Table of Contents

2 Suspension 11 Exhaust System

Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
MacPherson Strut Front Suspension . . . . . . . . . . . . . . . . . 2-2 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Coil-Over-Tube Front Suspension (Four-Wheel Drive) . . . 2-3
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 14 Fuel System
Leaf Spring/Solid Beam Axle Rear Suspension (FWD). . . 2-5 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Coil-Over-Tube Rear Suspension (RWD) . . . . . . . . . . . . . . 2-6 Air Intake/Variable Induction . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

3 Differential and Driveline 19 Steering

Rear Wheel Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
Front Wheel Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Four Wheel Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 21 Transmission
Front Wheel Drive Automatic Transaxle . . . . . . . . . . . . . . . . 21-1
5 Brakes Front Wheel Drive Manual Transaxle and Clutch . . . . . . . . 21-2
Base Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Rear Wheel Drive Automatic Transmission . . . . . . . . . . . . . 21-3
Four-Wheel Disc Brake System . . . . . . . . . . . . . . . . . . . . . . 5-2 Rear Wheel Drive Manual Transmission and Clutch . . . . . 21-4
Antilock Brake System (ABS) with Traction Control . . . . . . 5-3
22 Tires/Wheels
7 Cooling Tire Wear Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
24 Heating and Air Conditioning
8 Electrical Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-2
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Door-Mounted Power Systems . . . . . . . . . . . . . . . . . . . . . . . 8-3 25 Emissions Control
Airbag and Restraint Systems . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Emissions Control Components . . . . . . . . . . . . . . . . . . . . . . 25-1

9 Engine
In-Line 4 Engine (Overhead Cam) . . . . . . . . . . . . . . . . . . . . 9-1
Cam-in-Head V6 Engine (Overhead Cam) . . . . . . . . . . . . . 9-2
Cam-in-Block V8 Engine (Overhead Valve) . . . . . . . . . . . . . 9-3
Engine Lubrication (Overhead Cam Shown) . . . . . . . . . . . . 9-4
Front Suspension

Ball Joint

Rear Wheel Drive

Front Wheel Drive Upper
Control Coil
Arm Spring
Upper
Strut Control Shock
Assembly Arm Absorber
w/Coil
Spring

Steering
Knuckle
Stabilizer
Bar
Brake
Rotor
Lower
Control Arm/ Outer Tie
Spring Seat Front
Hub and Rod Spindle
Bearing
Stabilizer
Bar Lower Control
Arm Outer Tie Rod
2-1
MacPherson Strut Front Suspension
MacPherson Strut
Assemblies

Stabiliizer Bar
Link
Steering
Outer Tie Rod Knuckle
Steering
Gear

Lower Control
Steering Arm
Knuckle

Front
Suspension FRONT OF
VEHICLE
Hub and Cradle
Bearing Lower Control
Arm

2-2
Coil-Over-Tube Front Suspension (Four-Wheel Drive)

Shock Absorbers
Steering
Gear

Front Differential
and Axle Tube
Coil
Front Spring
Knuckle

Brake
Rotor

Tie Rod
Adjustment Sleeve FRONT OF
Hub and Drag Link VEHICLE
Bearing Adjustment Sleeve

2-3
Rear Suspension

Rear Wheel Drive

Front Wheel
Drive Shock
Absorbers

Coil
Upper
Spring
Control
Arm

Rear Axle and

Rear Differential
Knuckle
Shock
Absorber Leaf
Springs

Hub and
Bearing
Trailing Lower
Arm Control Arm

2-4
Leaf Spring/Solid Beam Axle Rear Suspension (FWD)

FRONT OF
VEHICLE

Track
Bar

Leaf Springs

Solid Beam
Axle

Stabilizer Bar

2-5
Coil-Over-Tube Rear Suspension (RWD)
Shock Absorbers
Coil Spring

Stabilizer
Bar Rear
Differential

Coil
Spring

Lower Suspension
Arms

2-6
Rear Wheel Drive System

Rear Differential
and Solid Axle Drive Shaft

Ring
Gear
Universal Joint
(U-Joint)

