0, LUW – AT
Crankshaft Balancer Replacement — MT – D16, D20
Crankshaft Front Oil Seal Replacement
Crankshaft Rear Oil Seal Replacement
Positive Crankcase Ventilation Hose/Pipe/Tube Replacement — 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
Engine Front Cover with Oil Pump Replacement
Oil Pressure Relief Valve Replacement
Oil Flow Check Valve Replacement
Oil Level Indicator Tube Replacement — 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
Engine Replacement — Automatic Transmission
Engine Replacement — Manual Transmission
Engine Oil and Oil Filter Replacement — 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
Camshaft Seal Replacement — 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
Camshaft Cover Replacement — 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
Camshaft Position Actuator Adjuster Replacement
Camshaft Position Actuator Solenoid Valve Replacement
Camshaft Replacement — 1.6L LDE, LXV, and 1.8L 2H0
Camshaft Cleaning and Inspection
Valve Clearance Adjustment — 1.6L LDE, LXV, 1.8L 2H0
Valve Guide Reaming, and Valve and Seat Grinding
Valve Spring Inspection and Measurement
Engine Support Fixture
Timing Belt Inspection — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Timing Belt Adjustment — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Draining Fluids and Oil Filter Removal — 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
Automatic Transmission Flex Plate Removal — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Engine Flywheel Removal — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Crankshaft Rear Oil Seal Removal
Power Steering Pump Belt Removal
Drive Belt Removal
Drive Belt Tensioner Removal
Timing Belt Upper Front Cover Removal — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Timing Belt Center Front Cover Removal
Crankshaft Balancer Removal
Timing Belt Lower Front Cover Removal
Timing Belt Removal — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Timing Belt Tensioner Removal
Timing Belt Idler Pulley Removal
Crankshaft Sprocket Removal
Camshaft Position Actuator Solenoid Valve Removal
Camshaft Position Actuator Adjuster Removal
Crankshaft Front Oil Seal Removal
Timing Belt Rear Cover Removal
Throttle Body Assembly Removal — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Intake Manifold Removal — 1.8L 2H0 and LFH
Oil Level Indicator and Tube Removal — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Exhaust Manifold Removal — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Engine Coolant Thermostat Removal
Engine Coolant Thermostat Housing Removal
Engine Oil Cooler Housing Removal — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Engine Oil Cooler Removal
Water Pump Pulley Removal
Water Pump Removal
Oil Pan Removal
Engine Front Cover and Oil Pump Removal
Ignition Coil Removal
Camshaft Cover Removal
Camshaft Removal
Tappet Removal — 1.6L LDE, LXV, LLU and 1.8L 2H0, LFH
Cylinder Head Removal
Piston, Connecting Rod, and Bearing Removal
Crankshaft and Bearing Removal
Intake Manifold Disassemble — 1.8L 2H0
Cylinder Head Disassemble
Piston and Connecting Rod Disassemble — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Engine Block Disassemble — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Intake Manifold Cleaning and Inspection — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Exhaust Manifold Cleaning and Inspection — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Oil Pan Cleaning and Inspection
Oil Pump Cleaning and Inspection
Cylinder Head Cleaning and Inspection
Piston, Connecting Rod, and Bearing Cleaning and Inspection
Crankshaft and Bearing Cleaning and Inspection — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Engine Block Cleaning and Inspection
Service Prior to Assembly
Engine Block Assemble — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Piston and Connecting Rod Assemble
Cylinder Head Assemble
Intake Manifold Assemble — 1.8L 2H0
Crankshaft and Bearing Installation
Piston, Connecting Rod, and Bearing Installation
Cylinder Head Installation
Tappet Installation — 1.6L LDE, LXV, LLU and 1.8L 2H0, LFH
Camshaft Installation
Camshaft Cover Installation
Ignition Coil Installation
Engine Front Cover and Oil Pump Installation
Oil Pan Installation
Water Pump Installation
Water Pump Pulley Installation
Engine Oil Cooler Installation
Engine Oil Cooler Housing Installation — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Engine Coolant Thermostat Housing Installation
Engine Coolant Thermostat Installation
Exhaust Manifold Installation — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Oil Level Indicator and Tube Installation — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Intake Manifold Installation — 1.8L 2H0 and LFH
Throttle Body Assembly Installation — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Crankshaft Front Oil Seal Installation
Timing Belt Rear Cover Installation
Camshaft Position Actuator Adjuster Installation
Camshaft Position Actuator Solenoid Valve Installation
Crankshaft Sprocket Installation
Timing Belt Idler Pulley Installation
Timing Belt Tensioner Installation
Timing Belt Installation — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Timing Belt Lower Front Cover Installation
Crankshaft Balancer Installation
Timing Belt Center Front Cover Installation
Timing Belt Upper Front Cover Installation — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Drive Belt Installation
Drive Belt Tensioner Installation
Power Steering Pump Belt Installation
Engine Flywheel Installation — LDE, LED, LFJ, LXV, 2H0, LUW
Automatic Transmission Flex Plate Installation — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Crankshaft Rear Oil Seal Installation
Description and Operation
Engine Control Module Description
Fuel System Description
Throttle Actuator Control (TAC) System Description
Camshaft Actuator System Description
Evaporative Emission Control System Description
Electronic Ignition System Description
Knock Sensor System Description
Air Intake System Description
Engine Component Description — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Lubrication Description — LDE, LED, LFJ, LXV, 2H0, LUW, LFH
Special Tools and Equipment
Special Tools
Visual Identification
Disassembled Views
Engine Identification — LDE, LED, LFJ, LXV, 2H0, LFH
Introduction
Cleanliness and Care
Replacing Engine Gaskets
Separating Parts
Tools and Equipment
Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
LNP or 2.2L LNQ Diesel
Specifications
Fastener Tightening Specifications
Altitude Versus Barometric Pressure
Temperature Versus Resistance — ECT and IAT Sensor
Temperature Versus Resistance — Exhaust Temperature Sensor
Engine Mechanical Specifications
Adhesives, Fluids, Lubricants, and Sealers
Schematic and Routing Diagrams
Engine Controls Schematics
Diagnostic Information and Procedures
DTC P0011 — LNP or LNQ
DTC P0016 — LNP or LNQ
DTC P0030-P0032 — LNP or LNQ
DTC P003A — LNP or LNQ
DTC P0045, P0047, or P0048 — LNP or LNQ
DTC P0069 — LNP or LNQ
DTC P0087 or P0088 — LNP or LNQ
DTC P0090, P0091, or P0092 — LNP or LNQ
DTC P0093 — LNP or LNQ
DTC P0096, P0097, P0098, or P0099 — LNP or LNQ
DTC P0101, P0102, or P0103 — LNP or LNQ
DTC P0107 or P0108 — LNP or LNQ
DTC P0111-P0113 — LNP or LNQ
DTC P0116-P0119 — LNP or LNQ
DTC P0181, P0182, or P0183 — LNP or LNQ
DTC P0190, P0191, P0192, or P0193 — LNP or LNQ
DTC P0201, P0202, P0203, or P0204 — LNP or LNQ
DTC P0219 — LNP or LNQ
DTC P0253 or P0254 — LNP or LNQ
DTC P0263, P0266, P0269, or P0272 — LNP or LNQ
DTC P029C, P02A0, P02A4, or P02A8 — LNP or LNQ
DTC P02CC-P02D3 — LNP or LNQ
DTC P02E0-P02E3, P02E8, P02E9, P02EB, or P122B — LNP or LNQ
DTC P0326 or P0331
DTC P0335 — LNP or LNQ
DTC P0336 or P0339 — LNP or LNQ
DTC P0340 or P0341 — LNP or LNQ
DTC P0344 — LNP or LNQ
DTC P037E or P037F — LNP or LNQ
DTC P0383 or P0384 — LNP or LNQ
DTC P0400-P0402 — LNP or LNQ
DTC P0404-P0406 — LNP or LNQ
DTC P049D — LNP or LNQ
DTC P0524 — LNP or LNQ
DTC P0545 or P0546 — LNP or LNQ
DTC P0604 — LNP or LNQ
DTC P0606 — LNP or LNQ
DTC P0627 or P0628 — LNP or LNQ
DTC P062B — LNP or LNQ
DTC P0641 — LNP or LNQ
DTC P064C — LNP or LNQ
DTC P064D — LNP or LNQ
DTC P0650 — LNP or LNQ
DTC P0651 — LNP or LNQ
DTC P066A — LNP or LNQ
DTC P0670 — LNP or LNQ
DTC P0671, P0672, P0673, or P0674 — LNP or LNQ
DTC P0689, P068A, P068B, or P0690 — LNP or LNQ
DTC P0697 — LNP or LNQ
DTC P06B8 — LNP or LNQ
DTC P1125 — LNP or LNQ
DTC P1159, P1161, P1168, P1402, or P1407 — LNP or LNQ
