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2008 Outlander Series 500
Can-Am 2008 Outlander Series 500 Manuals
Manuals and User Guides for Can-Am 2008 Outlander Series 500. We have
1
Can-Am 2008 Outlander Series 500 manual available for free PDF download: Service Manual
Can-Am 2008 Outlander Series 500 Service Manual (505 pages)
2008 Can-AM
Brand:
Can-Am
| Category:
Offroad Vehicle
| Size: 30.25 MB
Table of Contents
Table of Contents
2
Safety Notice
9
General Information
10
Vehicle Information
11
Engine Emissions Information
11
Model Number
11
Vehicle Identification Number (VIN)
11
Self-Locking Fasteners Procedure
12
Loctite Application Procedure
12
Owner Responsibility
12
ERA Emission Regulations
12
Stud in Blind Holes
13
Preassembled Parts
13
Adjusting Screw
13
Stripped Thread Repair
14
Gasket Compound
14
Standard Thread Repair
14
Repair of Small Holes/Fine Threads
14
Tightening Torques
15
Mounting on Shaft
15
Case-In Components
15
Mounting with a Press
15
Fastener Grade/Torque
16
Maintenance Chart
20
Preseason Preparation
24
Storage Procedures
26
Fuel Stabilizer
26
Engine Lubrication
26
Rags Installation
26
Coolant Density
27
Drive and Driven Pulleys Protection
27
Vehicle Cleaning
27
Vehicle Protection
27
Special Procedures
28
Service Products
28
Turn over
28
ATV Immersion
28
Troubleshooting Chart
30
Starter Does Not Turn
30
Starter Turns, but Does Not Crank the Engine
31
Starter Motor Keeps Running
31
High Engine Operating Temperature
31
Battery Not Charging or Charging Voltage Inadequate
32
Low or no Oil Pressure/High Oil Consumption
33
Oil Contamination
33
Unusual Engine Noise And/Or Vibration
34
Oil Contamination on Cylinder And/Or Head
34
Unusual Engine Noise And/Or Vibrations
34
Unusual Gearbox Noise And/Or Vibrations
34
Gear Indication Fails
35
Gear(S) Is (Are) Hard to Shift
35
Wheel Drive Indication Fails
37
Wheel Drive Does Not Engage or Disengage
37
Unusual Acceleration Behavior
37
Engine Maximum RPM Is too High and Top Speed Is Not Reached
38
Drive Pulley Noise in Idle Speed
38
Drive Pulley Noise When Accelerating/Decelerating
38
Vibrations Originating from Drive Pulley
39
Vibrations Originating from Driven Pulley
39
Pulley's Do Not Down/Up Shift Properly
39
Belt Glazed Excessively or Having Baked Appearance
39
Belt Worn Excessively in Top Width
40
Belt Disintegration
40
Cracks between Cogs
40
Engine Cranks but Fails to Start
40
Engine Does Not Start
41
Engine Hard to Start
41
Engine Suddenly Turns off
41
Engine Backfires
42
Engine Does Not Offer Maximum Power And/Or Does Not Reach Maximum Operating RPM
43
Engine Removal and Installation
45
Service Tools
45
Engine Removal
46
Vehicle and Engine Preparation
46
Engine Installation
52
Final Assembly Procedure
52
Engine Mount Replacement
53
Air Intake System
55
Air Filter Housing
56
Air Filter Removal
57
Air Filter Housing Removal
57
Air Filter Housing Installation
59
Restrictor Removal
59
Restrictor Installation
59
Exhaust System
61
Front Exhaust Pipe Inspection
62
Front Exhaust Pipe Removal
62
Front Exhaust Pipe Installation
62
Muffler Removal
63
Muffler Installation
63
"Y" Exhaust Pipe Removal
63
"Y" Exhaust Pipe Installation
63
Fuel Tank Protector Removal
64
Fuel Tank Protector Installation
64
Lubrication System
65
Lubrication System Components
66
Engine Oil
68
Recommended Oil
68
Engine Oil Viscosity
68
Engine Oil Level Verification
68
Engine Oil Pressure
69
Oil Filter Removal
69
Oil Pressure Switch (OPS)
70
Oil Filter Inspection
70
Oil Filter Installation
70
Oil Pressure Switch Activation
70
Engine Oil Pressure Regulator
71
Oil Pressure Switch Removal
71
Oil Pressure Switch Installation
71