Pinion Gear

3-1
Front Wheel Drive System

Constant
Transaxle
Velocity (CV)
Joint

Constant
Halfshaft
Velocity (CV)
Joint Boot

Ring Gear and

Differential Assembly

3-2
Four Wheel Drive System
Transfer Driveshaft
Constant Velocity Front
Case
(CV) Joint Driveshaft

Halfshaft

Universal
Joint
(U-Joint)

Rear
Differential

Pinion Gear

Front Differential

Ring Gear
Transfer Case
Drive Chain
3-3
 Base Brake System (Disc/Drum)
Brake Power Brake Parking Brake Lever
Fluid Booster
Reservoir
Master
Cylinder
Proportioning
Valve Wheel
Cylinder

Caliper
Piston

Disc Brake
Caliper
Disc Brake
Pads

Brake Shoes
Hydraulic Connection
Cable Connection Brake Drum
Rotor

5-1
Four-Wheel Disc Brake System
Power Brake Parking
Brake Booster Brake Lever
Fluid
Reservoir

Master
Cylinder

Disc Brake
Pads
Caliper
Piston

Proportioning
Valve

Hydraulic Connection Disc Brake

Cable Connection Caliper

Rotor
5-2
Antilock Brake System (ABS) with Traction Control
Master Cylinder and
Brake Fluid Reservoir

Hydraulic
Control Unit

Wheel Speed
Sensor

Controller -
Antilock
Brake (CAB)

Hydraulic Connection

Electrical Connection Tone

Ring

5-3
Engine Cooling

Thermostat
Radiator Open

Upper Inlet Heater Core

Heater Supply
Closed Line
(Bypass)
Radiator

Water
Pump

Cooling
Fan
Heater
Return Line

Radiator Lower Outlet Coolant Fill and

Recovery Bottle

7-1
Starting System
Powertrain Control
Ignition Coil Module (PCM)
(Coil-on-Plug
Type)
Battery

Starter Solenoid
and Motor
Assembly

Power Distribution
Center (PDC) Flywheel or
Flex Plate

8-1
Charging System
Charging
Starter Indicator Lamp
Powertrain Control or Gauge
Generator Module (PCM)
Battery
Interior Fuse
Panel

Ground
Charging System
Power Distribution
Maxi-Fuse
Center (PDC)

8-2
Door-Mounted Power Systems
Door Lock Key
Cylinder

Door Handle

Manual Door Power Window and

Lock Knob Lock Switches

Door Latch and

Ajar Switch Power Mirror
Switch

Power Door
Lock Motor

Driver Door
Handle
Power Window
Motor
Speaker

8-3
Airbag and Restraint Systems
Side Curtain
Airbags

Seat-mounted
Side Airbag

Passenger
Airbag Unit

Seat Belt
Pretensioner

Side Impact
Sensor
Front Impact Driver
Sensors Airbag Unit
Occupant Restraints
Controller (ORC)

8-4
In-Line 4 Engine (Overhead Cam)
Overhead
Cam Follower
Camshaft
and Lifters
Cylinder Head
and Gasket
Valves
Exhaust
Intake Manifold
Manifold and Gasket
and Gasket

Valve
Cover and Cylinder
Gasket Oil
Filter Block
Oil Pump
and Gasket Pistons

Timing
Belt Bed
Plate
Crankshaft

Water Oil Pan and

Pump Gasket

9-1
Cam-In-Head V6 Engine (Overhead Cam)
Valve Cover
Piston Rear Main Overhead
and Gasket
Seal Camshafts

Camshaft
Sprockets
Timing
Chain Water
Valves
Pump

Front
Cover

Cylinder Head
and Gasket
Front
Seal
Flywheel or
Crankshaft Flex Plate Exhaust
Sprocket Manifold and
Gasket
Crankshaft
Crankshaft
Pulley
Main Bearing
Oil Pan Caps

9-2
Cam-In-Block V8 Engine (Overhead Valve)
Distributor
and Rotor
Intake Manifold Valve
Cover and
Gasket
Engine
Block
Water Pump and
Crankshaft Piston Valves
Pulley
Camshaft
Accessory
Drive Belt
Cylinder
Head and
Gasket
Oil Filter

Timing
Chain and
Sprockets
Crankshaft

Exhaust Manifold
Oil Pan and Gasket

9-3
Engine Lubrication (Overhead Cam Shown)