DTC P122C or P122D — LNP or LNQ
DTC P1248, P1249, P124A, or P124B — LNP or LNQ
DTC P160E — LNP or LNQ
DTC P161C — LNP or LNQ
DTC P16F3 — LNP or LNQ
DTC P2008-P200A, P2010, P2016, or P2017 — LNP
DTC P200C — LNP or LNQ
DTC P2032 or P2033 — LNP or LNQ
DTC P2080 — LNP or LNQ
DTC P2081, P2085, or P242E — LNP or LNQ
DTC P2122, P2123, P2127, P2128, or P2138 — LNP or LNQ
DTC P2147, P2148, P2150, or P2151 — LNP or LNQ
DTC P2195 — LNP or LNQ
DTC P2228 or P2229 — LNP or LNQ
DTC P2237 or P2238 — LNP or LNQ
DTC P2245, P2246, or P2251 — LNP or LNQ
DTC P2263 — LNP or LNQ
DTC P2264 — LNP or LNQ
DTC P2269 — LNP or LNQ
DTC P228C or P228D — LNP or LNQ
DTC P2299
DTC P2428 — LNP or LNQ
DTC P242B — LNP or LNQ
DTC P242C or P242D — LNP or LNQ
DTC P2453-P2455 — LNP or LNQ
DTC P245A-P245D — LNP or LNQ
DTC P2463 or P246C — LNP or LNQ
DTC P2564 or P2565 — LNP or LNQ
DTC P2687-P2689 — LNP or LNQ
DTC P268C-P268F — LNP or LNQ
DTC P2A00 — LNP or LNQ
Symptoms – Engine Controls
Malfunction Indicator Lamp (MIL) Diagnosis
Water-in-Fuel Lamp Diagnosis
Engine Cranks But Does Not Run
Fuel Leak Diagnosis
Fuel Pump Electrical Circuit Diagnosis
Fuel System Diagnosis
Ignition Relay Diagnosis
Fuel Specific Gravity Testing
Fuel Injector Balance Test with Scan Tool
Fuel Tank Leak Test
Contaminants-in-Fuel Diagnosis
Symptoms – Engine Mechanical
Base Engine Misfire without Internal Engine Noises
Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Noise Under Load
Engine Will Not Crank – Crankshaft Will Not Rotate
Coolant in Combustion Chamber
Coolant in Engine Oil
Fuel in Engine Oil
Turbocharger Whine Noise
Turbocharger Hissing Noise
Turbocharger Oil Leak From Compressor Seal
Turbocharger Oil Leak From Turbine Seal
Turbocharger Lack of Oil Supply
Engine Compression Test
Oil Consumption Diagnosis
Oil Pressure Diagnosis and Testing
Oil Leak Diagnosis
Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Tensioner Diagnosis
Dual Mass Flywheel Diagnosis
Repair Instructions
Exhaust Particulate Filter Cleaning
Fuel Injector Flow Rate Programming
Engine Control Module Replacement
Accelerator Pedal Position Sensor Replacement
Heated Oxygen Sensor Replacement
Throttle Body Assembly Replacement
Engine Coolant Temperature Sensor Replacement
Intake Air Pressure and Temperature Sensor Replacement
Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Fuel Pressure Gauge Installation and Removal
Fuel System Cleaning
Fuel System Priming
Camshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Fuel Tank Draining
Fuel Tank Filler Pipe Replacement
Fuel Tank Filler Hose Replacement
Fuel Tank Replacement
Fuel Tank Fuel Pump Module Replacement
Fuel Tank Fuel Pump Module Wiring Harness Replacement
Plastic Collar Quick Connect Fitting Service
Fuel Filter Replacement
Fuel Feed Pipe Replacement
Fuel Feed Pipe Replacement – Fuel Filter to Fuel Feed Pipe
Fuel Feed Pipe Replacement – Fuel Tank Fuel Pump to Fuel Filter Housing
Fuel Return Pipe Replacement
Fuel Return Pipe Replacement – Fuel Return Pipe to Fuel Pump
Fuel Injector Replacement
Fuel Injection Fuel Rail Assembly Replacement
Fuel Injection Fuel Return Hose Replacement
Fuel Injection Fuel Feed Pipe Replacement – Fuel Injection Pump to Fuel Rail
Fuel Injection Fuel Feed Pipe Replacement – Fuel Rail to Fuel Injector
Fuel Injection Pump Replacement
Vacuum Pump Assembly Replacement
Vacuum Pump Hose Replacement
Vacuum Modulator Replacement
Intake Air Tuning Valve Vacuum Control Solenoid Valve Replacement
Intake Manifold Tuning Valve Vacuum Control Solenoid Valve Hose Replacement
Exhaust Gas Recirculation Valve Cooler Replacement
Exhaust Gas Recirculation Valve Replacement
Exhaust Gas Recirculation Pipe Replacement
Exhaust Gas Recirculation Vacuum Regulator Solenoid Valve Vacuum Hose Replacement
Exhaust Gas Recirculation Valve Cooler Bypass Control Solenoid Valve Replacement
Exhaust Temperature Sensor Replacement – Position 1
Exhaust Temperature Sensor Replacement – Position 2
Exhaust Temperature Sensor Replacement – Position 3
Exhaust Pressure Differential Sensor Replacement
Glow Plug Controller Replacement
Glow Plug Replacement
Glow Plug Controller Bracket Replacement
Knock Sensor 1 Replacement
Knock Sensor 2 Replacement
Air Cleaner Assembly Replacement
Air Cleaner Replacement
Intake Air Duct Replacement
Rear Intake Air Duct Replacement
Air Cleaner Outlet Duct Replacement
Drive Belt Replacement
Drive Belt Tensioner Replacement
Belt Idler Pulley Replacement – Upper
Belt Idler Pulley Replacement – Lower
Engine Front Cover Replacement
Engine Sight Shield Replacement
Crankshaft Pulley Replacement
Camshaft Timing Chain Replacement
Timing Chain Tensioner Replacement
Timing Chain Guide Replacement
Timing Chain Dampener Replacement
Intake Manifold Replacement
Intake Manifold Bracket Replacement
Engine Mount Replacement
Engine Mount Bracket Replacement
Engine Lift Front Bracket Replacement
Engine Lift Rear Bracket Replacement
Engine Support Fixture
Positive Crankcase Ventilation Valve Replacement
Positive Crankcase Ventilation Hose/Pipe/Tube Replacement
Oil Level Indicator Tube Replacement
Camshaft Cover Replacement
Exhaust Camshaft Replacement
Intake Camshaft Replacement
Hydraulic Valve Lash Adjuster Replacement
Valve Rocker Arm Replacement
Valve Stem Oil Seal and Valve Spring Replacement
Cylinder Head Replacement
Crankshaft Balancer Replacement
Crankshaft Rear Oil Seal Replacement
Crankshaft Front Oil Seal Replacement
Crankshaft Sprocket Replacement
Engine Flywheel Replacement
Automatic Transmission Flex Plate Replacement
Upper Oil Pan Replacement
Lower Oil Pan Replacement
Engine Oil Level Indicator Switch Replacement
Turbocharger Replacement
Turbocharger Oil Return Pipe Replacement
Turbocharger Oil Feed Pipe Replacement
Engine Oil Pressure Switch Replacement
Engine Oil and Oil Filter Replacement
Oil Filter Adapter and Oil Cooler Assembly Replacement
Piston, Connecting Rod, and Bearing Replacement
Engine Replacement — Automatic Transmission
Engine Replacement — Manual Transmission
Exhaust Temperature Sensor Removal – Position 2
Exhaust Temperature Sensor Removal – Position 3
Exhaust Particulate Filter Heat Shield Removal – Front
Exhaust Particulate Filter Removal
Exhaust Particulate Filter Heat Shield Removal – Rear
Oil Level Indicator and Tube Removal
Exhaust Temperature Sensor Removal – Position 1
Turbocharger Heat Shield Removal
Turbocharger Coolant Return Pipe Removal
Turbocharger Coolant Feed Pipe Removal
Turbocharger Oil Feed Pipe Removal
Turbocharger Oil Return Pipe Removal
Turbocharger Removal
Exhaust Manifold Heat Shield Removal
Exhaust Manifold Removal
Lower Oil Pan Removal
Upper Oil Pan Removal
Fuel Injection Fuel Feed Pipe Removal
Fuel Injection Fuel Return Hose Removal
Fuel Injector Removal
Fuel Rail Removal
Glow Plug Removal
Vacuum Pump Removal
Fuel Injection Pump Removal
Positive Crankcase Ventilation Valve Removal
Camshaft Cover Removal
Camshaft Bearing Cap Removal – Rear
Exhaust Camshaft Removal
Intake Camshaft Removal
Camshaft Cleaning and Inspection
Engine Lift Front Bracket Removal
Engine Lift Rear Bracket Removal
Drive Belt Tensioner Removal
Oil Filter Adapter Removal
Engine Oil Cooler Outlet Hose Removal
Engine Oil Cooler Removal
Drive Belt and Pulley Cover Removal
Crankshaft Pulley Removal
Drive Belt Idler Pulley Removal – Upper
Drive Belt Idler Pulley Removal – Lower
Engine Mount Bracket Removal
Crankshaft Balancer Removal
Engine Front Cover Removal
Crankshaft Front Oil Seal Removal
Camshaft Timing Chain Removal
Timing Chain Tensioner Removal
Air Conditioning Compressor Bracket Removal
Thermostat Bypass Pipe Removal
Water Pump Pulley Removal
Water Pump Removal
Engine Coolant Thermostat Housing Removal
Engine Water Outlet Adapter Removal
Exhaust Gas Recirculation Pipe Removal
Exhaust Gas Recirculation Valve Removal
Exhaust Gas Recirculation Valve Cooling Feed Hose Removal
Exhaust Gas Recirculation Manifold Cooling Return Hose Removal
Exhaust Gas Recirculation Cooler Removal
Throttle Body Assembly Removal
Intake Manifold Removal
Automatic Transmission Flex Plate Removal
Cylinder Head Removal
Cylinder Head Disassemble
Cylinder Head Cleaning and Inspection
Engine Flywheel Removal
Piston, Connecting Rod, and Bearing Removal
Piston, Connecting Rod, and Bearing Cleaning and Inspection
Crankshaft and Bearing Removal
Crankshaft and Bearing Cleaning and Inspection
Crankshaft Rear Oil Seal Removal
Lower Crankcase Removal
Piston Oil Nozzle Removal
Crankshaft Balancer Cleaning and Inspection
Engine Block Cleaning and Inspection