Oil Pump Removal
72
Oil Pump Inspection
72
Oil Pump Installation
73
Engine Oil Strainer Removal
74
Engine Oil Strainer Cleaning and Inspection
74
Reed Valve Removal
74
Reed Valve Inspection
74
Cooling System Service Tools
75
Radiator
76
Water Pump
77
Cooling System Leak Test
78
Coolant Replacement
79
Recommended Coolant
79
Draining the System
79
Refilling the System
79
Thermostat Removal
80
Radiator Cap
81
Coolant Tank
81
Thermostat Installation
81
Radiator Installation
81
Coolant Temperature Sensor (CTS)
82
Radiator Fan Relay (R1)
82
Relay Installation
82
Relay Operation Test
82
Radiator Fan Operation
83
Radiator Fan Test
84
Water Pump Housing
85
Radiator Fan Removal
85
Water Pump Housing Removal
85
Radiator Fan Installation
85
Water Pump Impeller
86
Water Pump Shaft and Seals
86
Water Pump Housing Inspection
86
Water Pump Housing Installation
86
Shaft/Seal Installation
88
Magneto System
91
Magneto Cover Removal
93
Magneto Cover Inspection and Cleaning
93
Magneto Cover Installation
93
Stator Removal
94
Stator Inspection
94
Stator Installation
94
Rotor Removal
95
Rotor Inspection
95
Rotor Installation
95
Sprag Clutch Removal
96
Sprag Clutch Inspection
96
Sprag Clutch Installation
96
Sprag Clutch Gear Removal
97
Sprag Clutch Gear Inspection
97
Starter Drive Gears
97
Sprag Clutch Gear Installation
97
Gear Removal
98
Gear Inspection
98
Gear Installation
98
Intake Manifold, Cylinder Head and Cylinder
99
Intake Manifold
100
Cylinder Head No.1
101
Cylinder Head No.2
102
Cylinders and Pistons
103
Maintenance
104
Valve Adjustment
104
Valve Clearance
104
Leak Test Inspection
105
Intake Manifold Removal
107
Valve Cover Removal
108
Intake Manifold Inspection
108
Intake Manifold Installation
108
Timing Chain Tensioner Removal
109
Timing Chain Tensioner Inspection
109
Timing Chain Tensioner Installation
109
Camshaft Timing Gear Removal
110
Camshaft Timing Gear Inspection
110
Camshaft Timing Gear Installation
110
Rocker Arm Removal
112
Rocker Arm Inspection
112
Timing Chain
113
Rocker Arm Installation
113
Rocker Arm Shaft
113
Cylinder Head Removal
114
Cylinder Head Inspection
114
Camshaft
115
Cylinder Head Installation
115
Camshaft Timing
115
Camshaft Timing Cylinder 2
116
Camshaft Timing Cylinder 1
117
Camshaft Inspection
119
Valve Spring Removal
120
Camshaft Installation
120
Valve Spring Inspection
121
Valve Spring Installation
121
Valve Removal
122
Valve Inspection
122
Valve Stem Seal
122
Valve Stem Diameter
122
Valve Installation
123
Valve Face and Seat
123
Valve Seat Contact Width
123
Valve Guide Removal
124
Valve Guide Inspection
124
Valve Guide Installation
124
Cylinder Removal
125
Cylinder Inspection
125
Cylinder Taper in Diameter
125
Cylinder Installation
126
Cylinder out of Round
126
Piston Removal
126
Piston Inspection
127
Piston/Cylinder Clearance
127
Piston Pin Diameter
128
Connecting Rod/Piston Pin Clearance
128
Piston Installation
129
Connecting Rod Small End Diameter
129
Piston Rings
131
Ring Removal
131
Ring Inspection
131
Ring Installation
131
Bottom End
133
Engine Drive Shaft
134
Crankcase and PTO Cover
135
Crankshaft
136
Oil Seal Removal
137
Engine Drive Shaft Removal
137
Engine Drive Shaft Inspection
137
Engine Drive Shaft Installation
138
PTO Cover Oil Seal Removal
139
PTO Oil Seal Inspection
139
PTO Oil Seal Installation
139
PTO Cover Removal
139
PTO Cover Inspection
140
Plain Bearing Replacement Procedure
140
Plain Bearing Removal
140
PTO Cover Installation
141
Plain Bearing Installation
141
Drive Gears Removal
142
Drive Gears Inspection
142
Drive Gear Installation
142
Timing Chain Removal (Magneto Side)
143
Timing Chain Removal (PTO Side)
143
