Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Disassembly All vehicles 1. Remove the two multifunction switches. 1. Depress the retaining tangs. 2. Lift the switches upwards. 2. Detach the driver air bag module from the steering wheel. 3. Remove the driver air bag module. Release the three clips. Disconnect the air bag module electrical connector. 4. Remove the passive anti-theft system (PATS) transceiver. 5. Remove the steering wheel. 1. Disconnect the speed control electrical connector (if equipped). 2. Remove the steering wheel retaining bolt. 6. Remove the tolerance ring. 7. NOTE: Make sure the clockspring is not allowed to rotate. Secure in the central position with a piece of suitable tape. Remove the clockspring. Using a thin bladed screwdriver, release the two retaining clips. 8. Remove the ignition switch. Release the clips. 9. Remove the ignition switch lock cylinder. 1. Insert and turn the ignition key to position I (Accessory). 2. Using a thin bladed screwdriver, depress the detent. 3. Remove the ignition switch lock cylinder. Vehicles with stability assist 10. Fully extend the steering column 1. Release the locking lever. 2. Fully extend the steering column. 11. NOTE: The steering column two halves must be marked before separating. Mark the two halves of the steering column. All vehicles 12. Remove the Allen bolt. 13. Separate the steering column two halves. Vehicles with stability assist 14. Remove the steering wheel rotation sensor clamp. 1. Remove the screws. 2. Using a thin bladed screwdriver, depress the locking tangs and remove the steering wheel rotation sensor clamp. 15. Remove the steering wheel rotation sensor retaining screws. 16. Remove the steering wheel rotation sensor. Assembly Vehicles with stability assist 1. WARNING: Do not install a new steering wheel rotation sensor, if the locking pin has been removed. Failure to follow this instruction may result in personal injury. WARNING: Before fitting the steering wheel rotation sensor, make sure the rotor is in the correct position. Failure to follow this instruction may result in personal injury. Check that the alignment indicator is in the correct position.

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WARNING: WHEN DRAINING FUEL FROM THE FUEL TANK, KEEP SPARKS, SMOKING MATERIALS, AND OPEN FLAMES AWAY FROM THE VEHICLE. WARNING: THE FUEL SYSTEM CONTAINS PRESSURIZED FUEL AFTER THE VEHICLE IS SHUT DOWN AND WILL MAINTAIN THE PRESSURE FOR A LONG PERIOD OF TIME. 1. Relieve the fuel pressure; refer to Section 310-00. 2. Disconnect the battery ground cable (14301); refer to Section 414-01. 3. Raise and support the vehicle; refer to Section 100-02. 4. Disconnect the fuel tank filler pipe hose (9047) from the fuel tank (9002). 5. Drain the fuel from the fuel tank (9002); refer to Section 310-00. 6. Disconnect the fuel tank vent tube (9A228) from fuel tank filler pipe (9034). 7. Disconnect the fuel pump electrical connector. 8. If equipped, remove fuel tank skid plate. 1. Remove the five fuel tank skid plate bolts. 2. Lower the fuel tank skid plate. 9. Position a suitable jack under the fuel tank (9002). 10. Remove the front fuel tank support strap (9092). 1. Remove the two bolts. 2. Remove the front fuel tank support strap (9092). 11. Remove the rear fuel tank support strap (9092). 1. Remove the three bolts. 2. Remove the rear fuel tank support strap. 12. Partially lower the fuel tank and disconnect the two EVAP emissions hoses. 13. Remove the two safety clips from the fuel lines. 14. Disconnect the fuel lines from the fuel pump (9350). 1. Install and push the (A) fuel line disconnect tool into the (B) female fitting. 2. Separate the male and female fitting. 15. Remove the fuel tank. 16. Remove the fuel pump. 1. Remove the fuel pump locking retaining ring (9C385). 2. Remove the fuel pump and discard the O-ring. Installation 1. Install the fuel pump (9350). 1. Install a new O-ring and fuel pump (9350). 2. Install the fuel pump locking retainer ring (9C385). 2. With a suitable jack, position the fuel tank (9002). 3. Connect the fuel lines. 4. Connect the safety clips. 5. Connect the EVAP emissions hoses.

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WARNING: Do not open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. 1. Disconnect the battery ground cable. For additional information, refer toSection 414-01. 2. Relieve the fuel system pressure. For additional information, refer to Section 310-00. 3. Raise and support the vehicle. For additional information, refer to Section 100-02. 4. Drain the fuel tank. For additional information, refer toSection 310-00. 4WD vehicles 5. Remove the fuel tank skid plate. 1. Remove the four bolts. 2. Remove the fuel tank skid plate. All vehicles 6. Use a suitable jack to support the fuel tank. 7. Position the fuel tank support strap aside. 1. Remove the bolt. 2. Position the fuel tank support strap aside. 8. Remove the front bolts and push the fuel tank back until the lip clears the support bracket. 9. Partially lower the fuel tank. 10. Disconnect the fuel pump electrical connector. 11. Disconnect the evaporative vapor tube connector. For additional information, refer to Section 310-00. 12. Disconnect the fuel line connector. For additional information, refer to Section 310-00.