Piston Oil Nozzle Installation
Lower Crankcase Installation
Crankshaft Rear Oil Seal Installation
Crankshaft and Bearing Installation
Piston, Connecting Rod, and Bearing Installation
Cylinder Head Installation
Automatic Transmission Flex Plate Installation
Engine Flywheel Installation
Cylinder Head Assemble
Intake Manifold Installation
Throttle Body Assembly Installation
Exhaust Gas Recirculation Cooler Installation
Exhaust Gas Recirculation Manifold Cooling Return Hose Installation
Exhaust Gas Recirculation Valve Installation
Exhaust Gas Recirculation Pipe Installation
Engine Water Outlet Adapter Installation
Engine Coolant Thermostat Housing Installation
Water Pump Installation
Water Pump Pulley Installation
Thermostat Bypass Pipe Installation
Air Conditioning Compressor Bracket Installation
Timing Chain Tensioner Installation
Camshaft Timing Chain Installation
Crankshaft Front Oil Seal Installation
Engine Front Cover Installation
Crankshaft Balancer Installation
Engine Mount Bracket Installation
Drive Belt Idler Pulley Installation – Lower
Drive Belt Idler Pulley Installation – Upper
Crankshaft Pulley Installation
Drive Belt and Pulley Cover Installation
Oil Filter Adapter Installation
Engine Oil Cooler Outlet Hose Installation
Engine Oil Cooler Installation
Drive Belt Tensioner Installation
Engine Lift Front Bracket Installation
Engine Lift Rear Bracket Installation
Intake Camshaft Installation
Exhaust Camshaft Installation
Camshaft Bearing Cap Installation – Rear
Camshaft Cover Installation
Positive Crankcase Ventilation Valve Installation
Fuel Injection Pump Installation
Vacuum Pump Installation
Glow Plug Installation
Fuel Rail Installation
Fuel Injector Installation
Fuel Injection Fuel Return Hose Installation
Fuel Injection Fuel Feed Pipe Installation
Upper Oil Pan Installation
Lower Oil Pan Installation
Exhaust Manifold Installation
Exhaust Manifold Heat Shield Installation
Turbocharger Installation
Turbocharger Oil Return Pipe Installation
Turbocharger Oil Feed Pipe Installation
Turbocharger Coolant Feed Pipe Installation
Turbocharger Coolant Return Pipe Installation
Turbocharger Heat Shield Installation
Exhaust Temperature Sensor Installation – Position 1
Oil Level Indicator and Tube Installation
Exhaust Particulate Filter Heat Shield Installation – Rear
Exhaust Particulate Filter Installation
Exhaust Particulate Filter Heat Shield Installation – Front
Exhaust Temperature Sensor Installation – Position 3
Exhaust Temperature Sensor Installation – Position 2
Heated Oxygen Sensor Removal
Heated Oxygen Sensor Installation
Exhaust Gas Recirculation Valve Cooling Feed Hose Installation
Description and Operation
Fuel System Description
Engine Control Module Description
Turbocharger System Description
Accelerator Pedal Position System Description
Exhaust Gas Recirculation (EGR) System Description
Exhaust Particulate Filter System Description
Glow Plug System Description
Drive Belt System Description
Lubrication Description
Cleanliness and Care
Separating Parts
Replacing Engine Gaskets
Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
Engine Component Description
Special Tools and Equipment
Special Tools
Visual Identification
Disassembled Views
Engine Identification
Engine Cooling
Specifications
Fastener Tightening Specifications — LDE, LLU, LXV, 2H0, LUW and LFH
Fastener Tightening Specifications — 2.0L Diesel LNP
Engine Cooling System Specifications — 2.0L Diesel LNP
Schematic and Routing Diagrams
Engine Cooling Schematics
Diagnostic Information and Procedures
DTC P00B3 or P00B4
DTC P00B7
DTC P0480, P0481, or P0482 — LNP
DTC P0480-P0482 or P0691-P0696 — LNP or LNQ
DTC P0597-P0599
DTC P0691-P0694 — LDE, LXV or 2H0
Symptoms – Engine Cooling
Cooling Fan Always On — LNP
Cooling Fan Inoperative — LNP
Engine Overheating
Loss of Coolant
Thermostat Diagnosis — 2.0L Diesel LNP
Thermostat Diagnosis — LDE, L2W, LXT, LXV, 2H0, LUW and LFH
Engine Fails To Reach Normal Operating Temperature
Cooling System Leak Testing
Repair Instructions
Cooling System Draining and Filling
Coolant System Flushing
Radiator Cleaning
Radiator Surge Tank Replacement
Radiator Surge Tank Outlet Hose Replacement — 2.0L Diesel LNP
Radiator Inlet Hose Replacement — LDE, LGE, LLU, LXV, 2H0, LUW and LFH
Radiator Inlet Hose Replacement — 2.0L Diesel LNP
Radiator Outlet Hose Replacement — 2.0L Diesel LNP
Radiator Outlet Hose Replacement — 1.8L 2H0
Engine Coolant Inlet Hose Replacement — 2.0L Diesel LNP
Radiator Mounting Stud Repair
Charge Air Cooler Replacement — Diesel and LUJ with MT
Radiator and Charge Air Cooler Bracket Repair
Engine Coolant Fan Wiring Harness Replacement — 2.0L Diesel LNP
Radiator Lower Bracket Replacement
Radiator Upper Bracket Replacement
Engine Coolant Fan Resistor Mount Repair — Single Coolant Fan
Engine Coolant Fan Resistor Mount Repair — Double Coolant Fan
Radiator Vent Valve Replacement
Charge Air Cooler Inlet Hose Replacement — 2.0L Diesel LNP
Charge Air Cooler Outlet Hose Replacement — LNP and Automatic Transmission
Charge Air Cooler Outlet Hose Replacement — LNP and Manual Transmission
Throttle Body Heater Inlet Hose Replacement — LDE, LXV, 2H0, LUW and LFH
Throttle Body Heater Outlet Hose Replacement — 1.8L 2H0
Engine Oil Cooler Replacement — LDE, LXV, LUW, 2H0 and LFH
Engine Oil Cooler Replacement — 2.0L Diesel LNP
Engine Oil Cooler Outlet Hose Replacement — 2.0L Diesel LNP
Engine Oil Cooler Inlet Pipe Replacement — LDE, LGE, LXV, LUW, 2H0 and LFH
Engine Coolant Fan Replacement — 2.0L Diesel LNP
Engine Coolant Fan Replacement — 1.8L 2H0 – Automatic Transmission
Engine Coolant Fan Replacement — 1.8L 2H0 – Manual Transmission
Turbocharger Coolant Feed Pipe Replacement — 2.0L Diesel LNP
Turbocharger Coolant Return Pipe Replacement — 2.0L Diesel LNP
Exhaust Gas Recirculation Valve Cooling Feed Hose Replacement
Exhaust Gas Recirculation Manifold Cooling Return Hose Replacement — 2.0L Diesel LNP
Thermostat Bypass Hose Replacement
Water Pump Inlet Hose Replacement
Engine Coolant Thermostat Housing Replacement — 2.0L Diesel LNP
Engine Coolant Thermostat Replacement — 2.0L Diesel LNP
Engine Coolant Thermostat Replacement — 1.6L LDE, LXV, 1.8L LUW, 2H0 and LFH
Engine Coolant Thermostat Housing Cover Replacement
Engine Coolant Air Bleed Hose Replacement — 2.0L Diesel LNP
Engine Water Outlet Adapter Replacement — 2.0L Diesel LNP
Thermostat Bypass Pipe Replacement
Water Pump Pulley Replacement — LDE, LXV, 2H0, LUW and LFH
Water Pump Pulley Replacement — 2.0L Diesel LNP
Water Pump Replacement — LDE, LXV, 2H0, LUW and LFH
Water Pump Replacement — 2.0L Diesel LNP
Radiator Drain Cock Replacement
Engine Coolant Fan Shroud Replacement — 2.0L Diesel LNP
Engine Coolant Fan Shroud Replacement — 1.8L 2H0 – Automatic Transmission
Engine Coolant Fan Shroud Replacement — 1.8L 2H0 – Manual Transmission
Radiator Replacement — 1.8L 2H0 – Manual Transmission
Radiator Replacement — 1.8L 2H0 – Automatic Transmission
Radiator Replacement — 2.0L Diesel LNP – AT
Radiator Replacement — 2.0L Diesel LNP – MT
Description and Operation
Cooling System Description and Operation — 2.0L Diesel LNP
Cooling System Description and Operation — LDE, LLU, LXV, 2H0 LUW and LFH
Special Tools and Equipment
Special Tools
Engine Electrical
Specifications
Fastener Tightening Specifications — 2.0L Diesel LNP
Fastener Tightening Specifications — LDE, LLU, LXV, 2H0, LUW and LFH
Battery Usage
Generator Usage
Schematic and Routing Diagrams
Starting and Charging Schematics
Diagnostic Information and Procedures
DTC B1325, B1330, B1517, C0800, P0560, P0562, or P0563
DTC B1516
DTC B151A
DTC B1527
DTC P0615, P0616, or P0617
DTC P0621, P2500, or P2501
DTC P0622
DTC P0625 or P0626
Symptoms – Engine Electrical
Battery Inspection/Test
Battery Charging
Battery Electrical Drain/Parasitic Load Test
Charging System Test
Generator Noise Diagnosis
Starter Solenoid Does Not Click
Starter Solenoid Clicks, Engine Does Not Crank
Engine Cranks Slowly
Starter Noise Diagnosis
Repair Instructions
Battery Negative Cable Disconnection and Connection — without Start/Stop System
Battery Current Sensor Replacement
Battery Positive and Negative Cable Replacement — Gasoline
Battery Positive and Negative Cable Replacement — 2.0L Diesel LNP
Battery Negative Cable Replacement — without Start/Stop System
Battery Positive Cable Replacement
Battery Replacement — Diesel
Battery Replacement — Gasoline
Battery Tray Replacement
Battery Cover Replacement
Starter Replacement — 2.0L Diesel LNP with AT