Timing Chain Inspection
143
Timing Chain Installation
143
Timing Chain Guide
144
Chain Guide Inspection
144
Chain Guide Installation
144
Crankcase Disassembly
144
Crankcase Cleaning
145
Crankcase Inspection
145
Oil Strainer
145
Plain Bearing Replacement
146
Crankcase Assembly
147
Crankshaft Locking Procedure
148
Crankshaft Inspection
150
Crankshaft Axial Play
150
Connecting Rod Big End Axial Play
150
Connecting Rod Big End Radial Play
150
Crankshaft Radial Play MAG/PTO Side
151
Crankshaft Assembly
152
Crankshaft Radial Play (PTO Side Support Bearing)
152
Crankshaft Installation
153
Outlander 500
153
Outlander 650 and 800
153
Gearbox and 4X4 Coupling Unit
155
Gearbox Components and 4X4 Coupling Mechanism
156
Gearbox Housing and 4X4 Actuator Unit
157
Gearbox Oil Change
158
Draining Procedure
158
Gearbox Position Indicator Switches Removal
159
Gearbox Position Indicator Switches Installation
159
4WD Indicator Switch Removal
160
4WD Indicator Switch Test
160
4WD Indicator Switch Installation
160
Oil Seals Removal
160
Countershaft Oil Seal
161
Shift Shaft Oil Seal
161
Output Shaft Oil Seal
161
Output Shaft and Countershaft Oil Seal
161
Actuator Test
162
Actuator Removal
162
Output Shaft and Coupling Mechanism
164
Output Shaft Backlash Procedure
164
Coupling Sleeve Groove Width
167
Coupling Fork Claw Thickness
167
Gearbox Removal
169
Gearbox Disassembly
169
Bevel Gear Axial Clearance
169
Bearing Removal in Housing
173
Gearbox Inspection
173
Shift Forks
174
Shift Drum
174
Levers
174
Gears
174
Width of Shift Fork Engagement Groove
175
Intermediate Gear Shaft
175
Bevel Gear Adjustment
176
Bevel Gear Backlash Procedure
177
Bevel Gear Axial Clearance Procedure
178
Bearing Installation in Housing
179
Other Gearbox Components
180
Shifter Service Products
187
Transmission Lever
188
Shifter Lever Removal
188
Link Rod Removal
189
Shifter Lever Inspection
189
Shifter Lever Installation
189
Shifting Plate
190
Link Rod Inspection
190
Link Rod Installation
190
Shifting Plate Removal
190
Shifting Plate Inspection
191
Shifting Plate Installation
191
Overview
193
Front
193
Engine Management System Overview
193
Operating Principle
194
Air Induction
194
Fuel System
194
Throttle Body
194
Fuel Rail
195
Fuel Pump Module
195
Fuel Pressure Regulator
195
Fuel Filter
195
Electrical System
196
Engine Control Module (ECM)
196
Power Distribution
196
Engine Management System
198
Electronic Fuel Injection
198
Ignition
198
ECM and VFB Interaction with the Electrical System
198
Engine Modes of Operation
199
Ignition Timing
199
Vehicle Speed Limiter
199
Limp Home Mode
199
Monitoring System
200
Diagnostic Mode
200
Battery Voltage Warning Device
200
Low Oil Pressure Warning Device
200
Engine Management System Flow Chart
201
EMS Diagnostic
203
On-Board Diagnostic
203
Fault Codes
204
TPS (Throttle Position Sensor) Faults
204
TPS "Out of Range" Fault
204
Fault Code P2119
204
Fault Code Table
205
Adjustment and Repair Procedures
213
Diagnostic Tools
215
Resistance Measurement
215
ECM Connectors
216
Engine Connector
216
Temperature Sensor Table
216
Basic Adjustments
217
Idle Speed
217
Throttle Cable
217
Closed Throttle and Idle Actuator Reset
218
Repair Procedures
219
Main Relay
219
D1 Diode (ECM)
219
Diode (D1) Installation
219
Diode (D1) Test
220
Quick Test to Validate ECM Operation
220
ECM Power Supply and Ground Pinout
220
ECM Power Supply Verification
220
If ECM Works When Bypassing Relay
222
ECM Replacement
222
Fuel Injector
223
Security Exchange
223
Leakage Test
223
Electrical Test
223
Fuel Injector Replacement
225
Fuel Injector Removal
225
Fuel Injector Installation
225
Fuel Rail Replacement
226
Fuel Rail Removal