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1. NOTE: The location of engine mountings and engine support insulators are described looking from the transaxle to the engine. Remove the front wheels. For additional information, refer to Section 204-04. 2. Remove the battery. For additional information, refer to Section 414-01. 3. Remove the hood. 4. Remove the bolts and the water pump pulley cover. 1. Detach the coolant hose from the clip. 2. Remove the bolts. 3. Remove the cover. 5. Remove the air cleaner (ACL). For additional information, refer to Section 303-12B. 6. Drain the cooling system. For additional information, refer to Section 303-03. 7. Disconnect the accelerator and speed control cables. 1. Detach the cables from the bracket. 2. Disconnect the accelerator and speed control cables. 8. Remove the selector cable. 1. Remove the bolts. 2. Disconnect the cable. 9. Disconnect the bulkhead electrical connectors. 1. Disconnect the electrical connector. 2. Remove the bolt and disconnect the electrical connector. 10. Detach the central junction box (CJB) and position it to one side. 11. Disconnect the cables. 1. Battery cables. 2. Electrical connector. 3. Ground cable. 12. Disconnect the fan motor electrical connectors. 13. Remove the battery bracket bolts and remove the two ground cables. 14. Remove the battery bracket. 15. Disconnect the fuel line. For additional information, refer to Section 310-00. 16. Disconnect the heater hoses. 17. Disconnect the coolant hoses from the radiator and from the coolant passage.

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The A4WD system is an electronic shift 4×4 system that allows the operator to choose between three different 4×4 modes as well as 2-wheel drive. The operator can switch between 2WD, A4WD, and 4WD HIGH modes at speed. To engage or disengage LOW Range, the vehicle speed must be less than 5 kph, the brake depressed, and the transmission must be in NEUTRAL. A4WD In A4WD, the generic electronic module (GEM) varies the torque split between front and rear drivelines by controlling the transfer case clutch. Under most conditions, the GEM activates the transfer case clutch at a minimum duty cycle (percentage of time the clutch is turned on) which allows for slight speed differences between the front and rear driveshafts which normally occurs when negotiating a corner on dry pavement. When the rear wheels are overpowered, the GEM detects this slip condition, and the duty cycle to the transfer case clutch is increased until the speed difference between driveshafts is reduced. In this manner, the GEM can redirect up to 50% of engine torque to the front wheels when the rear wheels lose traction, yet still allow operation in the A4WD mode on dry pavement without driveline wind-up. NOTE: When the ABS system is active, the GEM will default to a minimum duty cycle for the transfer case clutch. Feature Inputs: 4WD mode switch (various resistances). Front/rear driveshaft speed sensors (Hall effect sensor output: 26.67 Hz/mph). ABS active input (battery voltage when ABS is active, grounded when inactive). Contact plate position inputs A, B, C, D (grounded when closed, open circuit when open). Feature Outputs: Solid state clutch relay output (pulse width modulated signal: grounded when relay is on, battery potential when relay is off). 4×2/4×4 vacuum solenoid (ground when activated, open circuit when deactivated). A4WD indicator (ground when activated, open circuit when deactivated). Shifting Between 2WD, A4WD, and 4WD HIGH Shifts between 2WD, A4WD, and 4WD HIGH can be made at any speed. Listed below are the inputs and outputs needed by the GEM to execute a change between any of these modes. Feature Inputs: 4WD mode switch (various resistances). Contact plate position inputs A, B, C, D (grounded when closed, open circuit when open:). Feature Outputs: 4×4 shift motor relay outputs. Solid state clutch relay (pulse width modulated signal; grounded when relay is on, battery potential when relay is off). 4×2/4×4 vacuum solenoid (ground when activated, open circuit when deactivated). Cluster indicators (ground when activated, open circuit when deactivated). Shifting Into/Out of LOW RANGE When shifting into or out of LOW RANGE, the GEM requires that the vehicle speed is less than 5 kph, the brake is applied, and the transmission is in NEUTRAL. Feature Inputs: 4WD mode switch (various resistances). Contact plate position inputs A, B, C, D (grounded when closed, open circuit when open:). VSS Sensor (sinusoid signal: 0.7V-20V, 2.2 Hz/mph). Brake input (battery voltage when brake is depressed, open circuit when not activated). Digital transmission range (DTR) sensor (ground when transmission is in neutral, open circuit otherwise). Start/clutch depressed input. Feature Outputs: 4×4 shift motor relay outputs. 4×2/4×4 vacuum solenoid (ground when activated, open circuit when deactivated). Cluster indicators (ground when activated, open circuit when deactivated).