Starter Replacement — 2.0L Diesel LNP with MT
Starter Replacement — 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
Generator Replacement — 2.0L Diesel LNP
Generator Replacement — 1.8L 2H0
Engine Control Module Wiring Harness Replacement — 2.0L Diesel LNP
Description and Operation
Battery Description and Operation
Charging System Description and Operation
Electrical Power Management Description and Operation
Load Shed System Description and Operation
Starting System Description and Operation
Special Tools and Equipment
Special Tools
Engine Exhaust
Specifications
Fastener Tightening Specifications — 2.0L Diesel LNP
Fastener Tightening Specifications — LDE, LXV, 2H0, LUW and LFH
Diagnostic Information and Procedures
Symptoms – Engine Exhaust
Restricted Exhaust — Diesel
Exhaust Leakage
Exhaust Noise
Repair Instructions
Exhaust Manifold Replacement — 2.0L Diesel LNP
Exhaust Manifold Replacement — 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH
Exhaust Front Pipe Replacement — 2.0L Diesel LNP
Exhaust Front Pipe Replacement — LDE, LLU, LXT, LXV, L2W, 2H0, LFH,LGE
Exhaust System Replacement — 2.0L Diesel LNP
Exhaust System Replacement — 1.8L 2H0
Catalytic Converter Replacement — LDE, LXV, 2H0, LUW and LFH
Exhaust Particulate Filter Replacement — 2.0L Diesel LNP
Exhaust Particulate Filter Heat Shield Replacement – Front
Exhaust Particulate Filter Heat Shield Replacement – Rear
Exhaust Pipe Front Hanger Bracket Replacement — 2.0L Diesel LNP
Catalytic Converter Heat Shield Replacement — LDE, LXV, 2H0, LUW and LFH
Exhaust Heat Shield Replacement — Diesel and Gasoline
Fuel Tank Heat Shield Replacement — 2.0L Diesel LNP
Exhaust Manifold Heat Shield Replacement — 2.0L Diesel LNP
Exhaust Manifold Heat Shield Replacement — LDE, LXV, 2H0, LUW and LFH
Turbocharger Heat Shield Replacement
Exhaust Rear Muffler Heat Shield Replacement — except 2.0L LBN
Exhaust Rear Muffler Replacement — except 2.0L LBN
Description and Operation
Exhaust System Description — LDE, LXT, LXV, 2H0, LUW and LFH
Exhaust System Description — 2.0L Diesel LNP
Special Tools and Equipment
Special Tools
11. HVAC
Heating, Ventilation, and Air Conditioning
Specifications
Fastener Tightening Specifications
Adhesives, Fluids, Lubricants, and Sealers
Refrigerant System Specifications
Diagnostic Information and Procedures
Leak Testing
Air Conditioning (A/C) System Performance Test
Air Conditioning Compressor Oil Diagnosis
Repair Instructions
Refrigerant Recovery and Recharging
Flushing
Air Conditioning Compressor Oil Balancing
Air Conditioning Compressor Replacement — LNP
Air Conditioning Compressor Replacement — 1.6L LDE and 1.8L 2H0
Air Conditioning Clutch Replacement
Compressor Pressure Relief Valve Replacement — LDE, 2H0 and LFH
Compressor Pressure Relief Valve Replacement — 2.0L Diesel LNP
Air Conditioning Compressor Bracket Replacement — 2.0L Diesel LNP
Air Conditioning O-Ring Seal Replacement
Air Conditioning Compressor and Condenser Hose Replacement — 2.0L Diesel LNP
Air Conditioning Evaporator Hose Assembly Replacement
Air Conditioning Refrigerant Desiccant Replacement
Air Conditioning Evaporator Thermal Expansion Valve Replacement
Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement
Air Conditioning Condenser Replacement — 1.8L 2H0 and 2.0L Diesel LNP
Heater and Air Conditioning Evaporator Case Replacement
Air Conditioning Evaporator Replacement
Air Conditioning Evaporator and Blower Module Drain Hose Replacement
Heater Inlet Hose Replacement — 1.8L 2H0 and LFH
Heater Inlet Hose Replacement — 2.0L Diesel LNP
Heater Outlet Hose Replacement — 1.8L 2H0 and LFH
Heater Outlet Hose Replacement — 2.0L Diesel LNP
Passenger Compartment Air Filter Replacement
Air Inlet Housing Replacement
Blower Motor Control Module Replacement — Right Hand Drive
Blower Motor Control Module Replacement — Left Hand Drive
Blower Motor Replacement — Left Hand Drive
Blower Motor Replacement — Right Hand Drive
Instrument Panel Outer Air Outlet Replacement – Left Side
Instrument Panel Center Air Outlet Replacement
Instrument Panel Outer Air Outlet Replacement – Right Side
Body Air Outlet Deflector Replacement
Radio Cooling Duct Replacement — Left Hand Drive
Floor Front Air Outlet Duct Adapter Replacement
Floor Front Air Outlet Duct Replacement – Right Side — Right Hand Drive
Floor Front Air Outlet Duct Replacement – Right Side — Left Hand Drive
Floor Front Air Outlet Duct Replacement – Left Side — Left Hand Drive
Floor Front Air Outlet Duct Replacement – Left Side — Right Hand Drive
Front Floor Console Front Air Duct Replacement
Front Floor Console Rear Air Duct Replacement
Front Floor Console Rear Air Duct Adapter Replacement
Front Floor Console Rear Air Outlet Replacement
Instrument Panel Outer Air Outlet Duct Replacement
Windshield Defroster Outlet Duct Replacement
Windshield Defroster Nozzle Replacement
Floor Rear Air Outlet Duct Replacement
Air Conditioning Refrigerant Service Valve Replacement
Front Side Door Air Outlet Replacement
Heater Core Replacement
Auxiliary Heater Core Replacement
Description and Operation
Heating and Air Conditioning System Description and Operation
Special Tools and Equipment
Special Tools
HVAC – Automatic
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
HVAC Schematics — Automatic
Diagnostic Information and Procedures
DTC B0163 or B0183
DTC B0173, B0178, or B3933
DTC B018A, B048C, B048F, or B1395
DTC B0193
DTC B0223, B0233, B023A, or B0408
DTC B048D or B048E
DTC B3843
DTC P0530, P0532, or P0533
DTC P0645, P0646, or P0647
DTC P2519-P2521
Symptoms – HVAC Systems – Automatic
Air Conditioning Compressor Malfunction
Blower Motor Malfunction
Air Temperature Malfunction
Air Delivery Improper
Air Recirculation Malfunction
Afterblow Enabling
Actuator Recalibration
Repair Instructions
Heater and Air Conditioning Control Replacement
Heater and Air Conditioning Remote Control Replacement
Air Conditioning Module Wiring Harness Replacement — Left Hand Drive
Air Conditioning Module Wiring Harness Replacement — Right Hand Drive
Vent Valve Lever Replacement — Left Hand Drive
Vent Valve Lever Replacement — Right Hand Drive
Air Inlet Valve Lever Replacement – Front — Left Hand Drive
Air Inlet Valve Lever Replacement – Front — Right Hand Drive
Air Inlet Valve Lever Replacement – Rear — Left Hand Drive
Air Inlet Valve Lever Replacement – Rear — Right Hand Drive
Air Inlet Valve Actuator Gear Replacement — Left Hand Drive
Air Inlet Valve Actuator Gear Replacement — Right Hand Drive
Air Inlet Valve Actuator Replacement — Left Hand Drive
Air Inlet Valve Actuator Replacement — Right Hand Drive
Air Inlet Valve and Inside Air Valve Control Cam Replacement — Left Hand Drive
Air Inlet Valve and Inside Air Valve Control Cam Replacement — Right Hand Drive
Mode Control Cam Actuator Replacement — Left Hand Drive
Mode Control Cam Actuator Replacement — Right Hand Drive
Mode Control Cam Replacement — Left Hand Drive
Mode Control Cam Replacement — Right Hand Drive
Mode Control Cam Cover Replacement — Left Hand Drive
Mode Control Cam Cover Replacement — Right Hand Drive
Temperature Valve Actuator Replacement — Left Hand Drive
Temperature Valve Actuator Replacement — Right Hand Drive
Air Conditioning Refrigerant Temperature Sensor Replacement – Right Side — Left Hand Drive
Air Conditioning Refrigerant Temperature Sensor Replacement – Right Side — Right Hand Drive
Ambient Air Quality Sensor Replacement
Ambient Air Temperature Gauge Sensor Replacement
Inside Air Temperature Sensor Replacement – Left Side Upper — Left Hand Drive
Inside Air Temperature Sensor Replacement – Left Side Upper — Right Hand Drive
Inside Air Temperature Sensor Replacement – Left Side Lower — Left Hand Drive
Inside Air Temperature Sensor Replacement – Left Side Lower — Right Hand Drive
Inside Air Moisture and Windshield Temperature Sensor Replacement
Sun Load Temperature and Headlamp Automatic Control Ambient Light Sensor Replacement
Sun Load Temperature Sensor Replacement
Blower Motor Control Module Replacement — Left Hand Drive
Blower Motor Control Module Replacement — Right Hand Drive
Description and Operation
Automatic HVAC Description and Operation
Special Tools and Equipment
Special Tools
HVAC – Manual
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
HVAC Schematics
Diagnostic Information and Procedures
DTC B0193
DTC B0223, B0233, B023A, or B0408
DTC B048D or B048E
DTC B3933
DTC P0530, P0532, or P0533
DTC P0645, P0646, or P0647
DTC P2519-P2521
Symptoms – HVAC Systems – Manual