226
Fuel Rail Installation
226
Mechanical Inspection
227
Electrical Inspection
227
Throttle Body Replacement
227
Throttle Position Sensor (TPS)
230
TPS Wear Test
230
TPS Resistance Test
231
TPS Input Voltage Test
231
TPS Replacement
231
Idle Bypass Valve (IBV)
232
IBV Information in B.U.D.S. Software
232
IBV Resistance Test
232
IBV Visual Inspection
233
Crankshaft Position Sensor (CPS)
234
CPS Resistance Test
234
CPS Replacement
234
Camshaft Position Sensor (CAPS)
235
CAPS Voltage Test
235
Manifold Air Pressure and Temperature Sensor (Mapts)
236
CAPS Replacement
236
Sensor Pressure Function
236
Voltage Test
236
Quick Test
237
Sensor Temperature Function
237
Resistance Test
237
MAPTS Replacement
237
CTS Resistance Test
238
CTS Replacement
238
Fuel Tank and Fuel Pump
239
Fuel Tank Leak Test Inspection
241
Check Valve and Pressure Relief Valve
242
Fuel Pressure Test
244
Fuel Hose and Oetiker Clamps
245
In-Line Fuel Filter
245
Fuel Hose Replacement
245
Oetiker Clamp Replacement
245
Fuel Tank Draining
246
Fuel Tank Removal
246
Fuel Tank Protector
247
Fuel Tank Inspection
247
Fuel Tank Installation
247
Fuel Pump Circuit Test
248
Fuel Pump Power Supply
248
Fuel Pump Ground Circuit
249
Fuel Pump Removal
249
Fuel Pump Installation
249
Fuel System Diagnostic Flow Chart
250
Communication Tools and B.U.D.S. Software
251
Multi-Purpose Interface (MPI)
251
MPI Supply
251
Connections with Vehicle
251
Multi-Purpose Interface-2 (MPI-2)
252
MPI-2 Supply
253
B.U.D.S. Software
253
Changes in ECM
254
Ignition System
255
Ignition Switch
255
Switch Resistance Test
255
Switch Wiring Test (Ignition Function)
256
Switch Wiring Test (DESS Function)
256
Engine Run/Stop Switch
257
Switch Resistance Test (Ignition Function)
257
Switch Resistance Test (DESS Function)
257
Ignition Coil Input Voltage
258
Ignition Coil Resistance Test
259
Spark Plug Removal
260
Troubleshooting Fouled Spark Plug
260
Spark Plug Analysis
260
Spark Plug Installation
260
Charging System
263
Magneto
263
Voltage Regulator/Rectifier
263
DC Current Test with an Inductive Ammeter
264
DC Current Test with a Multimeter
264
Stator
266
Static Test: Continuity
266
Static Test: Insulation
267
Dynamic Test: AC Voltage
267
Battery Information
268
Battery Troubleshooting
268
Discharged or Weak Battery
268
Battery Unloaded Test
268
Battery Removal
269
Battery Cleaning
269
Battery Inspection
270
Battery Storage
270
Main Ground
271
Starting System
273
Engine Cranking Conditions
273
Ignition Switch and Engine Run/Stop Switch
273
Electrical Cable and Connections
273
Fuses
274
D2 Diode (Starter Solenoid)
274
Start Button
275
Start Button Resistance Test
275
Start Button Wiring Test
275
Starting Solenoid
276
Solenoid Signal Test
277
Electric Starter
278
Starter Test
278
Digitally Encoded Security System (DESS)
281
DESS Key Programming
281
Lights, Gauge and Accessories
283
Diagnostic
283
Checking for Shorts between 2 Wires
283
Recommended Tools
283
Electrical Connectors
284
Fuses in Front Service Compartment
284
Fuse Located at the Rear
284
Accessory Relay (R3)
285
Multifunction Gauge
286
Unit Selection (MPH Vs Km/H)
286
Gauge Operation
286
Tachometer
289
Transmission Position Display
289
Fuel Level Display
289
Indicator Lamps
290
Multifunction Display (Normal Display Mode)
290
Multifunction Display (Temporary Display Mode)
291
Multifunction Display Codes/Messages
291
Function Display Problems
293
Fuel Level
293
2/4WD Pilot Lamp
293
HI Beam Pilot Lamp
293
Multifunction Gauge Pinout
294
Multifunction Gauge Removal
295
Multifunction Gauge Installation
295
New Multifunction Gauge Registration (Coding)
295
Country Selection
295