Crankshaft
Bearings

Oil Pan
Oil Filter
Oil Pump
Pickup Tube

9-4
Exhaust System

Downstream Oxygen
(O2) Sensor Muffler

Exhaust
Manifold

Resonator
Catalytic
Converter
Upstream Oxygen
(O2) Sensor

11 - 1
 Turbocharger System
Compressor Section Turbine Section
Exhaust Gas

To Exhaust Pipe
Fresh Air
Turbocharger
Assembly
Turbocharger- Compressed
Air to Exhaust Gas
to-Charge Air Engine Fresh Air
Fresh Air
Cooler Hose Hose
Inlet

Bearing
Housing

Charge Air
Cooler-to-
Throttle
Body Hose

Charge
Air Cooler

FRONT OF
VEHICLE Throttle
Body
11 - 2
Fuel System

Fuel Pump/Filter/
Throttle Level Sender Fuel Filler
Fuel Injector Body Assembly Tube

Overflow
Tube

Air Filter

14 - 1
Air Intake / Variable Induction

Throttle Positon
Upper Intake Sensor
Manifold

Manifold Tune
Valve

Throttle
Body

Lower Intake
Manifold

14 - 2
Steering Systems

Rack & Pinion Recirculating Ball

Steering
Power Gearbox
Steering Pump Steering Worm
Fluid Gear Gear
Reservoir
Pitman Shaft

Fluid
Reservoir
Pitman Arm

Power
Steering
Pump

Rack Gear Pinion Gear

19 - 1
Front Wheel Drive Automatic Transaxle
Final Drive
Gear Friction Clutch
Assemblies
Differential Planetary Gearset

Transfer Gear

Output Speed
Sensor

Input Speed
Sensor

Vehicle Speed
Sensor

Torque Converter
Assembly Transmission
Valve Range Sensor
Body
Fluid Pump

21 - 1
Front Wheel Drive Manual Transaxle and Clutch

Countershaft
and Gears

Input Shaft
and Gears

ENGAGED DISENGAGED
Synchronizer
Clutch
Pressure Plate
Clutch
Disc

Output Shaft
and Gears
Release
Clutch
Fork
Ring Gear Differential Release
Bearing

21 - 2
Rear Wheel Drive Automatic Transmission
Clutch Clutch Packs
Torque Converter Packs and and Rear
Assembly Front Planetary
Flex Plate
Input Planetary Gearset Output
Shaft Gearset Shaft

Valve Body
Parking Pawl
and Shaft

21 - 3
Rear Wheel Drive Manual Transmission and Clutch

Transmission
Release
Shift Lever
Bearing

Clutch Release
Pressure Fork
Plate Shift Shaft
and Forks

Roller
Clutch Master Bearing
Cylinder and
Fluid Reservoir
Clutch
Disc
Output
Clutch Shaft
Slave Main Shaft
Input Shaft
Cylinder and Gears
Countershaft and Synchro
DISENGAGED ENGAGED Gears Sleeve

21 - 4
Tire Wear Patterns

Positive Camber Negative Camber

Wear Over- Under-

Indicator inflation inflation

Toe In Toe Out

Camber Feathering Spotty/

Wear (Excessive Toe In Chopped Wear
or Toe Out) (Multi-Problem)
Negative Caster Positive Caster

Tire Bead

Diagonal Wear/ Local Wear/

Heel & Toe Wear Flat Spot

Cutaway View of Tire and Rim

22 - 1
Heating System

Blower Motor

Water Pump

Radiator
Upper Inlet

Radiator
Heater
Core
Radiator Fan
Radiator Lower
Coolant Recovery Bottle Outlet

24 - 1
Air Conditioning System
Blower Evaporator
Motor

Expansion Valve

Refrigerant
Service Port

A/C Compressor

HVAC Housing
Condenser

Receiver-Dryer w/Low-
Pressure Cutout Switch

24 - 2
Emissions Control Components
Exhaust Gas Positive Crankcase
Recirculation Ventilation (PCV) Valve
(EGR) Valve
Leak Detection Evaporative
Pump (LDP) Emissions Vapor
Recovery Tube

Leak Detection
Breather Filter
Vapor Canister

EVAP Purge
Solenoid

25 - 1