Air Conditioning Compressor Malfunction
Blower Motor Malfunction
Air Temperature Malfunction
Air Delivery Improper
Air Recirculation Malfunction
Afterblow Enabling
Actuator Recalibration
Repair Instructions
Heater and Air Conditioning Control Replacement
Temperature Valve Actuator Replacement — Left Hand Drive
Temperature Valve Actuator Replacement — Right Hand Drive
Vent Valve Lever Replacement — Left Hand Drive
Vent Valve Lever Replacement — Right Hand Drive
Air Inlet Valve Actuator Gear Replacement — Left Hand Drive
Air Inlet Valve Actuator Gear Replacement — Right Hand Drive
Air Inlet Valve Actuator Replacement — Left Hand Drive
Air Inlet Valve Actuator Replacement — Right Hand Drive
Air Inlet Valve and Inside Air Valve Control Cam Replacement — Left Hand Drive
Air Inlet Valve and Inside Air Valve Control Cam Replacement — Right Hand Drive
Mode Control Cam Replacement — Left Hand Drive
Mode Control Cam Replacement — Right Hand Drive
Air Conditioning Module Wiring Harness Replacement — Left Hand Drive
Air Conditioning Module Wiring Harness Replacement — Right Hand Drive
Air Conditioning Refrigerant Temperature Sensor Replacement – Right Side — Left Hand Drive
Air Conditioning Refrigerant Temperature Sensor Replacement – Right Side — Right Hand Drive
Description and Operation
Manual HVAC Description and Operation
Special Tools and Equipment
Special Tools
13. Power and Signal Distribution
Data Communications
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Data Communication Schematics
Body Control System Schematics
Diagnostic Information and Procedures
Control Module U Code List
DTC B1000
DTC B1001
DTC B101D
DTC B101E
DTC C0550
DTC C056D
DTC C056E
DTC U0001
DTC U0002
DTC U0020
DTC U0073 or U2100
DTC U0074
DTC U0100-U02FF
DTC U0300-U0336
DTC U0400-U05FF
DTC U1500-U15BF
DTC U1814
DTC U18B9-U18BF
DTC U2099
DTC U2101
DTC U2103
DTC U2105-U2199
Symptoms – Data Communications
Scan Tool Does Not Power Up
Scan Tool Does Not Communicate with Chassis High Speed GMLAN Device
Scan Tool Does Not Communicate with High Speed GMLAN Device
Scan Tool Does Not Communicate with Low Speed GMLAN Device
Data Link References
Repair Instructions
Body Control Module Replacement
Body Control Module Bracket Replacement
Description and Operation
Body Control System Description and Operation
Data Link Communications Description and Operation
Power Outlets
Schematic and Routing Diagrams
Cigar Lighter/Power Outlet Schematics
Diagnostic Information and Procedures
Symptoms – Power Outlets
Power Outlet Receptacle Malfunction
Repair Instructions
Cigarette Lighter Receptacle Retainer Replacement
Cigarette Lighter Replacement
Cigarette Lighter Receptacle Replacement
Accessory Power Receptacle Replacement
Description and Operation
Power Outlets Description and Operation — 12V
Special Tools and Equipment
Special Tools
Wiring Systems and Power Management
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Harness Routing Views
Electrical Schematic Symbols
Vehicle Zoning Strategy
Master Electrical Schematic Icons
Power Distribution Schematics
Power Moding Schematics
Ground Distribution Schematics
Component Locator
Master Electrical Component List
Front of Vehicle/Engine Compartment Component Views
Powertrain Component Views
Instrument Panel/Center Console Component Views
Passenger Compartment/Roof Component Views
Door Component Views
Luggage Compartment/Rear of Vehicle Component Views
Wheels/Vehicle Underbody Component Views
Ground Views
Visual Identification
Electrical Center Identification Views
Component Connector End Views
Inline Harness Connector End Views
Diagnostic Information and Procedures
DTC B1370-B1379, B1380-B1389, or B1440-B1443
DTC B144A
DTC B144B
DTC B147E
DTC B147F
Symptoms – Wiring Systems
Power Mode Mismatch
Retained Accessory Power Malfunction
General Electrical Diagnosis
Checking Aftermarket Accessories
Circuit Testing
Basic Digital Multimeter Requirements
Using Connector Test Adapters
Probing Electrical Connectors
Troubleshooting with a Digital Multimeter
Troubleshooting with a Test Lamp
Using Fused Jumper Wires
Measuring Voltage
Measuring Voltage Drop
Measuring Frequency
Testing Ground and Low Reference Circuits
Testing for Continuity
Testing for Short to Ground
Testing for a Short to Voltage
Testing for Intermittent Conditions and Poor Connections
Inducing Intermittent Fault Conditions
Testing for Electrical Intermittents
Scan Tool Snapshot Procedure
Circuit Protection – Fuses
Circuit Protection – Circuit Breakers
Circuit Protection – Fusible Links
Wiring Repairs
Repairing Damaged Wire Insulation
Flat Wire Repairs
GMLAN Wiring Repairs
High Temperature Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Splicing Copper Wire Using Splice Sleeves
Splicing Twisted or Shielded Cable
Splicing Inline Harness Diodes
SIR/SRS Wiring Repairs
Connector Repairs
Connector Position Assurance Locks
Terminal Position Assurance Locks
AFL/EPC Connectors
Bosch Connectors — 2.8 JPT
Bosch Connectors — ECM
Bosch Connectors — 0.64
Bosch Connectors — BSK
Delphi Connectors — 12-Way
Delphi Connectors — Push To Seat
Delphi Connectors — Weather Pack
Delphi Connectors — Micro .64
Delphi Connectors — Pull To Seat
Delphi Connectors — Micro-Pack 100W
Delphi Connectors — Steering Gear
FCI Connectors — Lever Lock
FCI Connectors — SIR
FEP Connectors — Steering Gear
JST Connectors
Kostal Connectors — Transmission
Kostal Connectors — Glow Plug Control Module
Molex Connectors
Sumitomo Connectors
Tyco/AMP Connectors — 43-Way
Tyco/AMP Connectors — Door Module
Tyco/AMP Connectors — SIR
Tyco/AMP Connectors — 0.25 Cap
Tyco/AMP Connectors — Sensor
Tyco/AMP Connectors — Seat
Tyco/AMP Connectors — 102-Way Inline
Tyco/AMP Connectors — CM 42-Way
Yazaki Connectors — 16-Way
Yazaki Connectors — 2-Way
Repairing Connector Terminals
Terminal Removal
Ignition Key Cannot Be Inserted, Rotated, or Removed from the Ignition Lock Cylinder
Repair Instructions
Relay Replacement — Attached to Wire Harness
Fuse Block Replacement
Front Compartment Fuse Block Replacement
Front Compartment Fuse Block Housing Replacement
Front Compartment Fuse Block Cover Replacement
Body Wiring Harness Replacement
Roof Wiring Harness Replacement
Ignition and Start Switch Replacement
Ignition and Start Switch Housing Replacement
Description and Operation
Power Mode Description and Operation
Retained Accessory Power Description and Operation
Special Tools and Equipment
Special Tools
14. Roof
Luggage Rack and Roof Trim
Specifications
Fastener Tightening Specifications
Repair Instructions
Luggage Carrier Side Rail Replacement
Luggage Carrier Cross Rail Replacement
Luggage Carrier Rear Rail Replacement
Sunroof
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Sunroof Schematics
Component Locator
Sunroof Component Views
Diagnostic Information and Procedures
DTC B3664
DTC B3697
DTC B369C
Symptoms – Roof
Power Sunroof Malfunction
Repair Instructions
Sunroof Air Deflector Replacement
Sunroof Air Deflector Cover Replacement
Sunroof Frame Replacement
Sunroof Housing Front Drain Hose Replacement
Sunroof Housing Rear Drain Hose Replacement
Sunroof Module Assembly Replacement
Sunroof Window Motor Replacement
Sunroof Sunshade Replacement
Sunroof Switch Replacement
Sunroof Window Height and Opening Fit Adjustment
Sunroof Window Replacement
Description and Operation
Sunroof Description and Operation
Sunroof Window Motor Initialization
Water Management Description and Operation
Special Tools and Equipment
Special Tools
15. Safety and Security
Immobilizer
Schematic and Routing Diagrams
Immobilizer Schematics
Diagnostic Information and Procedures
DTC B2955
DTC B3006
DTC B3031
DTC B3055
DTC B3060
DTC B389A
DTC B3902
DTC B3935
DTC B3976
DTC B3984
DTC P0513
DTC P0633
DTC P1629
DTC P1631
DTC P1632
DTC P1649
DTC P1678
Symptoms – Immobilizer
Hood Ajar Indicator/Message Malfunction
Security Indicator Always On or Flashing
Security Indicator Inoperative
Repair Instructions
Theft Deterrent Module Replacement
Immobilizer System Component Programming
Adding Keys
Replacing Keys
Description and Operation
Immobilizer Description and Operation
Object Detection
Schematic and Routing Diagrams
Object Detection Schematics
Diagnostic Information and Procedures
DTC B0958, B0959, B0960, or B0961
DTC B1015
DTC B1405
Symptoms – Object Detection
Parking Assist System Malfunction
Repair Instructions
Rear Object Alarm Control Module Replacement
Rear Parking Assist Alarm Sensor Replacement
Description and Operation
Object Detection Description and Operation