Vehicle Speed Sensor (VSS)
296
Fuel Level Sender
297
Multifunction Switch
297
Low/Hi Beam Switch
298
Override Switch
298
12-Volt Auxiliary Power Outlet
299
12-Volt Auxiliary Power Outlet Test
299
12-Volt Power Outlet Removal
299
12-Volt Power Outlet Installation
299
Headlamp Test
300
Headlamp Bulb Replacement
300
Headlamp Beam Aiming
302
Headlamp Adjustment
302
Taillight Bulb Replacement
303
Winch Test
303
Winch Motor
303
Voltage Supply to Switch
303
Winch Control Switch
304
Winch Relay
304
Winch Removal
305
Winch Installation
305
D5 and D6 Diodes (Winch Relay)
306
Winch Control Switch Removal
306
Winch Control Switch Installation
306
Continuously Variable Transmission (CVT)
309
Drive Belt Removal
311
Drive Pulley
312
Drive Belt Inspection
312
Drive Belt Installation
312
Drive Pulley Removal
313
Drive Pulley Disassembly
314
Sliding Sheave
315
Fixed Sheave
315
Drive Pulley Cleaning
315
Drive Pulley Inspection
316
Drive Pulley Governor Cup
316
Drive Pulley Roller and Slider Shoe
316
Centrifugal Lever Bore Diameter
317
Centrifugal Lever Pivot Bolt Bore Diameter
317
Sliding Sheave Large Bushing
317
Drive Pulley Assembly
318
Sliding Sheave Small Bushing
318
Spring Free Length
318
Spring Sleeve Length
318
Friction Washer
319
Driven Pulley Removal
320
Bushings Bore Diameter
322
Bushing Bore Diameter
322
Wear on Teeth both Sides
322
Width on Top Surface
323
Wear on Contact Surface
323
Clutch Spring Squareness
323
CVT Air Guide Removal
325
CVT Air Guide Inspection
325
CVT Air Guide Installation
325
Front Drive
327
Tires and Wheels
329
Wheel Hub Removal
329
Wheel Hub Inspection
330
Wheel Hub Installation
330
Front Drive Shaft Removal
330
Drive Shaft Inspection
331
Drive Shaft Installation
331
Drive Shaft Boot Inspection
332
Drive Shaft Boot Removal
332
Drive Shaft Boot Installation
332
Front Differential Oil Level
332
Front Differential Oil Change
333
Front Differential Removal
333
Front Differential Inspection
334
Front Differential Disassembly
334
Ring Gear Carrier/Ring Gear
334
Pinion Gear
334
Ring Gear Adjustment
335
Backlash
335
Front Propeller Shaft Removal
336
Front Propeller Shaft Inspection
337
Front Propeller Shaft Installation
337
Propeller Shaft U-Joint Removal
337
Propeller Shaft U-Joint Installation
337
Rear Drive
339
Differential Protector Removal
342
Differential Protector Installation
342
Drive Shaft Removal
342
Rear Propeller Shaft
343
Steering System
351
Handlebar Grip Removal
353
Handlebar Grip Installation
353
Handlebar Cover Removal
353
Handlebar Cover Installation
353
Handlebar Inspection
354
Handlebar Installation
354
Steering Column Removal
354
Steering Column Inspection
354
Steering Column Bearing Removal
355
Steering Column Installation
355
Tie-Rod
355
Tie-Rod Removal
356
Tie-Rod Installation
356
Knuckle Removal
356
Knuckle Inspection
358
Wheel Bearing Inspection
358
Wheel Bearing Removal
358
Wheel Bearing Installation
359
Multifunction Switch Removal
359
Throttle Handle Removal
359
Multifunction Switch Installation
360
Handle Brake Removal
360
Handle Brake Hose Removal
360
Steering Alignment
360
Front Suspension
363
Shock Absorber and Spring Removal
367
Shock Absorber and Spring Disassembly
368
Shock Absorber and Spring Inspection
368
Lower Suspension Arm Protector Removal
369
Lower Suspension Arm Protector Installation
369
Lower Suspension Arm Inspection
369
Lower Suspension Arm Removal
369
Lower Suspension Arm Installation
370
Lower Ball Joint Removal
371
Lower Ball Joint Installation
371
Upper Suspension Arm Lubrication
372
Upper Suspension Arm Inspection
372
Upper Suspension Arm Removal
372
Upper Suspension Arm Installation
373
Upper Suspension Arm Bracket Removal
373
Upper Suspension Arm Bracket Inspection
374
Upper Suspension Arm Bracket Installation
374
Upper Ball Joint Inspection
374
Upper Ball Joint Removal
374
Upper Ball Joint Installation
375
Rear Suspension
377
Rear Shock Removal
379
Rear Shock Disassembly
379
Rear Shock Inspection
380
Rear Shock Assembly and Installation
380
Torsion Bar Removal
380
Torsion Bar Inspection
381
Torsion Bar Installation
381
Trailing Arm Removal
381
Trailing Arm Inspection
382
Trailing Arm Installation
382
Trailing Arm Bearings Inspection
382
Trailing Arm Bearings Removal
382
Trailing Arm Bearings Installation
384
Front and Rear Brakes
385
Hydraulic Brakes System
389
Parking Brake
389
Brake Recommended Fluid
389
Brake Fluid Level
389
Brake Fluid Replacement
390
Brake Fluid Draining
390
Brake Fluid Filling and Bleeding
390
With a Vacuum Pump
390
Rear Brake Light Switch Inspection
391
Rear Brake Light Switch Test
391
Rear Brake Light Switch Removal
392
Rear Brake Light Switch Installation
392
Front Brake Light Switch Inspection
392
Parking Brake Mechanism Removal
392
Front Brake Light Switch Installation
393
Brake Lever Removal
393
Brake Lever Installation
393
Front Master Cylinder Removal
393
Front Master Cylinder Disassembly
394
Front Master Cylinder Assembly
394
Front Master Cylinder Installation
394
Rear Master Cylinder Removal
394
Rear Master Cylinder Disassembly
395
Rear Master Cylinder Inspection and Lubrication
395
Rear Master Cylinder Assembly
395
Rear Master Cylinder Installation
396
Caliper Removal
396
Caliper Disassembly
397
Caliper Inspection
397
Caliper Assembly
397
Brake Pads Removal
397
Brake Pads Installation
398
Brake Disc Inspection
399
Brake Disc Removal
399
Brake Disc Installation
400
Brake Pedal Removal
400
Brake Pedal Installation
400
Brake Hoses Inspection
400
Brake Hoses Removal
401
Brake Hoses Installation
401
Body
403
Outlander Series Body Parts (Front View)
404
Outlander Series Body Parts (Rear View)
405
Outlander Series Body Parts (Side View)
406
Outlander Series Seat
407
Outlander Series XT Package
408
Renegade Models Body Parts (Front View)
409
Renegade Models Body Parts (Rear View)
410
Renegade Models Body Parts (Side View)
411
Renegade Models Seat
412
Vehicle Care
413
Plastic Rivet
413
Decal Removal
413
Decal Installation
413
Seat Removal
414
Seat Installation
415
Seat Cover Replacement
415
Central Panel Removal
415
Central Panel Installation
416
Dash Board Removal
416
Side Panel Removal
416
Side Panel Installation
416
Footrest Removal
417
Inner Fender Removal
417
Inner Fender Installation
417
Bumper Removal
417
Bumper Installation
418
Front Bumper/Front Skid Plate/Front Fascia Removal
418
Luggage Rack Removal
419
Luggage Rack Installation
419
Fender Removal
419
Fender Installation
421
Fender Support Removal
422
Fender Support Installation
422
Frame
423
Footrest Support Removal
425
Footrest Support Inspection
425
Battery Support Removal
425
Battery Support Installation
426
Hitch Removal
426
Hitch Installation
426
Hook Removal
426
Hook Inspection
427
Hook Installation
427
Frame Cleaning
427
Frame Welding
427
Technical Specifications
429
Outlander Series
429
Renegade Models
439
Deutsch Connectors
449
Removal from Engine Connector Bracket
449
Connector Disassembly
449
Terminal Removal
451
Terminal Crimping (Kostal)
452
Multifunction Speedometer Connector
453
Battery and Starter Cable Terminals
454
Crimping
454
Wiring Diagrams
457
Wiring Connectors Coding
457
Wire Colors
457
Wire Gauge
457
Wire Location in Connector
458
Distribution System
459
Injection/Ignition System
461
Cooling System
463
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