Remote Functions
Schematic and Routing Diagrams
Remote Function Schematics
Diagnostic Information and Procedures
DTC B097B
DTC B3101
DTC B3105
DTC B3106
DTC B3109-B3113
DTC B310D-B310F
DTC B3119
DTC B3120
DTC B3121
DTC B3122
DTC B3123
DTC B3124
Symptoms – Remote Functions
Keyless Entry System Malfunction — without ATH
Keyless Entry System Malfunction — with ATH
Repair Instructions
Ignition Lock Key Transmitter Antenna Replacement
Keyless Entry Control Module Replacement
Keyless Entry Control Module Bracket Replacement
Remote Control Door Lock Receiver Replacement
Remote Control Door Lock Transmitter Programming — with or without ATH
Description and Operation
Keyless Entry System Description and Operation — without ATH
Keyless Entry System Description and Operation — with ATH
Special Tools and Equipment
Special Tools
Seat Belts
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Seat Belt Schematics
Diagnostic Information and Procedures
Symptoms – Seat Belts
Seat Belt Does Not Retract
Seat Belt Indicator Circuit Malfunction – Driver
Seat Belt Indicator Circuit Malfunction – Passenger
Repair Instructions
Repairs and Inspections Required After a Collision
Seat Belt Latch Stop Installation
Front Seat Belt Buckle Replacement
Rear Seat Center Shoulder Belt Replacement
Rear Seat Number 2 Shoulder Belt Replacement
Shoulder Belt Replacement – Rear
Front Seat Belt Guide Adjuster Replacement
Rear Seat Shoulder Belt Buckle Replacement
Rear Seat Number 2 Shoulder Belt Buckle Replacement
Description and Operation
Seat Belt System Description and Operation
Supplemental Inflatable Restraints
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
SIR Schematics
Component Locator
SIR Identification Views
Diagnostic Information and Procedures
DTC B0012 or B0013
DTC B0014-B0045
DTC B001A or B001B
DTC B0051
DTC B0052
DTC B0083-B0088
DTC B0091
DTC B1001
DTC B1019
Symptoms – SIR
Air Bag Indicator Circuit Malfunction — Driver
Air Bag Indicator Circuit Malfunction — Passenger
SIR Disabling and Enabling
Introduction
SIR Service Precautions
Repair Instructions
Front End Inflatable Restraint Discriminating Sensor Replacement
Inflatable Restraint Side Impact Sensor Replacement
Inflatable Restraint Sensing and Diagnostic Module Replacement
Steering Wheel Inflatable Restraint Module Replacement
Steering Wheel Airbag Coil Replacement
Inflatable Restraint Steering Wheel Module Coil Centering
Instrument Panel Inflatable Restraint Module Replacement
Driver or Passenger Seat Side Inflatable Restraint Module Replacement
Inflatable Restraint Instrument Panel Compartment Module Disable Switch Replacement
Roof Side Rail Inflatable Restraint Module Replacement
Front Seat Belt Anchor Plate Tensioner Replacement
Driver or Passenger Seat Retractor Side Belt Replacement
Repairs and Inspections Required After a Collision
Inflatable Restraint Module Handling and Scrapping
Pretensioner Handling and Scrapping
Description and Operation
SIR System Description and Operation
Special Tools and Equipment
Special Tools
Theft Deterrent
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Theft Deterrent System Schematics
Diagnostic Information and Procedures
DTC B0685
DTC B291B
Symptoms – Theft Deterrent
Content Theft Deterrent Malfunction
Glass Breakage Sensor Malfunction
Security Indicator Malfunction
Theft Deterrent Alarm Malfunction — Power Sounder
Repair Instructions
Theft Deterrent Alarm Replacement
Description and Operation
Content Theft Deterrent (CTD) Description and Operation
16. Seats
Seat Hardware, Trim, and Upholstery
Specifications
Fastener Tightening Specifications
Repair Instructions
Driver or Passenger Seat Replacement
Front Seat Outer Recliner Upper Finish Cover Replacement
Driver or Passenger Seat Adjuster Vertical Actuator Handle Replacement
Driver or Passenger Seat Adjuster Handle Replacement
Driver or Passenger Seat Head Restraint Replacement
Driver or Passenger Seat Head Restraint Guide Replacement
Driver or Passenger Seat Cushion Frame Replacement
Front Seat Cushion Outer Trim Panel Replacement
Front Seat Cushion Inner Trim Panel Replacement
Front Seat Cushion Cover and Pad Replacement
Driver or Passenger Seat Back Cushion Cover and Pad Replacement
Driver or Passenger Seat Back Cushion Frame Replacement
Driver or Passenger Seat Recliner Handle Replacement
Rear Seat Replacement — 40 Percent Seat
Rear Seat Replacement — 60 Percent Seat
Rear Seat Armrest Replacement
Rear Seat Head Restraint Replacement
Rear Seat Head Restraint Guide Replacement
Rear Seat Frame Front Finish Cover Replacement – Lower
Rear Seat Cushion Cover and Pad Replacement — 40 Percent Seat
Rear Seat Cushion Cover and Pad Replacement — 60 Percent Seat
Rear Seat Cushion Frame Replacement — 40 Percent Seat
Rear Seat Cushion Frame Replacement — 60 Percent Seat
Rear Seat Latch Release Strap Bezel Replacement
Rear Seat Shoulder Belt Opening Bezel Replacement
Rear Seat Back Cushion Panel Replacement
Rear Seat Back Cushion Cover and Pad Replacement – Left Side
Rear Seat Back Cushion Cover and Pad Replacement – Right Side
Rear Seat Back Cushion Frame Replacement — 40 Percent Seat
Rear Seat Back Cushion Frame Replacement — 60 Percent Seat
Rear Seat Back Cushion Latch Release Handle Replacement — 40 Percent Seat
Rear Seat Back Cushion Latch Release Handle Replacement — 60 Percent Seat
Rear Seat Recliner Inner Finish Cover Replacement
Rear Seat Recliner Outer Finish Cover Replacement
Rear Number 2 Seat Replacement
Rear Seat Number 2 Back Cushion Latch Release Handle Replacement
Rear Seat Number 2 Back Cushion Panel Replacement
Rear Seat Number 2 Cushion Cover and Pad Replacement
Rear Seat Number 2 Cushion Frame Replacement
Rear Seat Number 2 Head Restraint Replacement
Rear Seat Number 2 Back Cushion Cover and Pad Replacement
Rear Seat Number 2 Back Cushion Frame Replacement
Rear Seat Riser Finish Cover Replacement
Rear Seat Number 2 Inner Riser Replacement
Rear Seat Number 2 Outer Riser Replacement
Thread Repair
Special Tools and Equipment
Special Tools
Seat Heating and Cooling
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Heated/Cooled Seat Schematics
Diagnostic Information and Procedures
DTC B1925 or B2170
DTC B2345
DTC B2425 or B2430
DTC B242A
Symptoms – Seat Heating and Cooling
Front Heated Seat Malfunction
Repair Instructions
Front Seat Heater Control Module Replacement
Driver or Passenger Seat Back Cushion Heater Replacement
Driver or Passenger Seat Cushion Heater Replacement
Description and Operation
Heated Seats Description and Operation
17. Steering
Power Steering
Specifications
Fastener Tightening Specifications
Power Steering Pump Specifications
Adhesives, Fluids, Lubricants, and Sealers
Schematic and Routing Diagrams
Power Steering Schematics
Diagnostic Information and Procedures
DTC C0176
DTC C044A
DTC C0456
DTC C0475
DTC C047A
DTC C0545
DTC C0565
DTC C0569
DTC C0710
Symptoms – Power Steering System — Electronic Power Steering
Symptoms – Power Steering System — Hydraulic Power Steering
Variable Effort Steering Malfunction
Power Steering System Test
Power Steering Fluid Leaks
Rattle, Clunk, or Shudder Noise from the Power Steering System — Hydraulic Power Steering
Rattle, Clunk, or Shudder Noise from the Power Steering System — Electronic Power Steering
Whine or Growl Noise from the Power Steering System — Electronic Power Steering
Whine or Growl Noise from the Power Steering System — Hydraulic Power Steering
Increase in Effort While Turning Steering Wheel
Poor Return of Steering Wheel
Steering Effort Hard or Too Easy in One or Both Directions — Electronic Power Steering
Steering Effort Hard or Too Easy in One or Both Directions — Hydraulic Power Steering
Repair Instructions
Power Steering System Bleeding
Checking and Adding Power Steering Fluid
Power Steering Fluid Reservoir Replacement
Power Steering Pump Pulley Replacement
Power Steering Pump Replacement — 1.6L LDE and 1.8L 2H0
Power Steering Pump Replacement — 2.0L Diesel LNP
Steering Linkage Outer Tie Rod Replacement
Steering Gear Boot Replacement
Power Steering Fluid Reservoir Outlet Hose Replacement
Power Steering Gear Inlet Pipe/Hose Replacement
Power Steering Gear Outlet Pipe/Hose Replacement
Steering Gear Replacement — Electronic Power Steering
Steering Gear Replacement — Hydraulic Power Steering
Steering Gear Bushing Replacement
Steering Linkage Inner Tie Rod Replacement — Hydraulic Power Steering
Steering Linkage Inner Tie Rod Replacement — Electronic Power Steering
Power Steering Assist Motor Replacement
Power Steering Control Module Calibration
Description and Operation
Power Steering System Description and Operation — Electronic Power Steering
Power Steering System Description and Operation — Hydraulic Power Steering
Variable Effort Steering System Description and Operation
Special Tools and Equipment
Special Tools
Steering Wheel and Column
Specifications
Fastener Tightening Specifications
Adhesives, Fluids, Lubricants, and Sealers
Diagnostic Information and Procedures
Symptoms – Steering Wheel and Column
High Telescoping Effort
High Effort While Tilting Column
Noise in Steering Column
Looseness in Steering Column
Repair Instructions
Intermediate Steering Shaft Replacement
Steering Column Upper Trim Cover Replacement
Steering Column Lower Trim Cover Replacement
Turn Signal Switch Replacement
Turn Signal Switch Bracket Replacement
Steering Wheel Replacement
Steering Wheel Spoke Lower Cover Replacement
Steering Column Replacement
Steering Angle Sensor Replacement
Description and Operation
Steering Wheel and Column Description and Operation
18. Suspension
Front Suspension
Specifications
Fastener Tightening Specifications
Component Locator
Front Suspension Components
Repair Instructions
Stabilizer Shaft Replacement
Stabilizer Shaft Link Replacement
Front Wheel Bearing and Hub Replacement
Steering Knuckle Replacement
Lower Control Arm Replacement
Front Lower Control Arm Bushing Replacement
Wheel Stud Replacement
Strut Assembly Removal and Installation
Shock Absorber Disposal
Strut, Strut Component, or Spring Replacement
Description and Operation
Front Suspension Description and Operation
Special Tools and Equipment
Special Tools
Rear Suspension
Specifications
Fastener Tightening Specifications
Component Locator
Rear Suspension Components — Compound Crank
Repair Instructions
Rear Wheel Bearing and Hub Replacement — Disc Brake
Rear Axle Bushing Replacement — Compound Crank
Shock Absorber Replacement
Shock Absorber Disposal
Rear Spring Insulator Replacement
Rear Spring Replacement
Rear Axle Replacement
Wheel Stud Replacement
Description and Operation
Rear Suspension Description and Operation — Compound Crank
Special Tools and Equipment
Special Tools
Suspension General Diagnosis
Diagnostic Information and Procedures
Symptoms – Suspension General Diagnosis
Vehicle Leads/Pulls
Body Leans or Sways in Corners
Torque Steer
Memory Steer
Noise Diagnosis – Front Suspension
Noise Diagnosis – Rear Suspension
Suspension Strut and Shock Absorber Testing – On Vehicle
Wheel Bearings Diagnosis
Trim Height Inspection
Special Tools and Equipment
Special Tools
Tire Pressure Monitoring
Diagnostic Information and Procedures
DTC C0569
DTC C0750, C0755, C0760, or C0765
DTC C0775
Symptoms – Tire Pressure Monitoring
Low Tire Pressure Indicator Malfunction
Repair Instructions
Tire Pressure Indicator Sensor Learn
Description and Operation
Tire Pressure Monitor Description and Operation
Tires and Wheels
Specifications
Fastener Tightening Specifications
Adhesives, Fluids, Lubricants, and Sealers
Diagnostic Information and Procedures
Radial Tire Lead/Pull Correction
Repair Instructions
Tire and Wheel Removal and Installation
Tire Repair
Tire Dismounting and Mounting
Description and Operation
P-Metric Sized Tires Description
Wheel Alignment
Specifications
Wheel Alignment Specifications
Repair Instructions
Wheel Alignment Measurement
Front Camber Adjustment
Front Caster and Camber Adjustment
Wheel Alignment – Steering Wheel Angle and/or Front Toe Adjustment
Rear Caster and Camber Adjustment
Rear Camber Adjustment
Rear Toe Adjustment
Description and Operation
Camber Description
Caster Description
Toe Description
19. Transmission
Automatic Transmission – 6T30/6T40/6T45/6T50
Specifications
Fastener Tightening Specifications
Transmission General Specifications — 6T40/45/50
Adhesives, Fluids, Lubricants, and Sealers
Fluid Capacity Specifications — 6T40/45/50
Fluid Pump Selective Specifications
Range Reference
Shift Solenoid Valve State and Gear Ratio
Transmission Fluid Pressure Switch Logic
Transmission Internal Mode Switch Logic
Solenoid Valve Pressure — Gen 1
Schematic and Routing Diagrams
Automatic Transmission Controls Schematics
Component Locator
Disassembled Views — 6T40/45
Component Location
Bushing, Bearing, and Washer Locations — Gen 1
Seal Locations — Gen 1
Ball Check Valve Locations — Gen 1
Fluid Passages — Gen 1
Diagnostic Information and Procedures
DTC P0218
DTC P0562 or P0563
DTC P0601-P0604 or P062F
DTC P0634
DTC P0658 or P0659
DTC P0667, P0668, or P0669
DTC P06AC, P06AD, or P06AE
DTC P0711, P0712, or P0713
DTC P0716, P0717, P07BF, or P07C0
DTC P071D
DTC P0722, P0723, P077C, or P077D
DTC P0741 or P0742
DTC P0751 or P0752
DTC P0776 or P0777
DTC P0796 or P0797
DTC P0815, P0816, or P0826
DTC P0842 or P0843
DTC P0850-P0852
DTC P0872 or P0873
DTC P0877 or P0878
DTC P0961-P0963
DTC P0965-P0967
DTC P0969-P0971
DTC P0973 or P0974
DTC P0989 or P0990
DTC P150C
DTC P1761
DTC P182E or P1915
DTC P1876
DTC P2534
DTC P2714 or P2715
DTC P2719-P2721
DTC P2723 or P2724
DTC P2728-P2730
DTC P2762, P2763, or P2764
Symptoms – Automatic Transmission
Control Solenoid Valve and Transmission Control Module Assembly Inspection
Control Solenoid Valve and Transmission Control Module Assembly Input Shaft Speed/Output Shaft Speed Input Test
Control Solenoid Valve and Transmission Control Module Assembly Solenoid Performance Test
Transmission Adaptive Values Learn
Transmission Fluid Level and Condition Check
Line Pressure Check
Road Test
Torque Converter Diagnosis
Clutch Plate Diagnosis
Engine Coolant/Water in Transmission
Fluid Leak Diagnosis — Non Hybrid
Case Porosity Repair
Transmission Fluid Cooler Flushing and Flow Test
Bushing and Mating Shaft Inspection
Noise and Vibration Analysis
Whine/Growl Noise
Automatic Transmission Fluid Leaks
Shift Indicator Indicates Wrong Gear Selection
No Park
Harsh Garage Shift
No Drive in All Ranges
No First and Reverse Gears
No First, Second, Third, and Fourth Gear
No Second and Sixth Gear
Harsh or Late First, Second, Third, and Fourth Shift
Harsh First and Reverse Shift
No Third, Fifth, and Reverse Gear
Harsh or Late Second and Sixth Shift
No Fourth, Fifth, and Sixth Gear
Harsh or Late Third, Fifth, and Reverse Shift
Harsh Fourth, Fifth, and Sixth Shift
No Torque Converter Clutch Apply
No Torque Converter Clutch Release
Harsh Torque Converter Clutch Apply, or Inoperative or No Electronically Controlled Capacity Clutch Control
No Reverse Gear
Fluid Pressure High or Low
Repair Instructions
Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement
Transmission Control Lever Knob Replacement
Transmission Control Replacement
Automatic Transmission Range Selector Lever Replacement
Range Selector Lever Cable Replacement
Range Selector Lever Cable Adjustment
Range Selector Lever Cable Bracket Replacement
Transmission Fluid Cooler Pipe Connector Replacement – Radiator — except 1.4L LUJ
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection
Transmission Fluid Cooler Outlet Pipe Replacement — LBN, LLW
Transmission Fluid Cooler Inlet Pipe Replacement — LBN, LLW
Automatic Transmission Fluid Pressure Test Hole Plug Replacement
Front Wheel Drive Shaft Seal Replacement – Left Side
Front Wheel Drive Shaft Seal Replacement – Right Side
Manual Shift Shaft and Seal Replacement
Control Solenoid Valve and Transmission Control Module Assembly Replacement
Control Valve Body Cover Replacement — 2.0L Diesel LNP
Control Valve Body Cover Replacement — except 2.0L Diesel LNP
Control Valve Body Replacement
Output Speed Sensor Replacement
Input Speed Sensor Replacement
Transmission Mount Bracket Replacement – Rear — LNP
Transmission Mount Replacement – Left Side
Transmission Front Mount Replacement
Transmission Rear Mount Replacement — Hydraulic Power Steering
Transmission Rear Mount Replacement — Electronic Power Steering
Transmission Replacement — 2.0L Diesel LNP
Transmission Replacement — 1.6L LXT, L2W, LDE and 1.8L 2H0
Lift Plate and Holding Fixture Installation
Torque Converter Removal
Control Valve Body Assembly Removal
Input and Output Speed Sensor Removal
Torque Converter Housing with Fluid Pump Assembly Removal — Non Hybrid
Front Differential Carrier Assembly Removal — 6T40/45/50
Drive and Driven Sprocket, Drive Link, and Park Pawl Removal — 6T40/45/50
Internal Components Removal
2-6 Clutch Piston Removal
Manual Shift Detent Lever with Shaft Position Switch Assembly and Park Pawl Actuator Removal
Manual Shift Shaft Seal Removal
Input Shaft Support Replacement — Gen 1
3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring Replacement — Gen 1
Front Wheel Drive Shaft Seal Replacement – Case Side
Transmission Case Cleaning and Inspection
Manual Shift Detent Lever with Shaft Position Switch Assembly and Park Pawl Actuator Installation
Manual Shift Shaft Seal Installation
2-6 Clutch Piston Installation — 6T40/45/50
Low and Reverse and 1-2-3-4 Clutch Housing, Low and Reverse Clutch Assembly, Output Sun Gear, and 2-6 Clutch Plate Disassemble — Gen 1
Input, Reaction, and Output Carrier Disassemble
3-5-Reverse and 4-5-6 Clutch Housing Disassemble — 6T40/45/50 – Gen 1
3-5-Reverse and 4-5-6 Clutch Housing Assemble — 6T40/45/50 – Gen 1
Input, Reaction, and Output Carrier Assemble — Gen 1
3-5-Reverse and 4-5-6 Clutch Housing, and Input, Reaction, and Output Carrier Installation
Low and Reverse Clutch Assembly and Low and Reverse Clutch Plate Installation
Low and Reverse and 1-2-3-4 Clutch Housing Disassemble
Low and Reverse and 1-2-3-4 Clutch Housing Cleaning and Inspection
Low and Reverse and 1-2-3-4 Clutch Housing Assemble
Low and Reverse and 1-2-3-4 Clutch Housing, and 1-2-3-4 Clutch Plate Installation — 6T40/45/50
Drive Sprocket, Driven Sprocket, and Drive Link Cleaning and Inspection
Drive and Driven Sprocket, Drive Link, and Park Pawl Installation — 6T40/45/50
Front Differential Carrier Cleaning and Inspection
Front Differential Carrier Installation — 6T40/45/50
Transmission Fluid Pump, Front Differential Carrier Baffle, and Front Differential Ring Gear Removal — 6T40/45
Front Wheel Drive Shaft Seal Replacement – Torque Converter Housing Side
Torque Converter Housing Cleaning and Inspection
Transmission Fluid Pump Disassemble — 6T40/45/50
Fluid Pump Selective Measurement
Transmission Fluid Pump Assemble — 6T40/45/50
Transmission Fluid Pump, Front Differential Carrier Baffle, and Front Differential Ring Gear Installation — 6T40/45
Torque Converter Housing with Fluid Pump Assembly Installation — 6T40/6T45/6T50 Non Hybrid
Input and Output Speed Sensor Installation
Control Valve Body Assembly Disassemble — Gen 1
Control Valve Body Cleaning and Inspection — Gen 1
Control Valve Channel Plate Cleaning and Inspection — 6T40/45/50 – Gen 1
Control Valve Body Assembly Assemble — Gen 1
Control Valve Body Assembly Installation
Control Solenoid Valve and Transmission Control Module Assembly Installation
Control Valve Body Cover Installation
Torque Converter Fluid Seal Replacement
Torque Converter Installation
Lift Plate and Holding Fixture Removal
Description and Operation
Definitions and Abbreviations
Transmission Identification Information
Transmission General Description
Transmission Component and System Description
Transmission Adaptive Functions
Transmission Indicators and Messages
Electronic Component Description
Park – Engine Running — Gen 1
Reverse — Gen 1
Neutral – Engine Running — Gen 1
Drive Range, First Gear Engine Braking — Gen 1
Drive Range, First Gear — Gen 1
Drive Range, Second Gear — Gen 1
Drive Range, Third Gear — Gen 1
Drive Range – Fourth Gear — Gen 1
Drive Range, Fifth Gear — Gen 1
Drive Range, Fifth Gear Default — Gen 1
Drive Range, Sixth Gear — Gen 1
Special Tools and Equipment
Special Tools
Clutch
Specifications
Fastener Tightening Specifications
General Specifications
Diagnostic Information and Procedures
Symptoms – Clutch
Clutch Does Not Disengage
Clutch Slipping
Clutch Grabbing
Clutch Rattle
Release Bearing Noisy with Clutch Engaged
Clutch Noisy
Clutch Pedal Hard to Push
Repair Instructions
Brake, Accelerator, and Clutch Pedal Replacement
Clutch Pedal Return Spring Replacement — Tension Spring
Clutch Master Cylinder Reservoir Hose Replacement — Left Hand Drive
Clutch Master Cylinder Reservoir Hose Replacement — Right Hand Drive
Clutch Master Cylinder Replacement
Clutch Actuator Cylinder Front Pipe Replacement — D16, D20, and Left Hand Drive
Clutch Actuator Cylinder Front Pipe Replacement — D16, D20, and Right Hand Drive
Clutch Actuator Cylinder Front Pipe Replacement — F40 and Left Hand Drive
Clutch Actuator Cylinder Front Pipe Replacement — F40 and Right Hand Drive
Clutch Actuator Cylinder Pipe Replacement — F40
Clutch Actuator Cylinder Pipe Replacement — D16
Hydraulic Clutch System Bleeding
Clutch Pedal Position Sensor Replacement
Clutch Pressure and Driven Plate Replacement — D16 and D20
Clutch Pressure and Driven Plate Replacement — LBS , LNP with MYJ
Clutch Actuator Cylinder Replacement — F40-6
Clutch Actuator Cylinder Replacement — D16
Description and Operation
Clutch System Description and Operation
Special Tools and Equipment
Special Tools
Manual Transmission – D16/D20
Schematic and Routing Diagrams
Manual Transmission Schematics
Diagnostic Information and Procedures
DTC P0806-P0808
DTC P080A
DTC P0812
Clutch Pedal Position Sensor Learn
Repair Instructions
Transmission Mount Bracket Replacement – Rear
Transmission Front Mount Replacement
Transmission Rear Mount Replacement
Transmission Mount Replacement – Left Side
Manual Transmission Shift Lever and Selector Lever Cable Replacement
Transmission Control Replacement
Backup Lamp Switch Replacement
Speedometer Driven Gear Replacement
Front Wheel Drive Shaft Seal Replacement – Left Side
Front Wheel Drive Shaft Seal Replacement – Right Side
Transmission Replacement
Manual Transmission Shift Lever and Selector Lever Cable Adjustment
Transmission Fluid Level Inspection
Backup Lamp Switch Removal
Selector and Shift Lever Cable Bracket Removal
Speedometer Driven Gear Removal
Clutch Actuator Cylinder Removal
Shift Control Housing Removal
Transmission Cover Removal
Transmission Case Removal
Holding Fixture Installation
5th Shift Fork Removal
5th Gear Synchronizer Removal
5th Driven Gear Removal
5th Gear Removal
5th Shift Blocking Lever Removal
Shift Shaft Detent Removal
Shift Shaft and Fork Assemblies Removal
Input Shaft and Main Shaft Removal
Transmission Magnet Removal
Clutch and Differential Housing Cover Removal
Front Differential Assembly Removal
Front Differential Assembly Disassemble
Front Differential Assembly Assemble
Front Differential Assembly Installation
Clutch and Differential Housing Cover Installation
Transmission Magnet Installation
Input Shaft and Main Shaft Installation
Shift Shaft and Fork Assemblies Installation
Shift Shaft Detent Installation
5th Shift Blocking Lever Installation
5th Gear Installation
5th Driven Gear Installation
5th Gear Synchronizer Installation
5th Shift Fork Installation
Holding Fixture Removal
Transmission Case Installation
Transmission Cover Installation
Shift Control Housing Installation
Clutch Actuator Cylinder Installation
Speedometer Driven Gear Installation
Selector and Shift Lever Cable Bracket Installation
Backup Lamp Switch Installation
Input Shaft Disassemble
Input Shaft Assemble
Main Shaft Disassemble
Main Shaft Assemble
Description and Operation
Transmission System Description and Operation
Special Tools and Equipment
Special Tools
Manual Transmission – F40
Specifications
Fastener Tightening Specifications
Manual Transmission Specifications
Schematic and Routing Diagrams
Manual Transmission Schematics
Component Locator
Manual Transmission Component Views
Diagnostic Information and Procedures
DTC P0806-P0808
Clutch Pedal Position Sensor Learn
Symptoms – Manual Transmission
Repair Instructions
Manual Transmission Shift Lever and Selector Lever Cable Adjustment
Selector and Shift Lever Cable Bracket Replacement
Transmission Control Replacement
Manual Transmission Shift Lever and Selector Lever Cable Replacement
Backup Lamp Switch Replacement
Shift Control Housing Seal Replacement
Transmission Front Mount Replacement
Transmission Rear Mount Replacement — Hydraulic Power Steering
Transmission Mount Replacement – Left Side
Transmission Mount Bracket Replacement – Rear
Front Wheel Drive Shaft Seal Replacement – Left Side
Front Wheel Drive Shaft Seal Replacement – Right Side
Transmission Replacement
Transmission Fluid Level Inspection
Description and Operation
Transmission System Description and Operation
Special Tools and Equipment
Special Tools
Shift Lock Control
Schematic and Routing Diagrams
Shift Lock Control Schematics
Diagnostic Information and Procedures
DTC B270A
Symptoms – Automatic Transmission Shift Lock Control
Transmission Control Lever Malfunction
Repair Instructions
Automatic Transmission Shift Lock Control Actuator Replacement
Description and Operation
Automatic Transmission Shift Lock Control Description and Operation